NOVA 55175 Use and Care Manual
Contents
1. PP 23 Learning MR E 24 IN LTS Br GUIDE RE 25 Programming the Favourate SPeeds cccccsssccccccssseeccceceeeeceeccaeeseceeecseuseeeeeseaaeeeeeeesaaseeeessaaeeeessaaagss 29 Maintaining the Nova 33 General Maintenance REM 33 Cleaning the Toolslide nire etx enitio ede xta 34 Geanina ME cue TET E E E queens 34 PM CUT NG m 35 Voltage selection ERN E E Tm 36 Troubleshooting GUIQE sess aa nennen nnn nnne sn na nnns 38 Troubleshooting Guide continued sess nenne nnn nnns earn nnn nnns 40 DVR WOO ae Pars EIE TE TET 41 hiec ccod Y 44 PCC 1 T REOR 45 NOK 46 Copyright 2001 2013 by Teknatool International All Rights Reserved Nova DVR XP is a trademark of Teknatool International Ltd 6 115 0513 003 The information and specifications contained herein are subject to change Teknatool is not responsible for errors or omissions herein or for incidental damages in connection with the furnishing or use of this information GENERAL SAFETY RULES A Warning Failure to follow these rules may result in serious personal injury 1 FOR YOUR OWN SAFETY READ T2. Ck Part 55012 55145 M5 55040 55019 55014 55010 55049 M3 CSK Screw 95003 99103 99007 99005 99050 55009 55146 55004 55006 6207RS1 CO 5 55051 G0606 99011 55174 95100 55130 99018 55212 MP05010 55124 LHB 55152 55061 55172 55081 Description Swivel Pin Headstock Headstock M5x10 screw Backing Plate Interface Board Front Control Cover Keypad Memebrane LCD Interface Board M3x10 Countersunk Screw Headstock Spindle 1 1 4 8 UNS RH Headstock Spindle M33 X 3 5 RH Rotor Lamination Set Spacer Ring Rotor Key Stator Bearing Carrier Position Disc Encoder Ring Trimax Bearings Rear Circlip Rear Bearing Fan Key M6X6 Grub Screw Fan Fan Index Plate Sensor Guard EMI Filter Control Board Version Vary Heatsink Aluminium Pan Pozi Screw IEC SNAP Inlet Handbrake handwheel Switch Toggle Chilly Holder Fuse Safety Endcover EMI DVR Operating Bar 115 0513 003 42 Nova DVRXP Lathe 115 0701 001 Accessories Add On Bed Extension 55195 Extend the bed of your Nova DVR XP Woodlathe for greater capacity for turning between centers Each bed unit adds 510mm 20in Lathe Stand The stand pieces are cast from a high grade of Cast iron with extremely good section thickness and CAD generated internal gussets at all critical points to withstand extremely high stresses with practically no distortion Cast i
3. 21 35 Shop Requirements 10 opeed 2 3 8 9 15 16 17 18 22 35 Spindle Index 2 9 16 19 20 32 opindle Threads 2 9 20 Spur Center 8 9 21 35 Stand 2 10 11 14 26 37 42 Standard Equipment 8 Swing 8 owiveling the Headstock 12 19 Tailstock parts list 38 39 41 Tailstock 2 8 9 12 13 14 22 33 Teknatool 4 5 6 20 33 42 Toolrest 9 13 16 21 26 33 Toolslide Parts List 38 39 Troubleshooting 35 37 Turning between Centers 20 Turning Speeds 21 Turning 2 3 4 8 9 10 14 18 19 20 21 22 32 35 42 43 Unpacking 12 Vacuum Coupler 9 43 Vibration 3 10 11 18 35 Warranty 45 Website 4 115 0513 003 46 Teknatool Warranty Teknatool Five Year Limited Warranty 2 year on electrical parts This Teknatool product is backed by a warranty from the date of purchase Teknatool International Ltd will repair or replace at its expense and option this Teknatool product which in normal use has proven to be defective in workmanship or material provided that the customer returns the product prepaid to an authorized Teknatool service center with proof of purchase of the product within TWO YEARS and provides Teknatool with reasonable opportunity to verify the alleged defect by inspection Teknatool will pay return product by most cost effective surface transport to customer Any special freight services above this will be at customer cost Furthermore Teknatool International Ltd extends
4. 4 Loosen the Lockpin 1 2 turns mE Push the Headstock Release Important note Swiveling the head before inserting Handle down and rotate the the lock pin may result in the tapped hole on the Headstock so the spindle points to Swivel pin becoming mis aligned the tailstock and lines up parallel to the lathe bed Tighten lock pin again Note Do not use excessive force when tightening the Lockpin 5 Assemble the handles Installing Handles D Note Some handles may come pre assembled Toolrest Clamp Handle insert the rod through the handle and screw the ball knobs onto each end of the rod Toolslide Clamp Handle screw the lock handle into the toolslide Tailstock Clamp Handle screw the lock handle into the tailstock Teelock Handle Lock Handle Adding an Extension Bed Each cast iron extension bed adds 510mm 20in to the lathe s capacity to turn between centers 1 Clean the joining ends of both bed sections with a petroleum based solvent Make sure there are no dents or burrs on either mating surface Remove burrs and high spots with a smooth file ocrew in cap screws tight Secure the bed sections together with four M12x30 cap screws using a 10mm Allen wrench It may be necessary to move the lathe so the cap screws can be reached 13 115 0513 003 with the wrench from the bottom of the bed N Warning Do not use a metal hammer to pound on the extension bed This may damage the
5. 8 22 every 2nd 30 24 every hole 15 115 0513 003 Headstock The headstock houses the Rotor Stator Electronics bearings and the Spindle The headstock spindle accepts centers and accessories with no 2 Morse taper 2 MT plus threaded faceplates and chucks Country United States Canada Australia New Zealand Spindle Thread Size Threads 1 1 4 x 8 TPI RH South Africa United Kingdom Europe excluding the UK Mounting a faceplate or chuck 1 Use the Spindle Index Pin to lock the headstock spindle 2 Remove the side locking screw then wind the faceplate or chuck onto the spindle threads A spindle washer in between may be used to make removal easier A Warning The faceplate or chuck body must contact the shoulder on the spindle bearing 3 Pull and turn the Index Pin and place it in the safe indentation in the headstock 4 A vee groove is provided in the spindle for a special locking grubscrew that is used in conjunction with Nova chucks and accessories to prevent unwinding during reverse operations Wind in the side locking grub screw and lock firmly in place without over tightening A Warning It is important that all Chucks and Faceplates that are used on the DVR XP spindles have a side locking function Some older Teknatool products may not have a side locking function If any of these products are intended to be used on the DVR XP spindle they will need to undergo a modific
6. 9 a 1 SUD WS J j 7 For further details about Teknatool s lathe accessories please contact your local retailer for more information or contact us for a free product catalogue This catalogue can also be downloaded from our website at www teknatool com 45 115 0513 003 Index Accessories 42 43 Assembling 11 Bed Lathe 2 3 9 13 14 21 22 23 33 35 9 42 43 Camshaft 33 38 Centerlines Turning 8 20 Centers 8 9 13 20 21 22 33 42 Changing Speeds 15 16 Cleaning 32 33 Components 3 8 12 Connecting to Power 14 Contents 5 Distance between Centers 9 Electrical 3 7 8 10 14 Extension Bed 13 37 Extension Cords 10 14 Faceplate 2 8 9 20 35 43 Function 3 7 16 17 20 42 43 Handles 8 12 13 19 21 22 33 Handwheel 9 22 33 37 42 Headstock Lockpin 12 19 37 Headstock 2 3 8 9 10 12 14 19 20 21 32 35 97 Lathe Stand Requirements 10 35 Live Center 9 33 35 42 Maintenance 2 6 32 Mounting Faceplate or Chuck 8 20 35 Mounting Lathe 2 13 14 35 Nova DVR3000 Specifications 9 Oil 32 33 35 Operating 7 8 19 Operating Bar 12 19 22 Outrigger Unit 9 14 43 Parts List 38 39 Power 2 3 7 8 10 14 15 16 17 18 32 35 Problems 35 37 Quill 8 9 22 32 33 35 Removing Centers and Tapers 22 Revolving Center System 42 Rpm 9 15 16 17 18 35 oafety 6 7 Sanding 8 10 11 18
7. DVR XP delivers big turning capacity e Asa bowl lathe for those just wanting to turn bowls Swivel Head Au dy ne v Ln p C 1 A 3 E YER 1 A 7 M Gi d i M 5 d 1 vau 2 Elimination of left hand outboard turning techniques and no extra outboard chucks and faceplates are necessary Swivel head lathes have many advantages Space saving Allows the turner not the machine to decide the most comfortable position for your turning saving you from backstrain There are a number of swivel head lathes available but the Nova DVR XP has by far the most sophisticated accurate and easy to use swivel head on the market The Nova DVR XP lathe can be easily and quickly swiveled to any position 360 degrees It can be solidly locked in any position plus it has the added security of a detent pin lock at 0 22 5 45 90 degrees plus 315 for left hand use The swivel head turns locks easily and has a very accurate detent position to lock the spindle in line with the tailstock The combination of rigid Tailstock construction and detent pin delivers superb accuracy and is unique to the Nova DVR XP 2 115 0513 003 Solid Construction Well proven design the Nova DVR XP is made from Cast Iron components for strength and rigidity Added features like the heavy duty TRIMAX triple bearing system and special webbed bed design makes the lathe well equipped
8. leveraging against when removing faceplates inserts and chucks For this we recommend holding the spindle using the operating bar through the 2 LHB holes Left Hand Brake 115 0513 003 Using a spur center Mount the spur center to the work piece as shown and then insert the spur center and work piece into the headstock spindle AN Warning Do not pound work piece into headstock drive center when turning between centers or you may damage the headstock To remove the center insert a 10mm 3 8 inch diameter wooden dowel or steel rod through the headstock spindle hole While holding the center so it doesn t fall tap it out For Hardwoods drill centers and saw diagonals for spur drive centre Toolrest To move the toolslide along the bed loosen the Toolslide Clamp Handle move the slide to the desired position and tighten the clamp handle To adjust the toolrest loosen the Toolrest Clamp Handle position the toolrest and tighten the clamp handle Adjust the toolrest close to the work piece Exact positioning may be varied to suit the turner Before turning revolve the stock by hand to make sure it clears the rest At intervals stop the lathe and readjust the toolrest A Warning Lathe tools and chisels should remain on the toolrest whenever the tool is in contact with the work piece Remove the toolrest when sanding or polishing so fingers do not get pinched For softumoods stock cen
9. of motor rotation PROGRAM KEY SELECTOR KEY MODE KEY UP KEY and DOWN KEY Increase Decrease and set the parameter incrementally 115 0513 003 26 4 0 CONTROL FUNCTIONS Drive Parameter Settings Set Function HMI display lines contain the parameters which can be edited Press key A to incrementally increase the parameter or to decrease it Hard Reset Function Press key hold it and then press key in order to provide the Hard Reset of the drive Another way is to switch off the power wait 10 seconds and switch it on again Use this function if you want to return the factory preloaded values of the drive parameters Also try to use this function if you have a problem with the drive for example if the system is not responding to the keys 2 115 0513 003 5 0 CONTROL OPERATIONS AT STOP MODE 5 1 Starting operation Insert the drive power plug into the 220 230 115v 50 60 Hz socket There must be the sound signal and display messages step by step will be shown on the next page TEKNATOOL Int v4 54xs03 2006 TEKNATOOL PROMO TES SAFETY FIRST ALWAYS WEAR FACE SHIELD ENSURE CORRECT SPEED SELECTED Beeper will sound twice Wait for end it or press key A to cancel After that the display message will be TEKNATOOL Int v4 54xs03 2006 The version number means v4 54 control software version X XC164CS Infineon microcontroller with flash memory S Serial interface 03 Interface softw
10. screw from the tailstock If necessary turn the Handwheel to I expose the set screw S 2 Using a screwdriver remove the keeper plate from the tailstock body 3 Remove the quill and Handwheel from the Talstock tailstock body Casting 4 Wipe cleans all parts including the inside of the tailstock 5 Lubricate the quill and tailstock slot with lightweight oil and apply a small amount of grease to the quill threads Handwheel 6 Reassemble 115 0513 003 34 Aligning the Tailstock 1 Crank the Handwheel back so the quill is all the way in 2 Place any 2 MT accessories you have that have a sharp point like a spur center or live center in the tailstock quill and another center in the headstock spindle Note Tailstock alignment be made easier by using the Teknatool Acruline Accessory Center in place of the centers 3 Move the tailstock close to the headstock so the two centers nearly touch check the alignment of the center points Move the tailstock away from the headstock and extend and lock the quill The points of the centers should align when the quill is halfway extended fully extended and fully retracted If the centers are aligned at all three locations no adjustment is necessary 4 f the tailstock does not meet the conditions in step 3 follow the steps below This indicates that the tailstock is not parallel to the lathe bed and you will need to realign the tailstock 5 First make sure the
11. tailstock alignment plate is not binding inside the bed If the tailstock doesn t move freely then remove the tailstock and look for burrs or high spots on the bed rails or the alignment plate Using a smooth file remove any burrs or high spots When done replace the tailstock on the bed 6 Slightly loosen the four tailstock cap screws with a 5mm Allen wrench Tap the tailstock with a wooden mallet in the appropriate direction to align the centers Check and adjust the positioning of the tailstock The centers should align when the quill is halfway extended fully extended and fully retracted as previously described in step 3 7 Lock the tailstock in place with the Tailstock Clamp Handle and fully tighten the two cap screws The cap screws must be fully tightened in order to avoid slippage during work 8 Check the alignment of the Tailstock by bringing it together with the Headstock with the Live center and Spur center in each spindle The Points on the centers should be within 0 50mm 0 020 height and width of each other 35 115 0513 003 Voltage selection By removing a small jumper the unit will efficiently run on 220V and a gain in power can be achieved Or the jumper can be replaced to enable the unit to run on 115V 1 Ensure that the power is off and that the plug is disconnected from the wall 2 Allow minimum of 3 minutes discharging time for capacitors before opening rear panel 3 Remove the rear lower switch panel T
12. this two year period for three additional years excluding labor costs and electrical parts provided the aforementioned conditions are met All electrical parts and electronics are covered by a TWO YEAR warranty from the date of purchase Teknatool will not be responsible for any asserted defect which has resulted from normal wear misuse abuse Power surges or excess voltage fluctuation repair or alteration made by anyone other than an authorized service facility or representative Under no circumstances will Teknatool International Ltd be liable for incidental special indirect and consequential damages or expenses including loss of profits or loss of operations This warranty is Teknatool International Ltd sole warranty There are no other warranties whether written or verbal whether expressed or implied by law trade custom or otherwise whether of merchantability fitness for purpose or otherwise except for remedies available to customers under the Consumer Guarantees Act or other legislation OVERSEAS CUSTOMERS Our Teknatool Distributors and agents will issue their own warranty to cover this product Terms may vary from those stated above please check with your dealer In North America warranty covers Continental USA only For Alaska Hawaii and other areas warranty covers replacement of parts only and excludes transport costs D Note Did you know you can register your warranty with Teknatool online Visit our website on www tekn
13. to take heavy turning stresses The bed has been designed with vibration dampening qualities a solid 1 2 cross rib is positioned along the bed unit quickly dissipating any vibration as it travels down the bed The new powerful trapezoidal bed design delivers even more vibration damping properties All this combined with Bed Extension Segment Main Bed Segment cosmetically appealing smooth flowing lines Cast iron has always been the material of choice for Woodlathe construction for its inherent mass and an excellent modulus of vibration New 5 Favourite Speeds Function Pre program your most favourite speeds for easy retrieval New Trapezoidal Bed Design Powerful with smooth flowing lines new bed design delivers even more vibration dampening properties New Headstock Design One piece design increases strength and vibration dampening properties Micro analysed for optimum design Same popular swivel headstock as used in the older DVR and 3000 Lathe models saves strain on your back Adaptive Control Software Smart adaptive computer technology actually measures the weight of the workpiece and adjusts its performance accordingly Safety Sensing Feature Intelligent DVR computer controller senses abnormal turning conditions e g a chisel dig in or index left engaged and instantaneously shuts down power to the spindle Normal safety precautions would still apply see pages 7 8 Energy Efficient Unlike other dumb elec
14. 4119 55029 FW12 55037 55026 24040 25026 G0610 55028 55153 TP0820 24065 24043 55027 55025 24048 25029 FW8 BHC0816 2 002 K1225 24120 865913 29001 24026 99153 24020 G0610 K1225 2 002 FW12 BNMZ12090 24048 24009 HP 16 55036 TPI31658 99033 99035 6207RS1 CO Description Lock Pin Main bed Machined Detent Pin Detent Spring Detent Lever M8 nut spring Washer M12 Flat Washer M12 Cap Screw M12 X 30 Bed Extension Lever Quill Locking Flat Washer ZP M12 Dowel Pin D12 X 30 Shaft Quill Lock Keeper Plate Adjustable Tailstock M6X10 Grub screw Tailstock Quill Tailstock 1 5 Dia Lock arm Tailstock Tension Pin 8X20 Handle Handwheel Handwheel Casting oleeve camshaft Camshaft Tailstock Camnut Tailstock Alignment Plate Flat Washer M8 Capscrew Button Head M8 Lock plate Tailstock M12X25 Countersunk screw Tailstock Toolrest Knob Ball Tee lock arm Tee lock body Lock arm Toolslide Camshft Toolslide M6X10 Grub screw Tailstock M12X25 Countersunk screw Toolslide Lock plate Toolslide Flat Washer M12 ZP 1 6MM Thick Bolt ENG M12X 90 ZP Camnut Toolslide Tooslide Hole Plug Index Knob 3 16 5 8 Tension Pin Index Pin Fan Index Guide Bush Trimax Bearings Front 115 0513 003 Item Qty 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 13 74 75 76 77 78 79 80 81 82 0 ree Cd fl
15. 513 003 Swiveling the Headstock 1 Stop the lathe Insert the operating bar into a hole in the Headstock Lockpin Loosen the Lockpin half a turn 2 Slide the Headstock Release Handle towards outboard end of lathe and rotate the headstock to a Headstock S detent position Do not push down ne on the handle N gating Warning Use the detent latch positions to prevent headstock movement during turning Headstock Headstock Release Handle 0 4 Firmly tighten the Headstock Lockpin with the operating bar but do not use excessive force Remove the operating bar 22 5 90 45 Detent Positions Right hand Turners Left hand Turners Detent Positions 0 22 5 45 90 degrees 180 337 5 degrees Spindle Index The spindle index pin locks the headstock spindle It is selectable in 15 degree increments 24 divisions There is sight hole to read index numbers 0 through 23 1 Stop the lathe 2 Pull the index knob and turn it left until the pin drops into the hole To lock the spindle it must engage into a hole in the headstock pulley A Warning Make sure the index pin is out before operating the lathe The pin should drop into the Divisions Index Number Degrees indentation in the headstock to 2 0 12 180 prevent it from engaging while 3 0 8 16 every 8th 120 the spindle is turning 4 0 6 12 18 every 6th 90 6 0 4 8 12 16 20 every 4th 60 8 0 3 6 9 12 15 18 21 every 3rd 45 12 0 2 4 6
16. 80mm 3in Faceplate Not all countries see notes below Not all countries see notes below Spur Center and Live Center Outboard Handwheel Handwheel Power Socket Lockpin Headstock release handle Lockpin Operating bar Nova 3000 Bowl Lathe Version Specifically for bowl turning does not include bed extension tailstock and centers Optional Accessories Precision Midi Chuck SuperNova 2 Chuck Titan Chuck 80mm 3in Faceplate Vacuum Faceplate 100mm 4in Toolrest Bowl Toolrest Outrigger Toolrest Unit Vacuum Coupler Revolving Center System Faceplate rings Notes 1 Applicable to Europe excluding the UK 2 Applicable to United States Canada United Kingdom Australia New Zealand amp South Africa Note Standard equipment varies from country to country In some markets the faceplate is an optional accessory Check with your reseller if you are unsure C For Europe Australasia UK and South Africa Directives this equipment complies with Low voltage directive LVD 73 23 EEC 93 68 EEC Machinery directive MD 89 392 EEC 91 368 EEC 93 68 EEC Electromagnetic compatibility directive EMCD 89 336 EEC 92 31 EEC 93 68 EEC Harmonized Standards applied in order to verify compliance with Directives EN 61029 1 2000 Low Voltage Directive and Machinery Directive EN 55014 1 1997 EN 55014 2 1997 EN 61000 3 2 1995 EN 61000 3 3 1995 Nathan Stantiall Development Manager
17. HE MANUAL BEFORE OPERATING THE TOOL Learn the machine s application and limitations plus the specific hazards particular to it 2 ALWAYS USE A FULL FACE SHIELD Strongly recommended must comply with ANSI STANDARD Z87 1 USA Everyday eye glasses usually are only impact resistant and safety glasses only protect eyes A full face shield will protect the eyes and face Also use face or dust mask if cutting operation is dusty 3 WEAR PROPER APPAREL Do not wear loose clothing gloves neckties rings bracelets or other jewelry which may get caught in moving parts Non slip footwear is recommended Wear protective hair covering to contain long hair 4 USEEAR PROTECTORS Use ear muffs for extended period of operation Use muffs rated to 103 DBA LEQ 8 hour 5 DON T USE IN DANGEROUS ENVIRONMENT Don t use power tools in damp or wet locations or expose them to rain Keep work area well lighted The DVR XP Lathe is intended for indoor use only Failure to do so may void the warranty 6 KEEP WORK AREA CLEAN Cluttered areas and benches invite accidents Build up of sawdust is a fire hazard 7 KEEP CHILDREN AND VISITORS AWAY The Nova DVR XP is not recommended for children and infirm Such personnel and onlookers should be kept a safe distance from work area 8 MAKE WORKSHOP CHILDPROOF with locks master switches or by removing starter keys 9 GROUND ALL TOOLS If the tool is equipped with a three prong plug it should b
18. NOVA DVR xp WOODLATHE INTERNATIONAL Publication 115 0513 003 115 0513 003 1 IVANVIN NOILONGLSNI Models 1 55175 spindle thread 1 1 4 x 8 tpi 115v 2 55180 spindle thread M33x3 5 220 240v Europe 3 55177 spindle thread 1 1 4 x 8 tpi 220 240v Australasia 4 55178 spindle thread 1 1 4 x 8 tpi 220 240v UK 5 55181 spindle thread 1 1 4 x 8 tpi 220 240v South Africa Nova DVR XP Lathe Features at a glance DVR Electronic drive The Nova DVR XP lathe is unique The DVR incorporates the motor built as part of the headstock the spindle and motor are one unit The motor is almost maintenance free and designed with high reliability The Digital Variable Reluctance motor uses smart motor technology to provide an incredibly smooth and powerful drive This drive takes turning to a new level The controller monitors the spindle position constantly and maintains spindle speed very closely Additional power is added as it senses extra load from the tool Add on Bed System A lathe that meets your woodturning needs your workshop space and your pocket Each segment is 20 or 510mmin length This feature appeals for many different reasons e As a compact lathe standard configuration it is great for small turning workshop spaces DVR XP extended lathe Standard model plus one bed segment e Asan extended lathe for those wanting to do extra long spindles beyond the traditional between center of most lathes the Nova
19. Quill Lock Handwheel Lock Handle Lock Handle 115 0513 003 Setting Up Your Workshop Workshop Requirements Consideration Lathe location Lighting Electrical Ventilation Recommendation Locate the Nova DVR XP close to a power source in an area with good lighting Leave enough clearance on all sides of the lathe allow for motor clearance when the headstock is swiveled Other machines in your shop should not interfere with the operation of the lathe Your shop should have adequate lighting The work area of the lathe should be well lit there should not be shadows cast on your work If possible locate near a window A portable spotlight may be helpful The Nova DVR XP requires the appropriate power outlet nearby to power the motor Wiring and outlets should adhere to local electrical codes If in doubt seek advice from an electrician Minimize use of extension cords See Connecting to power section for Surge Protector requirements Your shop should be adequately ventilated The degree of ventilation will vary based on the size of the shop and the amount of work done The use of dust collectors and filters will minimize risks to your health Lathe Stand Recommendations A sturdy and rigid stand is required so that the Nova DVR XP Woodlathe can deliver optimum performance A common flaw with many woodlathe installations is an inadequate stand for the lathe The larger the size of your turnings the greater the i
20. Richard Raffan By Ernie Conover by Richard Raffan Woodturning A Foundation Course by Keith Rowley The Fundamentals of Woodturning Creative Woodturning By MIS DANON by Dale Nish 115 0513 003 24 CONTROLLER USER S GUIDE NOVA DVR SWITCHED RELUCTANCE DRIVE Control Software versions 4 54x Interface Software version s03 Teknatool International 13 July 2006 1 0 INTRODUCTION 1 1 General This guide contains the basic information on use of the Digital Variable Reluctance DVR electrical drive for DVR 3000 XP lathe 1 2 Overview The DVR integrated electrical drive system contains the DVR motor with the Rotor Position Sensor RPS the drive control board and the human machine interface HMI The control board RPS and HMI represent the control system of the drive The DVR is connected with the control board by six power wires and RPS cable The control board contains power input devices input rectifier power factor corrector with the DC link reactor three phase inverter and the control circuit based on the 16 bit Infineon microcontroller The HMI contains the interface board the LCD and keyboard The interface board is based on the 8051 family Atmel microcontroller and connected with the control board through the insulated serial RS232 interface Both microcontrollers have flash program memory The interface board microcontroller also contains the EEPROM memory in order to change and store the drive parameters The
21. USE LATHE FOR USES OTHER THAN FOR WHICH IT WAS DESIGNED 2 SEEK INSTRUCTION If you are not thoroughly familiar with the operation of woodlathes obtain advice from your supervisor instructor or other qualified person Instruction from a qualified person is strongly recommended 3 DO NOT OPERATE LATHE until it is completely assembled and installed Follow instructions and recommendations 4 FOLLOW ELECTRICAL CODES Make sure wiring codes and recommended electrical connections are followed and that the machine is properly grounded 5 WHEN REPLACING THE FUSE on relevant models completely isolate power when removing the fuse It is imperative the plug is removed from the mains supply before the fuse is removed Replace fuse cap before reconnecting to mains 6 DVR XP Do not open the switch and rear covers Components can carry dangerous voltages even when isolated from mains power 7 DVR XP Always ensure spindle fixtures e g faceplates etc are locked to spindle in case spindle reverse is engaged Otherwise they will unwind from spindle See Mounting a Faceplate to a chuck section 8 WHEN SPINDLE REVERSE IS ENGAGED DO NOT USE CHISELS OR CUTTING TOOLS USE FOR SANDING ONLY 9 KEEP WORK AREA CLEAN Do not turn the lathe on before clearing the lathe of all objects tools scraps of wood etc Keep the nearby area and floor clear of debris CHECK SET UP with spindle Off Examine the set up carefully and rotate t
22. al the computer first does a self check 2 Red OFF key Pressing this key will stop spindle rotation The ON OFF keys in the above panel only switch the motor on and off The selected speed will remain until adjusted or computer switched off 3 UP RPM To raise speed one press of the key will increase speed by 5 rpm Continuing to hold key pressed will continue to raise speed The speed can be adjusted with the spindle running or off To make a large adjustment in speed it is quicker when the spindle is OFF 4 Down RPM Press to lower speed this key operates the same as up key The UP and Down keys can also be used in program mode to change the parameters 5 FWD REV key Pressing this key will change the motor rotation from forward to reverse Pressing again will select forward You can verify the direction by the two arrows at the bottom left or right of the screen Important always verify the forward or reverse is selected correctly before switching spindle on 17 115 0513 003 The Direction of rotation setting is only available in the ready to start mode Press stop if necessary and press FWD REV to toggle direction of rotation The two arrows on the left side indicate reverse Whenever reverse is selected a Warning Reverse Selected will flash on screen for about 1 2 seconds before spindle starts Special and Parameter settings A You may wish to change the stabilization setting from time to time depending on the typ
23. are version Note This guide is updated for the v4 54x control software versions and s03 interface software version which are compatible with each other The control software versions v4 41x and higher will also work but without some functions The drive will make the preparation procedure check the fault conditions and after that the LCD will show the Main display page for Stop operation LCD View Comments Set 500rpm 2D S Reference speed and number D default speed number Ready to run gt gt R lt lt gt gt reference direction forward reverse Note S parameter can be modified using Set Function R P parameter s can be modified by one of keys in accordance with the keyboard description legend see above The drive is in Stop mode and ready to run the motor forward with the speed of 500 rpm 115 0513 003 28 5 2 Reference speed setting Preset favorite speed selection and set function There are 5 preset speeds available in the drive The factory preloaded reference speeds are Speed rpm 1020 1250 Note The speed 2 is default soeed number The letter D after the number 2 indicates it is default e Press the key hold it and press A Or in order to go from one preset speed number to the next one If the next preset speed is higher than 500 rpm you will see warning LCD View Comments Go to 500rpm S Preset speed P confirm E Esc Press the key to confirm the choice or Escape
24. athe to operate correctly the bed must not twist if necessary use shims between the bed and stand top 4 Use bolts of suitable length not included to secure the lathe Tighten the two headstock bolts first then the two tailstock bolts and finally tighten the last two bolts on top 5 The two M10 threaded holes underneath the outrigger end of headstock can be optionally used making a total of 8 bolt positions Ensure that the bolt is a metric M10 x 1 5mm pitch and that the length is correct to ensure that the bolt doesn t bottom in the threaded hole and potentially damage casting Connecting to Power The power cord should be 3 wire having a grounding conductor and a grounding plug The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with local electrical codes The DVR XP can run on either 115v or 220v 240v but the voltage must be selected with an internal jumper see Voltage Selection page 36 If the lathe is purchased in USA it will already be setup for 115v operation All other countries are preset for 220v 240v A Warning Improper connection of the motor can result in a risk of electrical shock If it is necessary to use an extension cord the cord should be grounded Use the correct wire size for the extension cord for a given cord length to avoid power loss and over heating IMPORTANT A Surge Protection Device rated to at least 15 amps for USA and Canada o
25. ation to include the side locking function or new products purchased with a side locking function All spindle mounted products produced by Teknatool International for the DVR Lathe have side locking functions The side locking function should be used at all times while running the chuck on the spindle during operation Without this function engaged the Chuck or Faceplate may unwind from the spindle during operation 21 M33 x 3 5 RH ry chuck body must contact shoulder on the Spindle bearing Wren Faceplate or A Warning When installing or removing the Faceplate or Chuck from the spindle the side locking grub screw MUST be completely removed This avoids any potential damage to the spindle that the grub screw may cause if it were not completely removed when winding the Faceplate or Chuck on or off the spindle Exception 1 When an insert is used with a FP150Z faceplate on the DVR3000 or a Spindle adaptor the insert or adaptor must be located onto the faceplate to avoid it unwinding when the spindle is run in reverse Loctite 272 Threadlocker is recommended Exception 2 Customers with dedicated threaded Teknatool chucks who intend using the chuck on the DVR XP Spindle must have a side locking function adapted to the chuck before running it Chucks with M33 threads may apply for Europe IMPORTANT NOTE The Index Pin is designed for indexing and not for
26. atool com to register your warranty faster today Or you can fill out the card below cut fold seal and post Teknatool Warranty Card Return this card to validate your warranty or register online To help us provide services and products that are better tailored to your at www teknatool com needs please answer the following Name 1 Where did you purchase the product check one 1 Local Woodturning Specialty J Manufacturer adiu 1 Local General Woodworking 1 Mail order Catalog 1 Other specify _ 2 Did you receive all information you required and expected Email Address I Yes I No Phone If no explain eee 3 What other products did you buy along with lathe purchase Teknatool Product Model 0 0 0 0 0 Lathe Chuck J Finishes L Power Tools Serial Number at the front of headstock Lathe Chisels 1 Abrasives 1 Other Products Date of Purchase 1 Lathe Accessories list Reseller 4 Why did you buy the Nova Lathe L Features Quality Warranty 1 Store Advice Would you like to be on our mailing list and receive Price I NZ Made O Accessories i Product Support complimentary copies of our Teknatool Newsletter Personal information is kept confidential J Recommended Reputation of Brand 5 Rate your woodturning and woodworking experience J Yes by email J No 1 Beginner lJ Intermediate J Advanced Comments 0 Note To locate the serial number look to the front of the headstock under the control
27. bed affect accuracy and tailstock action and may prevent you from adding another extension bed 4 Bring the Tailstock along until it is on top of the join area where the bed extension face meets the lathe bed face The bed extension may need to be manipulated up and down and sideways in order for the Tailstock to fit 5 Check that the toolslide and tailstock move freely over the mating joint and also over the full length of the add on extension If there is a ridge between the two mating surfaces then repeat steps 1 4 again use a smooth file to file the surfaces flush 6 Follow the suggestions under Mounting the Lathe to a Support Surface 115 0513 003 14 Mounting the Lathe to a Support Surface Maximum of 25mm 1in Required only for mounting the Outrigger Unit option Mounting Holes 6 M12 x 1 75 Bolts The lathe must be fastened to a support Optional Mounting surface such as a lathe stand or bench Underneath lathe 2 M10 x 1 5 1 Place the lathe on the stand top Locate the front and left corner of the lathe approximately 25mm 1in from the corner edge of the stand top This provides a comfortable reach when turning and allows the optional outrigger unit to be easily installed 2 If necessary mark the six hole locations on the top and drill M12 holes 3 Place a spirit level along the top of the lathe bed Any movement of the bubble as the lathe is secured indicates a twist on the bed For the l
28. ce and may show error current overload under higher loadings 9 Theunit can now run 220V 240V 37 115 0513 003 Troubleshooting Guide Problem Excessive vibration Faceplate or chuck running out of true Turning tools not sliding smoothly across Toolrest Spur drive center or live center not holding into the spindle taper or quill taper when turning Display screen not on Possible Cause and Solution Out of balance or large work piece Reduce lathe speed to the lowest speed possible and turn the work piece to a true circle Adjusting the speed using the up down keys will change the speed in 10 rpm increments If you try adjusting the speed up or down you will find that it is easy to find speed points that will minimize vibration and is one of the biggest advantages of DVR technology Work piece is not held in the center Check work piece mounting and correct Work piece is not secure or held tight enough Check work piece mounting Lathe incorrectly bolted to stand or bench Refer to this manual for lathe stand recommendations otand or bench not well constructed too light or not level on the floor Make sure the stand is solidly constructed Use sandbags to weigh down the stand The metal floor stand should be Rawl bolted to the floor at the 4 hole points Dirt build up on the rear of the faceplates or chuck Clean off all build up and dirt Faceplates and chucks must mount securely against th
29. control system has been specifically designed for control flexibility and to provide optimal drive performance 2 0 MAIN PARAMETERS AND FEATURES The motor type Switched Reluctance Motor DVR Nominal operating output power 1 25 1 5 kW 2 HP 220V Power supply range 115V 60Hz 230V 50 Hz Power factor correction PF 2 0 95 Speed range 100 3500 rpm omooth speed setting by keys 5 preset favorite speeds with save function speed controller with adaptive coefficients 3 preloaded coefficient curves SOFT NORMAL and HARD Load inertia measurement for improving the PI speed controller coefficients Reverse function Torque and speed ramp functions Overload protection Under voltage PFC fault protection 25 115 0513 003 3 0 HUMAN MACHINE INTERFACE DESCRIPTION The Human Machine Interface HMI provides a flexible choice of the drive parameters run stop motor speed direction of rotation speed controller coefficients HMI contains 2 lines 16 position LCD display and keyboard The drive parameters can be set by decreasing increasing values incrementally Some parameter values can be stored in the EEPROM of HMI DVR DRIVE ae NOVAK FUTURE TECH Figure 1 Keyboard view 3 1 Keyboard Description The keys description Short Description START KEY run the motor STOP KEY stop the motor and reset system REVERSE KEY change the direction
30. ctly select speed if different from Default speed Warning Do not push several keys together as special coded combinations of keys open diagnostic and service functions Some of these disable control and protection functions If an unfamiliar screen is displayed switch off the computer and leave for one minute before rebooting If the DVR hasn t been used for some period over one month it is helpful to switch the unit on 30 60 minutes before use 115 0513 003 18 Turning Tips The Nova DVR XP drive technology is not just a variable speed motor its smart motor technology takes turning to a new level The speed vibration and load sensing work with the conditions and turning The machine will reward skilled turning with exceptional finish conditions There is often no need for sanding As you apply load chisel pressure or depth of cut the control will sense the change in spindle conditions and compensate accordingly Get a feel of the communication between yourself and the motor turning by applying increasing force The motor will respond by applying increased power to exactly maintain speed LOW SPEEDS 100 350 Select Hard Mode see Special and Parameter settings Note at low speeds 100 350 rpm control of the chisel is important At 250 rpm the motor still has good torque in fact the torque is more or less the same as at 400 or 1000 but at low speeds there is a difference the DVR Is a unique type of motor in that the cont
31. e NOVA product family Your choice shows you want the best for your woodturning and you recognise the superb DVR drive technology and the host of other unique features the Nova DVR XP offers We strive to achieve the best value for your money providing quality innovative features a wide range of accessories plus comprehensive ongoing support latest manuals downloadable from our website newsletters projects etc We are only a phone call or email away with technical advice or assistance on the operation of your lathe or your woodturning queries Please feel free to contact us about any aspect of our products or service we regard our customers as our best development and improvement team we would love to hear from you Once again welcome to the NOVA Family We trust that you enjoy our products and hope they enhance the pleasure you experience from the wonderful craft of woodturning Best Regards Brian Latimer Marketing Director Teknatool International Ltd 4 115 0513 003 Contact NOVA New Zealand and Rest of the World Teknatool International Ltd Phone 64 9 477 5600 Email service teknatool com Website www teknatool com United States NOVA Innovation and Customer Care Center Phone 727 346 4775 Email service teknatool com Website www teknatool com Or you can contact the retailer where you purchased your NOVA DVR XP Wood lathe for the contact details please see our website www teknatool co
32. e inner bearing ring surface of the spindle Damaged surface on toolrest face caused by sharp edged tools File the toolrest using a fine smooth file and polish with extra fine sandpaper Also remove the sharp edges from the corners of turning tools omall end of Morse taper is damaged due to dropping or hitting File or polish away any damage Check that inside of tapers have not been scored Grease or oil inside of Morse tapers Wipe clean the inside of the tapers Insufficient pressure when installing the center Use a quick firm action by hand to install a taper Do not knock in using any solid object Is master switch on Toggle master switch to ON position Check machine is plugged into wall socket and switched on Check that the wall switch plug is live by plugging in another power tool if the other power tool doesn t go check your board fuse Check the master fuse on the lower rear guard Ensure machine unplugged see Additional safety rules at the front of this manual If blown replace with the spare fuse that comes with the lathe Do not replace with a higher amp fuse 115 0513 003 38 Display screen shows Rotor Fault lt Flashing gt RP State Error lt Flashing gt LCD screen shows PFC Corrector lt Flashing gt QD Note Can t find the answer in this Trouble Shooting guide Press off button switch off computer by master switch wait one minute and switch on again Check that the spindle index
33. e of work piece you are working on You have 3 options preset for you 1 SOFT For light work at speeds lower than 500 rom 2 NORMAL Suitable for most work and is the default setting 3 HARD For heavy and or out of balance work at speeds lower than 500 rpm a Press OFFs if necessary b Press PROGRAM key 6 on diagram The stabilization setting will be displayed The default setting is NORMAL Press SELECTOR key 7 on diagram to toggle between the options as mentioned above NOTE Pressing MODE key 8 on diagram allows the user to change the parameter settings in more detail This breaks it down into Proportional Kprop and Integration Kint settings which make up the PID control of the DVR The 3 options of SOFT NORMAL and HARD have been preprogrammed for your convenience and are balanced for optimum output To clear special settings and return to default switch off computer at the master switch d Press PROGRAM button to return to ready state Ready to start mode While the machine is running if you push Mode 8 the screen will display various diagnostics Operation of the machine is not effected Each time mode is pressed a different screen will show This area is only used for advanced programming functions Auto safety If the power is lost to the machine when power is restored the computer will reboot but the machine will not start until the ON switch is pressed Remember to corre
34. e plugged into a three hole electrical receptacle If an adapter is used to accommodate a two prong receptacle the adapter plug must be attached to a known ground Never remove the third prong 10 MAKE SURE TOOL IS DISCONNECTED FROM POWER SUPPLY while the motor is being mounted connected or reconnected 11 DISCONNECT TOOLS from wall socket before servicing and when changing accessories such as blades bits cutters and fuses etc 12 AVOID ACCIDENTAL STARTING Make sure switch is in the Off position before plugging in power cord 13 NEVER LEAVE MACHINE RUNNING UNATTENDED Do not leave machine unless it is turned off and has come to a complete stop 14 15 16 17 18 19 20 21 22 23 24 25 26 27 KEEP GUARDS IN PLACE in working order USE CORRECT TOOLS Do not use a tool or attachment to do a job for which it was not designed USE RECOMMENDED ACCESSORIES The use of improper accessories may cause hazards DON T FORCE THE TOOL It will do the job better and be safer at the rate for which it was designed MAINTAIN TOOLS IN TOP CONDITION Keep tools sharp and clean for best and safest performance Follow instructions for lubricating and changing accessories NEVER STAND ON TOOL Serious injury could occur if the tool is tipped or if the cutting tool is accidentally contacted REMOVE ADJUSTING KEYS AND WRENCHES Form a habit of checking to see that keys and adjus
35. ecking conditions all the time Visit the Lathe Support Section on our website this is packed with Frequently Asked Questions Or Contact Us details are at the front of this manual 39 115 0513 003 Troubleshooting Guide continued Problem Tailstock and headstock center not lining up correctly Tailstock Handwheel hard to turn or will not turn Tailstock quill hard to move Tailstock not locking correctly onto bed or tailstock not sliding smoothly on bed ways Tailstock binds Tailstock jumps where bed sections join Possible Cause and Solution Bed incorrectly bolted to stand causing twist Ensure stand and lathe are correctly installed Headstock not returned to detent position after it has been rotated Ensure that the headstock is locked into a detent position Headstock Lockpin not fully seated Twist the headstock back and forth to make sure it is properly seated and then tighten the Lockpin Dirt or wood dust accumulated in the headstock swivel pin hole Remove the Headstock Lockpin and clean out hole Quill lock is locked unlock the quill lock If necessary lightly tap a block of wood against the handwheel handle tap the handle in a clockwise direction as viewed from the tailstock end Build up of dust and wood resin on the quill or inside of the handwheel thread Remove clean and lubricate the quill and tailstock as described under Cleaning the Tailstock The quill has been ext
36. ended too far and is locked against the handwheel Push the quill back into the tailstock when turning the handwheel Quill lock is locked unlock the quill lock The quill is damaged turn the handle to expose the quill and check for marks along the quill especially on the edges of the slotted keyway Remove the high spots with a smooth file and test the quill travel Replace the quill if necessary Tailstock adjustment plate not adjusted correctly adjust as described under Aligning the Tailstock Dirty bed ways and underside of tailstock body Clean bed ways and underside of tailstock body with a petroleum based solvent The inside of the bed has a high spot File the area with a smooth flat file until the tailstock moves freely The tailstock adjustment plate has a rough spot or a burr Remove the tailstock and file the plate with a smooth flat file The machined flat surfaces are not flush File the area with a smooth flat file until the tailstock moves freely 115 0513 003 40 DVR XP Woodlathe Parts List Item Qty 41 1 N O IOA Po 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 3 38 39 40 41 42 43 44 45 46 47 48 49 1 1 1 1 1 1 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 4 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 Part 55048 24118 24023 24060 55176 NHZ8 SW 12 FW 12 24011 2
37. he work piece by hand to check clearance and check speed is correctly selected before turning on spindle 11 DO NOT MAKE ADJUSTMENTS when the lathe or work piece is turning Make all adjustments with power Off TIGHTEN ALL CLAMP HANDLES on the headstock tailstock and toolrest before operating lathe EXAMINE WORK PIECE and glue joints before turning to make sure it has no defects that would cause it to break when turning DVR XP ALWAYS CHECK CORRECT SPEED IS SELECTED BEFORE SWITCHING ON SPINDLE USE LOWEST SPEED when turning a new or unbalanced work piece TURN AT RECOMMENDED SPEED Always operate the lathe at the recommended speeds Consult this manual for suggested speeds ADJUST TOOLREST close to the work piece Before turning revolve the stock by hand to make sure it clears the rest At intervals stop the lathe and readjust the toolrest 18 19 20 21 22 23 24 29 26 27 KEEP TOOL TOOLREST The lathe tool or chisel should be on the toolrest before the lathe is turned On Tools should remain on the toolrest whenever the tool is engaged in contact with the work piece REMOVE TOOLREST when sanding or polishing so fingers do not get pinched USE CORRECT LATHE TOOLS Do not use spindle turning chisels for faceplate mounted work and vice versa Spindle turning tools used for faceplate mounted work may grab the work piece and pull the chisel from your control WHEN ROUGHING STOCK do
38. his will expose the main control panel in the lower compartment 4 Use a pair of long nose pliers and earth yourself first by momentarily placing a hand on the lathe casting This will remove any static electricity that could damage sensitive components Visually locate the jumper It will be between the 2 square blue capacitors 115 0513 003 36 5 Carefully place your index finger on the edge of the board avoiding any soldier points Using the top of your finger as a guide run the pliers along and lightly grab the jumper in the pliers Do not squeeze too tight as you may crush the jumper This is important as the jumper will need to be placed back should you want to run 115V again 6 Reattach rear guard ensuring all wiring is captured inside casting Be careful as the back of the fuse and switch protrude out and should not hit any components as you position the guard in place 7 Securely fasten the guard with the 4 cap screws 8 Change the plug to a suitable 220V type either for 15 or 20 amp plug fitting Note Your 220V power supply may be such that the voltage is split 110 V down each the phase and neutral If so then the neutral supply should be switched also which requires the switch to be replaced with a double pole single throw switch DPST If the unit is plugged into a 115 volt outlet with the jumper now set to 220v it will not damage the electronics and the motor will still run but it will not have the same performan
39. icago IL 60611 in the Accident Prevention Manual of Industrial Operations and also in the Safety Data Sheets provided by the NSC Also refer to the American National Standards Institute ANSI 01 1 Safety Requirements for Woodworking Machines and the U S Department of Labor OSHA 1910 213 Regulation Guidelines to symbols used in this manual N Warning Symbol Pay close attention Note Information Symbol Please read important information for you 115 0513 003 8 DVR XP Woodlathe Specifications Size 1100mm L x 240mm W x 412mm H 43 1 3 L x 9 1 2 W x 16 1 4 H Weight 82kg 181 LB Swing Over Bed 400mm 16in Distance Between Centers 600mm 24in extendable in 510mm 20in units with add on Bed sections Swing Outboard 740mm 29in with headstock at 90 using outrigger toolrest Headstock Spindle Thread M33 x 3 5 RH or 1 1 4 x 8 TPI RH Headstock Bore No 2 Morse Taper 2 MT Headstock Swivel O to 360 degrees with detents at 0 22 5 45 and 90 degrees Outboard End Internal Thread M20 x 1 5 LH opindle Index 24 divisions every 15 degrees 15mm through hole through Headstock Tailstock Tailstock Bore No 2 Morse Taper 2 MT Quill Travel 85mm 3 1 4in Hole Through Tailstock 15mm 9 16in Toolrest Length 300mm 12in Shaft Diameter 25 4mm 1in Speeds rpm 100 3500 in 5rpm increments Favourite Speeds 5 presets Standard Equipment 300mm 12in Toolrest
40. ions coefficients for your type of load Press it and press end up and down in order to select the display line which is ready to edit Use the Set Function see 4 1 in order to increase decrease the coefficient values to adjust the A or in order to move the symbol at the display line Note f you will change one of these values it will be fixed and will not automatically change as the speed is adjusted It will also over ride load inertia until software hard reset e Use the Hard Reset Function in order to return the factory curves of these parameters CO 1 115 0513 003 5 5 Serial Number view PROGRAM P e Press Page again to see Board Serial Number LCD View Comments SERIAL NUMBER 04067648 The Control Board Serial Number Press Main to go to Main display page from any other display pages 115 0513 003 32 Maintaining the Nova DVR3000 General Maintenance Always isolate from power supply unplug before carrying out any maintenance Interval Maintenance After each use Clean the work area and Lathe Vacuum shavings and dust from the Headstock Tailstock under the Toolslide and in between the bed Monthly Wax exposed cast iron parts with a good quality paste wax especially the bed rails Buff out the wax thoroughly Check tightness of nuts and bolts Lubricate with one or two drops of light weight oil the tailstock quill threads index pin shaft and the toolslide cam
41. is not engaged or that something is preventing the spindle from turning Note leaving the spindle index unit in will not harm the motor however it will put some strain on the index unit It is likely that the spindle index will be left in from time to time and the motor is designed for this The optical sensors that give the spindle position feedback Rotor Position State are obscured damaged or have been disconnected Dust over a long period of time may have settled on the sensors Firstly spin the spindle by hand to create a draught through the sensors Re try the motor If the error remains with the power switched off and disconnected remove the upper rear guard and remove any wood dust with a vacuum cleaner Avoid getting the nozzle too close to the electronics After this step dust may fall into the Headstock so suck the dust out through the vent at the front of the Headstock under the spindle Do this sequence a few times Try blowing if available with Vacuum or Air gun Replace guard The computer has built in voltage condition and temperature sensors if this message appears check the temperature of the lower section of the headstock If it is very hot switch off the master switch and leave the machine to cool down for a period If the headstock is relatively cool the computer may have detected an under and over voltage from the mains power Switch off and try rebooting The DVR has a high level of protection and is intelligently ch
42. likened to a wood plane if it is pushed very slowly much force is needed to break the fibers if the plane is pushed at a higher speed less forces are involved and a better cut results Use 250 rpm when needed but it is better turning at 400 600 rpm Tailstock A Warning Never loosen the tailstock quill or tailstock while the work piece is turning To move the tailstock along the bed loosen the Tailstock Clamp Handle slide the tailstock to the desired position and tighten the clamp handle To move the tailstock quill in or out loosen the Quill Lock and turn the Handwheel Lock the quill in place with the Quill Lock and lock tailstock Can be operated forward or back whichever 15 The tailstock quill accepts centers and accessories with no 2 Morse taper 2 MT To install a taper use a quick firm action by hand Do not pound the taper in To remove a taper insert the operating bar through the tailstock quill hole While holding the taper so it doesn t fall tap it out The tailstock quill is hollow allowing you to bore holes through turnings if a hollow center is used 23 115 0513 003 Learning Turning The art and technique of turning is a subject beyond the scope of this instruction manual It is recommended that you receive hands on instruction on lathe turning and or refer to books and videos on the subject For reference some woodturning books are The Lathe Book Turning Wood With
43. m 115 0513 003 5 Table of Contents Ce eA Mey 2 ol a8 dii cee ee ee eee E eee eee 7 ADDITIONAL SAFETY RULES FOR WOODLATHES sss 8 DVR XP Woodlathe Specifications sss 9 Workshop i e VIII RTT Um 10 Lathe Stand Recommendations sss 10 Example of Shop made Lathe Stand sss 11 Assembling the Nova DVR XP sns 12 Nova DVR XP Components After Unpacking nnne 12 Installing the Headstock 13 Adding an Extension Bed sss 13 Mounting the Lathe to a Support Surface ssssesssssissssssseeeeen eene nenne 15 Connecting uisum e 15 HE NOV Alp iue 16 DVR Drive FUNCIONS sosesc neen nae E 17 TIMING 1 NOS 19 WIV CHING HE ICA SIO CM usata a SOE 20 sje pea gt A nn Pn u 20 micros Geer ne eee A oe a 21 SPINS Thread SEC Seuss inosine ars E E n 21 ji 22 qu
44. mber R lt lt reverse direction 115 0513 003 30 5 4 Speed Control Loop The PI Speed Control coefficients setting The control system of the DVR Drive has Speed Control Loop which provides the PI speed controller function The KPror and Klnt are the values of the Proportional and Integral coefficient of speed control loop They are functions of motor speed See Appendix A for the basic curves of the PI speed controller coefficients There are three possible choices Normal default Soft and Hard coefficient curves The values Kprop amp Kint are multiplied by 100 given as a percentage P e Press to go to next display page order to select the coefficient curves LCD View Comments SPEED CONTROL em NORMAL E Normal coefficient curves selected e Press to toggle changing the other coefficient curves LCD View Comments SPEED CONTROL lt E gt SOFT E Soft coefficient curves selected LCD View Comments SPEED CONTROL mem HARD E Hard coefficient curves selected e Press Page again to see the PI coefficients LCD View Comments Kprop 250 Kint 2000 s S Proportional coefficient value in percent for selected speed S Integral coefficient value in percent sec for selected speed Note The LCD shows the values of the Proportional and Integral coefficient of speed control loop for selected speed The parameters Kprop amp Kint get their values from the curves and calculat
45. mportance of the lathe stand design Consideration Lathe Height from floor Stand Top Stand Weight Stand Legs Recommendation The height of the stand should locate the centerline of the lathe spindle at the elbow height of the turner illustration next page The stand top should be flat so the lathe does not twist when it is bolted down Check for any gaps between lathe feet and stand top before bolting down Shim and prepare stand as necessary The stand should have enough weight and mass so that it doesn t move when turning large work pieces and so that the stand can absorb vibrations A lathe stand s stability can be improved by weighing it down with sand bags on a lower shelf The stand should sit level on the floor and not rock 115 0513 003 10 Example of Shop made Lathe Stand This has been designed with economy of space in mind Heavier sections wider rails and gussets on the corners are encouraged For stability and vibration dampening it is highly recommended that the base is filled with sand Top 43 x 16 x 2 in Upper Leg Brace 2 1 1 2 x 3 1 2 x 13 in j Machine t Upper Rail 2 1 1 2 x 3 1 2 x 33 in plywood bottom compartment for sand Lower Rail 2 1 1 2 x 7 1 2 x 33 in 297mm Recessed Hole 11 11 16 in drill hole and chisel one a Leg Brace 2 side square for nut Leg 4 1 1 2 x 7 1 2 x 13 in 1 d X 3 1 2 in x T height to suit
46. not jam the lathe tool or chisel into work piece or take too big a cut DO NOT POUND WORK PIECE into headstock drive spur center when turning between centers Pound the drive center into the work piece with a soft mallet before installing it between centers in the lathe DO NOT USE TAILSTOCK to drive work piece into the drive spur center when turning between centers Secure work between centers with light pressure from the tailstock quill action FASTEN STOCK SECURELY BETWEEN CENTERS Make sure the tailstock is locked before turning on the power NEVER LOOSEN TAILSTOCK SPINDLE or tailstock while work piece is turning CORRECT USE OF FACEPLATE When faceplate turning make sure work piece is securely fastened to the faceplate and that appropriate size faceplate is used to support the work piece Any screw fasteners must not interfere with the turning tool at the finished dimension of the work piece Rough cut the work piece as close as possible to finished shape before installing on faceplate DO NOT OPERATE LATHE IF DAMAGED OR FAULTY If any part of your lathe is missing damaged or broken in any way or any electrical component fails shut off the lathe and disconnect the lathe from the power supply Replace missing damaged or failed parts before resuming operation ADDITIONAL SAFETY INFORMATION regarding the safe and proper operation of this product is available from the National Safety Council 444 N Michigan Avenue Ch
47. panel The serial number is printed on the safety label sticker 47 115 0513 003 Steps to registering your Warranty by Mail 1 Fill out the information on page 36 duplicate your serial number here for your future reference Serial Number 2 Cut along the dotted line as indicated by the scissors icon 3 Take the cut out and fold along dotted line as shown 4 Seal edges with sellotape glue tape etc 5 Affix appropriate Postage Stamps for postage to New Zealand and post 6 Optional List your return address details in the event of mishandled post e lt e DOQ i ne S 0 lt 0 i LA i J lt z N EE A FSB ENN 2 i l O O oo lt S O 5 5 lt 5 2 E lt O lt c x yo N op Lu 8 S m c c gt LI S e 0 G Oo Tf ET d 0225 cr E 115 0513 003 48 49 115 0513 003 Nova DVR XP Woodlathe Manual Publication Code 115 0701 001 Teknatool International 2007 B B 115 0513 003 50
48. rol only supplies enough power to maintain the spindle at the commanded speed It needs to sense the load from the chisel and then it will apply power as needed At very low speeds the chisel can move fast compared with the rotation of the wood The important thing is to have good control of the chisel and maintain steady cuts using the same woodturning practices that produce quality cuts and finishes In this way surprisingly heavy cuts can be achieved However rapid or incautious use of the chisel will be immediately sensed by machine and spindle will shut down and then automatically try a restart Will The Machine Shut Down on Interrupted Cuts No as long as the cut is within the normal range of Woodturning cuts An interrupted cut at slow rom may cause a loss of control of the chisel and a dig in may occur A way to understand chisel feed rates is to consider that at 100 rom the work piece has only rotated about 1 and a half turns in one second and at 250 rpm 4 turns Considering that chisel feed or movement under normal turning can be anything between say 5 and 100mm per second at normal Woodturning turning speeds At very low rpms it is easy to move the chisel too fast for good cutting conditions In general low rpm is only used for special processes or conditions Speeds below 350 are generally not Woodturning speeds The machine will operate down to 100 rpm but this is generally for applying finishes and other applications 19 115 0
49. ron has always been the material of choice for wood lathe construction because of its inherent mass and excellent modulus of vibration dampening The cast iron stand has been purposely designed to be heavy solid and robust keeping this in mind New Hybrid Stand The hybrid stand is a combination of cast iron and rectangular hollow section Compared to its original predecessor the hybrid was designed to be light weight and style Small Toolrest TR100 1 A small 100mm 4in toolrest not shown for turning small work pieces or reaching into recessed areas Bowl Toolrest A curved toolrest which gives you better chisel support on both the outside and inside of a bowl Because of the curve you are able to position your chisel support closer to the bowl Revolving Center System NLCS or NLCS1 A multi function live center system to expand your options when turning between centers It includes quick change tapers a hollow cup center point threaded center cone center and an extension center Made with three bearings and precision machined for a high quality finish Handwheel Unit LHB The handwheel is mounted on the outboard end of the headstock spindle so you can manually position work or to slow it down The vacuum coupler can also be added to this unit to make a vacuum holding option 115 0701 001 Revolving Center xO ud CER 44 Accessories Faceplates SFP80L with side locking function Facepla
50. shaft remove plastic plugs and toolslide front camshaft bore 6 Months Grease tailstock quill threads Turn the handwheel so the quill threads are exposed apply grease to the threads crank the handwheel back and forth to work in the grease wipe off any excess Lubricate the tailstock slot with one or two drops of light weight oil With the power switched off and dis connected remove the upper rear guard and remove any wood dust with a vacuum cleaner Avoid getting the nozzle too close to the electronics After this step dust may fall into the Headstock so suck the dust out through the vent at the front of the Headstock under the spindle Replace guard 33 115 0513 003 Cleaning the Toolslide If the toolslide becomes hard to move and adjust cleaning and lubricating are required 1 the toolslide slide more freely along the bed make sure the bed rails are clean Apply some paste wax to the rails Camshaft 2 Ifthe toolslide is hard to move towards or away from you remove the toolslide from the lathe bed Clean the toolslide camshaft round eccentric rod with a petroleum based solvent Lubricate the rod with lightweight oil or a silicone spray 3 Slide the base back onto the lathe bed Toolslide Bottom View Cleaning the Tailstock If the tailstock quill becomes hard to use or the Handwheel is hard to turn cleaning and lubricating are required Guil 1 Remove the 6mm set
51. ters A punch Centers Starting Guidelines Adjust Toolrest as Needed 3 mm O stock Toolrest Toolrest Clamp Handle Toolslide Clamp Handle 115 0513 003 22 Lathe Turning speeds Work Diameter inches 0 3 4 6 8 12 HM 46 18 20 WARNING m Turn out of balance work 000 at a suitable speed z 2800 2400 2180 1800 a 11 Find work diameter i450 1200 Al Follow vertical line D to mark j across for rpm BS0 SFO 360 300 Key O m roughing stock 250 o general turning 80 100 150 200 250 300 350 400 450 500 Work Diameter millimeters Correct selection of turning speeds is important for safety and finish cut quality It is important to take into account the fixing of the work piece it should be made as secure as possible Various techniques are available for this consult books on the subject and seek training opportunities There are safety and out of balance considerations Aim for a good balance in turning speed ensure good fixing and try to balance timber as much as possible before installing on lathe In general wood likes being sliced and if too low a speed is used the timber can hammer against the cutting tool tearing fibers and imposing large forces on the tool and work piece This can often be dangerous it is best to select a higher speed the cut will be smoother and less force is imposed on the work piece It can be
52. tes are used to mount the work piece when faceplate turning bowls or platters Faceplates are available in 80mm 3 diameter A vacuum faceplate is also available The 80mm 3 faceplate is made of solid steel This faceplate has a small contact area to allow maximum freedom while shaping It comes with 2 notches on the outside diameter for removing the faceplate from the spindle This can be done with a light drift and mallet Vacuum Coupler 25008 The Vacuum Coupler not shown fits onto the Handwheel Unit It provides a secure attachment for your vacuum cleaner hose For those turners who are interested in vacuum chucking this is a simple system Outrigger Unit OR3000 Extend the bowl turning capacity of the Nova DVR XP Woodlathe to up to 740mm 29in in diameter This unit is made from cast iron is easy to position and control and mounts to the headstock end of the lathe Precision Midi Chuck Ideal for mini midi and all lathes up to 6 centre height 12 diameter over bed Can also be used for small work on large lathes Supernova 2 Chuck Designed for the tough demands of modern woodturning Body is precision machined from high quality K1045 machine steel Gearing is heavy section hardened steel to provide a powerful action The greater holding strength stability and precision decreases vibration from small delicate turnings right up to large bowls and platters work up to 29 40mm Outrigger Unit 3
53. ther countries 10 or 15 amps must be used to protect the DVR electronics from electrical spikes or surges similar to those used on most Home PC s Ground Fault Interrupters GFI s or Residual Current Detectors RCD s are helpful and are a recommended protection device for any powertool They can be used in conjunction with a DVR lathe Note some makes of GFI may be compatible 15 115 0513 003 Using the Nova DVR XP Parts of the Nova DVR XP Woodlathe Tailstock die c Handwheel Index Pin Headstock Handbrake AN 4 Toggle Switch 0 l i Li Quill gt Toolrest MEET S CF KZ x Tailstock Lock pr Handle M Toolslide Controller DN LL Headstock Lockpin Toolslide Lock Handle Headstock Lockpin Operating Bar DVR Variable Speed Controller The Nova DVR XP drive is a unique type of motor and controller where the motor and controller interact The motor provides data to the controller on its position and load conditions The motor provides high torque even at low rpm and inherits extremely close speed control With the toggle switch in the Off position plug lead into wall socket and switch on An electronic tune will be heard as the controller computer boots up and the LCD display will show a two line display DVR Drive Parameters Motor Type Digital Variable Reluctance Accuracy of Speed Stabilization lt 2 5 Mo
54. ting wrenches are removed from tool before turning it on DON T OVERREACH Keep proper footing and balance at all times DIRECTION OF FEED Feed work into a blade or cutter against the direction of rotation of the blade or cutter only ATTENTION TO WORK Concentrate on your work If you become tired or frustrated leave it for awhile and rest SECURE WORK Use clamps or a vice to hold work when practical It s safer than using your hand and frees both hands to operate tool CHECK DAMAGED PARTS Before further use of the tool any part that is damaged should be carefully checked to ensure that it will operate properly and perform its intended function Check for alignment of moving parts binding of moving parts mounting and any other conditions that may affect its operation Any damaged part should be properly repaired or replaced DRUGS ALCOHOL MEDICATION Do not operate machine while under the influence of drugs alcohol or any medication DUST WARNING The dust generated by certain woods and wood products can be harmful to your health Always operate machinery in well ventilated areas and provide means for proper dust removal Use wood dust collection systems whenever possible 115 0513 003 ADDITIONAL SAFETY RULES FOR WOODLATHES A Warning Failure to follow these rules may result in serious personal injury Important ALWAYS BEFORE SWITCHING SPINDLE ON CHECK SCREEN FOR CORRECT SETTING 1 DO NOT MODIFY OR
55. to return to previous speed e Use the Set Function see 4 0 in order to increase decrease the reference speed In this case if the reference speed is not equal to the preset speed of the current speed number the symbol will be removed from the LCD For example if you will decrease the reference speed using key the LCD will be LCD View Comments Set 450rpm 2D Ready to run gt gt S Reference speed is now not equal to preset speed 2 R gt gt forward direction If you go back to the speed 500 rpm using key A then the symbol will show on LCD Programming the Favourate Speeds 29 115 0513 003 e Pick a preset number you would like to change IMPORTANT Note The default speed 20 can not be set at more than 500 rpm and the saved preset speed values will work also after Hard Reset Function e Press the key in order to make the request for saving the new value of pre selected speed in the EEPROM memory It will display the symbol at the end of LCD line Change the speed you require P e Press key to store the new value There will be the symbol instead the symbol e Your new setting is now stored 5 3 Set the direction of rotation Forward Reverse function e Press to set the direction of rotation Forward Reverse Each key pressing will toggle the direction In reverse mode the LCD will be LCD View Comments Set 500rpm 2D Ready to run lt lt S Reference speed and nu
56. tor Power 1 75 Hp for 115v 2 3 Hp for 230v Regulator Type PID Efficiency gt 0 80 Speed Stabilization Current level pulse width Motor Speed Range 100 3500 rpm Default speed when powering up 500 RPM Speed Control Button brpmincrement 115 0513 003 16 DVR Drive Functions DVR 55010 TECHNOKOSY o fo OFF SELECTOR PROGRAM d AN P E J NOVA VI te A two string liquid crystal display panel LCD displays the current information Ready to start at XXXXrpm gt gt XXXX is the reference motor speed gt gt Indicates forward direction of rotation 1 Green ON Press to start machine at the commanded speed always check that the speed has been selected correctly When the computer is first switched on it is set at a default speed of 500 rpm Remember that whenever the computer is switched off at the wall or at the incoming power supply switch the computer will restart at the default setting The spindle cannot restart until 1 ON is depressed As with any Woodlathe ensure that the index is off and the workpiece is free to turn without hitting the toolrest etc Ensure that the work piece is secure and the appropriate speed is selected Speed CCCC rpm Ref gt RRRR rpm CCCC current value of the motor speed RRRR reference value Value selected When the On button is first pushed the screen will display Go Low rpm and then 4 retries left These messages are norm
57. tric motors the Smart DVR Motor only inputs enough power to maintain the set speed giving you potential for power savings over conventional motors Wide Speed Range 100 3500 rpm easy push button speed change DVR Direct Drive Motor Driven by unique Direct Drive Variable Reluctance Motor Technology with superior performance over AC or DC motors Proven technology many thousands of users No power loss through belts or transmission Provides digital electronic push button variable speed with no belt changes Ultra Smooth Cutting Power Selected RPM is closely maintained and the DVR has no belt stretch or motor bounce which affects smooth cutting The DVR motor runs smooth with almost no vibration Trimax Bearing System Unique Trimax Bearing System is a triple bearing system to provide a smooth heavy duty load bearing support for the spindle which can easily absorb turning stresses 5 Year Warranty limited On all castings mechanical parts and components 2 Year Warranty on all electronics and electrical components Plug and Play Just bolt to stand or bench plug it in and you are turning No complex motor set ups or adjustments Low Mantainence The motor is simple brushless with no rotor windings rotor is solid steel The industrial grade electronics are built to last There are no drive pulleys or belts to set up or come loose 115 0513 003 3 Welcome Thank you for choosing our Nova DVR XP Woodlathe and welcome to th
58. turner ue and screw leg pieces 11 115 0513 003 Assembling the Nova DVR XP 1 Unpack the lathe and components from the shipping container This is best done by cutting down the sides of the box to expose the lathe A Warning Have other people help when moving or lifting the Nova DVR XP Woodlathe it weighs about 82kg 181 LB 2 Clean any parts coated with rust preventative with a cloth moistened with a petroleum based solvent or cleanser such as paint thinner Coat the lathe bed with paste wax Nova DVR XP Components After Unpacking DVR Controller Hand Wheel bs J ge Lock Handles Live Center Operating Bar 115 0513 003 12 Installing the Headstock Lockpin 3 Remove the plastic shipping tube from headstock base Immediately ipiis posioned screw the Headstock Lockpin into ey oo the threaded hole at the bottom of the headstock Insert the operating bar into the hole in the Lockpin and firmly tighten the Lockpin to lock the Heacktock headstock in position then remove n the operating bar NOTE When the pin is fully engaged the groove machined into the pin furthest from the thread should line up with the edge of the hole in the casting By doing this the pin will be engaged in Important Note Swiveling the head before inserting the lockpin may result in the tapered hole becoming misaligned Headstock Release Handle Operating Bar the hole of the swivel pin
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