TECHNICAL SPECIFICATION HYPERTURN 45 MODULAR CNC-TURNING CENTRE FOR COMPLETE MACHINING OF COMPLEX PARTS

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1 EMCO GmbH Salzburger Straße 80 A-5400 Hallein-Taxach AUSTRIA TECHNICAL SPECIFICATION HYPERTURN 45 MODULAR CNC-TURNING CENTRE FOR COMPLETE MACHINING OF COMPLEX PARTS with SINUMERIK 840 D / SolutionLine or FANUC 31i-B

2 EMCO HYPERTURN Page 2 of 67 MACHINE CONCEPT: The HYPERTURN 45 was designed to further increase productivity in the range of universal machine tools. Highly dynamical drive systems provide not only more productivity but also improve precision and rigidity for complex turned and milled components. The implemented Y-axis with broad-based, pre-stressed linear roller guide ways enables stable turning and milling operations. Depending on the machine type the machine concept offers a perfect foundation to produce precision turned and milled work pieces. Machine bed: The compact 72 slant bed unit is the base unit of the machine. Designed as a extremely stiff and compact welded steel construction it is the foundation for a robust and accurate lathe. Reinforcing steel plates internal guarantee additional rigidity at higher stressed zones. Steel instead of cast iron offers short warm-up periods and better rigidity. All linear axes are based on pre-loaded linear roller guide ways. The guide ways are mounted on precise machined surfaces to ensure the best guide characteristics. Covers mounted on each guide rail as well as stainless steel covers increase the reliability and the lifetime. Main and Counter spindle: Powerful integrated spindle motors on both spindles guarantee perfect conditions for machining steel but also aluminium parts. Precision spindle bearings and a symmetrical designed headstock body ensure a large speed range combined with minimal thermal displacements. Perfect roundness and high quality surfaces on machined parts are the result out of this. Three temperature sensors mounted on each headstock control the water cooling system. At the HYPERTURN 45 the counter spindle is mounted on linear guide ways and travels in a range of 510mm. A coolant flooded part ejector tube is used to eject the finished part into the parts catcher. The stroke is monitored to guarantee a save process. On demand, the counter spindle actuator can be switched to a hollow clamping cylinder allowing long shafts up to ø45mm to be unloaded through the spindle. Tool turret: The fast 12-station servo tool turret for VDI25 tools can be set-up with driven tools at every position (coupling style according to DIN 5480). The operator is able to control the indexing speed with the Override-switch at any time. The tools are mounted radial and this allows free access to the main and counter spindle. Bi-directional indexing with nonlifting turret disc makes the process safe and reduces cycle time. EMCO s tool alignment system further improves the VDI quick change system. No alignment is necessary anymore. C-axis: The C-axis is part of the standard features of the machine. It allows to position the spindle within a resolution of 0,001. The direct mounted, non-contact encoder, runs without belt, guarantees a precise C-axis need for any kind of milling and drilling operation.

3 EMCO HYPERTURN Page 3 of 67 Y-axis: The Y-axis is the highlight of the MAXXTURN series. It is designed into the machine as a key element. Broad based and pre-loaded linear roller guide ways are carrying the 90 saddle. Short overhangs ensure top stability for turning, milling and drilling operation. Better surface finish and longer tool life are a result of this formation. Feed drives: Highly dynamical synchronous motors in all linear axis with pre-tensioned ball-screws ensure high axis force and good repeatability. Measuring system: Incremental measuring systems in all axes ensure top precision. Positioning scatter Ps according to VDI3441 in X/Y/Z: 0,003/0,003/0,003mm Clamping system: All MAXXTURN version are set-up with an through hole clamping cylinder. The bar capacity is ø45mm. An analog clamping stroke monitoring system mounted at the actuator can be set easily within the Teach-In-Mode. No proximity switches need to be set at difficult reachable areas. Lubrication: Fully automated central lubrication with >oil saver logic<. Depending of the amount of stroke the lubrication is activated. The unit has a floater as well as a pressure switch for safety reasons. Coolant system: The coolant system is a standard feature of the MAXXTURN. The line goes through the turret right to the tool nose. Additional coolant lines are mounted to keep the machine and the chucking system clean. Hydraulic unit: The compact hydraulic unit is built into the machine housing. The pump is cooled by the motor fan. Machine covers: The machine is completely closed. The machine door is monitored with safety switches to prevent the operator from injuries. Into the machine door there is a large safety glass for an optimum sight into the machine. Finished part catcher(option): The part catcher is mounted on pneumatic activated guide rods to unload the finished part either from the main or from the counter spindle. Parts are gently transferred to the finished part box or to an optional finished part conveyor. Max. part length:120mm; max. ø 45mm; max. weight: 2kg Flexible automated solutions EMCO offers two type of bar loader system. One to load short bar stock up to 1 meter into the main spindle and another one to load 3 meter bar stock. For chucking parts EMCO offers the SWING LOADER to load and unload fully automatically.

4 EMCO HYPERTURN Page 4 of 67 Overview of the modular concept: Content: MAIN MACHINE OPTIONS 9 CONTROL LANGUAGES: 11 EMCOnnect for SINUMERIK 840D-sl 13 OPTIONS FOR EMCOnnect /SINUMERIK 840D-sl 13 CONTROL OPTIONS FOR FANUC 31i-B 18 MACHINE INSTALLATION KIT 20 EMCO CPS-PILOT 21 ESPRIT PROGRAMMING SYSTEM: 22 ACCESSORIES FOR BAR MACHINING: 23 EMCO SHORT BAR LOADER: 24 FURTHER MACHINE ACCESSORIES 31 AUTOMATION (Only for machines w/ Siemens) 35 PACKING FOR GANTRY LOADER 40 UNLOADING THROUGH THE COUNTER SPINDLE 40 CLAMPING DEVICE / MAIN SPINDLE (A2-5) 41 CLAMPING DEVICES FOR BIGBORE VERSION (A2-5) 44 TOOL HOLDER: VDI25 46 PACKING FOR MACHINE: 56 PACKING FOR MACHINE WITH SWING LOADER: 56 TECHNICAL DATA FOR HYPERTURN CONTROL DESCRIPTION: 840D Solution Line 60 CONTROL DESCRIPTION: FANUC 31i-B 64

5 EMCO HYPERTURN Page 5 of 67 HYPERTURN 45 SM2 / SIEMENS with driven tools S3A S02 HT 45 SM2 / SIEMENS with driven tools CNC-turning center for complete machining of complex turned and milled parts with 2 spindles, 2 turrets, 5 linear axes and 2 rotation axes, integrated spindle motor (ISM) at main and counter spindle (water cooled), pre-loaded roller-type slide systems. Drive power: Main spindle - 15 kw Counter spindle - 15 kw Spindle speed: Main spindle rpm Counter spindle rpm Spindle connection (DIN 55026): Main spindle: A2-5 (max. bar capacity ø 45mm) Counter spindle: A2-5 Includes: Through hole clamping cylinder for main spindle Draw tube for main and counter spindle Mechanical spindle brake (main/counter spindle) Part ejector and coolant through the counter spindle Steuerung Sinumerik 840D-sl / OPERATE o SHOPTURN conversational programming o USB-interface o Ethernet interface o 15 TFT colour display o 3D graphical simulation o etc. 2x 12-station radial tool turret VDI 25 with bi-directional logic for up to 2x 12 driven tools positions! Turret indexing speed adjustable by the feed-override switch. o Power max rpm o Torque: max. 16 Nm o Speed range: rpm o C-axis at the main and counter spindle o TRANSMIT software for simple C-axis programming Chip conveyor with a height of 1100mm ( hinged type ) Coolant tank well integrated to the chip conveyor 2 high pressure coolant pumps - 14 bar 2 standard pumps for flushing - 3,7 bar Hydraulic unit Machine lamp Interface for foot pedal switch and chip conveyor Documentation

6 EMCO HYPERTURN Page 6 of 67 HYPERTURN 45 SM2Y / SIEMENS with driven tools and Y-axis Y C S3A S03 C HT 45 SM2Y / SIEMENS with driven tools and Y-axis CNC-turning center for complete machining of complex turned and milled parts with 2 spindles, 2 turrets, 6 linear axes and 2 rotation axes, integrated spindle motor (ISM) at main and counter spindle (water cooled), pre-loaded roller-type slide systems. Drive power: Main spindle - 15 kw Counter spindle - 15 kw Spindle speed: Main spindle rpm Counter spindle rpm Spindle connection (DIN 55026): Main spindle: A2-5 (max. bar capacity ø 45mm) Counter spindle: A2-5 Y-axis: Travel range: +40 / -30mm Rapid rate: 15m/min Includes: Through hole clamping cylinder for main spindle Draw tube for main and counter spindle Mechanical spindle brake (main/counter spindle) Part ejector and coolant through the counter spindle Steuerung Sinumerik 840D-sl / OPERATE o SHOPTURN conversational programming o USB-interface o Ethernet interface o 15 TFT colour display o 3D graphical simulation o etc. 2x 12-station radial tool turret VDI 25 with bi-directional logic for up to 2x 12 driven tools positions! Turret indexing speed adjustable by the feed-override switch. - Power max rpm - Torque: max. 16 Nm - Speed range: rpm - C-axis at the main and counter spindle - TRANSMIT software for simple C-axis programming Chip conveyor with a height of 1100mm ( hinged type ) Coolant tank well integrated to the chip conveyor 2 high pressure coolant pumps - 14 bar 2 standard pumps for flushing - 3,7 bar Hydraulic unit Machine lamp Interface for foot pedal switch and chip conveyor Documentation

7 EMCO HYPERTURN Page 7 of 67 HYPERTURN 45 SM2 / FANUC with driven tools S3C F02 HT 45 SM2 / FANUC 31i with driven tools CNC-turning center for complete machining of complex turned and milled parts with 2 spindles, 2 turrets, 5 linear axes and 2 rotation axes, integrated spindle motor (ISM) at main and counter spindle (water cooled), pre-loaded roller-type slide systems. Drive power: Main spindle - 15 kw Counter spindle - 15 kw Spindle speed: Main spindle rpm Counter spindle rpm Spindle connection (DIN 55026): Main spindle: A2-5 (max. bar capacity ø 45mm) Counter spindle: A2-5 Includes: Through hole clamping cylinder for main spindle Draw tube for main and counter spindle Mechanical spindle brake (main/counter spindle) Part ejector and coolant through the counter spindle Fanuc 31i-B control o SHOPTURN conversational programming o USB-interface o Ethernet interface o TFT colour display 15 o 3D graphical simulation o Interface RS 232, etc. 2x 12-station radial tool turret VDI 25 with bi-directional logic for up to 2x 12 driven tools positions! Turret indexing speed adjustable by the feed-override switch. o Power max rpm o Torque: max. 16 Nm o Speed range: rpm o C-axis at the main and counter spindle Chip conveyor with a height of 1100mm ( hinged type ) Coolant tank well integrated to the chip conveyor 2 high pressure coolant pumps - 14 bar 2 standard pumps for flushing - 3,7 bar Hydraulic unit Machine lamp Documentation

8 EMCO HYPERTURN Page 8 of 67 HYPERTURN 45 SM2Y / FANUC with driven tools and Y-axis Y S3C F03 C C HT 45 SM2Y / FANUC 31i with driven tools and Y-axis CNC-turning center for complete machining of complex turned and milled parts with 2 spindles, 2 turrets, 6 linear axes and 2 rotation axes, integrated spindle motor (ISM) at main and counter spindle (water cooled), pre-loaded roller-type slide systems. Drive power: Main spindle - 15 kw Counter spindle - 15 kw Spindle speed: Main spindle rpm Counter spindle rpm Spindle connection (DIN 55026): Main spindle: A2-5 (max. bar capacity ø 45mm) Counter spindle: A2-5 Y-axis: Travel range: +40 / -30mm Rapid rate: 15m/min Includes: Through hole clamping cylinder for main spindle Draw tube for main and counter spindle Mechanical spindle brake (main/counter spindle) Part ejector and coolant through the counter spindle Fanuc 31i-B control o SHOPTURN conversational programming o USB-interface o Ethernet interface o TFT colour display 15 o 3D graphical simulation o Interface RS 232, etc. 2x 12-station radial tool turret VDI 25 with bi-directional logic for up to 2x 12 driven tools positions! Turret indexing speed adjustable by the feed-override switch. - Power max rpm - Torque: max. 16 Nm - Speed range: rpm - C-axis at the main and counter spindle Chip conveyor with a height of 1100mm ( hinged type ) Coolant tank well integrated to the chip conveyor 2 high pressure coolant pumps - 14 bar 2 standard pumps for flushing - 3,7 bar Hydraulic unit Machine lamp Documentation

9 EMCO HYPERTURN Page 9 of 67 MAIN MACHINE OPTIONS S4Y 020 S3Y 950 S3Y 960 R2Z 465W SURCHARGE HYPERTURN 45 BigBore Max. bar capacity 2 inch (ø50,8 mm) instead of ø45 mm. Spindle nose (DIN 55026): A2-5 Max. spindle speed: 7000 rpm Max. torque: 100 Nm Max. power: 15 kw Max. chuck size: ø175 mm Factory installed only! SURCHARGE HSC-TURRET HT45-UPPER ONE The standard upper tool turret will be replaced by the HIGH-SPEED-turret from SAUTER. Max. spindle speed: 8000 rpm Max. continuous speed: 6000 rpm Max. drive power: 4 kw Max. torque: 16 Nm Tool holder interface: VDI25 Attention: The turret disc is larger in diameter by 20 mm. Total height of tool holder max. 100 mm! Factory installed only! SURCHARGE HSC-TURRET HT45-LOWER ONE The standard lower tool turret will be replaced by the HIGH-SPEED-turret from SAUTER. Max. spindle speed: 8000 rpm Max. continuous speed: 6000 rpm Max. drive power: 4 kw Max. torque: 16 Nm Tool holder interface: VDI25 Attention: The turret disc is larger in diameter by 20 mm. Total height of tool holder max. 100 mm! Factory installed only! ANGULAR DRILLING/MILLING HOLDER LEFT/RIGHT FOR HSC-TURRET For drilling, milling and synchronized tapping at the main or counter spindle, Inclusive EMCO adjustment plate no alignment necessary! ER 20 collets or Quick Flex-Modular system, i=1:1, clamping range ø1-13mm, max rpm, external coolant supply, 75 mm long (total height: 98 mm) VDI 25 / coupling DIN 5480 WTO:

10 EMCO HYPERTURN Page 10 of 67 R2Z 405W ANGULAR DRILLING/MILLING HOLDER DOUBLE FOR HSC-TURRET For drilling, milling and synchronized tapping at the main and counter spindle, Inclusive EMCO adjustment plate no alignment necessary! ER 20 collets or Quick Flex-Modular system, i=1:1, clamping range ø1-13mm, max rpm, external coolant supply, 75 mm long (total height: 98 mm) VDI 25 / coupling DIN 5480 WTO:

11 EMCO HYPERTURN Page 11 of 67 CONTROL LANGUAGES: Standard-Languages: DE6 400 EN6 400 TA6 400 Control language / GERMAN Standard version includes two languages switchable from German to English. Additional languages available as per surcharge. Control language / ENGLISH Standard version includes two languages switchable from German to English. Additional languages available as per surcharge. Control language / ITALIAN Standard version includes two languages switchable from German to English. Additional languages available as per surcharge. We reserve the right, that not all the displayed text is incorporated in the special language at the control. Additional languages for extra costs: FR6 400 SP6 400 SE6 400 CZ6 400 DK6 400 Control language / FRENCH Additional control language, switchable to English when needed. We reserve the right, that not all the displayed text is incorporated in the special language at the control. Control language / SPANISH Additional control language, switchable to English when needed. We reserve the right, that not all the displayed text is incorporated in the special language at the control. Control language / SCHWEDISH Additional control language, switchable to English when needed. We reserve the right, that not all the displayed text is incorporated in the special language at the control. Control language / CZECH Additional control language, switchable to English when needed. We reserve the right, that not all the displayed text is incorporated in the special language at the control. Control language / DANISH Additional control language, switchable to English when needed. We reserve the right, that not all the displayed text is incorporated in the special language at the control.

12 EMCO HYPERTURN Page 12 of 67 NL6 400 FI6 400 HU6 400 PL6 400 PT6 400 RU6 400 TR6 400 CN6 400 Control language / DUTCH Additional control language, switchable to English when needed. We reserve the right, that not all the displayed text is incorporated in the special language at the control. Control language / FINNISH Additional control language, switchable to English when needed. We reserve the right, that not all the displayed text is incorporated in the special language at the control. Control language / HUNGARIAN Additional control language, switchable to English when needed. We reserve the right, that not all the displayed text is incorporated in the special language at the control. Control language / POLISH Additional control language, switchable to English when needed. We reserve the right, that not all the displayed text is incorporated in the special language at the control. Control language / PORTUGUESE Additional control language, switchable to English when needed. We reserve the right, that not all the displayed text is incorporated in the special language at the control. Control language / RUSSIAN Additional control language, switchable to English when needed. We reserve the right, that not all the displayed text is incorporated in the special language at the control. Control language / TURKISH Additional control language, switchable to English when needed. We reserve the right, that not all the displayed text is incorporated in the special language at the control. Control language / CHINESE-SIMPLE Additional control language, switchable to English when needed. We reserve the right, that not all the displayed text is incorporated in the special language at the control.

13 EMCO HYPERTURN Page 13 of 67 EMCOnnect for SINUMERIK 840D-sl S3Z 580 EMCOnnect - Your Control center " for the entire production process EMCOnnect user interface for easier machine operation, including 22 "multitouch screen, industrial PC and premium PC keyboard. EMCOnnect provides the necessary connectivity for networking the production environment and forms the basis for digital transformation. Basic functions: Dashboard, Docu-App, Remote Desktop, Calculator, MDE / BDE function, Cutting Data Calculator, Note- App, Tech-Sheet, and much more. Factory installed only! Note: In conjunction with the EMCOnnect option, the SIEMENS control panel components OP15 (15 "screen) KB483 and MCP483 (NC keyboard and machine control panel) are no longer required. The control hardware base for the EMCOnnect option forms a 22 "Panel Industrial PC (IPC477: Intel Core i3-6102e / 3x Gigabit Ethernet (IE / PN) / 4GB Memory and HMI Operating System Windows 7 Ultimate / 240GB Solid-State Drive SATA ) and a customized Premium PC keyboard and machine control panel (MCP530). Networkable with CAD / CAM products. Open for forward-looking EMCOnnect APP extensions. Uniform surface for all new high-tech machines from EMCO. OPTIONS FOR EMCOnnect /SINUMERIK 840D-sl X3Z 610 ELECTRONIC HANDWHEEL 840D-sl Portable electronic hand-wheel for SIEMENS or FANUC controls. Offers a convenient manual operation of the machine also with open machine door. ATTENTION: For machines with gantry or swing loader, this hand-wheel is replaced by the operating and display element Siemens HT2. Retrofit able through EMCO technician!

14 EMCO HYPERTURN Page 14 of 67 X3Z 161 EMCO TOOL LOAD MONITORING 840D-sl This system is used to check the tool load during the machining. If the current load exceeds the set values for tool breakage, tool wear or tool missing, the machine will shut-off immediately. X3Z 670 X3Z 710 X3Z 720 Retrofit able through EMCO technician! GEAR HOBBING 840D-sl Siemens software option electronic gear shaft used for gear hobbing (gear machining). Enables an oriented synchronization of the leading spindle to the following spindle due to definition of the respective coupling factors. The achievable gear quality depends on the drive-train of the machine (main spindle drive system and milling spindle drive chain). Factory installed only!! BALANCE CUTTING / 840D-sl Enables the simultaneous cutting of a contour with two cutting tools. The control software makes it possible to program this highly sophisticated machining task directly on the machine without the need for a CAD/CAM system. Retrofitable through EMCO technician! ALTERNATE SPINDLE SPEED / 840D-sl When machining workpieces, vibrations can occur which can be reduced by permanent speed changes. With the simple input of 3 parameters in an input mask thus increased process reliability can be achieved. Retrofitable through EMCO technician! X3Z 740 TAILSTOCK-FUNCTION FOR TURRET / 840D-sl This cycle allows the use of a live-center mounted on the turret to support the workpiece. Therefore shaft parts can be supported and machined in machines without tailstock but with the help of the second turret. The max. feed force is limited to 50% of the max. axis force. Retrofitable through EMCO technician!

15 EMCO HYPERTURN Page 15 of 67 X3Z 750 X3Z 301 X3Z 690 TAILSTOCK-FUNCTION FOR COUNTER SPINDLE / 840D-sl This cycle allows the use of the counter spindle with mounted live-center to support the workpiece. So shaft parts can also be supported and machined in machines without a tailstock but with the help of the counter spindle being used. The max. feed force is limited to 50% of the max. axis force. Retrofitable through EMCO technician! EMCO NETSERVICE / SIEMENS Activation of the Netservice Function at the machine control and connection to a server. The period of use is limited to 12 months, but extendable by additional 12 months. Advantage: Online-Diagnoses, Online- Updates, Internet based, etc. Simple as a web-mail and safe as onlinebanking! Retrofitable through EMCO technician! SHOPTURN EXTENSION PACKAGE Consisting of: Rest material removing cycle Monitoring function for simulation X3Z 460 X3Z 390 Retrofitable through EMCO technician! CAD-READER FOR SINUMERIK Functions by the CAD Reader: Import DXF files Hide graphics layers Automatic contour trace Optional workpiece zero per contour/drill point Several contours/drill points can be selected simultaneously Create and convert contours or drill patterns for ShopMill, ShopTurn, SINUMERIK Operate Display existing contours/drill points in geometry processor/cycles support. Available for HMI OPERATE 4.7 and higher! Retrofitable through EMCO technician! ENERGY CONTROL FOR SINUMERIK A simple to use energy control page enables the operator to switch-off auxiliary drives or the complete machine to stand-by mode after the production has stopped. The additional >Control-Energy< function makes it possible to analyze the electric energy consumption of each servo or of the hole machine.

16 EMCO HYPERTURN Page 16 of 67 Factory installed only!! S3Z 20S GLASS SCALE IN X1-AXIS-Siemens Absolute, direct measuring system (HEIDENHAIN) for the X-axis including sealing air. S3Z 21S Factory installed only!! GLASS SCALE IN Y1-AXIS-Siemens Absolute, direct measuring system (HEIDENHAIN) for the Y-axis including sealing air. S3Z 22S Factory installed only!! GLASS SCALE IN Z1-AXIS-Siemens Absolute, direct measuring system (HEIDENHAIN) for the Z-axis including sealing air. S3Z 23S Factory installed only!! GLASS SCALE IN X2-AXIS-Siemens Absolute, direct measuring system (HEIDENHAIN) for the X-axis including sealing air. S3Z 24S Factory installed only!! GLASS SCALE IN Z2-AXIS-Siemens Absolute, direct measuring system (HEIDENHAIN) for the Z-axis including sealing air. Factory installed only!!

17 EMCO HYPERTURN Page 17 of 67 OPTIONS FOR SINUMERIK 840D-sl (without EMCOnnect) X3Z 270 X3Z 435 PC-KEYBOARD WITH USB-INTERFACE PC-keyboard for comfortable programing at the Sinumerik control. American key assignment - QWERTY Retrofit able through EMCO technician! MEMORY EXTENSION/SIEMENS 840D-sl Programs can be stored on a Micro-USB- Stick with a memory capacity of 4 GB. Retrofit able through EMCO technician!

18 EMCO HYPERTURN Page 18 of 67 CONTROL OPTIONS FOR FANUC 31i-B X3Z 600 ELECTRONIC HANDWHEEL Portable electronic hand-wheel for SIEMENS or FANUC controls. Offers a convenient manual operation of the machine also with open machine door. X3Z 150 Retrofit able through EMCO technician! EMCO TOOL LOAD MONITORING- FANUC 31i This system is used to check the tool load during the machining. If the current load exceeds the set values for tool breakage, tool wear or tool missing, the machine will shut-off immediately. X3Z 335 Retrofit able through EMCO technician! MEMORY EXTENSION FANUC 31i Programs can be stored on a Compact Flash card with a memory of 2GB. X3Z 380 X3Z 085 ENERGY CONTROL FOR FANUC 31i A simple to use energy control page enables the operator to switch-off auxiliary drives or the complete machine to stand-by mode after the production has stopped. The additional >Control-Energy< function makes it possible to analyze the electric energy consumption of each servo or of the hole machine. Retrofit able through EMCO technician! GEAR HOBBING FANUC 31i Fanuc software option electronic gear shaft used for gear hobbing (gear machining). Enables an oriented synchronization of the leading spindle to the following spindle due to definition of the respective coupling factors. The achievable gear quality depends on the drive-train of the machine (main spindle drive system and milling spindle drive chain). Factory installed only!!

19 EMCO HYPERTURN Page 19 of 67 S3Z 26F GLASS SCALE IN X1-AXIS-FANUC Absolute, direct measuring system (HEIDENHAIN) for the X-axis including sealing air. S3Z 21F Factory installed only!! GLASS SCALE IN Y1-AXIS-FANUC Absolute, direct measuring system (HEIDENHAIN) for the Y-axis including sealing air. S3Z 22F Factory installed only!! GLASS SCALE IN Z1-AXIS-FANUC Absolute, direct measuring system (HEIDENHAIN) for the Z-axis including sealing air. S3Z 23F Factory installed only!! GLASS SCALE IN X2-AXIS-FANUC Absolute, direct measuring system (HEIDENHAIN) for the X-axis including sealing air. S3Z 24F Factory installed only!! GLASS SCALE IN Z2-AXIS-FANUC Absolute, direct measuring system (HEIDENHAIN) for the Z-axis including sealing air. Factory installed only!! Attention: Glass scales are only available for max. number of 4 axes this is due to the FANUC SDU-Box, which can only handle 4 measuring inputs. More than 4 glass scales possible only on request!

20 EMCO HYPERTURN Page 20 of 67 MACHINE INSTALLATION KIT S3Z 460 MACHINE INSTALLATION KIT HT45 Consisting of: 4x vibration absorbing, height adjustable levelling elements 4x angle plates to fasten the machine to the floor 4x anchor bolts to lag the machine to the floor LASER MEASUREMENT AND PITCH ERROR COMPENSATION Measurement of the positioning tolerance to ISO 230 and VDI/DGQ 3441 made for all linear axis of the machine over the whole stroke including documentation for all measured axis. ATTENTION: The values can only be guaranteed under EMCO standardised environmental conditions. ONLY IN THE FACTORY Factory installed only!!

21 EMCO HYPERTURN Page 21 of 67 EMCO CPS-PILOT EMCO CPS-PILOT FOR HYPERTURN Following native data formats can be imported: ACIS, DXF, IGES, Inventor (*.ipt, *.iam), Parasolid (X_T, X_B), Solid Edge (*.par, *.psm,*.asm), SolidWorks (*.sldprt, *.sldasm), VDA; Feature transfer from Inventor, Solid Edge and SolidWorks Optional data readers are available for: CATIA, Pro/ENGINEER, SIEMENS NX, STEP, STL. The EMCO CPS-PILOT is the virtual EMCO HYPERTURN running on a PC. The user is working on an external programming unit with the virtual copy of the machine. This enables to write, test and optimize NC-programs before setting up the machine. This all allows the user to reach up most machine running time and minimizes the machine set-up time to zero. Including ToolShapes to configure the tooling for the simulation. The advantages: Siemens OPERATE user surface identical to the one of the machine The user is working as usual on the Siemens-user surface 3D simulation behaves the same as the real machine Collision monitoring for chucking, work piece, tools, tool holders and machine components. JOG and MDA mode as on the real machine Ideal for internal machining and operator training Increase of the real productivity! Automation equipment will not be simulated! Customer data: Company:. Address:. Tel.: Fax.:. Contact person:. . Customer P.O.-No.: EMCO CPS-PILOT (ADDITIONAL MACHINE ADAPTATION WITH IDENTICAL SW-VERSION) Additional machine adaptation for EMCO CPS-PILOT (224530) with the precondition, that the machine got the identical software version. (Example: Customer has a HYPERTURN 45 and wants to simulate a HYPERTURN 65-DUOTURN. In this case, both machines must have the identical Siemens software version (e.g. OPERATE 4.7) BASIC TRAINING FOR EMCO CPS-PILOT 1 day training for EMCO CPS-PILOT. Max. number of persons: 2 persons Location: EMCO in Hallein/Austria (Training at the customers facility on request!) 2 days are generally enough!

22 EMCO HYPERTURN Page 22 of 67 ESPRIT PROGRAMMING SYSTEM: EMCO-ESPRIT PACKAGE / HYPERTURN MC plus RRP LIST PRICE: ,- EURO ATTENTION: SPECIAL PRICE ACCORDING TO OFFER ONLY IN CONNECTION WITH NEW MACHINE PURCHASE! The most powerful CAD/CAM programming software for turning, milling and drilling. In only a few steps you can create the CNCprogram from a CAD drawing. 3D dynamic solid simulation shows the work piece, chucks, tools and the working area of the machine. It eliminates the need for expensive dry runs on the NC machine and prevents machine crashes. ESPRIT reads data from the following native formats: ACIS, DXF, IGES, Inventor (*.ipt, *.iam), Parasolid (X_T, X_B), Solid Edge (*.par, *.psm,*.asm), SolidWorks (*.sldprt, *.sldasm), VDA; Feature transfer from Inventor, Solid Edge and SolidWorks Optional data readers are available for: CATIA, Pro/ENGINEER, SIEMENS NX, STEP, STL. The package supports programming of: 2 spindle 2 tool turret 1 steady-rest (not synchronized) C-axes Y-axis Driven tools The package includes: ESPRIT Basis License, ESPRIT SolidTurn Production, ESPRIT SolidMillTurn Advanced, EMCO HYPERTURN standard postprocessor for Siemens or Fanuc EMCO HYPERTURN machine-model simulation Incl. ToolShapes Customer data for licensing: Company: Address: Tel.: Fax.: Contact Person: Customer P.O.-No.: ESPRIT Software-Maintenance contract not included BASIC TRAINING FOR ESPRIT CAD/CAM 3 days basic training for ESPRIT CAD/CAM software. Max. number of persons: 3 persons Location: EMCO in Hallein/Austria (Training at the customers facility on request!) S3Z 003D 3D-MACHINE DATA/HT45 3D machine model inclusive work area in STP-format. The 3D machine model data will be delivered on USB-STICK. Copyright EMCO. Passing on to third parties is not permitted in any case!

23 EMCO HYPERTURN Page 23 of 67 ACCESSORIES FOR BAR MACHINING: S3Z 700 PARTS CATCHER HYPERTURN 45 Standard parts catcher system to unload the components from the main or counter spindle into a standard part box or to the conveyor belt (optional). X1Z 140 R9Z 030 Max. finished part length: 120mm (180 mm in combination with the optional conveyor) Max. finished part diameter: 45 (51) mm Max. finished part weight: 2kg Factory installed only!! EMCO BAR LOADER INTERFACE FOR SECOND-PARTY BAR LOADERS Bar loader interface to connect non EMCO bar loader systems. The programming is done via M-functions. The signal exchange from Machine to bar loader goes through 24-pin HARDING-plug. The bar loader manufacturer must adopt the wiring and signals according to EMCO s standard pinning! NEW: Safety signals are carried out with two channels! Retrofit able through EMCO technician! MACHINE STATUS LAMP / LED The machine status lamp is divided in 3 color ranges: Red... Alarm Green... Automatic mode White... Material handling Retrofit able through EMCO technician! R6Z 220 PLASTIC INSERT PUSHING SIZE 45 to be machine customised according to bar diameter. (Ø45,4-0,1 x 68,5+0,1-11 pieces required) S4Z 270 PLASTIC INSERT PUSHING SIZE 52 to be machined customised according to bar diameter. (Ø51,4-0,1 x 74 +0,1 10 pieces required)

24 EMCO HYPERTURN Page 24 of 67 S4Z 300 FINISHED PART CONVEYOR Finished part conveyor belt to protect the parts from crashing into each other inclusive coolant recirculation and chip tray. It replaces the standard finished part box and is controlled via M-function. Effective surface for storage: 340 x 750mm Factory installed only!! EMCO SHORT BAR LOADER: S3Z 930 EMCO SL1200 FOR E45/E65/MT45/MT65/HT65-PM INCL. EMCO INTERFACE Short bar loading magazine for automatic loading of short bar stock with a diameter from 8 to 95 mm and a length up to 1200mm. The loading magazine is very compact and space-saving and also very simple to be used. Including EMCO Interface!! TECHNICAL DATA: Bar length: Bar diameter: Max. feed rate: Time for bar feed: Time for bar change: Bar storage surface: Storage capacity: or Bar in-feed side: Power supply: Air main supply: Length: Width: Pusher rod/spindle height: Weight: Safety features: mm 8 95 mm 60 m/min approx. 3 sec approx. 15 sec 560 x 1210 mm 10 bars with ø 55 mm 70 bars with ø 8 mm Backside 24 Volt DC (Interface) 6 bar 1700 mm 1250 mm mm approx. 500 kg according to CE Includes: Push rod ø 15 mm Push rod ø 8 mm Fastening material Slide system to move the loader longitudinal (approx. 400 mm) Documentation Advantages: Small foot print Simple to operate Simple and quick set-up change Possibility to load billets Easy adjustment of the diameter High-Speed function EMCO Design Loading of hexagon and square bar stock not possible!! Retrofit able through EMCO technician!

25 EMCO HYPERTURN Page 25 of 67 S3Z 450 S3Z 520 ZVZ ZVP ZVP DE 1200 EN 1200 TA 1200 FR 1200 SP 1200 SE 1200 CZ 1200 DK 1200 NL 1200 FI 1200 HU 1200 PL 1200 PT 1200 RU 1200 TR 1200 CN 1200 SPINDLE EXTENSION FOR HT45 To be able to load and support bar stock up to a length of 1200 mm through the spindle, this spindle extension is necessary. Includes 3 reduction bushings. The material must be supported very precisely with the reduction bushings to achieve a failurefree operation! Necessary in case a SL1200 is installed at the HT45 with standard 45er trough hole! Nachrüstbar durch EMCO Fachpersonal! SPINDLE EXTENSION FOR HT45-BIGBORE To be able to load and support bar stock up to a length of 1200 mm through the spindle, this spindle extension is necessary. Includes 3 reduction bushings. The material must be supported very precisely with the reduction bushings to achieve a failurefree operation! Necessary in case a SL1200 is installed at the HT45 with BigBore 51 main spindle! Nachrüstbar durch EMCO Fachpersonal! STANDARD PACKING SL1200 For easy pick-up with the forklift. Consisting of: pallet, Rolamit-cover CLIMATE PACKING SL1200 for transportation over-sea. Consisting of: pallet, dehumidifier, aluminum-cover and miscellaneous WOODENBOX SL1200 Additional protection for critical transportation SL1200 Instruction Manual / GERMAN SL1200 Instruction Manual / ENGLISH SL1200 Instruction Manual / ITALIAN SL1200 Instruction Manual / FRENCH SL1200 Instruction Manual / SPANISH SL1200 Instruction Manual / SCHWEDISH SL1200 Instruction Manual / CZECH SL1200 Instruction Manual / DANISH SL1200 Instruction Manual / DUTCH SL1200 Instruction Manual / FINNISH SL1200 Instruction Manual / HUNGARIAN SL1200 Instruction Manual / POLISH SL1200 Instruction Manual / PORTUGUESE SL1200 Instruction Manual / RUSSIAN SL1200 Instruction Manual / TURKISH SL1200 Instruction Manual / CHINESE-SIMPLE

26 EMCO HYPERTURN Page 26 of 67 EMCO TOP LOAD 8-42 / 3200: S4Z 902 EMCO TOP LOAD 8-42/3200 INCLUSIVE EMCO BAR LOADER INTERFACE- NEW Single channel Bar loader for automated loading of bar stock. Diameter range: 8 to 42mm Length: up to 3,2 meter. Economical facts: Inclusive EMCO bar loader interface Compact and stable construction Slide system to move the loader longitudinal No reduction bushings necessary Easy and fast change over Perfect bar support Remnant unloading to the back side up to ø35 mm > 35 mm to the front SERVO controlled feeding system Required bar quality: Max. deviation regarding straightness: 0,5 mm/m Bar ends must be free of burrs and may not be bent! TECHNICAL DATA: Bar length: mm Bar diameter: 8 42 mm Travelling speed: 0-30 m/min Storage capacity: approx. 235 mm (at front) Power supply: 24 Volt DC (Interface) Air pressure: min. 6,5 bar Air supply rate: approx. 45 l/min Oil filling / Viscosity: 80 litre / ISO VG 100 Length: 4310mm Width: 790mm Total height: mm Weight: approx kg Safety devices: CE compliant Includes: Fastening material Slide system to move the loader longitudinal (approx. 800mm) Conical centering sleeve 42 Clamping sleeve blank 42 (Polymer) 2x adapter (ø14/ø20mm) Documentation Retrofit able through EMCO technician! SEAWORTHY PACKING TOP LOAD 8-42/3200 and 8-50/3200 The loader is packed with aluminium bandage, for transportation over-seas.

27 EMCO HYPERTURN Page 27 of 67 S4Z 912 EMCO TOP LOAD 8-42/3200 MULTI LEVEL INCL. EMCO BAR LOADER INTERFACE- NEW Single channel Bar loader for automated loading of bar stock. Diameter range: 8 to 42mm Length: up to 3,2 meter. Economical facts: Inclusive EMCO bar loader interface Extended bar storage Compact and stable construction Slide system to move the loader longitudinal No reduction bushings necessary Easy and fast change over Perfect bar support Remnant unloading to the back side up to ø35 mm > 35 mm to the front SERVO controlled feeding system Required bar quality: Max. deviation regarding straightness: 0,5 mm/m Bar ends must be free of burrs and may not be bent! TECHNICAL DATA: Bar length: mm Bar diameter: 8 42 mm Travelling speed: 0-30 m/min MULTI LEVEL bar storage: approx mm (at front) Power supply: 24 Volt DC (Interface) Air pressure: min. 6,5 bar Air supply rate: approx. 45 l/min Oil filling / Viscosity: 80 litre / ISO VG 100 Length: 4310mm Width: 925mm Total height: mm Weight: approx kg Safety devices: CE compliant Includes: MULTI LEVEL Material storage Fastening material Slide system to move the loader longitudinal (approx. 800mm) Conical centering sleeve 42 Clamping sleeve blank 42 (Polymer) 2x adapter (ø14/ø20mm) Documentation Retrofit able through EMCO technician! SEAWORTHY PACKING TOP LOAD 8-42/3200 and 8-50/3200 The loader is packed with aluminium bandage, for transportation over-seas.

28 EMCO HYPERTURN Page 28 of 67 EMCO TOP LOAD 8-50 / 3200 FOR BIG BORE MACHINE: S4Z 917 EMCO TOP LOAD 8-50/3200 INCLUSIVE EMCO BAR LOADER INTERFACE- NEW Single channel Bar loader for automated loading of bar stock. Diameter range: 8 to 50mm Length: up to 3,2 meter. Economical facts: Inclusive EMCO bar loader interface Compact and stable construction Slide system to move the loader longitudinal No reduction bushings necessary Easy and fast change over Perfect bar support Remnant unloading to the back side up to ø45 mm > 45 mm to the front SERVO controlled feeding system Required bar quality: Max. deviation regarding straightness: 0,5 mm/m Bar ends must be free of burrs and may not be bent! TECHNICAL DATA: Bar length: mm Bar diameter: 8 50 mm Travelling speed: 0-30 m/min Storage capacity: approx. 235 mm (at front) Power supply: 24 Volt DC (Interface) Air pressure: min. 6,5 bar Air supply rate: approx. 45 l/min Oil filling / Viscosity: 80 litre / ISO VG 100 Length: 4310mm Width: 790mm Total height: mm Weight: approx kg Safety devices: CE compliant Includes: Fastening material Slide system to move the loader longitudinal (approx. 800mm) Conical centering sleeve 50 Clamping sleeve blank 50 (Polymer) 2x adapter (ø14/ø20mm) Documentation Retrofit able through EMCO technician! SEAWORTHY PACKING TOP LOAD 8-42/3200 and 8-50/3200 The loader is packed with aluminium bandage, for transportation over-seas.

29 EMCO HYPERTURN Page 29 of 67 S4Z 927 EMCO TOP LOAD 8-50/3200 MULTI LEVEL INCL. EMCO BAR LOADER INTERFACE- NEW Single channel Bar loader for automated loading of bar stock. Diameter range: 8 to 50mm Length: up to 3,2 meter. Economical facts: Inclusive EMCO bar loader interface Extended bar storage Compact and stable construction Slide system to move the loader longitudinal No reduction bushings necessary Easy and fast change over Perfect bar support Remnant unloading to the back side up to ø45 mm > 45 mm to the front SERVO controlled feeding system Required bar quality: Max. deviation regarding straightness: 0,5 mm/m Bar ends must be free of burrs and may not be bent! TECHNICAL DATA: Bar length: mm Bar diameter: 8 50 mm Travelling speed: 0-30 m/min MULTI LEVEL bar storage: approx mm (at front) Power supply: 24 Volt DC (Interface) Air pressure: min. 6,5 bar Air supply rate: approx. 45 l/min Oil filling / Viscosity: 80 litre / ISO VG 100 Length: 4310mm Width: 925mm Total height: mm Weight: approx kg Safety devices: CE compliant Includes: MULTI LEVEL Material storage Fastening material Slide system to move the loader longitudinal (approx. 800mm) Conical centering sleeve 50 Clamping sleeve blank 50 (Polymer) 2x adapter (ø14/ø20mm) Documentation Retrofit able through EMCO technician! SEAWORTHY PACKING TOP LOAD 8-42/3200 and 8-50/3200 The loader is packed with aluminium bandage, for transportation over-seas.

30 EMCO HYPERTURN Page 30 of 67 ACCESSORIES FOR EMCO TOP LOAD: CLAMPING SLEEVE (STEEL) This clamping sleeve is made out of hardened steel and needs to be ordered according to the bar stock diameter. Clamping range: Nominal diameter +/-0,25mm Clamping sleeve (steel) ø6mm Clamping sleeve (steel) ø7mm Clamping sleeve (steel) ø8mm Clamping sleeve (steel) ø9mm Clamping sleeve (steel) ø10mm Clamping sleeve (steel) ø11mm Clamping sleeve (steel) ø12mm Clamping sleeve (steel) ø13mm Clamping sleeve (steel) ø14mm Clamping sleeve (steel) ø15mm Clamping sleeve (steel) ø16mm Clamping sleeve (steel) ø17mm Clamping sleeve (steel) ø18mm Clamping sleeve (steel) ø19mm Clamping sleeve (steel) ø20mm Clamping sleeve (steel) ø21mm Clamping sleeve (steel) ø22mm Clamping sleeve (steel) ø23mm Clamping sleeve (steel) ø24mm Clamping sleeve (steel) ø25mm Clamping sleeve (steel) ø26mm Clamping sleeve (steel) ø27mm Clamping sleeve (steel) ø28mm Clamping sleeve (steel) ø29mm Clamping sleeve (steel) ø30mm Clamping sleeve (steel) ø31mm Clamping sleeve (steel) ø32mm Clamping sleeve (steel) ø33mm Clamping sleeve (steel) ø34mm Clamping sleeve (steel) ø35mm Clamping sleeve (steel) ø36mm Clamping sleeve (steel) ø37mm Clamping sleeve (steel) ø38mm Clamping sleeve (steel) ø39mm Clamping sleeve (steel) ø40mm Clamping sleeve (steel) ø41mm Clamping sleeve (steel) ø42mm Clamping sleeve (steel) ø45mm CLAMPING SLEEVE BLANK (POLYMER) 42 Needs to be machined according to the used bar stock diameter. Outside diameter 42mm. Absorbs vibration in a good way!! Tip: first into a freezer, than machining!

31 EMCO HYPERTURN Page 31 of 67 FURTHER MACHINE ACCESSORIES S3Z 610 S3Z 110 TOOL PRESETTER HT45 To measure the tool length inside the machine. The tool measuring arm is manually mounted in the machine and can be used to set tool length on both turrets. After use the arm can be stored in a storage location inside the machine housing. Advantage: Quick change over Precise tool setting Adjustment gauge VDI25 (S3Z110) to be ordered separately!! Retrofit able through EMCO technician! ADJUSTMENT GAUGE VDI 25 - RADIAL Gauge to adjust the tool presetter S3Z 610 in the machine. S4Z 140 COOLANT PISTOL / MULTIFLOW To clean the machining area from chips with coolant (Note: never use air to clean the machine!) S3Z 640 S3Z 160 Retrofit able through EMCO technician! FULL AUTOMATIC MACHINE DOOR- HT45 Automatic servo driven machine door especially for manual loaded machines. Single key operation including door safety switch-bar. Time per stroke: approx. 2sec Attention: Not possible with gantry loader! Factory installed only! AIR CONDITIONING SYSTEM HT45 used for electrical cabinet especially if the machine is located in dusty, oily and hot areas. No air exchange between outside and inside Retrofit able through EMCO technician!

32 EMCO HYPERTURN Page 32 of 67 S3Z 010 R9Z 025 S3Z 070 OIL MIST SEPARATOR Mechanical oil mist separator (RECOJET -2) for separation of water based aerosols such as cooling lubricant or spray mist. Air through put: 1000 qm/h Wattage: 250 Watt Connection diameter: ø160 mm (When using oil instead of water soluble, heavy smoke can be generated during the operation. In this case we recommend the use of an electrostatic separator. In case of low smoke generation, a filter attachment can be mounted on top of it.) Retrofit able through EMCO technician! FILTER ATTACHMENT FOR RECOJET-2 EUREVEN-F2011 filter top unit with moisturerepelling, synthetic filter material. Easy to clean. Suitable for low smoke generation. Can be easily mounted on top of the RECOJET 2 housing. Retrofit able through customer! CONNECTION NOZZLE/VACUUM SYSTEM Connection nozzle ø 160 mm to connect the machine to a centralized air vacuum system. Retrofit able through EMCO technician! CHIP TIPCART- 400 LITER Chip tipcart for emptying at ground level or with a fork truck. Safety chain at the backside. Welded sheet metal with reinforcement frame watertight. 1 steerable roller and 2 fixed rollers made of rubber ø250mm. Incl. perforated steel plate and drain hole Color: RAL 9004 / black Filling volume approx. 400 Liter (H x W x D =1090 x 900 x 1330mm) R3Z 580 FOOT PEDAL to actuate chuck or tailstock (one foot pedal needed for each) Retrofit able through EMCO technician!

33 EMCO HYPERTURN Page 33 of 67 S3Z BAR HIGH PRESSURE COOLANT PUMP / HT45-50Hz The standard pumps will be replaced by two high pressure coolant pumps with max. pressure of 24 bar. (Type. Grundfos MTR 3-36/36-50Hz) S3Z 090 Factory installed only!! 22 BAR HIGH PRESSURE COOLANT PUMP/ HT45-60Hz (NORTH AMERICA) The standard pumps will be replaced by two high pressure coolant pumps with max. pressure of 22 bar. (Type. Grundfos MTR 3-36/23-60Hz) S3Y 300 Factory installed only!! SURCHARGE FOR PAPER BAND FILTRATION UNIT INCL. CHIP CONVEYOR FOR HYPERTURN45 / BMF- BÜRENER - Coolant tank capacity 600 Liter - Floor space LxWxH:1100x1100x800mm - Filter capacity: 150 l/min for water soluble - Average output purity: approx µm - 2x screw spindle pumps MTS20-40 Delivery pressure: 25 bar Flow rate approx. 24 l/min Power: 3 kw - 2x immersion pumps (flushing) SPK2-23/15 Delivery pressure: 4,3 bar Flow rate approx. 35 l/min Power: 0,75 kw - 1 roll of filter paper - 1 unit hinge-type chip conveyor incl. prefiltration, tank and lifting pump (delivery volume approx. 170 l/min) - Electrical a. mechanical adoption - PLC adaption / painting: Graphite grey RAL7024 This is replacing the standard chip conveyor including standard coolant pumps of the basic machine! Factory installed only!

34 EMCO HYPERTURN Page 34 of 67 R2Z 670 TEST MANDREL-MAIN SPINDLE A2-5 Test mandrel (long) for main spindle A2-5 according to DIN R6Z 620 TEST MANDREL - COUNTER SPINDLE A2-5 Test mandrel (short) for counter spindle A2-5 according to DIN R2Z 650 TEST MANDREL - VDI 25 Two test mandrels VDI 25 to check turret alignment and reference point of the machine. Consisting of: Test mandrel R2Z Test mandrel R2Z S4Z 630 TEST FLANGE A2-5 To check the alignment of the X and Y axes in relation to the spindle alignment.

35 EMCO HYPERTURN Page 35 of 67 AUTOMATION (Only for machines w/ Siemens) SWING LOADER S3A M01 SWING LOADER HYPERTURN 45 GREIFERSYSTEME: Integrated loading and unloading system, programmable via Sinumerik 840D control. Two NC-servo axis guarantee a flexible and free programmable loading process. This process can be stored into the part program work-sheet. Change-over is only a matter of calling up a different work-piece. Raw parts can be stored in a gravity chute, chain-feeder or other solutions can be offered. Max. travelling speed: 60 m/min Max. swiveling speed: 180 /sec Factory installed only!! FINGER-GRIPPER W/ 180 OPENING Pneumatically operated toggle lever gripper for loading of shafts. The parts are fed in horizontally in a chute or on a conveyor. Parts can be swallowed by the chuck or clamped between centres. The unloading is done by the parts catcher. Max. part size: approx. ø30 x 200 mm Max. part weight: approx. 2 kg Factory installed only!! FINGER- GRIPPER W/ 180 OPENING MOUNTED ON AN INDEXING UNIT Pneumatically operated toggle lever gripper for loading of shafts. The parts are fed in horizontally or vertically. Parts can be swallowed by the chuck or clamped between centres. This gripper enables to flip the part for the 2 nd operation. The unloading is done by the parts catcher. Max. part size: approx. ø60 x 100 mm Max. part weight: approx. 2 kg Factory installed only!!

36 EMCO HYPERTURN Page 36 of FINGER-PARALLEL GRIPPER W/ 90 INDEXING UNIT Pneumatically operated parallel gripper to pick-up raw parts from a conveyor system. This enables oriented loading of casting and forgings. The unloading is done by the parts catcher. Max. part size: approx. ø60 x 100 mm Max. part weight: approx. 2 kg Factory installed only!! FEED-IN / FEED-OUT SYSTEMS: CHAIN FEEDER SYSTEM Conveyor system to store and feed-in raw parts. Effective length: 1300mm Effective width: 567mm (Chain module: 27,1mm). The raw parts are stored in part specific fixtures. These fixtures need to be offered and clarified by the Automation Department of EMCO in Hallein. Factory installed only!! On request! SINGLE/MULTIPLE FEED-IN CHUTE This system is used to store and feed-in round components. The parts must roll down the chute to the pick-up position. Depending on the part length, the system can be extended to up to 10 chutes. Each single chute includes raw part sensor and pick-up logic to guarantee unmanned production. Effective width to use: 600mm Factory installed only!! S3Z 700 PARTS CATCHER HYPERTURN 45 Standard parts catcher system to unload the components from the main or counter spindle into a standard part box or to the conveyor belt (optional). Max. finished part length: 120mm Max. finished part diameter: 45mm Max. finished part weight: 2kg Factory installed only!!

37 EMCO HYPERTURN Page 37 of 67 S4Z 300 FINISHED PART CONVEYOR Finished part conveyor belt to protect the parts from crashing into each other inclusive coolant recirculation and chip tray. It replaces the standard finished part box and is controlled via M-function. Effective surface for storage: 340 x 750mm Factory installed only!! GANTRY-LOADER (Only for machines w/ Siemens) S3A M02 GANTRY LOADER HYPERTURN 45 Universal loading system for HT45. NC-controlled via the machine control Sinumerik 840D solutionline. The gripper head is mounted on a rotary servo driven axis. This enables to swing the head while the gantry loader is moving. Attention: Only left-hand setup possible Traverse rates: Horizontal: 120 m/min Vertical: 60 m/min Swivel module : 1 sec/90 Loading time depends on the used gripper system: Depending on loading sequence between 8 and 20sec. Time to prepare a new raw part: approx 15sec Factory installed only! R7Y 600 WORKPIECE MAGAZINE HYPERTURN 45 Used to store raw or finished parts on 20 revolving pallets. Includes raw part recognition switch, safety guard, function control board and coolant pan. The magazine can be installed left or right. (Note in the P.O. necessary!!) Pallet size: 265x270mm Due to raw part specific fixture, the storage capacity can be increased considerable and raw parts can be pre-oriented. A finished part conveyor can be offered as an option. Factory installed only!

38 EMCO HYPERTURN Page 38 of FINISHED PART CONVEYOR HT45 The conveyor system can be installed between machine and magazine table. Attention: Right-hand setup needs special chip conveyor layout. (Note in the P.O. necessary!!) S3Y 820 ZWZ Dimension: 550x1900mm Factory installed only! 2x 3-JAW GRIPPER HEAD HT45 Four-faced gripper head PZN100 for gripper jaws with tongue and groove joint. Stroke: 10 mm Prehensile power: 1800 N Inclusive spring loaded pusher for raw part positioning. Raw part dimension: Max. diameter: 120 mm Max. length: 100 mm Max. weight: 5 kg SOFT JAW (SBR100) - LONG One soft jaw (SBR100) for gripper head PZN100 with tongue and groove joint. L H=100mm L=51mm B=30mm H B R7Y SOFT JAW (SBR100) - SHORT One soft jaw (SBR100) for gripper head PZN100 with tongue and groove joint. L H=50mm L=51mm B=30mm H B

39 EMCO HYPERTURN Page 39 of 67 R7Y JAW MACHINING ATTACHMENT (SBR100) Used to machine the soft jaws ZWZ with tongue and groove joint. R7Y JAW ADAPTOR FOR SERATED JAWS (RÖHM ø130) Necessary when using standard jaws ( or ) with a serration of 1/16 x 90 together with four sided gripper head PZN100. R7Y T-NUT FOR R7Y piece T-nut for R7Y SET OF 3 HARD JAWS Set of reversible hard jaws for RÖHM ø130 with a serration of 1/16 x SET OF 3 SOFT JAWS Set of soft jaws for for RÖHM ø130 with a serration of 1/16 x 90

40 EMCO HYPERTURN Page 40 of 67 ATTENTION: To ensure a quick and effective order-processing within the customers, our partners and EMCO, every automated project must go thru EMCO s Automation department before orderacceptance. Therefore EMCO has setup a form Catalogue of requirements Special items description (VA ). This form must be filled and forwarded to department TSS. Raw part and finished part drawings including sample parts should be forwarded as well. PACKING FOR GANTRY LOADER ZVZ ZVP ZVP STANDARD PACKING - GANTRY LOADER HT65/MT65 For easy pick-up with the forklift. Consisting of: pallet, rolamit-cover CLIMATE PACKING - GANTRY LOADER HT65/MT65 for transportation over-sea. Consisting of: pallet, dehumidifier, aluminium-cover and miscellaneous. WOODENBOX - GANTRY LOADER HT65/MT65 Additional protection for critical transportation. UNLOADING THROUGH THE COUNTER SPINDLE Information PREPARATION TO UNLOAD SHAFTS THROUGH THE COUNTER SPINDLE The standard machine can be modified to enable the unloading of long shafts through the counter spindle. Therefore the solid clamping cylinder and part ejector gets replaced by a through hole clamping cylinder. Max. work piece diameter: ø45mm (ø50)

41 EMCO HYPERTURN Page 41 of 67 CLAMPING DEVICE / MAIN SPINDLE (A2-5) POWER COLLET CHUCK 173E / A2-5 SMW- dead length collet chuck, complete with bayonet lock, for short taper A2-5 (DIN 55026), incl. mounting screws and draw tube adaptor, collets not included, Type KSZ-MB 40-A05 (nmax.:6000 rpm), clamping range: ø2-42 mm Collets refer to >spec_collets_en.doc< SPANNTOP-MODULAR COLLET CHUCK (A2-5) HAINBUCH collet chuck (pull-back style) size BZI 52 for spindle nose size A2-5, max. bar capacity ø45 (ø52)mm, no internal part-stop possible; collet changer necessary, (nmax.: 7000 rpm), incl. draw adapter SPANNTOP- COMBI COLLET CHUCK (A2-5) HAINBUCH collet chuck (pull-back style) size BZI 52 for spindle nose size A2-5, max. bar capacity ø45 (ø52)mm, incl. internal part-stop, collet changer necessary, (nmax.: 7000 rpm), incl. draw adapter SPANNTOP- COMBI AXFIX COLLET CHUCK (A2-5) HAINBUCH collet chuck (dead-length style) size BZI 52 for spindle nose size A2-5, max. bar capacity ø45 (ø52)mm, incl. internal part-stop, collet changer necessary, (nmax.: 7000 rpm), incl. draw adapter Advantage: No axial collet stroke and therefore no unfavorable tension between both spindles during take over!

42 EMCO HYPERTURN Page 42 of COLLET SK 52 BZI - ROUND HAINBUCH Collet SK 52 BZI for round bar stock, total clamping range ø 5-52mm; 0,5mm steps, To clamp on raw or finished surfaces with serrated or smooth clamping surface. Please define the clamping diameter and whether the clamping surface should be serrated or smooth! COLLET SK 52 BZI - HEXAGON HAINBUCH Collet SK 52 BZI for hexagon bar stock, total clamping range 7-45mm in 1mm steps, Please define the hexagon size to be clamped on COLLET SK 52 BZI - SQUARE HAINBUCH Collet SK 52 BZI for square bar stock, total clamping range 8-36mm in 1mm steps, Please define the square size to be clamped on MANUAL COLLET CHANGER BZI 52 To change HAINBUCH collets BZI 42/52 (Hainbuch: MQ 42/52) JAW CHUCK KFD-HS 160/3 - A2-5 RÖHM power-chuck KFD-HSø160/3 hydraulic operated, for high spindle speed and with large through-hole (ø46), incl. 1 set of hardened reversible jaws with a serration of 1/16 x 90, to mount on spindle nose size A2-5, (nmax.:8000rpm)

43 EMCO HYPERTURN Page 43 of JAW CHUCK KFD-HE A2-5 RÖHM power-chuck KFD-HE 170, hydraulic operated, with through hole (ø43), incl. set of soft jaws with a serration of 1/16 x 90 and draw tube adapt for EMCOTURN E45, for spindle nose size A2-5 (nmax. 6300rpm) smallest clamping diameter: 20mm SET OF 3 HARD JAWS Set of reversible hard jaws for and with a serration of 1/16 x 90 R3Y 230 SET OF 3 SOFT JAWS Set of soft jaws for and with a serration of 1/16 x JAW-CHUCK KNCS-N 170/3 A2-5 SMW-AUTOBLOK power chuck with quick change jaw system type KNCS-N A05 (hydraulically operated). Through hole diameter 43mm, Incl. 1 set of hardened monobloc-step jaws ground when mounted on chuck, to mount on spindle nose A2-5 (DIN55026) (nmax.:6300 rpm) SET OF 3 HARDENED BASE JAWS Set of 3 hardened base jaws type GBK 160 for power chuck with quick change jaw system Type KNCS-N A05 (574680)

44 EMCO HYPERTURN Page 44 of SET OF 3 SOFT TOP JAWS Set of 3 soft top jaws type WAK for power chuck with quick change jaw system Type KNCS-N A05 (574680) GREASE GUN SMW INCL. 2 ADAPTORS Grease gun including: - Nosepiece for cone headed grease nipple - Nosepiece for funnel grease nipple g cartridge of special grease K05 Suitable for RÖHM and SMW power chuckes. CLAMPING DEVICES FOR BIGBORE VERSION (A2-5) SPANNTOP -NOVA -MODULAR COLLET CHUCK (A2-5) BIG BORE HAINBUCH collet chuck (pull-back style) size BZI 52 for spindle nose size A2-5, max. bar capacity ø52 mm, no internal part-stop possible; collet changer necessary, (nmax.: 7000 rpm), incl. draw adapter SPANNTOP -NOVA - COMBI COLLET CHUCK (A2-5) BIG BORE HAINBUCH collet chuck (pull-back style) size BZI 52 for spindle nose size A2-5, max. bar capacity ø52 mm, incl. internal part-stop, collet changer necessary, (nmax.: 7000 rpm), incl. draw adapter

45 EMCO HYPERTURN Page 45 of SPANNTOP -NOVA - COMBI AXFIX COLLET CHUCK (A2-5) BIG BORE HAINBUCH collet chuck (dead-length style) size BZI 52 for spindle nose size A2-5, max. bar capacity ø52mm, incl. internal part-stop, collet changer necessary, (nmax.: 7000 rpm), incl. draw adapter Advantage: No axial collet stroke and therefore no unfavorable tension between both spindles during take over! R 3 JAW CHUCK KFD-HS 175/3 A2-5 BIG BORE RÖHM power-chuck KFD-HS ø175/3 hydraulic operated, for high spindle speed and with large through-hole (ø52), incl. 1 set hardened reversible jaws with a serration of 1/16 x 90, to mount on spindle nose size A2-5 (nmax.7000rpm) SET OF 3 HARD JAWS Set of reversible hard jaws for and R with a serration of 1/16 x 90 R3Y 230 SET OF 3 SOFT JAWS Set of soft jaws for and R with a serration of 1/16 x GREASE GUN SMW INCL. 2 ADAPTORS Grease gun including: - Nosepiece for cone headed grease nipple - Nosepiece for funnel grease nipple g cartridge of special grease K05 Suitable for RÖHM and SMW power chuckes.

46 EMCO HYPERTURN Page 46 of 67 TOOL HOLDER: VDI W Tool holder package HT 45 VDI25 Tool holder package consisting of: Stationary tool holder: 2x Face and O.D. Turning holder M4 left (R2Z410W) 1x Face and O.D. Turning holder M3 left (R2Z420W) 2x Face and O.D. Turning holder M4 right (R2Z230) 1x Face and O.D. Turning holder M3 right (R2Z240) 1x Cut-off holder M3 - M4 (R2Z452W) 4x I.D. Turning holder left (R2Z330W) 4x I.D. Turning holder right (R2Z350W) 3x I.D. Turning holder universal (R2Z310W) 5x Collet holder ER25 (R6Z360W) 2x Reduction bushing (ø20mm) (442560W) 2x Reduction bushing (ø16mm) (442550W) 2x Reduction bushing (ø12mm) (442540W) 2x Reduction bushing (ø10mm) (442530W) Driven tool holder: 2x Drilling/Milling holder straight 73mm (R2Z471W) 2x Angular Drilling/Milling holder left (R2Z461) 2x Angular Drilling/Milling holder right (R2Z481) 1x Set of hand-tools (446305) TOOL HOLDER FOR O.D. MACHINING VDI25: R2Z 415W Face and O.D. Turning holder - Universal Single tool holder for machining at the main spindle or counter spindle. Shank 16 x 16 mm, Spindle direction M3 and M4 - VDI 25 (according to DIN 69880) R2Z 410W Face and O.D. Turning holder M4 - left Single tool holder for machining at the main spindle or between both spindles. Shank 16 x 16 mm, Spindle direction M4 - VDI 25 (according to DIN 69880) R2Z 420W Face and O.D. Turning holder M3 - left Single tool holder for machining at the main spindle or between both spindles. Shank 16 x 16 mm, Spindle direction M3 - VDI 25 (according to DIN 69880)

47 EMCO HYPERTURN Page 47 of 67 R2Z 230 RADIAL-TOOLHOLDER M4 RIGHT Single tool holder to work at the counter spindle or between spindles, for shank 16x16mm M4 spindle direction -VDI 25 (According to DIN 69880) R2Z 240 RADIAL-TOOLHOLDER M3 RIGHT Single tool holder to work at the counter spindle or between spindles, for shank 16x16mm M3 spindle direction -VDI 25 (According to DIN 69880) R2Z 810W Double Face and O.D. Turning holder Double tool holder for machining on both spindles for shank 16 x 16 mm, Spindle direction M3/M4 - VDI 25 (according to DIN 69880) W Double facing and O.D. turning holder offset in Y axes (VDI25) 4-fold tool holder for O.D. turning on main or counter spindle; Both spindle directions M3/M4 For square shank tooling 4x 16x16mm VDI 25 R2Z 430 Facing and I.D. Turning holder Axial-tool holder for face machining at the main- or counter spindle for shank 16 x 16 mm, Spindle direction M3/M4 Inclusive EMCO adjustment plate no alignment necessary!! - VDI 25 (according to DIN 69880)

48 EMCO HYPERTURN Page 48 of 67 R2Z 452W CUT-OFF HOLDER M3 - M4 VDI 25-Single tool holder for cut-off blades 26mm height, can be used for M3 or M4 spindle direction by changing set-up, following blades can be used: Sandvik No (2mm) No (2,5mm) No (3mm) No (4mm) Iscar: No. SGFH 26-1 (1,6mm) No. SGFH 26-2 (2,2mm) No. SGFH 26-3 (3mm) No. SGFH 26-4 (4mm) TOOL HOLDER FOR I.D. TURNING VDI25: R2Z 310W I.D. Turning holder universal For I.D. machining at the main or counter spindle with internal coolant supply, Clamping seat diameter ø25mm Inclusive EMCO adjustment plate no alignment necessary!! 75mm long - VDI 25 R2Z 315W I.D. Turning holder universal-long For I.D. machining at the main or counter spindle with internal coolant supply, Clamping seat diameter ø25mm Inclusive EMCO adjustment plate no alignment necessary!! 85mm long - VDI 25 R2Z 330W I.D. Turning holder left For I.D. machining at the main spindle with internal coolant supply, Clamping seat diameter ø25mm Inclusive EMCO adjustment plate no alignment necessary!! 75mm long - VDI 25

49 EMCO HYPERTURN Page 49 of 67 R2Z 350W I.D. Turning holder right For I.D. machining at the counter spindle with internal coolant supply, Clamping seat diameter ø25mm Inclusive EMCO adjustment plate no alignment necessary!! 75mm long - VDI 25 R2Z 320W Double I.D. Turning holder For I.D. machining at the main and counter spindle with internal coolant supply, Clamping seat diameter ø25mm Inclusive EMCO adjustment plate no alignment necessary!! 75mm long - VDI W Multiple I.D. Turning holder offset in Y axes (VDI25) Multiple tool holder for I.D. machining on the main or counter spindle with internal coolant supply; For shank diameter: 4x ø25mm Inclusive EMCO adjustment plate no alignment necessary!! 75mm long - VDI 25 R6Z 360W Collet holder ER25 Collet holder ø25mm for ER25 collets; Clamping range ø1-16mm W Reduction bushing ø8mm Reduction bushing ø25mm for boring bars ø8mm W Reduction bushing ø10mm Reduction bushing ø25mm for boring bars ø10mm.

50 EMCO HYPERTURN Page 50 of W Reduction bushing ø12mm Reduction bushing ø25mm for boring bars ø12mm W Reduction bushing ø16mm Reduction bushing ø25mm for boring bars ø16mm W Reduction bushing ø20mm Reduction bushing ø25mm for boring bars ø20mm. ø25 R1Z 410 ESX 16 FLOATING REAMER HOLDER For ESX 16 collets, clamping range ø1-10mm, internal coolant supply. R6Z 890 ø25 BAR STOP Special made dampened bar stop with a ø25mm shank to be used with an I.D. Tool holder. DRIVEN TOOL HOLDER VDI25 R2Z 471W DRILLING/MILLING HOLDER STAIGHT 73 mm For drilling, milling and synchronized tapping at the main or counter spindle, ER 25 collets or Quick Flex-Modular system, i=1:1, clamping range ø1-16mm, max rpm, external coolant supply, 73 mm long - VDI 25/coupling DIN 5480 WTO:

51 EMCO HYPERTURN Page 51 of 67 R2Z 491W DRILLING/MILLING HOLDER STAIGHT 57,5 MM For drilling, milling and synchronized tapping at the main or counter spindle, ER 20 collets or Quick Flex-Modular system, i=1:1, clamping range ø1-13mm, max rpm, external coolant supply, 57,5 mm long - VDI 25/coupling DIN 5480 R2Z 461W R2Z 481W R2Z 401W WTO: ANGULAR DRILLING/MILLING HOLDER LEFT For drilling, milling and synchronized tapping at the main spindle, Inclusive EMCO adjustment plate no alignment necessary! ER 25 collets or Quick Flex-Modular system, i=1:1, clamping range ø1-16mm, max rpm, external coolant supply, 75 mm long (total height: 106 mm!) Not useable for ET332! VDI 25 / coupling DIN 5480 WTO: L ANGULAR DRILLING/MILLING HOLDER RIGHT For drilling, milling and synchronized tapping at the counter spindle, Inclusive EMCO adjustment plate no alignment necessary! ER 25 collets or Quick Flex-Modular system, i=1:1, clamping range ø1-16mm, max rpm, external coolant supply, 75 mm long (total height: 106 mm!) Not useable for ET332! VDI 25 / coupling DIN 5480 WTO: R ANGULAR DRILLING/MILLING HOLDER DOUBLE For drilling, milling and synchronized tapping at the main and counter spindle, Inclusive EMCO adjustment plate no alignment necessary! ER 25 collets or Quick Flex-Modular system, i=1:1, clamping range ø1-16mm, max rpm, external coolant supply, 75 mm long (total height: 106 mm!) Not useable for ET332! VDI 25 / coupling DIN 5480 WTO: ADDITIONAL TOOL HOLDERS ON REQUEST!

52 EMCO HYPERTURN Page 52 of SET OF SINGLE-HAND-WRENCH Patented Single-hand-wrench size 25 for comfortable clamping and unclamping of Quick Flex-quick-change adaptors. Consisting of two wrenches QUICKFLEX -STARTERSET ER25 Quickflex starter set size ER25 to be used for several drilling and milling tool holders from WTO, consisting of: Single-hand wrench; Doppelschlüssel; Clamping wrench ER25; Weldon/Wistle-Notch-adaptor ø16mm; Milling arbor holder Ø16mm; Collet adaptor ER25; QUICKFLEX -STARTERSET ER20 Quickflex starter set size ER20 to be used for several drilling and milling tool holders from WTO, consisting of: Single-hand wrench; Clamping wrench; Jaw spanner size 30; Weldon/Wistle-Notch-adaptor ø12mm; Milling arbor holder Ø16mm; Collet adaptor ER20; ZETA Collet nut and spanner wrench: COLLET NUT ER-25QF-A (WTO) Collet nut ER-25QF-A short with external thread according to DIN6499. The ZETA -Safety clamping system is a safe and trouble-free clamping system developed for machine tools. WTO:

53 EMCO HYPERTURN Page 53 of ZETA SCREW-ON-ADAPTER ED32/ER25QF (WTO) Screw-on-adapter for ZETA collet nuts ER25. With this hand adapter the collet nut can be easily crews into the holder and fastened hand-tight. WTO: SPANNER WRENCH E 32 ZETA/ER25 Spanner wrench for collet nut ER-25QF-A short. The ZETA -Safety clamping system is a safe and trouble-free clamping system developed for machine tools. WTO:

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