SMITHYCNC 622 BED MILL OPERATOR S MANUAL

Transcription

1 SMITHYCNC 622 BED MILL OPERATOR S MANUAL VERSION

2 SmithyCNC 622 BED MILL Operator s Manual SmithyCNC (Smithy Co.) 170 Aprill Dr., Ann Arbor, Michigan USA Toll Free Hotline: Fax: International: International Fax: Copyright 2008 SmithyCNC & Smithy Co. All rights reserved. No part of this manual may be reproduced or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of Smithy Co. For information on getting permission for reprints and excerpts, comments, or suggestions, contact info@smithy.com While every precaution has been taken in the preparation of this manual, Smithy Co. shall have any liability to any person or entity with respect to any loss or damage caused or alleged to be caused directly or indirectly by the instructions contained in this manual or by the computer software and hardware products described in it. Please see section on warranty and safety precautions before operating the machine. Printed and bound in the United States of America

3 TABLE OF CONTENTS 1 INTRODUCTION Thank You Important Reminder Suggestions or Comments Customer Information SMITHYCNC SYSTEM WARRANTY GENERAL SAFETY GUIDELINES Overview Safety Symbols Used in this Manual Basic Points of Safety Clothing & Safety Safety Aspects Related to Tools Work Holding Safety Aspects Related to Maintenance Safety Aspects Related to Workpiece Safety Equipment INSTALLATION & SET-UP Set-up Clearances & Conditions Power Requirments Stand Requirements Moving from Pallet to Stand Attaching the Machine to the Stand Installing Your Control Box Leveling MECHANICAL COMPONENT IDENTIFICATION & FUNCTIONS MECHANICAL MAINTENANCE Maintenance Schedule Daily Maintenance Periodic Maintenance Lubrication System Ballscrews & Guidewats Headstock & Spindle Bearings Period Maintenance Tasks Axis Bearing Adjustments/ Axis Backlash

4 X-Axis Ballscrew End Bearing Adjustment & Replacement Y-Axis Ballscrew End Bearing Adjustment Z-Axis Ballscrew End Bearing Adjustment Adjustmet of Gibs X-Axis Gibs Y-Axis Gibs Z-Axis Gibs TOOL HOLDING Overview Tool Holding Options Installing the Tooling CNC-622 BED MILL SPECIFICATIONS MACHINE PARTS DIAGRAMS Overview Diagram 1: Z-Axis Diagram 2: Column & Junction Box Diagram 3: X-Axis Table & Saddle Diagram 3A: Coolant Shield Diagram 4: Y-Axis & Machine Base Diagram 5: Stand ELECTRICAL DIAGRAM & PIN OUTS

5 1 INTRODUCTION THANK YOU FOR YOUR ORDER Congratulations on your purchase of a SmithyCNC bed mill. With proper setup and maintenance, your machine should provide many years of quality work and enjoyment. This manual covers general instructions regarding machine set-up, operation,maintenance and troubleshooting for SmithyCNC 622 Bed Mills. IMPORTANT REMINDER Before operating any SmithyCNC Bed Mill, this instruction manual and any accompanying instruction manuals must be read carefully. Instruction manuals should be kept in a safe place where they are always easily accessible for reference during the operation of the machine. While this manual has been compiled to give the general description and usage of the SmithyCNC 1240 Bed Mills, changes are possible due to continuous design and development efforts. Remember safety comes above all else. Carefully, read, follow and understand the safety information outline in chapter 3 of this manual and always let common sense be your guide. SUGGESTIONS OR COMMENTS We are interested in any suggestions you might have to improve our products and services. Feel free to contact us with your suggestions by phone or in writing. If you have comments about this operator s manual, or if you have a project you d like to share with other SmithyCNC owners, contact the SmithyCNC Company, P.O. Box 1517, Ann Arbor, MI You can also sales@smithy.com 24 hours a day. Or visit 1

6 SmithyCNC 622 Operator s Manual QUESTIONS If you have questions not covered in the manual, please call our toll-free number: Our friendly service technicians are available Monday through Friday from 8:00 a.m. to 5:00 p.m. Eastern Standard Time. You can also your questions 24 hours a day to sales@smithy.com. If you are calling from outside the United States, please dial You can also fax your questions to Don t forget to check our website periodically, where we will post updates and revisions to this manual as well troubleshooting techniques and technical advice. CUSTOMER INFORMATION Please record the information below about your SmithyCNC Bed Mill. Having this information readily available will save time if you need to contact Smithy for questions, service, accessories, or replacement parts. Model number: Serial Number: Purchase Date: Delivery Date: We look forward to a long working relationship with you, and thank you again for putting your trust in SmithyCNC. 2 Call Us Toll Free

7 2 WARRANTY INFORMATION SMITHYCNC SYSTEM WARRANTY 30 Day Trial Offer Try a Smithy for 30 days. If, for any reason within that time, you decide to return your Smithy, just call our Customer Service department at We will help you arrange shipping back to us. When we receive the machine back, we ll refund your full purchase price. Please note: return shipping charges and any shipping damage from improper repacking is your responsibility. Smithy Warranty Smithy 3-in-1 and Dedicated Machines are warranted for two years (unless otherwise noted)to the original purchaser against defects in materials and workmanship. During that time, Smithy will replace any defective parts that are returned to our warehouse, free of charge. Upon receipt of the defective parts, Smithy technicians will arrange with you to send replacement parts immediately. This warranty does not cover parts that are worn out through the negligence on the part of the operator nor does it cover consequential damages resulting from defects in material or workmanship. SmithyCNC warrants its machines and control systems for a period of one (1) year to the original purchaser from the date of purchase. If within one (1) year form the date of purchase a SmithyCNC machine and/or control system fails due to defect in material or workmanship, SmithyCNC will at their choice repair and/or replace components with new or remanufactured parts free of charge. (Some have asked why SmithyCNC machines have a shorter warranty period than Smithy manual machines. There are several reasons, but the greatest factor is that, on average, CNC automated machine tools, are operated a significantly greater number of hours per day than the average manual machine. Also, by comparison, most of our competitors selling benchtop CNC machines only offer a six (6) months warranty. Whereas SmithyCNC machine have a full one (1) year warranty.) Most warranty repairs and/or replacements are handled routinely, but sometimes request for warranty service many not be appropriate. This warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence, accidents, repairs, or lack of routine maintenance. This warranty is also void if the serial number of the machine or SmithyCNC control system has been removed or has been altered or modified. Or visit 3

8 SmithyCNC 622 Operator s Manual In no event shall Smithy be liable for indirect, incidental or consequential damages for the sale or use of the product. This disclaimer applies to both during and after the term of this warranty. We do not warrant or represent that the merchandise complies with the provisions of any law or acts unless Smithy Company so warrants. In no event shall Smithy's liability under this warranty exceed the purchase price paid for the product. Legal actions brought against Smithy Co. shall be tried in the State of Michigan, County of Washtenaw. Smithy Co. shall in no event be liable for death, injuries to persons or property for incidental, contingent, special or consequential damages arising from the use of our products. This is Smithy Co. s sole warranty and any and all warranties that may be implied by law, including any merchantability or fitness, for any particular purpose, are hereby limited to the duration of this written warranty. This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusions may not apply to you. Telephone Support (Service engineers are available 8 am to 5 pm EST): Service and Parts Tel No Fax No Address: sales@smithy.com Software and Programming Consultancy Services In addition to our customary technical support for the machines and controls, we also provide technical consulting support to our customers by providing engineering and G-code programming services. The standard rate for these services is $28.00 per hour. Our principal objective is to support you and to increase your productivity while reducing the machining cost. Give us a call for such support as and when required. Tel No Fax No Address: sales@smithy.com 4 Call Us Toll Free

9 3 GENERAL SAFETY GUIDELINES OVERVIEW General operational techniques and safety procedures will be outlined in this manual. You will note, for example, that all rotating parts, wherever feasible, are protected by specially designed covers and shields. If the machine is operated in accordance with the manufacturers instructions, it will provide you with reliable service. However, with machines of this nature, serious accidents may occur due to improper or careless operation. It is strongly recommended that you read this manual and accompanying manuals and understand thoroughly the contents of the manuals. Not every example of improper operation or unauthorized usage which may lead to malfunction or an accident can be anticipated. If a particular operation is not documented in this manual as an authorized usage of the equipment, it should be assumed that it is an unauthorized or improper usage with potential danger and should be avoided or the manufacturer should be consulted before the actual use. SAFETY This machine is provided with various safely devices to protect the operator and the machine. However, these cannot cover all aspects of safety. Therefore, the operator must thoroughly read and understand the content of this manual before the machine is turned on and operated. The operator should also take into consideration these and other aspects of safety related to his/her particular environmental conditions, materials and tools. Safety Symbols Used in this Manual Three categories of safety guidelines have been used throughout this manual. Please take note of these symbols and understand their meanings. DANGER If this action is not avoided, it will cause permanent harm to your health, such as death or serious injury, and it may also cause permanent damage to your machine. WARNING If this action is not avoided, it can cause potential harm to your health, resulting serious injury, and has potential to cause serious harm to your machine. Or visit 5

10 SmithyCNC 622 Operator s Manual CAUTION If this action is not avoided, it may cause potential harm to your health, such as minor to moderate injury, and may also cause moderate harm to your machine. Always observe the safety instructions inscribed on the safety nameplate fixed to the machine. DO NOT remove or damage these name plates. DO NOT attempt to operate or turn on the machine until you have read and understood the manuals supplied with the machine. BASIC POINTS OF SAFETY DANGER There are high voltage terminals on the electrical control panel, motors, junction boxes and other equipment. DO NOT touch any of these components under any circumstances, when the power supply is ON. Make sure that all safety covers are fitted and electrical boxes are closed and secured before the power is switched to ON. If any components or safety covers are to be removed, first switch off or disconnect the main plug. WARNING Memorize the position of the EMERGENCY STOP BUTTON on the machine so that you can press it immediately from any position in case of emergencies. DO NOT touch any of the switches accidently while the machine is in operations. DO NOT touch the tool holder while the machine is running. Under no circumstances, should you touch a rotating tool holder or workpiece while the machine is in operation mode. To prevent incorrect operation of the machine, carefully check the position of the switches before operation. If in doubt, consult this manual or a SmithyCNC technician for advise and suggestions. 6 Always unplug the main plug when the machine is not in use. Call Us Toll Free

11 General Safety Guidelines If more than one person is operating the machine, DO NOT proceed to the next step without informing the other operator(s) that you are about to do so. DO NOT modify the machine in any way that will affect safety. CAUTION DO NOT subject the machine,control box, operator panel, or the electrical control panel to high voltage surge. DO NOT change the parameters or electrical setting values without good reason. If it is becomes necessary to change the parameters or settings, first check with a Smithy technician to assue that it is safe to do so, then make a note of the original values so that it can be reset to that value, if necessary. DO NOT paint, soil, damage, modify, or remove any fo the safety nameplate. If the details become illegible or if the nameplate is lost, obtain a replacement from SmithyCNC and mount it in the original position. DO NOT remove any safety covers while the machine is in automatic operation mode. STOP all machine operations before cleaning the machine or any of the peripheral equipment. After a job has been completed, set up each part of the machine so that it is ready to be used for the next series of operations. CLOTHING & SAFETY DANGER Tie back long hair to prevent entangling with rotary tools. Wear safety equipment whenever possible. Always wear a protective mask when machining Magnesium alloys. Never wear loose or baggy clothes. DO NOT operate the machine while under the influence of drugs or alcohol. DO NOT operate the machine if you suffer from dizziness. Always use gloves when loading or unloading workpieces or tools and when removing chips from the work area to protect your hands from sharp chips and burns caused by heat generated during machining. Or visit 7

12 SmithyCNC 622 Operator s Manual WARNING Close all covers and junction boxes before running the machine. Check all electrical cables for damage to prevent electrical shock. DO NOT handle coolant with bare hands to avoid irritation. Always use wire rope or slings as per standards, suitable for the load to be supported. DO NOT remove or adjust switches to increase axis travel beyond the machine specifications. DO NOT wipe the workpiece or clear away chips with your hand or with a rag while the spindle is in operation. CAUTION DO NOT allow chips to accumulate in the work envelope. Warm up the spindle and axis motion before running the machine in automatic mode. DO NOT operate the keyboard or operation panel switches when wearing gloves. DO NOT disconnect the main power cable without switching off the CNC and PC connections. SAFETY ASPECTS RELATED TO TOOLS & WORK HOLDING WARNING Always use proper cutting tools and work holding clamps suitable for the work and within the specifications of the machine. DO NOT stall the machine during cutting due to improper feed and depth of cut suitable for the workpiece material. DO NOT operate the spindle above the rated speed of the accessories mounted in it such as tool holders. 8 Call Us Toll Free

13 General Safety Guidelines Replace worn tools as soon as they are identified. Take care not to place any part of your bocy in the machine pinching areas. CAUTION Make sure that the tool length to diameter ratio is proper to minimize vibration due to excessive overhang conditions. Make sure the drawbar and the tool holders are tightened to the proper cutting conditions before actual cutting operations. SAFETY ASPECTS RELATED TO MAINTENANCE DANGER Always disconnect the power to the machine before carrying out any maintenance work. After the power has been switched off for a minimum of 60 minutes, check voltage with a multimeter or equivalent to make sure that there is no residual voltage. WARNING Maintenance of electrical and mechanical components should only be carried out by individuals with working knowledge of the machine tool. DO NOT remove or modify switches. Clean the machine areas after the maintenance is completed. CAUTION DO NOT use compressed air to clean the machines. Or visit 9

14 SmithyCNC 622 Operator s Manual SAFETY ASPECTS RELATED TO THE WORKPLACE WARNING Always provide sufficient work space around the machine and peripheral equipment. Protect all cables from being damaged by cutting chips. SAFETY EQUIPMENT This machine is provided with various mechanical and electiracl safety devices to protect the operator and the machine. The safety devices include interlock devices and emergency stop switches. However, it is absolutely recommended and necessary that the operator familiarizes himself with the instruction manual of the machine before operating the machine. The manufacturer emphasizes that it is the sole responsibility of the operator to ensure that all operations using the SmithyCNC bed mill are carried out in completely safe manner. Neither the manufacturer nor its representative or dealers can assume responsibility for any mishaps, damage or personal injury which may occur as a result of improper operation or from failure to observe the safety precautions mentioned in this manual. 10 Call Us Toll Free

15 4 INSTALLATION & SET-UP SET-UP CLEARANCES & CONDITIONS When considering the permanent location for your SmithyCNC bed mill the following should be taken into consideration: The machine should be installed on a flat surface so that the machine does not rock or slide during operation. This location should be considered the machine s permanent location for your machine. If you need to move it, remove it from the stand first. Make sure your stand is level prior to placing the machine on the stand. Improper installation and an unleveled machine can cause both numerical error and loss of precision in your machining operation. The maximum temperature of your shop or working environment should not exceed 125 ºF. Humidity levels should not exceed 80%. Set up the bed mill stand so you have plenty of working space. Leave at least 3 to 4 feet of clearance on the operating side of the machine. Note the suggested clearances of the other sides of the machine in table 4.1. Figure 4.1 Set-up Clearances Or visit 11

16 SmithyCNC 622 Operator s Manual A Dimension B Dimension C Dimension D Dimension CNC 622 Mill 60 in 1524 mm 18 in 457 mm 30 in 762 mm 44 in 1524 mm Table 4.1 Clearance Dimensions POWER REQUIREMENTS Voltage Amps Amps CNC 622 Mill Single STAND REQUIREMENTS Table 4-2. Power Requirements You will need a stand that is capable of supporting the weight of your machine plus the maximum allowable workpiece depending on your bed mill. (Please refer to the specifications chart for the bed mill that you ordered to obtain this specification.) You will also need to add into this figure additional weight for work holding devices, cutters and coolant. A good rule is to build a stand that can support 5 to 6 times the weight of the machine without any appreciable, permanent deformation. The benchtop should be rigid, level and well-supported. If you purchased one of the optional bed mill stands available from Smithy, these stands have been designed to support the weight of the specified machine. Your work bench should be located in a vibration-free area with a floor that is designed to support the full weight of the bench, machine, accessories, and materials. Now that your machine is in place, it is important to properly secure it to your machine stand. If you purchased a stand from SmithyCNC, the holes in the stand are pre-drilled and tapped. If you make your own stand, please refer to the bolt pattern following this section. These instructions assume that you have assembled your stand per the manufacturers instructions. (The SmithyCNC-622 stand is pre-assembled.) If you purchased the optional Smithy Stand (Item ) then the holes for mounting your machine are pre-drilled and tapped. If you are making your own stand use the bolt pattern below. NOTE: The mounting holes in the base of the machine are 12 mm. 12 Call Us Toll Free

17 Installation & Set-up NOTE: Hole position in castings can vary +/- 5 mm. Before fabricating a stand check these dimensions on your machine. NOTE: Bolt hole is M12 Figure 4.2 Bolt Hole Pattern DANGER SmithyCNC strongly discourages the use of casters or wheels on metalworking machine stands. The weight of the machine could result in the stand tipping while being moved. Once the machine is mounted, consider your work bench to be permanent. If you must move the machine, first remove it from the bench. MOVING FROM PALLET TO STAND Once you have removed the crate per the instructions in the set-up guide. You will need to remove the machine from the pallet onto the stand. There are four bolts securing the machine to the base of the crate, use an adjustable wrench to remove the nuts located on the machine base. Once the nuts have been removed, tap the screws through the casting and pallet if they didn t fall through when removing the nuts. If possible, use a forklift to remove the SmithyCNC-622 from the pallet which is the method that we have elected to use and is the method illustrated below. If a forklift is not available, we suggest using an engine hoist and chains to remove your bed mill from the pallet. Step 1: Thread one strap under the machine towards the back and one strap under the machine near the front of the machine. Or visit 13

18 SmithyCNC 622 Operator s Manual Figure 4.3 Attach the tow ropes as illustrated above Step 2: Use appropriately sized tow straps or rope when lifting your machine from the pallet. (Lifting capacity should be three times the weight of the object you are lifting.) Thread one strap under the machine towards the back and one strap under the machine near the front of the machine. NOTE: Before utilizing the lifting straps, examine them for tears or fraying that might reduce the lifting capacity. Step 3: Remove the coolant shield from the table. The shield is attached to the table with a series of phillips head screws. Step 4: Remove the cap screws securing the One-Shot lube system reservoir to the machine, to avoid damage to it while removing your machine from the pallet. Figure 4.4 Remove the lubrication pump in order to attach the lifting straps/chains Step 5: Attach the tow straps or rope to the fork lift forks as illustration in figure 4.3. You should avoid straps riding on any sheet metal parts if possible as this could cause damage to these parts. Take caution when lifting your machine into position that you straps are fully supporting your machine. 14 Call Us Toll Free

19 Installation & Set-up Step 6: Once the tow ropes are in position slowly raise the machine from the pallet. Before raising the machine high enough to place it on the machine stand, check to make sure the machine is level. If it does not appear level, lower the machine back to the pallet and adjust the tow ropes so that the machine is level. Step 7: Now that the machine is relatively level, raise the machine so that it is hovering, no more then 3-4 inches, over the machine stand. Step 8: Using a straight rod (all-thread works well) to align the holes in the base of the machine to the holes in the stand. Align one corner on the front and one on the back. Step 9: Once the holes in the machine are aligned with holes in the stand, slowly lower the machine into position on the stand. Step 10: Secure the machine to the stand. (See the section in this document, securing machine to the stand.) Step 11: Once the holes in the machine are aligned with holes in the stand, slowly lower the machine into position on the stand. Step 12: Secure the machine to the stand. (See the section in this document, securing machine to the stand.) ATTACHING THE MACHINE TO THE STAND Now that your machine is in place, it is important to properly secure it to your machine stand. If you purchased a stand from Smithy, the holes in the stand are pre-drilled and tapped. If you make your own stand, please refer to the bolt pattern shown in figure 4.2 of this manual. These instructions assume that you have assembled your stand per the manufacturers instructions. Step 1: Once the holes in the base of the machine are aligned with those in the stand, secure the machine to the stand with the bolts provided with your Smithy stand. Step 2: If you have ordered the Kool-Catch Coolant Containment system with your machine, please follow the assembly instructions included with the Kool-Catch system. INSTALLING YOUR CONTROL BOX Now that your machine has been set-up, you are ready to install your control system. If you purchased a SmithyCNC EZ-Trol system or PC Ready System, please refer to the documentation sent with your control. If you have purchased the base machine, we have supplied you with the a set plugs that match the sockets on the junction box of the SmithyCNC bed mill that you purchased. You will be able to use these to wire your control system of choice to your bed mill. Please reference chapter 10 of this manual for pin-out information. Or visit 15

20 SmithyCNC 622 Operator s Manual LEVELING Before any machining of the workpiece is done, it is crucial to level your machine for best results. Step 1: Find a relatively flat place for the installation of the machine and place the machine stand in this spot taking note of the suggested clearances in table 4.1. Figure 4.5 Level shown parallel to the Y-Axis Step 2: Position the X & Y axes slides as close to the mid-stroke position as possible. (It is shipped in this position.) Step 3: Make sure your stand s feet or leveling pads are touching the ground at the same time. If not, adjust the feet to make sure the machine stand does not physically rock. Figure 4.6 Adjusting stand leveling pads Step 4: Once all the feet or leveling pads are touching the ground and the machine is not rocking. NOTE: Pictures shown in this document are assuming you have purchased the optional machine stand with your CNC bed mill. If you have constructed your own stand, adapt this process for your stand. Step 5: Place a machinist level on the mill table, parallel to the Y-axis. If the level bubble is not in the center of the scale, adjust the left and right side feet up or down to bring the bubble in the center (i.e you are tilting the machine sideways about the Y axis of the machine.) 16 Step 6: Now, place the level parallel with the X-Axis. If it is not in the center of the scale, adjust the feet at the front and rear of the machine to bring the bubble to the center. (i.e Call Us Toll Free

21 Installation & Set-up You are tilting the machine front to back about the X-axis of the machine.) Step 7: Keep the levels in place, drive the middle feet to the ground and make sure the bubble position does not change. Step 8: Once both adjustments are completed, reposition the slides several times and reposition the slides in the middle stokes. (NOTE: This is done after you have hooked the control system to your bed mill.) Step 9: Check to confirm that the machine is still level by repeating steps 5 and 6. If the machine appears to be unlevel, repeat steps 2-7. NOTE: This leveling procedure should be rechecked every 6 months to ensure machine leveling has not changed due to machine operation. Or visit 17

22 5 MECHANICAL COMPONENT IDENTIFICATION & FUNCTIONS OVERVIEW This chapter will help you to familiarize yourself with the major mechanical components and functions of the SmithyCNC-622 bed mill Figure 5.1 SmithyCNC 622 Bed Mill front view 1. Emergency Stop Button - Located at the top right side of the mill head. Press this button to stop movement of the slides and the mill spindle. Memorize the position of this switch Spindle - The SmithyCNC-622 is equipped with a 10:1 ratio spindle. The spindle nose is threaded with a build-in chuck system that uses the ER20 collets. Call Us Toll Free

23 Mechanical Component Identification & Functions 3. Working Shield - The working shield protects the user from hot chips. Opening the shield will cut power to the spindle until the shield is closed again. 4. Coolant Catch - Secured to the working table with a series of phillips head screws, the coolant catch contains coolant and chips. Coolant can be released through the drain plug located on the back left hand side of the table. 5. Y-Axis Ballscrew Cover - The Y-axis ballscrew cover protects the Y-Axis ballscrew and nut from coolant and metal chips. 6. Mill Table - The mill table supports your work piece and work holding devices. It travels along the X & Y axes via ballscrews. The table uses 7/16 t-slots. 7. X-Axis Stepper Motor - The SmithyCNC-622 mill is equipped with X, Y and Z axes stepper motors. This X-Axis stepper motor provides power for table movement along the X-Axis. See the machines specifications for motor sizes. 8. Z-Axis Bellows - Protective bellows, keep coolant and chips away from the Z-Axis column Figure 5.2 SmithyCNC 622 Bed Mill side & back view 9. Junction Box - The junction box allows for quick and easy connection to a control system. See chapter 10 for pin out information. Also, located with junction box is the access to the Z-Axis and Y-Axis stepper motors as well as the main spindle motor, driver and mill head support cylinder (compressed nitrogen gas shock.) Or visit 19

24 SmithyCNC 622 Operator s Manual 10. Power On/Off Switch - Located on the right side of the machine, when the switch is in the 12 o clock position, it is on and off is at the 3 o clock position. 11. Power Cord - The SmithyCNC-622 runs on 110 Volt power. 12. One-Shot Lube System - The one-shot lube system is located on the right hand side of the machine. The dovetail ways, ball nuts and liner bearings are lubricated when the lubrication system is activated. To sure that enough lubrication is provided, a minimum of two pumps is recommended and it is also advisable to visually check the lubrication delivery on the lubed surfaces. Lubrication is very important for machine tools since it greatly affects machine life. Use only recommended lubrication oils which are clean and free from foreign matter. Follow the maintenance scheduled in this manual. (Reference chapter 6.) 13. Mounting Points - There are four mounting holes located on the base of the machine. You will find a mounting point in each corner of the machine base. 14. Bed & Column - The bed and the column are a box type construction made of high quality grade 25 cast iron. They are designed for high rigidity with suitable cross section and ribs for reinforcement. Proper casting treatment is given to relieve the castings of any undue stress before assembly and machining is done. The X-axis, Y-axis and Z-axis slide components including the headstock assembly and table are mounted on the same base and column structure. 20 Call Us Toll Free

25 6 MECHANICAL MAINTENANCE MAINTENANCE SCHEDULE Maintaining your machine as per the schedule documented in this manual will help prolong the life of the machine and aid in the production of precision workpieces. It should be noted that the maintenance schedules listed herein, are intended to be used as a guide. The enviroment and working conditions of your shop should be taken into consideration. Daily Maintenance Perform these maintenance tasks at the beginning and at the end of work. AREA OF MAINTENANCE MAINTENANCE TASK HOW OFTEN Check for oil level Pressure build up during hand pumping Lubrication System Check for distribution film of oil on all At the start of work sliding surfaces Check for Leaks Cutting Tools & Tool Holders Tighten the drawbar Tighten work holding devices At the start of work Coolant Level (Optional) Check for level Machine Work Area Check for leakage and cleanliness Cleaning External Wiring & Cables Clean the work holding devices Clean guards Clean machine Clean Trays Check fit of cable connections Check for damaged cable At the start of work At the start & end of work At the start & end of work At the start of work Machine General Condition Check entire machien for loose or missing fasteners At the start of work Spindle Clean the spindle taper At the start of work Table 6.1 Daily Maintenance Table Or visit 21

26 SmithyCNC 622 Operator s Manual Periodic Maintenance Perform these maintenance tasks as per the schedule below. AREA OF MAINTENANCE MECHANICAL MAINTENANCE TASK HOW OFTEN Axes Backlash Check and compensate of necessary 6 months Ball Screw Guards Drive Belt Gib Adjustments* Machine Base/ Table Check condition Check condition Check tension Check table motion for fish tailing movement & adjust. Follow instructions. Check for level & mounting bolt loosening 6 months or replace as necessary 6 months or replace as necessary 6 months 6 months Tool Holder/ Drawbar Check for breakage & thread damage 1 month ELECTRICAL Electrical Cabinets Electrical Elements Check for cleanliness Check & secure any loose connections Check for proper working of push button switches 3 months 3 months Proximity Switches Check for proper operations 3 months Motors Check for condition & testing 1 month *Additional instructions given. Table 6.2 Period Maintenance Table 22 Call Us Toll Free

27 Mechanical Maintenance Lubrication System This section covers the lubrication of your machine. There are two primary areas of lubrication: areas lubricated by the single stroke lube system and the life greased bearings. CAUTION Remember, proper lubrication is very important. It greatly affects the performance and longevity of your machine. If a the machine is operated without supplying the lubricating oil, it will cause seizure of the sliding sufaces. Before opearting, visually inspect the oil on the actual machine surfaces. CAUTION Use only recommended lubrication oils which are clean and free from foreign matter. Periodically clean the tank and strainers/filters, if provided, inspect the equipment's functioning or lube supply pipes for damaged to ensure optimum machine operation. LUBRICATING POINTS LUBRICATING SYSTEM & RECOMMENDED OIL GRADE QUANTITY Headstock Bearings Grease Kluber Isoflex BU-15 Life Grease Ballscrews & Guideways Manual One Shot Lubrication Mobil-1 1 Liter Quill & Ballscrew Bearings Grease Kluber Isoflex NBU-15 Life Grease Table 6.3 Lubrication Grade Table Ballscrews & Guideways The ballscrews, liner guidways and dovetail slides are lubricated by the single stoke lubrication system. Follow the lubrication schedule in table 6.1. When lubridating the linear guideway and dovetail slide, pull the lever of the one shotlube system away and down from the machine. The number of pumps required will depend on your shop environment. Enough pumps should be administered until a thin layer of lubrication is present on the slides. Or visit 23

28 SmithyCNC 622 Operator s Manual Headstock & Spindle Bearings The bearings are of a precision class of accuracy. The spindle bearings are lubricated for life with high grade grease, such as Kluber Isoflex NBU-15. This grease maintains its lubrication properties at both low and high temperatures (- 70º F to 120º F). There is no necessary lubrication to these bearings. CAUTION If the spindle starts making abnormal noises or gets very warm above (120º F), check for damage of the spindle bearings after stopping the machine completely. The spindle should be warmed up for approximately minutes when the machine has been stopped for a long period (for example 5 or more days). PERIOD MAINTENANCE TASKS Axis Bearing Adjustment/Axis Backlash Backlash is the amount of movement the screw makes before the table engages. There are a number of signs that may indicate that there is excessive backlash with your system: Rough/uneven surface finishes Dimension inaccuracies Table shakes under machining force Even if none of these signs are present, it is recommended to check for backlash compensation every 3-6 months depending on your usage of the machine. Please note, SmithyCNC EZ-Trol software has provisions for compensating for backlash within the program. This section of the manual is addressing mechanical backlash compensation. There are three main mechanical reason for backlash: 1. Pre-loaded ball nut is damaged and is causing axial play between the nut and the screw. If the ball nut is damage, the only solution to this is to replace the ballscrew and ball nut assembly. 2. The end support bearings are damaged. If you find that the end bearings are damaged, follow the procedure below for replacing the bearings. 3. The ball nut mounting screws #70 on diagram 5, page 8-16 of this manual, are loose. In this case move the table to the end of the stroke so that the nut mounting screws #70 and #26 are accessible. Tighten the bolts and make sure the bolts or housing threads are not damaged before tightening. 4. The end bearing tightening nut is loose. Follow step 6 and 7 in the following procedure to tighten the bearings whenever required. 24 Call Us Toll Free

29 Mechanical Maintenance X-Axis Ballscrew End Bearing Adjustement & Replacement For this procedure, you will need to refer to diagram 3 on chapter 9 of this manual. Motor End Bearings Step 1: Remove #40 and 342 to see the ball screw end assembly. To replace the damaged bearings at the motor end, remove the Z axis motor #36. Remove coupling #33 by loosening the screws #31. Remove Nuts #30 and washer #39. Remove the bearings# 25, 27,26 and 24. Keep them as a set. Loosen the end bearing nuts first. Remove the damaged bearing from the housing and ball screw. Step 2: Make sure the bearings or the housing or the bearing ID seating on the screw are not heavily scored or damaged. If the bearings #25 are damaged, replace with a new set of bearings. Also ensure the new set of bearings are packed with proper amount and type of grease before replacing and tightening the end nuts #30. Step 3: First, Reinstall the coupling #33 on the ball screw. Make sure the coupling nuts are tightened properly and the coupling is seating true to the shaft. The coupling's indicated run out should be not more than 0.01 mm to 0.02 mm when measured using a dial gage. Make sure the bearing orientation is the same as the original mounting direction. Install the motor #36 back. Reinstall covers #42 and 40. Opposite End Bearings Step 4: Remove housing #5 by loosening screws #7 and removing pin #6. Step 5: Remove bearing #9 from the ball screw end. Install bearing #9 from outside of the housing. Step 6: Rotate the screw manually to ensure there is no jerky motion of the screw or the bearings are not creating any stop and go motion or are completely jammed. If you find that any of these actions, chances are that the bearing is not seated corrected, remove the bearing and reinstall. Y-Axis Ballscrew End Bearing Adjustement For this procedure, you will need to refer to diagram 4 on chapter 9 of this manual. Motor End Bearings Step 1: To replace the damaged bearings at the motor end, remove the Y axis motor #17. Remove Motor mounting plate #16. Remove coupling by loosening the screws #26. If the bearings are damaged or jammed, go to step 1A. If the lock nuts are found loose and everything else is found OK, tighten lock nuts #30 only and replace the coupling, motor mounting plate and motor. Put the covers back in place. Or visit 25

30 SmithyCNC 622 Operator s Manual Step 1A: For replacing the damaged bearing, remove lock nuts #24. Remove flange #28. Remove the bearings# 15, 32, 31,30,29. Keep them as a set. Note the orientation of the angular contact bearings and keep the same orientation after replacement. Step 2: Please make sure the bearings or the housing or the bearing ID seating on the screw are not heavily scored or damaged. If any one of bearing sets #15 and #30 are damaged, order a replacement set from the factory. Also ensure the new set of bearings are packed with proper amount and type of grease before replacing. Replace all the parts and tighten the end nuts #24. Rotate the screw and make sure the screws rotates freely and no jerky motion exists. If you feel a jerking motion, you will need to remove and reinstall the bearings so that they are seated properly. Step 3: Install the coupling back #25 first on the ball screw. Make sure the coupling bolts are tightened properly and coupling is seating true to the shaft. Coupling's indicated run out should be not more than 0.01 mm to 0.02 mm when measured using a dial gage. Reinstall the mounting plate #16 and motor #17. Install the covers #68 and 72 also. Opposite End Bearings Step 4: Remove Housing #2 by loosening screws #4 and the pin #3. Step 5: Remove bearing #6 from the ball screw end. Install bearing #6 on ball screw from outside of the housing. Replace the housing #2. Make sure bearings greased properly. Step 6: Rotate the screw manually to ensure there is no jerky motion of the screw or the bearings are not creating any stop and go motion or are completely jammed. If you feel a jerking motion, remove and reinstall the bearings so that are seated correctly. Z-Axis Ballscrew End Bearing Adjustment Motor End Bearings Step 1: Remove the covers #68 and 72 (if required). Move the Z axis slide at the top so that the ball nut is accessible. Support the spindle head by resting it on a wooden block placed between the head casting and X table first. Step 2: To replace the damaged bearings at the motor end, remove the Z axis motor #54. Remove coupling #49 by loosening the screws #51. Remove housing #48 by loosening screws #46 and #47. If the bearings are damaged or jammed, go to step 2A. If the lock nuts #45, are found loose and everything else is found OK, tighten lock nuts #45 properly only and replace the coupling, motor mounting plate and motor. Put the covers back in place. Step 2A: For replacing the damaged bearing, remove lock nuts #45. Remove flange #43, #41 (use #38) and spacer #44. Remove the set of bearings #42. Keep them as a set. Note the orientation of the angular contact bearings and keep the same orientation during replacement. Step 2: Please make sure the bearings or the housing or the bearing ID seating on the 26 Call Us Toll Free

31 Mechanical Maintenance screw are not heavily scored or damaged. If any one of the bearing sets #42 are damaged, order a replacement set of bearings from the factory. Also ensure the new set of bearings are packed with proper amount and type of grease before replacing. Reinstall housing #48. Replace all the parts in reverse order and tighten the end nuts #45. Rotate the screw and make sure the screws rotates freely and no jerky motion of the screw exists. If you feel a jerking motion, remove and reinstall the bearings so that are seated correctly. Step 3: Install the coupling back #49 first on the ball screw. Make sure the coupling bolts are tightened properly and he coupling is seating true to the shaft. Coupling's indicated run out should be not more than 0.01 mm to 0.02 mm when measured using a dial gage. Install the motor #54 and mounting housing #59 (if it was removed). Install the covers #68 and 72. Opposite End Bearings Step 4: Remove Housing #28 by loosening screws #30 and pin #29; Remove housing #32 also. Step 5: Remove bearing #31 from the ball screw end. Install bearing #31 on ball screw from outside of the housing. Replace the housing #32. Make sure bearings greased properly Step 6: Rotate the screw manually to ensure there is no jerky motion of the screw or the bearings are not creating any stop and go motion or are completely jammed. If you find a jerky motion present, remove and reseat the bearing until there no jerky motion present. Adjustment of Gibs The axes slides have taper gibs. If the slide motion proves to be sloppy or uneven, you will need to adjust the gibs until the motion evens out. The illustration in figure 6.1 shows an exaggerated cut-a-way view of the taper gib system on the SmithyCNC-622. By retracting the screw on the small end of the taper and tightening the adjustment screw on the large end of the taper, you are decreasing the gap between the saddle and the main table; thus, reducing the fish tail movement. Follow the procedure below for adjusting the gibs on each axis of the machine. Figure 6.1 Gib Adjustment Diagram Or visit 27

32 SmithyCNC 622 Operator s Manual Adjustment of X-Axis Gibs Step 1: Make sure that the slide is properly lubricated before you start adjusting the screws. Step 2: Loosen the slotted screw on the narrow end of the X-Axis table. This is number 14 on diagram 3 on chapter 9 of this manual. Step 3: Tighten screw number 22. This pushes the gib forward and reduces the the gap between the table and saddle. Note: It may be helpful to remove the limit switch cover, part number 2 by first removing parts. Step 4: Tighten number screw 14 to secure the gib in place. Adjustment of Y-Axis Gibs Step 1: Make sure that the slide is properly lubricated before you start adjusting the screws. Step 2: Loosen the slotted screw #38. Step 3: You will notice that the Y-Axis gib is notched in the front. Push the give forward, into the second notch and retighten the screw. Once the gib as worn past this point, it will need to be replaced. Adjustment of Z-Axis Gibs Step 1: To adjust the Z-Axis gib you will first need to remove part number 68, the junction box cover in diagram 2 on page 9-6 of this manual. The part does not need to be completely removed, only enough to expose the gib adjustment screw. Step 2: Loosen part number 13. Step 3: Tighten part number 8 which will push the tapered gib into the space between the dovetail column and the mill head slide. This will reduce any fishtail movement in the head. Step 4: Tighten part number 13 to secure the gib in place. Step 5: Replace part number Call Us Toll Free

33 7 TOOL HOLDING OVERVIEW The SmithyCNC-622 utilizes the a 10:1 ratio spindle with a build-in ER20 collet holder. Your machine comes complete with a set of 15 collets, ranging in size between 3/16 and 1. Tool Holding Options There are several tool holders that are used with milling machines. Arbors come in different sizes and lengths with one end tapered to suit the inside spindle taper or a straight shank arbor that works in conjunction with a collet. In the case of the SmithyCNC-622 an you will need a straight shank arbor with a diameter that can be held in the collet system. The term arbor is used for a general work holding device. Arbors can mount drill chucks, slitting saws, gear cutters and shell end mills. An arbor is secured in place with the drawbar system. Collets (Spring Collets) are the most commonly used work holding device. They come in a variety of styles and sizes. They are bored to hold a specific diameter. As the collet is drawn into the spindle of the machine, the spring collet closes or clamps down on the tool securing it in place. End Mill Adapters are made specifically to hold end mills. Like arbors they come in different sizes with one end tapered to fit the inside spindle taper or with a straight shank to work in conjunction with a spring collet. End mill adapters are bored to a specific size to hold endmills with a corresponding shank size. End mills are secured in the adapter by friction and a set screw clamps down on the flat of the end mill for extra security. Installing the Tooling Once you have determined the appropriate tooling for your operation, you will need to secure it in the mill spindle an appropriate sized supplied ER20 Collets. Step 1: Hold the collet holder with the supplied spanner wrench and place a M8 allen wrench in the cap screw at the top of the millhead. Remove the collect chuck collar. Step 2: Place the appropriate size R-8 collect in the spindle. Or visit 29

34 SmithyCNC 622 Operator s Manual Step 3: Insert your tooling into the collet. Step 4: Reinstall the collect chuck collar and tighten. Figure 7.1 (From Left to Right): Removing the collet chuck collar (1 & 2) and insterting collet (3) 30 Call Us Toll Free

35 8 CNC-622 BED MILL SPECIFICATIONS Dimension Inch Metric General Specifications Length 30.70" 780 mm Width 31.49" 800 mm Height 36.60" 930 mm Machine Weight 375 lbs 170 kg Footprint 36" x x mm Shipping Dimensions x x x 1040 x 1040mm Shipping Weight 1420 lbs 205 kg Maximum Work Capacities -Drilling mild steel Max dia 0.984" 25 mm -End Mill Capacity mm -Face Mill Capacity mm Specifications Table Size x x 160 mm Work Cube 12 x 6.5 x x 165 x 300 mm Maximum Weight on Table 33 lbs 15 kg T-Slot Size 7/16" 12 mm Slots on Table, Qty. 3 3 Table Travel X Axis 12" 300 mm Saddle Travel Y Axis 6.5" 165 mm Head Travel Z Axis 11.8" 300 mm Castings Cast Iron Cast Iron Table Surface Precision Ground Precision Ground Ways (X, Y Axis) Dovetail Dovetail Ways (Z Axis) Linear Bearings Linear Bearings Or visit 31

36 SmithyCNC 622 Operator s Manual Dimension Inch Metric Spindle Motor HP Rating 1.33 HP 1000 W Maximum Torque in-lb 5.5 Nm Drive System Geared Belt Geared Belt Minimum Speed 100 RPM 100 RPM Maximum Speed RPM 3500 RPM Positioning Accuracy + or " + or mm Repeatability " mm Quill Diameter 2.76" 70 mm Spindle to Column 7.75" mm Spindle Taper R-8 10:1 Taper 10:1 Taper Axes Stepper Motors X & Y Axis 566 in-oz 4 N-m Z-Axis 850 in-oz 6 N-m Ball Screws Pre-loaded Pre-loaded Hardened & Ground Hardened & Ground Ball Screw Size (X Axis) 0.78" x mm x 645 mm Ball Screw Size (Y Axis) 0.55" x mm x 336 mm Ball Screw Size (Z Axis) 0.78" x mm x 478 mm Ball Screw Pitch 0.157" 4 mm Ball Screw Precision P5 P5 Electrical Power Requirement 110 VAC 60 Hz 110 VAC 60 Hz Stand Specifications Stand Footprint 25.20" x 36.50" 640 x 927 mm Stand Dimensions 20 x 32 x x x 838 mm Stand Weight 75 lbs kg Stand Shipping Weight 80 lbs kg Floor Space Required 26" x 14 x x x1651 mm NOTE: Due to continual design improvements, specifications may change. To view the most up to date specifications, visit 32 Call Us Toll Free

37 9 MACHINE PARTS DIAGRAMS OVERVIEW This section shows all the necessary parts of the machine. All the diagrams are properly labellend and numbered. The reference codes and numbers are found on the Reference Chart after each diagram. Please have this section ready whenever you have questions, inquiries or in need of techinical help regarding the machine. If replacement parts are required, please call us at Toll Free to talk to a Smithy Techinician. Or visit 33

38 SmithyCNC 622 Operator s Manual DIAGRAM 1: Z-Axis 34 Call Us Toll Free

39 Machine Parts Diagrams DIAGRAM 1: Z-Axis Reference Chart Or visit 35

40 SmithyCNC 622 Operator s Manual DIAGRAM 1: Z-Axis Reference Chart 36 Call Us Toll Free

41 Machine Parts Diagrams DIAGRAM 2: Column & Junction Box Or visit 37

42 SmithyCNC 622 Operator s Manual DIAGRAM 2: Column & Junction Box Reference Chart 38 Call Us Toll Free

43 Machine Parts Diagrams DIAGRAM 2: Column & Junction Box Reference Chart Or visit 39

44 SmithyCNC 622 Operator s Manual DIAGRAM 2: Column & Junction Box Reference Chart 40 Call Us Toll Free

45 Machine Parts Diagrams DIAGRAM 3: X-Axis Table & Saddle Or visit 41

46 SmithyCNC 622 Operator s Manual DIAGRAM 3: X-Axis Table & Saddle Reference Chart 42 Call Us Toll Free

47 Machine Parts Diagrams DIAGRAM 3: X-Axis Table & Saddle Reference Chart Or visit 43

48 SmithyCNC 622 Operator s Manual DIAGRAM 3A: Coolant Shield 44 Call Us Toll Free

49 Machine Parts Diagrams DIAGRAM 4: Y-Axis & Machine Base Or visit 45

50 SmithyCNC 622 Operator s Manual DIAGRAM 4: Y-Axis & Machine Base Reference Chart 46 Call Us Toll Free

51 Machine Parts Diagrams DIAGRAM 5: Stand Or visit 47

52 SmithyCNC 622 Operator s Manual DIAGRAM 5: Stand Reference Chart 48 Call Us Toll Free

53 10 ELECTRICAL DIAGRAM & PIN OUTS OVERVIEW This section shows all the necessary electrical and pin out diagram of the machine. The diagram is properly labellend and numbered. The reference codes and numbers are found on the Reference Chart after each diagram. Please have this section ready whenever you have questions, inquiries or in need of techinical help regarding the machine. If replacement parts are required, please call us at Toll Free to talk to a Smithy Techinician. Or visit 49

54 SmithyCNC 622 Operator s Manual 50 Call Us Toll Free