Darex XPS-16 User Manual

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Table of Contents

The Darex Story ......................................................................... Page 3

Safety Instructions ..................................................................... Page 4

Cautions .................................................................................... Page 6

XPS-16 Specification Sheet .......................................................... Page 9

Capabilities & Performance .......................................................... Page 10

Touch Screen Icon Reference ...................................................... Page 13

Sharpening Your First Drill ........................................................... Page 17

Touch Screen Details .................................................................. Page 19

Custom Drill Geometry Section .................................................... Page 35

Download Details ........................................................................ Page 41

Chuck Information Standard & Collet Style ..................................... Page 47

Vacuum System Information ......................................................... Page 55

Wheel Information ....................................................................... Page

Trouble Shooting Section .............................................................. Page 63

Drill Nomenclature ....................................................................... Page 73

Drill Style Recommender ............................................................. Page 77

Machine & Vacuum Parts List w/Exploded Views ............................. Page 83

Electronics, Wiring diagrams, Service Parts Replacement Instruction

& Exploded Views ........................................................................ Page 91

Machine Axis Definition ................................................................ Page 11

Cutting Edge Advance Screen ....................................................... Page 39

Honing Information ..................................................................... Page 53

Sharpening Tips .......................................................................... Page 61

Sample Drill File Form .................................................................. Page 75

General Maintenance ................................................................... Page 79

*For Technical Service visit our web site at www.darex.com

Or call Darex 800-547-0222

PP12850KF - User Manual

The Darex Story

Darex Corporation began in 1973 in Beecher, Illinois. The D, A and R of Darex are the initials of three generations of the Bernard family; David, Arthur and Richard Bernard. David and his father Richard founded Darex. Grandfather Arthur Bernard, who earlier founded the Bernard Welding Company, contributed his energy and guidance to Darex. Art’s inventions revolutionized the welding industry.

In 1978, Darex relocated to Ashland, Oregon. Grandson Dave and son Dick carry on Arthur’s legacy of inventiveness. Darex grew to become the most recognized name in the cutting tool sharpening industry. Today, Darex is a world-leading manufacturer of precision cutting tool sharpeners.

Darex is proud to offer a complete line of quality precision cutting tool sharpeners at affordable prices. Before our first days, we at Darex had looked at our competitor’s sharpeners and asked ourselves: “Must cutting tool sharpeners be complicated? Why must the choice be limited to cost prohibitive accuracy or low price inaccuracy?” Our sharpeners prove you can have it all: Simplicity, Accuracy, and Affordability.

We have always emphasized innovative product design and tested tech n olog y. The experien ced personnel at our modern manufacturing facility use the latest production methods. The Darex marketing team knows first-hand the machines we sell and will guide you to the best machine for your needs. Our skilled technical service department is happy to answer your questions about our products or cutting tools.

The XPS-16 CNC Sharpener

The Darex XPS-16 CNC Drill Sharpener can be programmed to sharpen an infinite variety of conical, four-facet, split-point and/or radius split point drills. The XPS-16 can sharpen HSS and c arbide twist drills from 1/8” to 5/8” (316 mm) diameter, 2” to 8 ¾” long, and angles of 90 to 150 degrees. Memory stores user-defined drill point geometries. In a single set-up the Darex XPS-16 automatically sizes, aligns, then sharpens the drill and splits the point and can hone the drill’s cutting edges to minimize chipping. Benefits include: Convenient internal chuck holds drill; LCD screen display panel for one-touch programming; Long-lasting super-abrasive plated grinding wheels; “Grind Motion Control” monitors load on the grinding wheel; adjusts feed and speeds keeping drills cool, di agnostic software alerts operators of potential problems. To keep your Darex XPS-16 in top condition, please refer to the maintenance section of this manual. Replacement

wheels and parts are listed in the parts list on page 83 & 84. A schematic breakdown of the machine is on page 85 of the manual.

Safety Instructions

GROUNDING INSTRUCTIONS

• For all grounded, cord connected tools:

• In the event of a malfunction or breakdown, grounding provides a

path of least resistance for electric current to reduce the risk of electric shock. This tool is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances. Do not modify the plug provided-if it will not fit the outlet, have the proper outlet installed by a qualified electrician . I m proper connection of the equipment-grounding conductor can result in a risk of electric shock. The conductor with insulation, having an outer surface that is green with or without yellow stripes, is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal. Check with a qualified electrician or serviceman if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded. Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool’s plug. Repair or replace damaged or worn cord immediately. See Table 1. Minimum Gauge Cords below.

• Grounded, cord-connected tools intended for use on a

supply circuit having a nominal rating less than 150 volts:

This tool is intended for use on a circuit that has an outlet that looks like the one illustrated in Figure A. The tool has a grounding plug that looks like the plug illustrated in F ig ure A . A tem p orary adapter which looks like the adapter illustrated in Fig ures B and C, may be used (except in Canada) to connect this plug to a 2-pole receptacle as shown in Figure B if a properly grounded outlet is not available. The temporary adapter should be used only until a qualified electrician can install a properly grounded outlet. The green colored rigid ear lug, etc. extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box. See Fig. 1. Grounding methods below.

• Grounded cord-connected tools intended for use on a sup-

ply circuit having a nominal rating between 150-250 volts inclusive: See Table 1. Minimum Gauge Cords below.

Table 1 Minimum Gauge Cords

Fig .1

Grounding

methods

Grounding Pin

(A) (B)

Cover of

grounded

(C)

Metal

Screw

outlet box

Grounded

Means

(D)

Grounding Pin

Safety Instructions

FOR YOUR OWN SAFETY, READ INSTRUCTION MANUAL BEFORE OPERATING MACHINE! Caution:

DO NOT OPERATE MACHINE WITHOUT VACUUM SYSTEM

RUNNING

Airflow from vacuum cools grinding motor

Grinding dust inhaled/ingested can be harmful to your health

Grinding particles will cause damage to th e internal components

Caution:

WHEN USING ELECTRIC TOOLS, BASIC SAFETY PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO PREVENT THE RISK OF FIRE, ELECTRIC SHOCK AND PERSONAL INJURY, INCLUDING THE FOLLOWING:

WHEN MAINTENANCE IS PERFORMED ON SHARPENER

ALWAYS: Push the emergency stop button, unplug unit from

power supply and use a “LOCK OUT” “TAG OUT” procedure.

Follow instructions entitled “DAREX XPS-16

Maintenance" in this Instruction Manual.

Never touch internal parts of the sharpener when the

sharpener is on. The rotating grinding wheel can cause injury.

Use caution when replacing the grinding wheel. Follow

instructions entitled “Replacing The Grinding Wheel”, in this

truction Manual.

Ins

KEEP GUARDS IN PLACE and in working ord REMOVE WRENCHES and Adjusting Keys Always check to see that

any tools have been removed from the sharpener before turning it on.

KEEP WORK AREA CLEAN Cluttered areas and benches invite

accidents.

DON'T USE IN DANGEROUS ENVIRONMENT Do not use

power tools

STORE EQUIPMENT in a safe place when not in use. DON'T FORCE TOOL It will do the job better and safer at the

rate for which it was designed.

USE THE RIGHT TOOL Don’t force tool or attachment to do a

job it was not designed for.

ALWAYS USE SAFETY GLASSES TO MINIMIZE THE RISK OF

MAINTAIN TOOL WITH CARE Keep tools sharp and clean for

best and safest performance.

DISCONNECT TOOLS from the power supply before service or when changing accessories . AVOID ACCIDENTAL STARTING Make sure switch is in the

“OFF" position before plugging cord in to outlet or machine.

USE RECOMMENDED ACCESSORIES Consult the owner's

manual for recommended accessories. The use of improper accessories may cause hazards.

CHECK FOR DAMAGED PARTS Before further use of the tool, a

guard or other part that is dama ged should be carefully checked to assure that it will operate properly and perform its intended function. parts, breakage of parts, moun may affect its operation. A guard or other part that is damaged should be properly repaired or replaced.

NEVER LEAVE TOOL RUNNING UNATTENDED Turn power

off.

USE PROPER EXTENSION CORD Make sure extension cord is

in good condition. When using an extension cord be sure to use one heavy enough to carry the current the Drill Sharpener will draw. An undersize cord will cause a drop in line voltage, resulting in a loss of power and/or overheating.

DO NOT USE DAMAGED OR UNSHAPED WHEELS Use

in damp or wet locations, or expose them to rain.

INJURY, ALWAYS USE PROPER EYE AND RESPIRATORY PROTECTION: Everyday eyeglasses only have impact resistance lenses and they are NOT safety glasses. (See Decal at left.) Use appropriate respiratory face or dust mask.

Check for alignment of moving parts, binding of moving

ting and any other conditions that

er.

grinding wheels suitab

NEVER STAND ON TOOL

USE ONLY FLANGES (OR WASHERS) FURNISHED

WITH TOOL

THE CONTINUOUS A-WEIGHTED sound pressure level at

the operator’s ear is not over 60dB (A)

RISK OF INJURY DUE TO ACCIDENTAL STARTING.

Do not use in an area where children may be present.

THE WEIGHTED ROOT MEAN SQUARE ACCELERATION

VALUE to which the arms are subjected to does not exceed

2.5 m/s

KEEP CHILDREN AWAY. All visitors should be kept a

safe distance from work area.

MAKE WORKSHOP KID PROOF with padlocks, master

switches, or by removing starter keys.

WEAR PROPER APPAREL. Do not wear loose clothings,

neckties, rings, bracelets, or other jewlery which may get caught in moving parts. Nonslip footware is recommended.

Wear protective hair covering to contain long hair.

DON'T OVERREACH. Keep proper footing and balance at

all times.

le for speed of grinder

WARNING: This product contains a chemical

known to the State of California to cause cancer. Some dust created by power sanding and grinding as well as contents from the machine may contain chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Cautions

CAUTION

Do not operate machine without using vacuum system

• Grinding dust inhaled/ingested can be harmful to your health

• Grinding particles can cause damage or erratic operation of the sharpener

• Airflow from vacuum cools the grinding wheel & motor during sharpening

Do not alter length of vacuum hose

Remove wheel before cleaning

Do not operate machine in adverse environmental conditions

• Minimum 7°C (45°F) Maximum 32°C (90°F)

Do not remove jaws from springs OR springs from

spindle insert

• Jaws are positioned and then match ground. By disassembling you will compromise the concentric-

ity. Refer to information on page 47

Do not interrupt or shut down sharpening machine while in the

lube cycle

• Remove drill from chuck before pressing the Check icon to continue lube process

Do not interrupt or shut down sharpening machine while

downloading software

Use a Diamond wheel to grind carbide drills

• Grinding carbide on a CBN wheel will cause damage to the wheel

Use grounding straps and static dissipating

materials when handling electronics

Do not pinch, bend or crimp the Fiber optic

ble

• The thin black cable, can be found underneath the left side of the top

cover, fastened to the top of the spindle cartridge block

Do not over tighten chuck when securing drill

• May cause chuck to lock up

Do not replace interior lamp with substitute bulb

• Damage or erratic operation could result.

Material Safety Data Sheet

US DEPARTMENT OF LABOR Form Approved Occupational Safety and Health Administration 0MB No 44-Ri 367

Required under USDL Safety & Health Regulations for Ship Repairing, Shipbuilding and Chip breaking

MANUFACTURERS NAME: Professional Tool Mfg LLC EMERGENCY PHONE NO: (541) 488-2224 ADDRESS: 210 E. Hersey Street, Ashland, Oregon 97520 CHEMICAL NAME & SYNONYMS Diazon-Electroplated Diam Man-Made Diamond. RVG. MBG. MBS Product Families. Standard Series and 300 Series Diamond Micron Powder TRADE NAME & SYNONYMS: Electroplated CBN Wheels, Electroplated Diamond Wheels CHEMICAL FAMILY: Abrasive Any Grade

Materials are regulated by OSHA

SOLUBILITY IN WATER NI YTILIBULOS a/n ALCOHOL n/a

APPEARANCE AND ODOR Solid, Clear, White To Yellow To Dark Crystals Silver Color.

PRIMARY ROUTE(S) OF ENTRY: Inhalation, Ingestion, Skin, Eye(s)

INGESTION: If a dust, sympto .elbairav era sm

INHALATION: Move to fresh air. Give oxygen if necessary

EYE(S): Flush thoroughly with water. Obtain medical assistance

Nickel (Ni) is

INCOMPATIBILITY: (Materials to avoid) n/a HAZARDOUS COMPOSITIONS PRODUCTS: n/a CONDITIONS TO BE AVOIDED: Contact with strong acids/caustics, enclosed areas.

This page was intentionally left blank.

FORMULA: n/a

29 CFR 1910.1200, Hazard Communication Standard

SECTION IV - FIRE AND EXPLOSION HAZARD DATA

SECTION V - HEALTH, FIRST AID AND MEDICAL DATA

es fi yllaicepse( noitatirrI :NIKS

morf( noitatirrI :)S(EYE

listed as a carcinogen Avoid long exposure. Consult medical personnel for first aid and medical information

SECTION VI - CORROSIVELY AND REACTIVITY DATA

SECTION VII - SPILL, LEAK AND DISPOSAL PROCEDURES

EPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED: Normal clean up procedure

WASTE DISPOSAL METHOD: Waste will contain nickel. Dispose in accordance with all applicable Federal, state, and local regulations.

SECTION VIII – PERSONAL PROTECTION INFORMATION

RESPIRATORY PROTECTION: Respiratory protection as needed see OSHA-29 CFR 1910.134

VENTILATION: LOCAL EXHAUST: strongly preferred MECHANICAL (GENERAL): Use only if adequate to maintain below TLV’s. PROTECTIV EYE PROTECTION: Recommended see OSHA29 CFR 11910.215 OTHER PROTECTIVE EQUIPMENT: Use standard precautions for grinding operations.

NORMAL STORAGE AND HANDLING: Store in clean, dry area, away from chemicals. NORMAL USE: Use adequate ventilation (See Section VIII )

E GLOVES: As desired by user.

SECTION IX - STORAGE AND HANDLING PROCEDURES

MATERIAL SAFETY DATA SHEET

129 CFR 1915, 1916.19171

SECTION I

ond/CBN Products, Diamond (uncoated)

SECTION II COMPOSITION

SECTION III - PHYSICAL AND CHEMICAL DATA

/n TNIOP HSALF

dnomaiD lairtsudnI lekciN EMAN LACIMEHC

oN seY DETALUGER 3-04-2887 0-20-0447 :#SAC

)CONP( 3m gm 0.01 3mgm 0 1 VLT HIGA

oN seY NEGONICRAC

a/n TNIOP GNITLEM a/n )F( TNIOP GNILIOB a/n ERUSSERP ROPAV a/n YTIVARG CIFICEPS a/n ETAR NOITAROPAVE a/n YTISNED ROPAV

a/n TNEVLOS REHTO NI YTILIBULOS

a/n )%( EMULOV YB ELITALOV TNECREP

LEU LEL STIMIL ELBAMMALF )DESU DOHTEM(

a/n AIDEM GNIHSIUGNITXE

a/n :SERUDECORP GNITHGIF ERIF LAICEPS

a/n :SDRAZAH NOISOLPXE DNA ERIF LAUSUNU

ERUSOPXEREVO FO STCEFFE .)esu leehw morf tsuD( gnihtaerb ni ytluciffiD :NOITALAHNI

.) iN ot evitisn .)elcitrap dnomaid ro iN :NOITAMROFNI LACIDEM DNA DIA TSRIF

.noitnetta lacidem niatbO :NOITSEGNI

yrassecen fi pleh lacidem niatbO retaw htiw ylhguoroht hsaW :NIKS

SKSIR HTLAEH LAITNETOP REHTO

)x( elbatS ) ( elbatsnU :YTILIBATS

)x( rucco ton lliW ) ( rucco yaM :NOITAZIREMYLOP

This page was intentionally left blank.

XPS-16 Specification Sheet

CNC XPS-16

DRILL SHARPENER

DRILL HOLDER

WHEEL GUARD COVER

CHUCK

DOOR

EMERGENCY STOP

CYCLE START

CYCLE STOP

LCD TOUCH SCREEN

GRIND WHEEL STORAGE

GRIND WHEEL

XPS-16 Auto Measurement Features

Your XPS-16 has many features so carefully designed and engineered that you may not even be aware of their uniqueness. Once the cycle start button has been pushed, your Darex XPS-16 begins taking measurements of the drill, on the way to the grinding wheel. Your XPS-16 locates the end of the drill, calculates diameter, locates and positions the cutting edge, determines web thickness, identifies initial contact point of drill to the wheel and then sharpens. After sharpening and before splitting the drill, your XPS-16 sharpener again measures and re-locates the end of the drill, ensuring an accurate split.

Specifications

• Standard Grinding Wheels: 180 Grit CBN - HSS, Cobalt & 220 Grit DIA - Carbide

• Operating temperature: Not less than 7°C (45°F) or more than 32°C (90° F)

• Motor Specs: BLDC motor 115/230 V RPM 3800-3900 50/60 hz

• Power requirements: 8 amp @ 115 V; 4 amp @ 230 V

• Machine Dimensions: 66cm W x 56cm D x 30.5cm H (26” W x 22” D x 12” H)

• Machine Weight: 52 kg (115lbs)

• Shipping Dimension: 78cm W x 89cm D x 45cm H (31” W x 35” D x 18” H)

• Vacuum Dimensions: 36cm D x 49cm H (14” D x 18” H)

• Vacuum Weight: 14 kg (30lbs)

• Total Ship Weight: 66 kg (145lbs)

• Warranty: 1 year defective parts and labor

Capabilities & Performance

• Drill Types: Two fluted HSS, Cobalt or Carbide SAE & Metric twist drills

• Point Styles: Four Facet & Standard Conic points

• Split Point Styles: Standard X split and Radius split

• Point Angles: 90° - 150°

• Drill Diameter: 3mm - 16mm (.118 to .629)

• Drill Length 50.8mm - 222.3mm (2” to 8.750)

• Lip Height Accuracy: ANSI B94.11, NAS 907 and ISO 10899 Standards

• Point Angle: 90° - 150° with a tolerance of +/- 2°

• Relief: 5° - 18° margin relief with a tolerance of +/- 2°

• Split Angle: 120° - 170° with a tolerance of +/- 5°

• Fan Angle: Tolerance of +/- 15°

Tolerances

Approximate Grinding Performance Times using

drills with a standard web thickness

Material Point

Angle

(Degree)

HSS 118° .125 .005 11° 0 : 36

HSS 118° .375 .005 9° 0 : 45

HSS 118° .625 .005 7° 0 : 49 1:25

CARBIDE 135° .125 .006 11° 1 : 44

CARBIDE 135° .375 .006 9° 3 : 58

CARBIDE 135° .625 .005 7° 5 1:16

Diameter

(inch)

MTO

(inch)

Relief

(Degree)

Hone

Time

(sec)

*Grind Times:

No Split

*Grind Times: X-Split

: 56

1:13

1:08

1:30

1:59

*Approximate

grind times based on using a new grinding

wheel

Machine Axis Definition

Machine Axis definition

Touch Screen Icon Reference

TOUCH SCREEN ICON REFERENCE

For more information on Icons refer to the Touch Screen Details section pages 19 to 34

CYCLE START (GREEN) Refer to infor-

mation on page 32

CYCLE STOP (AMBER) Refer to infor-

mation on page 32

CONTINUE STOP or EXIT

HOME - SHUT DOWN/RETURN TO

Refer to information on page 32

MAIN SET UP SCREEN ICONS

POINT ANGLE SELECTION SCREEN

Refer to information on page 19

MINIMUM MATERIAL REMOVAL Re-

fer to information on page 20

MID RANGE MATERIAL REMOVAL Re-

fer to information on page 20

MAXIMUM MATERIAL REMOVAL Refer

to information on page 20

DIAMETER DETECTION SCREEN Refer

to information on page 20

WEB THICKNESS DETECTION SCREEN Refer to information on page

HONE OPTION SELECTED Refer to

information on page 21

NO HONE SELECTED Refer to infor-

mation on page 21

HONE ONLY Refer to information on

page 21

NO SPLIT SELECTED Refer to infor-

mation on page 22

STANDARD SPLIT POINT Refer to

information on page 22

RADIUS SPLIT POINT Refer to infor-

mation on page 22

MARGIN RELIEF SELECTION SCREEN

Refer to information on page 22

HIGH SPEED STEEL or COBALT MATERIAL Refer to information on page

CARBIDE MATERIAL Refer to infor-

mation on page 23

FILE MANAGEMENT - TEMPORARYMEMORY Refer to information on

page 23

Touch Screen Icon Reference

SPLIT POINT OFFSET Refer to information on page 29

TOOLS, OFFSET & MAINTENANCE PAGE Refer to information on page

QUICK START SET UP SCREEN

Found only in software with date code of

70129 or earlier

CONIC GRIND - MAIN SET UP SCREEN AND QUICK START Refer to

information on page 25

CONIC STANDARD SPLIT GRIND QUICK START Refer to information on

page 25

FACET GRIND - MAIN SET UP SCREEN AND QUICK START Refer to informa-

tion on page 25

FACET STANDARD SPLIT GRIND QUICK START Refer to information on

page 25

118-DEGREE POINT ANGLE - QUICK START Refer to information on page

135-DEGREE POINT ANGLE - QUICK START Refer to information on page

CANCEL AND RETURN TO MAIN SET UP SCREEN

MAIN SET UP 2ND

LEVEL SCREEN ICONS

“INCHES” - METHOD OF MEASUREMENT Refer to information on page

“METRIC” - METHOD OF MEASUREMENT Refer to information on page

ADVANCE Refer to information on

page 21

AUTO MODE SELECTOR Refer to in-

formation on page 20

MANUAL ALIGN KEY Refer to infor-

mation on page 21

CANCEL KEY

SAVE CHANGES

BACKSPACE WILL ERASE TEXT

TOOLS, OFFSET & MAINTE-

NANCE SCREEN 2

LEVEL

ICONS

SPACE Refer to information on page

DELETE FILE KEY Refer to informa-

tion on page 24

SAVE SCREEN - TO FLASH MEMORY

Refer to information on page 27

FILE OPEN Refer to information on

page 27

CURSOR DOWN ARROW CURSOR UP ARROW

PAGE DOWN ARROW PAGE UP ARROW

TO MOVE A MACHINE AXIS IN THE POSITIVE DIRECTION TO MOVE A MACHINE AXIS IN THE NEGATIVE DIRECTION

HONE TIMING ADJUSTMENT Refer to

information on page 31

SCREEN CONTRAST ADJUSTMENT

Refer to information on page 31

TOUCH SCREEN SENSITIVITY ADJUSTMENT Refer to information on

page 32

Touch Screen Icon Reference

HONING WHEEL POSITION OFFSET

Refer to information on page 31

HONE BRUSH EDGE OFFSET

HONE BRUSH FACE OFFSET

WHEEL POSITION OFFSET Refer to

information on page 28

WHEEL EDGE OFFSET

WHEEL FACE OFFSET

SPLIT POINT OFFSET Refer to infor-

mation on page 29

DOWN LOAD Refer to information on

page 27

UI Update Button (USER INTERFACE) – From PC to XPS-16 Refer to infor-

mation on page 41

Controller Update Button – From PC to XPS-16 Refer to information on

page 45

INACCESSIBLE TO CUSTOMER - FOR FACTORY USE ONLY Refer to infor-

mation on page 27

ALARMS AND MAINTENANCE

CONTROLLER DOWNLOADING WARNING

Refer to information on page 45

CUSTOM FILE SAVE OVER WARNING Re-

fer to information on page 24

PAUSE OR CANNOT CONTINUE AT THIS TIME Refer to information on

page 41

Restart machine Refer to infor-

mation on page 46

BROKEN CONNECTION - DOWN LOAD NOT SUCCESSFUL Refer

to information on page 64

SAVE FILES/SETTINGS - TO PC FROM XPS-16 Refer to information on page

OPEN/RESTORE FILES AND SETTING

- FROM PC TO XPS-16 Refer to infor-

mation on page 44

BELT CHANGE Refer to informat

page 28

ion on

IN LUBE CYCLE SCREEN

Refer to information on page 79

GRINDING WHEEL CHANGE NECESSARY Refer to infor-

mation on page 23

Z AXIS STAGE BEHIND THE LIMITS Refer to information on page 69

Touch Screen Icon Reference

MATERIAL TAKE OFF #1 ALARM UNABLE TO DETECT END OF DRILL Refer to

information on page 63

CUTTING EDGE DETECTION ALARM - UNABLE TO LOCATE CUTTING EDGE Refer to

information on page 63

MATERIAL TAKEOFF #2 ALARM Refer to

information on page 63

CLOSE DOOR ALARM

Refer to page 64

INSERT DRILL ALARM - NO DRILL DETECTED IN CHUCK Refer to

information on page 63

REMOVE DRILL ALARM - DRILL LEFT IN CHUCK

Refer to information on page 63

Z - AXIS ALARM Refer to

information on page 69

C-AXIS ALARM Refer to

information on page 64

A-AXIS ALARM Refer to

information on page 64

X-AXIS ALARM Refer to

information on page 64

GRIND MOTOR ERROR -

Refer to information on page 63

WHEEL TIME OUT ERROR

Refer to information on page 63

BAD CODE ERROR Re-

fer to information on page 64

Stick-Out/Facet Overlap Adjustment Refer to information on page 38

Sharpening Your First Drill

Steps to sharpening your

first drill on your CNC XPS-

Sharpening Your First Drill

1. Plug in machine and release emergency stop button.

16 Drill Sharpener.

Connect vacuum hoses and vacuum power cord to sharpener. Refer to information on page 55

2. Located on the right side of the machine is the ON/OFF rocker switch. To power up machine, push rocker switch up.

3. Touch the on the LCD Screen; the Self Test Initialization program will run. After initialization is complete the Main Set Up Screen will come up. Refer to information on page 19

4. Insert a drill in chuck. With the cutting edge rotated in approximately the 12:30 to 1:00 position, push in and hold the tip of drill up against plunger, while tightening chuck to secure drill position. Do not over tighten the chuck.

WARNING: DO NOT USE XPS-16 WITHOUT VACUUM CONNECTED. IN ADDITION TO REMOVING GRINDING PARTICLES, THE AIR FLOW COOLS THE GRINDING MOTOR.

NOTE: The plunger or stop is spring-loaded,

must push plunger

drill in all the way

5. Using the pictorial icon selections located on the Main Set Up Screen choose your desired drill point geometry. Refer to information on page 19

6. Close machine door.

7. Press cycle start

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Touch Screen Details

Power up the XPS-16 sharpener refer to informa-

tion on page 17 and connect vacuum system, for

details refer to information on page 55

Self Test Initialization Screen

The initialization screen displays important information. On the first line you will find the Darex toll free phone number, the 2 line displays the machine serial

#. The 3rd line has the current User Interface software version followed by the Controller software version. This information is necessary when updating your software or for technical inquiries.

• Remove the drill and touch the “check”

on the screen; the Self Test Initialization program will begin. The machine will begin initialization tests, checking sensors, verifying limit positions, moving and parking the machine at home. After initialization is successful, a screen will flash listing each test as passed, then immediately transferring to the Main Setup Screen.

• If initialization is unsuccessful, the word

FAILED will appear, making continuation impossible. Power down machine, restart and retry initialization. If initialization fails again, Call Darex for assistance.

XPS-16 SHARPENER TOUCH

SCREEN DETAILS

NOTE: If the touch screen remains idle for longer than 6 minutes, the LCD backlight and grinding wheel will shut down, however, the machine will remain powered up. Lightly, touch anyplace on the face of the LCD screen to activate the backlight.

Main Set-up Screen

Point Angle Screen Selector

• Sharpen point angles of *118° to 150°.

Touch the “POINT ANGLE SCREEN” Selector, the Point Angle Screen will

appear.

NOTE: Factory default is “118°”. *For 90° capabilities call Darex.

Point Angle Screen

• Type in desired point angle degree.

NOTE: If you enter a point angle outside the capability range of the sharpener, the setting will default to the closest MIN/MAX point angle degree.

• Use the “BACKSPACE” button to erase in-

formation incorrectly entered.

• Touch the “SAVE” button to store and

transfer the “New” information to the Main Set-up Screen.

• Selecting “CANCEL” will delete any

unsaved data, retrieving the most recently saved information, transferring you back to the Main Set-up Screen.

Touch Screen Details

Material Removal Selector

• Each touch of the icon

will bring up the next material removal option

You have three choices: MIN, MID or MAX

Use MIN when touching up your facet and conic ground drills Use MID when sharpening chipped facet and conic drills Use MAX when changing point angles or repairing heavily damaged points on conic drills only

MAX grind is not an option when a Facet point style is selected

NOTE: Factory default is “MIN”

SETTING

MIN .000 - .010 (.254mm) MID .005 - .015 (.127mm - .381mm) MAX .015 -.020 (.381mm - .508mm)

NOTE: The “MIN/MID/MAX” material removal grind amount is approximate. Point angle, lip relief and point style will cause the material removal amount to vary.

APPROXIMATE AMOUNT OF

MATERIAL REMOVAL

Diameter Screen Selector

• Sharpen drills with a diameter range

of .118 -.629 (3mm-16mm). Touch the icon to bring up the Diameter Screen, you have 2 options: Manual or Auto.

NOTE: Factory default is “AUTO” mode.

• When “AUTO” mode is selected, the drill

diameter will be detected automatically as it begins the sharpening cycle. The calculated diameter will be displayed in the diameter selector icon.

• Entering the drill diameter manually is an op-

tion and necessary when the drill being held in the chuck jaws is of a different diameter than that of the drill diameter actually being sharpened. (Example: Step Drill Pilot)

Diameter Selector Screen

• Use the number pad to type in the correct drill

diameter, including decimal point. The diameter entered will appear on the Main Screen Diameter Selector button and will disable the auto mode.

NOTE: If you enter a drill diameter size outside the capability range of the sharpener, the setting will default to the closest MIN/ MAX diameter size.

• Choose method of measurement, either

“inch” or “mm” (metric) . Each touch of this button will toggle between the two choices. The method of measurement selected is at the top and in slightly larger font is the selected type of measurement and all other numbers will be displayed in that choice of measurement.

• Use the “BACKSPACE” button to erase in-

formation incorrectly entered.

• Touch the “SAVE” button to store and

transfer the “New” information to the Main Set-up Screen.

• Selecting “CANCEL” will delete any

unsaved data, retrieving the most recently saved information, transferring you back to the Main Set-up Screen.

• To exit manual mode, touch the “AUTO”

button on the number pad.

Web Thickness

Screen Selector

• Detect Web thickness range from 15%

to 45% of the drills diameter or .018 .281 (.457mm-7.131mm). Touch the icon to bring up the Web Thickness Screen, you have 2 options: Manual or Auto.

NOTE: Factory default is “AUTO” mode.

• Sharpen in the “AUTO” mode when cre-

ating or regrinding drills with NO split or X split. A fiber optic sensor will calculate the web thickness as it locates the cutting edge.

• Entering the web thickness manually is neces-

sary when creating or regrinding an R split

Refer to page 35 or advancing the cutting

Touch Screen Details

edge. Refer to page 39

Web Detection Screen

• To manually input the web thick-

ness, measure thickness of the web of the drill. Measure web thickness across two points of the chisel line with calipers

• Type in web thickness, including

decimal point. The web thickness, manually entered, will appear on the Main Screen “WEB THICKNESS” Selector button and will disable the auto mode.

NOTE: If you enter a number outside the capability range of the sharpener, the setting will default to the nearest MIN/MAX web thickness for that specific diameter of drill.

Hone Selector

• With each touch of the icon

you will bring up the next honing option. You have 3

options: Hone, No Hone or Hone Only

NOTE: Factory default is “NO HONE”.

• Select “HONE” when sharpening carbide

drills. Honing the carbide cutting edge greatly influences tool life and the accuracy of the fi of hone time is adjustable. The longer the drills cutting edge remains in the honing cycle, the larger the radius produced on the cutting edge. Refer to page 53. Go to the Hone Timing Adjustment Screen in the Tools, Maintenance and Offset screen to make honing time adjustments. Refer to page 31

• Select “NO HONE” when sharpening

High Speed Steel or Cobalt drills.

• Select “HONE ONLY” when only honing

drills. Grinding and Splitting will be disabled.

nished surface. The length

Cutting Edge Advance Button

• Located within the Web Detection Screen is

the “ADVANCE” button. Using this feature may be necessary when the drills cutting edge aligns incorrectly. To compensate for incorrect cutting edge alignment, you can manually advance the cutting edge using the “ADVANCE” button . This may be necessary when sharpening drills with a hooked cutting edge

. Refer to page 39

Manual Align Button

• This feature allows you to bypass the

fiber optic sensor alignment process. Measure and enter the web thickness of the drill, if you do not enter the web thickness, the value will default to the minimum web thickness value within that range. If the diameter detection is in Auto, the web thickness value will default to the minimum once the diameter has been detected. Touch the Auto button in web detection, the Manual Align button will come up. Touch Save. Align and the web thickness will appear in the icon on the main page. Insert the drill with the cutting edge at 12 o’clock. Tighten chuck & press cycle start.

Grind Selector

• With each touch of the button

you will bring up the next point style option. The style options: Conic or Facet

NOTE: Factory default is “CONIC”.

• “CONIC” – This radial/cone style grind is

known as a conventional point through out the machine tool industry. A lip clearance of 12° to 15° at the periphery of the drill, increasing constantly toward the center, is considered standard for the average class of work.

• “FACET” – Multi faceted drill points

consist of a separate cutting lip (primary) and secondary heel clearance (relief) facet. The multi-faceted drill requires 150% less thrust and produces 70% less heat than a conventional drill.

• The width of the primary facet is determined

by the thickness of the drills web and cannot be changed. If your drill has a thin web, we do not recommend a facet point style. The width

re are 2 point

and used

Touch Screen Details

of the primary facet produced may be very thin. The thicker the web of your drill, the wider the primary facet will appear.

Facet with thin web Facet with thick web

Split Point Selector

• With each touch of the icon

you will bring up the next split style option. There are 3 split point options: No Split, X- split (Standard) and R- Split. (Radius) The XPS-16 will produce a chisel angle ground to approximately 130°.

NOTE: Factory default is “SPLIT”.

• “NO SPLIT” – Select when reproducing a

non-split drill point style.

• “X-SPLIT” – 4° split point rake angle is

created, producing a drill with a selfcentering point. Its advantages are the ability to reduce thrust and eliminate walking at the drill point. This is a distinct advantage where drilling bushings/fixtures are not used.

• “R-SPLIT” – The R-split selection is not

an option until the web thickness value has been manually entered. Changing the amount of radius and rotation is adjustable. This is done in the Split Point Offset screen . Refer to information on

page 35 for details.

• An R-split will produce a drill with a self-

centering point as well as act as a chip breaker producing smaller chips, which can readily be ejected. The radius will assist the flow of chips and reduce chip impaction at the tip of the drill.

Relief Screen Selector

• Select lip relief clearance from 5° to

18° +/-2°. The diameter and the point angle will determine the degrees of possible relief. See tables below.

NOTE: The degree of relief entered, will appear on the relief selector button on the main screen menu.

POINT ANGLE 118 – 124

DIAMETER DEGREES OF RELIEF

.118 – .245 8 – 18 .245 – .370 6 – 16

.370 – .495 5 – 14 .495 – .625 5 – 12

POINT ANGLE 125-134

DIAMETER DEGREES OF RELIEF

.118 – .245 8 – 16 .245 – .370 6 – 14 .370 – .495 5 – 12 .495 – .625 5 – 10

POINT ANGLE 135-144

DIAMETER DEGREES OF RELIEF

.118 – .245 8 –15 .245 – .370 6 – 13 .370 – .495 5 – 11 .495 – .625 5 – 9

POINT ANGLE 145-150

DIAMETER DEGREES OF RELIEF

.118 – .245 8 – 14 .245 – .370 6 – 12 .370 – .495 5 – 10 .495 – .625 5 – 8

Relief Screen

• Type in desired margin relief.

NOTE: If you enter a degree of relief outside the capability range of the sharpener or the drill diameter/point angle, the setting will default to the nearest MIN/ MAX relief amount for that specific diameter/point angle of drill.

Touch Screen Details

• Use the “BACKSPACE” button to erase in-

formation incorrectly entered.

• Touch the “SAVE” button to store and

transfer the “New” information to the Main Set-up Screen.

• Selecting “CANCEL” will delete any

unsaved data, retrieving the most recently saved information, transferring you back to the Main Set-up Screen.

Drill Material Selector

• With each touch of the icon you

will bring up the next drill material option. You have two material options: HSS (High Speed Steel) or Carbide.

NOTE: Factory default is “HSS”.

• “HSS” button is selected when sharpen-

ing drills made of High Speed Steel or Cobalt. A screen prompting you to change the wheel will appear, after changing to a CBN wheel, touch “OK”, you are ready to sharpen HSS & Cobalt drills.

• “CARBIDE” button is selected when

sharpening drills made of Carbide. The grinding speeds will be automatically reduced. A scree wheel will appear, after changing to a diamond wheel, touch “OK”, you are ready to sharpen carbide drills.

n prompting you to change the

File Management

Save/Open Screen

Selector

• You can create a file to save specific drill point

style settings or open an existing file. This will provide custom one touch setup and storage for your most frequently sharpened drills. Memory stores up to 25 user-defined drill point files.

• File 1. is the Darex Factory Standard default

file. Use this file to restore offsets to factory parameters. This file cannot be altered or deleted, and will reload its parameters and offset values each time the sharpener is powered up.

File “Open” Screen

Wheel Change prompt

• After changing

to the appropriate wheel, touch “OK” to continue. Main Set-up Screen will be brought back up. Refer

to page 58 for

wheel change information.

• This screen is just a prompt. The XPS-16 does

not know what wheel is mounted. Therefore, if you do not change the wheel as prompted, you risk damage to your wheel.

NOTE: After a wheel change, go to the File Management screen and open the #1. Darex File. Sharpen a drill and if necessary, adjust material removal and the split point center, using the Grinding Wheel Adjustment screen .

Saved files are re-opened in this screen.

• Using the “CURSOR UP” or “CURSOR

DOWN” button, move the cursor beside the file you wish to open, touch the “OPEN FILE” button .

• The information previously stored in that file

will be loaded and the Main Setup Screen will be brought up.

• The file name will appear at the top of

the “FILE SAVE/OPEN” button , identifying the file name that has been called up. All drills will be sharpened to the parameters of this file as long as the file name remains at the top of the icon.

NOTE: Any changes made while in ously saved file, will immediately exit you from that file. The file name displayed will disappear, indicating you are no longer sharpening from a saved file. To implement the

changes made, go back into the file save/ open screen and save over the existing file.

Refer to information on page 28

a previ-

Touch Screen Details

• To delete a previously saved file, place cursor

beside file and touch the “DELETE” button .

• To save a new file, touch the “SAVE”

button , the “FILE SAVE” screen will be brought up.

“File Save” Screen

In this screen, you are able to name or rename and save multiple files for future use.

Note: It is a good idea to make a hard copy using the Drill File Form. Refer to page 75

• Type in your new file name.

• Use the “SPACE” button to space between

text.

• Use the “BACKSPACE” button to erase in-

formation incorrectly entered.

• Type file name and touch the “SAVE” but-

ton . Your custom drill point style settings will be saved in Ram Memory.

• Selecting “CANCEL” will delete any

unsaved data, retrieving the most recently saved information, transferring you back to the Main Set-up Screen.

NOTE: To save over a custom file, move cursor beside the file you wish to overwrite. Touch the save button. The keypad to rename the file will come up, if it is not necessary to rename the file, touch the save button. The SAVE OVER warning will come up,

Save Over File Warning Screen

Touch the “CHECK” to complete the save over or the “X” to cancel, taking you back to the main setup screen.

Lockable Drill Files

The XPS-16 Drill Files can be locked so that they are secure from change or accidental deletion.

The method to lock the Drill File is to precede the filename with a “+” sign. Example: +135FACET

The filename can have up to nine characters including the “+” sign.

The steps to save the locked file are the same. Refer to “File Save” Screen section located on this page.

To delete or modify (re-save) the locked Drill File, users will be asked to enter the a User Password. Without the correct password, the file will remain unchanged.

To receive your User Password contact Darex at 800-547-0222.

Quick Start Screen Selector

Found only in software with date code of

70129 or earlier

• Brings up the Quick Start Main Screen

“Quick Start” Main

• This screen provides

quick, one touch point style set up. In this screen the specifications are factory set and are not adjustable, the Split Point Offset screen is disabled when using the Quick Start Screen

• Choose 4 standard

point styles, by touching the icon that resembles your desired point style.

This page was intentionally left blank.

Touch Screen Details

• As you touch the “POINT ANGLE” Selec-

tor icon in this screen, 118 or 135 will toggle alternately. The point angle brought up to the top and in slightly larger font will be the angle produced in the sharpening cycle .

• To sharpen, press “CYCLE START”.

Quick Start Point Style Selections

Conic/No Split

Conic/X Split Point

Facet/No Split

Facet/X Split Point

Quick Start Point Angle Choices

• 2 point angle options: 118° or 135°

NOTE: Factory default is “118°

Exit Quick Start Screen

• Takes you back to the Main Start-up

Screen

This page was intentionally left blank.

Touch Screen Details

Tools, Offset & Mainte-

nance Screen Selector

Main “TOOLS, OFFSETS & MAINTENANCE” Screen

Facet Overlap Adjustment See Addendum for details

Out of Limit Recovery See Addendum for details

Permanent File Save

Screen Selector

• Stores up to 25 drill files and settings at one

time. Back up your custom drill files in this screen. If files have not been saved to the permanent memory and LCD failure does occur, all custom settings and files will be lost.

WARNING: Permanent memory will hold up to 25 files at one time; to save more than 25, you must off load saved files to your PC. If you save 25 new files into permanent memory and have not saved or off loaded the previous 25 to your PC, the old files will be overwritten.

Permanent Memory Save Screen

Permanent Memory File Save Button

• To back up all files and settings saved

under Temporary Memory, touch the

“SAVE” button . Any custom files or settings changed in temporary memory will be overwritten and permanently stored.

Permanent Memory File Restoration Button

• Restore and retrieve the last 25 files and

settings saved in Permanent Memory. To restore files touch the “PERMANENT MEMORY FILE RESTORATION” button . The files will be loaded into your File SAVE/OPEN screen located on the Main set-up screen.

Setting Method of Measurement Increments, Inches or Metric.

• Use the Save Button to set the method of

measurement default for your XPS-16 sharpener. Whichever mode the machine is in at the time of saving will become the start up default.

Privacy Code Key

• Inaccessible to customer, for factory use only.

Down Load Screen

Selector

• Select this screen for in system programming

and down load capabilities. As upgrades and optional custom point styles become available, your machine is equipped to receive these files from our factory to yours. To utilize each of the following screens you will need:

1. Serial port converter with USB cable connected from PC to XPS-16

2. PC located close to XPS-16

3. Darex Sloader program must be used to transfer software upgrades and download files. For detailed instructions refer to information on

page 41 & 42

Touch Screen Details

Download Screen

UI Update Button – From PC to XPS16

Upgrade your USER INTERFACE software by touching the “UI update” button.

File Down Load Button

File Down Load button - To PC From XPS-16 Send and store your custom files to your PC

File Restoration Button

File Restoration button - From PC To XPS-16 Restore saved custom files from your PC.

Controller Update Button

Controller Update button - From PC to XPS16 Update Controller software

Belt Change Screen

Wheel Position Offset Screen

• After changing wheels, it may be necessary to

offset the edge and/or the face of the wheel. See Sharpening Tips on page 61

• After a wheel change, call up the Darex Fac-

tory default file,

Selector

• When selected, the machine will move the

grinding wheel assembly correctly into position for easy access to adjust or change the grind motor belt. Touch the “BELT CHANGE” button. The grinding wheel will move in to position to easily access the grind motor belt and pulley.

• The machine will go into an

the motor will shut down.

Restart Machine screen

structions on changing the grind motor belt.

Refer to Section 24

on hold

• Once the “Restart”

icon has come up on the screen, it is safe to

replace the belt.

• You will have to

power off the machine and restart to continue. For more in-

mode and

Wheel Position Offset Screen

Selector

• Adjust wheel offsets in this screen.

Make slight wheel offset adjustment after changing to a new or different wheel. For more information see MTO Calibration Refer to information on page 59

sharpen a drill and adjust wheel according to results produced in this program.

• Verify the amount of material removal

from the end of a drill, if it is incorrect; offset the wheel “FACE” accordingly, touch the +Z button , to increase the amount of material removed from the tip of the drill or the -Z button , to decrease the amount.

• Check the centering of the split point, if

off center, offset the wheel “EDGE” using the +X button , to move the center split line towards the chisel line on the drill point, sometimes referred to as under split or t away, some times call

he -X button to move it

ed over split.

Touch Screen Details

• After offsets are entered, touch the

“SAVE” button to store the “New” information and transfer you back to the previous screen. Changes to the wheel offset will return to previous setting unless the “PERMANENT FILE SAVE” is used. See Page 27.

• Selecting “CANCEL” will delete any

unsaved data, retrieving the most recently saved information, transferring you back to the previous screen.

Split Point Offset Screen

Selector

• In this screen you can offset 5 different areas

of the split point. A. Depth of split, B. Center of split, C. Fan Angle D. Split Angle and E. Radius Split.

Split Point Offset Screen

Α. Fan Angle: Thi

s option is more for drill aesthetics than functionality. Utilizing this option may be necessary to remove more or less of the heel to mimic a certain style. The selected split angle, amount of relief and degree of the point angle will determine the actual fan angle produced. Regard the degree entered as a reference number only, the fan angle produced has a tolerance of +/- 15°.

• Touch the “FAN ANGLE” button, the

Number Key Pad will come up.

Fan Angle

Split Angle

Depth of split: Increase depth of split

Α.

using the +Z button , or decrease depth of split using the -Z button

Past Center

To Center

Not To Center

Β. Center of split: Use the +X button , to

move the center split line towards the chisel line (removes more material) on the drill point, or the -X button , to

move

it away. (removes less material)

• Type in the desired fan angle degree.

• Touch the “SAVE” button to store the

“New” information and transfer you back to the previous screen.

• Selecting “CANCEL” will delete any

unsaved data, retrieving the most recently saved information, transferring you back to the previous screen.

D. Split Angle: Type in the desired split

angle, typically 120° to 130°. By increasing the rotation of the split angle

, the split portion of the drill meets the cutting lip at a greater angle, which will give that area more strength and durability. This added split angle creates a pointed profile at the very center of the drill, which will produce a self-centering effect and reduces drill point walking at the start of a hole.

Past Center

To Center

Not To Center

Touch Screen Details

Touch the Split Angle button, the Number Key Pad will come up.

• Type in the desired split angle degree, a toler-

ance of +/-5° can be expected.

• Touch the “SAVE” button to store the

“New” information and transfer you back to the previous screen.

• Selecting “CANCEL” will delete any

unsaved data, retrieving the most recently saved information, transferring you back to the previous screen.

*Do not use the “Split Point Offset Screen” to compensate for changes in the split point due to wheel wear or a wheel change. Make all adjustments for centering split or material removal amount in “Grinding Wheel Adjustment Screen”. Refer to page 28

E. Radius Split Offset: The R-Split button

will appear and will be functional only when a web thickness value is manually input into the “Web Thickness” Screen. The “Web Thickness” Screen is located on the “Main Set up” page. The XPS-16 calculates 30% of the entered web thickness and uses that as the offset default. If this does not produce the amount of radius desired, follow the steps below. For detailed information Refer to page 35

• Touch the “R-Split” button on the Split

Point Offset Screen; the Radius Offset Adjustment Screen will come up.

Radius Offset Adjustment Screen

• Touch the “OFFSET” button, the offset

keypad will come up.

Radius Offset Key Pad

• Adjust the radius offset by entering an offset

larger or smaller than the factory default.

• Type in the offset amount. An offset amount

of .001 will produce the largest possible radius on that drill. As your offset gets larger, the radius will become smaller.

• Touch the “SAVE” button to store the

“New” information and transfer you back to the previous screen.

• Selecting “CANCEL” will delete any

unsaved data, retrieving the most recently saved information, transferring you back to the previous screen.

Adjusting The Rotation of the ARC/C axis

• Adjust the stopping point of the C axis or ARC/

Rotation of the radius. The factory default is 5°. This will stop the cutting edge of the drill 5° from the grinding wheel. In most cases ad-

Touch Screen Details

justment of the C axis will not be necessary. Adjustment may be needed if the factory default allows too much rotation and the grinding wheel nicks the cutting edge.

• The +C button will stop the rotation of

the cutting edge further away from the grinding wheel.

• The -C button will stop the rotation of

the cutting edge closer to the grinding wheel. Refer to page 35 for details on R-Split

offsets.

• Touch the “SAVE” button to store the

“New” information and transfer you back to the previous screen.

• Selecting “CANCEL” will delete any

unsaved data, retrieving the most recently saved information, transferring you back to the previous screen.

Honing Wheel Offset Ad-

justment Screen Selector

• You will have up to .125 range of adjustment

to change the position of drill to the face and edge of the honing brush.

Honing Wheel Adjustment Screen

• After adjustments are entered, touch the

“SAVE” button to store the “New” information and transfer you back to the previous screen.

• Selecting “CANCEL” will delete any

unsaved data, retrieving the most recently saved information, transferring you back to the previous screen.

•

Hone Timing Adjustment

Screen Selector

• Adjust the length of time the cutting edge is in

the honing cycle. Select from .010 up to 60.0 seconds. To produce a larger radius, increase the length of time the cutting edge is in the hone cycle.

Use this screen to adjust the drills position relative to the honing brush.

• To move the drill position across the face

of the brush, adjust the wheel “EDGE”. Use the +X button, to move to the hone brush to the right or the -X button, to move it to the left.

• To adjust the depth the drill travels into

the brush, adjust the wheel “FACE” ac- cordingly; use the +Z button, to move drill deeper into the hone brush or the -Z button, to back out of the hone brush.

Hone Timing Adjustment Screen

• Type in desired seconds of hone time. For

more information on “Honing” see page 53

• After hone time is entered, touch the

“SAVE” button to store the “New” information and transfer you back to the previous screen.

• Selecting “CANCEL” will delete any

unsaved data, retrieving the most recently saved information, transferring you back to the previous screen.

Contrast Adjustment

Screen Selector

• Adjust the contrast of the LCD screen. Select

10 as darkest thru 65 as lightest.

NOTE: the factory default is 42

Touch Screen Details

Contrast Adjustment Screen

• Adjust screen contrast, using “ARROW

UP” to increase the contrast number, making the screen lighter or “ARROW DOWN” button to decrease the number, making the screen darker.

• After adjustment is entered, touch the

“SAVE” button to store the “New” information and transfer you back to the previous screen.

• Selecting “CANCEL” will delete any

unsaved data, retrieving the most recently saved information, transferring you back to the previous screen.

Touch Key Delay Screen

Selector

• Adjust the sensitivity of the touch screen but-

tons. Select 50 as the most sensitive setting and up to 550, as the least sensitive.

NOTE: Factory default is 200

Touch Key Delay Screen

• Adjust Touch Key sensitivity according to your

touch, using the “ARROW UP” button will increase the number, decreasing the sensitivity of the touch screen or the “ARROW DOWN” button will increase sensitivity, decreasing the number.

• After adjustment is entered, touch the

“SAVE” button to store the “New” information and transfer you back to the previous screen.

• Selecting “CANCEL” will delete any

unsaved data, retrieving the most recently saved information, transferring you back to the previous screen.

Cycle Start

• Start the sharpening process by touching

“CYCLE START”. If machine door is open you will get the Open Door alarm. Close door and press “CYCLE START” to continue.

Cycle Stop

• By touching the “CYCLE STOP” button , you

will immediately interrupt the sharpening process; the machine will pause and remain idle. You cannot resume sharpening once the sharpening cycle has been interrupted.

• The Home

Screen will appear.

• To abort the sharpening cycle, touch the

“HOME” Icon, the sharpening program will be aborted, the grinding motor will shut down and the sharpening fixture will return to its home position.

• If the “HOME” button is not selected, the

machine will start a 59 second count down, at the end of the countdown, the sharpening program will then be aborted, the grinding motor will shut down and the sharpening fixture will return to its home position. The Main Set-up Screen will come up.

• After re-chucking the drill, press “CYCLE

START”. The sharpener has retained the previous set up information.

Touch Screen Details

90° Software Update Hone Only Option

With this software upgrade you will now have all the great features of your original XPS-16 but will now have the ability to sharpen below the 118° point angle range. After the software has been successfully installed in your XPS-16, your point angle range will increase. You can now sharpen drills from 90° - 150°. Please read through the accompanying operating manual. In addition to the increase point angle range, there are some added features you may not be aware of and /or will need to know to successfully sharpen 90° drill points.

• Sharpening drills at 90°-117° can only be

sharpened as a CONIC point style, the FACET point option is disabled.

• You now have the option to bypass the fiber

optic sensor and align the drills cutting edge manually, see page 21 of the ops manual. When you choose a point angle of 90° - 117° your machine will default to manual alignment. This requires the operator to manually align the cutting edge vertically.

(12-o'clock) When correctly aligned the chisel angle produced should be between 120° 130°.

• The diameter range is limited to 5mm -16 mm.

• You can choose the Honing option just as

before. A new feature in this software package is a HONE ONLY option, see page 21 of the manual. When hone only has been chosen the grind and split options are disabled.

Manual Alignment

• The diameter detection can be used in Auto

or in Manual as before.

• We recommend that you measure and enter

the web thickness manually. You can use AUTO Web detection but the machine will then automatically calculate 15% of the detected diameter and register that number as the web thickness.

• You can select the lip relief amount just as

before. The relief will vary depending on how accurately the operator aligns the cutting edge of the drill in the vertical position. Advancing and retarding the cutting edge alignment will increase and decrease the chisel angle and relief respectively.

• We do not recommend sharpening drills 3mm

to 4mm in diameter at 90°-120°. These drills are too small. Most of the time, the drill will miss the MTO2 sensor, triggering an alarm and causing the machine to stop in cycle and go home.

This page was intentionally left blank.

Radius Spilt Offset Screen

Why & How to Offset the Radius Split

WHY: The Radius Split Offset feature is avail-

able and functional only after you have manually entered the web thickness in the Web Diameter Detection screen, located on the Main Screen Setup page.

• Some drill styles have more of a radius on the

split than others. When re-sharpening a drill, you may want to mimic an existing radius split or create even more of a radius. The Offset keypad allows you to change the default-offset value.

• The XPS-16 calculates 30% of the entered

web thickness as the radius split offset default.

• To create a smaller radius, enter a larger off-

set value, or a smaller value to create a larger radius. A value entered of .001 will produce the largest radius possible.

HOW: Touch the Web Thickness button

located on main screen.

• The Web Detection Screen will come up.

Web Detection Screen

• The web thickness must be en-

tered manually. Measure web of drill. Measure web thickness across two points of the chisel line with calipers.

• Type in web thickness.

• Touch the “SAVE” button to store

and transfer the “New” information to the Main Set-up Screen. The web thickness entered will appear on the “WEB THICKNESS” Selector button.

• On the TOOLS, OFFSETS & MAINTE-

NANCE page, touch the Split Point Off-

set button.

• The Split Point Offset screen will come

up.

Split Point Offset Screen

If a web thickness diameter has not been entered, the R-Split button is not an option and will not appear on the Split Point Offset screen.

• Touch the R-Split button on the Split

Point Offset page; the Radius Offset Adjustment Screen will come up.

Radius Offset Adjustment Screen

• Touch the OFFSET button; the Radius Offset

Keypad will come up.

Radius Spilt Offset Screen

Radius Offset Keypad

• Type in the offset amount. An offset amount

of.001 will produce the largest possible radius. As your offset gets larger the radius will become smaller.

Diagram of ra dius split s howing offset variable. Larger off set creates smaller radius, smaller off set creates larger radius. Offset can be from 1% - 5 0%o f web thickness dimension. Dotted lines indicate large and small radius.

Centerline of radius tangent to chisle l ine and c utting edge.

Chislelin e

Center line of radi us centers bisect t he chisle an gle of the chisle line and cutt ing edge.

Small o ffset from center

Chisle line

NOTE: It may be more difficult to achieve a larger radius on drills with split angles greater than 120°.

120° radius Split

120° Radius Split

Large offset from ce nter

View

The greater split angle, the less apparent the radius. See view B

160° Radius Split

160° radius Split

View

• Touch the “SAVE” button to store the

“New” information and transfer you back to the previous screen.

• Selecting “CANCEL” will delete any

unsaved data, retrieving the most recently saved information, transferring you back to the previous screen.

Adjusting The C axis

• Adjust the stopping point of the C axis. The

factory default is 5°. This will stop the opposite cutting edge of the drill 5° from the grinding wheel. In most cases, adjustment of the C axis will not be necessary. Adjustment is necessary only if the C axis rotates too far into the grinding wheel nicking the cutting edge of the drill.

If drill rotates to far, a negative

If drill rotates too far, a negative rake is noticeable on the outside corners of

rake is noticable on the outside

cutting lip

corners of cutting lip

Radius Spilt Offset Screen

• The +C button will stop the rotation of

the cutting edge further away from the grinding wheel.

Looking fromr ear ofdrillbit toward face of wheel. Drill bit rotating i nC +direction during radius split.

C+

Ro ta tio n

• Selecting “CANCEL” will delete any

unsaved data, retrieving the most recently saved information transferring you back to the previous screen.

NOTE: After values have been manually entered into the Web Thickness Screen, you cannot change the point angle, point style or split style. If you do, the values in Web and Advance will be removed. This is to prevent incorrectly sharpening the next drill.

• To disable the R-Split offsets, touch the

“AUTO” button, in the manual web detection screen.

Web Detection Screen

The -C button will stop the rotation of the cutting edge closer to the grinding wheel.

Looking f rom rear of drill bit toward face of wheel. Drill bit rotating in C- direction during radius split.

C-

Rotation

The Radius Split Offset feature will become disabled and you will exit manual web detection mode.

• Touch the “SAVE” button to store the

“New” information and transfer you back to the previous screen.

Facet Overlap Adjustment

4-Facet Overlap Adjust Procedure

NOTE: The XPS-16 is designed to create the 4Facet point with little or no facet overlap. Each machine is adjusted during factory calibration to have a facet overlap of 0.000” to 0.0025”. However, adjustment can be made through the calibration parameters of the machine. Hence, care must be taken to use these instructions carefully when one wants to modify the facet overlap. The user will be making changes that will affect the drill geometry of all drills.

1. From the Main menu, press the “Tools” icon in the lower right hand corner.

2. Press the icon in the third row.

The number showing is the factory value determined during calibration (Write it down).

To reduce facet overlap, the Stick-out parameter needs to increase (start with 0.005”to 0.010”). To increase facet overlap, the Stick-out parameter needs to decrease (start with the same increment).

Past Center

3. Type in a Stick-out value that is larger or smaller than the one shown and press the “Disk” icon.

4. Press the “X” icon twice to get to the Main menu.

5. Sharpen a test drill without splitting check the facet overlap. If it needs more adjustment go to step 1 and repeat through step 5. If the facet overlap is satisfactory, then the Stickout parameter should be saved in a drill file.

To Center Below Center

and

Note: When the machine is powered off and then on again, the stick out parameter is reset to the calibration value in the Darex file.

Cutting Edge Advance Screen

WHY: Your drill is

12:00

aligned with the aid of a fiber optic sensor. The fiber optic sensor locates and positions the cutting edge at 12 o’clock.

3:00

(vertical)

This alignment process was designed for drills with a straight cutting edge.

Drills with a hook in the cutting edge can still be sharpened, but the cutting edge may not align correctly. If this is the case, it may be necessary to manually correct the alignment position, using the Advance feature of the XPS-16.

As the drill moves towards and in front of the sensor, the sensor moves and positions itself at 55% of the drill diameter. The drill starts to rotate, once the cutting edge breaks the beam of light, it records that point and the sensor then moves to 80% of the drill diameter.

12:0012:00

The cutting edge continues to rotate, breaking the beam of light for a second time. The

3:00

machine recognizes the two detected points as the cutting edge,

THEN,

C+

rotates those points in to the 12 o’clock position. (vertical)

3:00

Most times, if the drills cutting edge is straight, the alignment will be correct, and a two-point alignment will successfully position the cutting edge.

BUT:

When the cutting edge of the drill is hooked, the second alignment pick point may be in the radius of the hook.

The true cutting edge

11 o’clock

12 o’clock

will not be positioned correctly at 12 o’clock. (vertical)

When you see the alignment is incorrect,

Cutting edge

touch Cycle Stop and bring the machine back to the home position. You must then compensate for the incorrect alignment using the cutting edge Advance Screen.

When using the Advance screen, the cutting edge will be detected

3:0 0

using only a single point detection process. The drills

Single point alignment on cutting lip

cutting edge will rotate into the beam of light as before, but will only pick one point,

12: 00

C+

Single point alignment on cutting lip rotatedt o 12:00 position

3:00

then the cutting edge will rotate as close to 12 o’clock (vertical) as possible. At this point, if the cutting edge does not rotate up to 12 o’clock (vertical), you will need to compensate manually.

HOW:

Web Detection Screen

Cutting Edge Advance Screen

The web thickness must be entered manually.

• Measure web of drill, and type in web thick-

ness.

• Touch the ADVANCE button on the web

detection screen.

• The ADVANCE screen will come up.

ADVANCE SCREEN

degree of advance entered will appear on the “WEB THICKNESS” Selector button.

NOTE: After values have been manually entered into the Web and or Advance screen, you cannot change the point angle, point style or split style. If you do, the values in Web and Advance will be removed. This is to prevent incorrectly sharpening a completely different drill.

• To exit manual mode, touch the “AUTO”

button, on the number pad. The Radius Split and Advance feature will become disabled.

• Press the +C button to rotate cutting

edge counter clockwise,

20°

Cutting edge

or the -C button to move the cutting edge clockwise.

20°

Cutting edge

• A value larger than 0

must be entered to enable the advance feature.

NOTE: Remember, as you look at the pictorial icon of the cutting edge, you are looking at the cutting edge opposite from the direction it will actually rotate.

• Touch the “SAVE” button to store and

transfer the “New” information to the Main Set-up Screen. The web thickness and

Download Details

Download Screen Selector

Select this button for in system programming and download capabilities. As up-

grades and optional custom point styles become available, your machine is equipped to receive these files from our factory to yours.

To utilize each of the following screens you will need:

Serial port converter with USB cable con-

•

nected from PC to XPS-16

• PC located close to XPS-16

• Darex Sloader program must be used to trans-

fer software upgrades and download files.

Download Details

• Touch the “X” to cancel the update proc-

ess.

• To start UI Update, touch the “check” to

continue.

• The UI Update Pause screen

will flash on the screen.

• After a few seconds the screen

will go dark.

• On your PC, call up the Darex Software Loader

program by clicking on START, PROGRAMS, DAREX and then select DAREX CNC SOFTWARE LOADER

• Click on “UI Update” tab.

Darex Software Loader Screen -

UI Update

Software Installation

• Insert the Darex XPS-16 Software Diskette in

the A: Drive

• Click on START and then click on RUN

• Type “A:\Install” and press the Enter key. The

program will automatically start

• To Run: Click START, PROGRAMS, DAREX and

then select DAREX CNC SOFTWARE LOADER

UI (User Interface) Update

UI Update Button – From PC to XPS16

• Make sure Serial Cable is connected from ma-

chine to PC.

• Upgrade your USER software by

touching the UI Update button.

UI Update Screen

Your current UI software version will be displayed in this screen.

• Click on “Serial Port Settings” drop-

down and select the correct COM Port for your computer.

• Type in file name in

Browse field or click on Browse button and navigate to desired file.

• Click on “Start Transfer”

• In the first line

of the Transfer Status Result Box, text will appear displaying current status. The second line will show progress of transfer.

Warning: Do not exit Software Loader Program or power down machine until the Transfer Status reads EXECUTING NEW SOFTWARE.

Download Details

• After transfer is com-

plete, a screen will appear prompting you to shut down machine and restart.

At this point downloading software was successful. Turn the machine off and then on again and run the Initialization program.

USB Communication Port Setup Instructions Cont.

USB Communication Port Setup Instructions

The computer interface to the XPS-16 is through an RS-232

(serial) port. Many PCs (especially notebooks) do not

contain serial ports. Provided in your tool kit is a USB to Serial Port Adaptor which emulates a Serial port through a USB port. The USB to Serial Port adaptor is used with

SLoader on systems running Windows XP and Vista

including desktop and notebook hardware.

The following steps should be followed for successful

implementation.

1. Go to www.Sabrent.com and install the latest Windows driver for this item (driver is also located on the

calibration CD supplied with the XPS-16). Do not plug the unit into the PC while installing the driver.

2. Connect the USB to Serial Adaptor to a port on your PC.

3. Check in the Windows Device Manager under Ports to see what COM port it assigned. It should show-up as

“Prolific USB-to-Serial Bridge” (see Figure 1).

SLoader needs the assignment to be ports 1 through 4.

Figure 2 – Port Settings

5. Click on the Advanced… button and set the COM Port Number to a lower value such as COM4

(see Figure 3).

Figure 3 – Advanced Settings

6. Close out of Device Manager and the Adaptor should now operate like a standard Serial port. Be sure to set the port number in SLoader to the

correct assigned port.

7. Proceed with normal upload and download

activities. When SLoader is closed and the

Adaptor removed from the PC, the port is released but it should re-acquire the same port number when the Adaptor is re-attached.

Figure 1 – Device Manager

4. If the assignment is higher than COM4, then you can force it to a lower unused port using the Advanced … menu

from the Port Settings page. To access this menu, double

click on the port in Device Manager and select the Port

Settings tab (see Figure 2).

Download Details

Get Drill Files (Custom File Download)

• On your PC, call up the Darex Software Loader

program.

• Click on “Get Drill Files” tab.

Darex Software Loader Screen -

Get Drill Files

• Click on “Serial Port Settings” drop

down and select the correct COM Port for your computer.

• Type the

directory name in the Browse field or click on Browse button and navigate to desired directory.

• Click Start Transfer on computer.

File Down Load Button- From XPS-16 To PC

• Connect the serial cable from PC to sharpener.

• Send and store your custom files to your PC

by touching the “FILE DOWNLOAD” button.

• Using the “CURSOR UP” or “CURSOR

DOWN” button, move the cursor beside the files you wish to save, touch the “Select File Stamp” button.

• Repeat until all de-

sired files are selected.

• Touch the “SAVE” button.

You have approximately 25 seconds between clicking on “SAVE” and clicking the “Start Transfer” button. If time exceeds 25 seconds an error will appear and you must start over.

Sending Drill Files Screen

The Send Files Screen will flash on the XPS-16 screen.

Save File to PC Screen

The Save File screen will come up.

Download Details

Send Drill Files (File Restoration )

File Restoration Button - From PC To XPS-16

• Connect the serial cable from PC to sharpener.

• Restore saved custom files from your PC

by touching the “File Restoration” button.

• On your PC, call up the Darex Software

Loader program.

• Click on “Send Drill Files” tab

Darex Software Loader Screen - Send

Drill Files

• Click on “Serial Port Settings” drop

down and select the correct COM Port for your computer.

• Click on Browse Folders to navi-

gate to desired directory.

• Drill files to be sent will be dis-

played in the left column of the “Send Drill Files” Down Load Screen.

• The files you wish to restore

need to be transferred to the column on the right.

• Select the

file you wish to restore by highlighting the file.

• Click on the

top Transfer Icon located between the two columns.

• Once all the necessary files are trans-

ferred to the column on the right, you are ready to start downloading to your XPS-16.

• Click the “SEND” button on the

computer.

• Touch the “RESTORATION”

button on the XPS-16.

Getting Drill Files

The “Getting Drill Files” Screen will flash on the XPS-16 screen.

The transfer will begin and when completed the Transfer status will display the number of files transferred.

You have approximately 25 seconds between clicking on the “RESTORATION” button and clicking the “SEND” button. If time exceeds 25 seconds an error will appear and you must start over.

Controller Update

Controller Update Button - From PC to XPS-16

• Connect the serial cable from PC to sharpener.

• Update your Controller software by

touching the Controller Update button.

• On your PC, call up the Darex Software

Loader program.

• Click on “Controller Update” tab

Darex Software Loader Screen –

Controller Update

• Click on “Serial Port Settings”

dropdown and select the correct COM Port for your computer.

• Locate file name in

Browse field or type in file name.

• Touch the Controller

Update button on your XPS-16.

Controller Update Screen

The “Controller Update” screen will come up.

Your current Controller version will be displayed on this screen.

• Touch the “X” to cancel the Controller

Update process.

• Touch the “check” to start the Controller

Update.

Download Details

The Controller Update screen will flash on the screen and then the LCD screen will go dark.

• Click “Start Transfer” on com-

puter. You have approximately 25 seconds between clicking on the “Controller Update” button and clicking the “Start Transfer” button. If time exceeds 25 seconds an error will appear and you must start over.

Warning: Do not exit Software Loader Program or power down machine until the download process is complete.

• The LCD screen will come back up and the

download progress will be displayed on the LCD.

• Once the LCD displays

100% complete, the 2 part of the Controller Update must be completed.

• The screen to complete the Controller Update

will come up.

Controller Update Screen Part 2

Warning: Do not power down machine until the download process is complete.

• The LCD screen will dis-

play the download progress. Once the LCD displays 100% complete this download is complete, your controller has been updated

• Touch the

“check” to complete the Controller Update.

• After transfer is complete, the RESTART MA-

CHINE SCREEN will appear

• Turn the machine off and then on again and

run the Initialization program.

CHUCK INFORMATION

Chuck Information

XPS-16 CHUCK

The XPS-16 6-jaw chuck system was designed with accuracy and simplicity in mind. As a result, the XPS-16 chuck allows you to quickly change from the largest drill diameter to the smallest in seconds. The accuracy of the chuck will produce drill concentricity exceeding ANSI, NAS 907 & ISO 10899 standards. The chuck holds drills from .118 to .629 (3mm to 16mm).

NOTE: Be careful when chucking up carbide drills. Center the drill in the jaws as you tighten the chuck. It is helpful to rotate the drill as you close the chuck. Be careful not to over tighten the chuck on small drills

Caution: When sharpening a 5/8 drill

make sure the drill is secure after tightening the chuck.

Morse Taper drills:

To secure a Morse Taper drill in the chuck, it is necessary for the drill to have a minimum flute length of 3.500 inches. The taper will then be free from the grasp of the jaws, eliminating interference with the larger tapered shank. The oth tion for holding these types of drills i ing. Bush the body of the drill up to, or larger than, the interfering diameter. Any drill held in a bushing will need to be sharpened on Manual Mode in the “Diameter Selector” screen . You must type in the actual body diameter of the drill to be sharpened, regardless of the shank or bushing size.

s a split bush-

er op-

CHUCK JAW DISASSEMBLY/

ASSEMBLY & MAINTENANCE

The vacuum system that comes with your sharpener will help reduce the amount of maintenance necessary, however, periodically the Chuck Jaw Spindle Insert assembly should be removed and any grinding residue brushed away.

1. Push the emergency stop button, unplug unit from power supply and use a “LOCK OUT” “TAG OUT” procedure.

2. Using the chuck knob, open chuck jaw assembly to its fully open capacity range.

3. Using a 3mm hex key, remove the Allen head cap screws from the chuck knob.

4. The chuck jaw assembly can now be removed through the back of the chuck spindle assembly.

four

4mm

Step drills:

In the case of a Step drill, you can sharpen the pilot of that drill but it must be sharpened on Manual Mode in the “Diameter Selector” screen. Type in the diameter of the pilot to be sharpened, regardless of the shank size.

End Mill shank drills:

Typically, an End Mill shank drill has a shank diameter larger than the body of the drill. Many End Mill shank drills can be sharpened on the XPS-16, depending on the length of the flute verses the length of the shank. If holding these types of drills on the shank they must be sharpened on Manual Mode in the “Diameter Selector” screen .

5. Brush or blow away any grinding residue.

6. Unthread the brass, Jaw Spring Retainer as-

sembly from the chuck knob. Clean external threads on brass and internal threads in chuck knob thoro

Make sure locating dots are in alignment, after thr the chuck knob. If so, unthread brass re-

tainer and rotate 180°, rethread into chuck knob.

NOTE: Do not remove jaws from chuck jaw spindle insert; the concentricity of the chuck will be compromised.

ughly.

eading the jaw retainer back into

Chuck Information

TO REINSTALL:

Reinstall in reverse order, making sure the diameter detector rod is oriented in spindle correctly.

CAUTION: If diameter detector rod is reinstalled improperly, damage to rod will occur.

• After chuck jaw assembly is properly replaced

and before the 4; 4mm bolts are in place, open or close the chuck knob until the bolt hole pattern on the chuck knob is in alignment with the bolt hole pattern on each of the chuck knob retainers. Call Darex to replace

any Chuck knob retainers with a single side bevel.

Chuck knob retainer showing bevel

Top

Chuck Exploded View

The position of the chuck knob retainers may need to be raised or lowered to meet the bolt hole pattern on the chuck knob. Carefully insert bolts and tighten.

PP12255FF

Chuck Information

CNC-XPS-16CC - COLLET CHUCK PARTS DIAGRAM

1 - PP12512TF - COLLET CHUCK KNOB SECONDARY 2 - PP12518NF - ER-25 COLLET SET - METRIC 2 - PP12519NF - ER-25 COLLET SET - ENGLISH 3 - SA12511TA - PRIMARY COLLET KNOB ASSEMBLY 4 - PP12571SF - SWING CASTING COVER - COLLET CHUCK

5 - PP12500CF - CHUCK SWING CASTING 6 - SA12506TA - COLLET CHUCK SPINDLE ASSEMBLY

NOT SHOWN - SA12501CA - COLLET CHUCK ASSEMBLY COMPLETE

Chuck Information

XPS-16 Collet Chuck

COLLET CHUCK USE: The XPS-16 Collet Chuck

uses ER-25 collets to hold the drill. The chuck is designed to use one or two collets to clamp the drill. Depending on the drill type and length, either the forward collet, the rear collet or both collets can used to secure the drill. The collet system offers the same performance and size range as the standard chuck although use of the rear collet by itself will degrade the run-out precision

somewhat. Collets are offered in both Metric and English sizing. To use the Collet Chuck, determine which collet configuration will best suit your needs. The sketch below shows the dimensions of the collets in relation to the machine home position. It can be used to visualize which collet configuration to use.

To use the forward collet only, remove the Primary Knob and insert the appropriate collet into the Collet Sleeve as shown below.

Install the Primary Knob into the Collet Chuck Spindle and tighten until contact of the collet is felt. Then back-off the knob ¼ turn. Insert the drill through the collet as normal and then tighten the knob until snug.

You are ready to sharpen the drill.

Chuck Information

XPS-16 Collet Chuck cont.

Use of the rear collet is similar to the forward

collet, first the Primary Knob must be installed in to the spindle omitting the ER collet. The collet is installed into the Secondary Knob as shown below.

Certain lengths of step-shank drills may require use of the rear collet by itself or the use of both collets (see drill photo).

To use both forward and rear collets together, first install the forward collet with Primary Knob and then the rear collet with Secondary Knob. The collets can both be the same size or the rear one may be larger. Insert the drill and tighten the Secondary Knob until both collets close and secure the drill.

This page was intentionally left blank.

Honing Information

HONING BRUSHES AND INFORMATION

HONING ON YOUR XPS-16

Your sharpener is equipped with “honing” capabilities. Edge prepping is done a number of different ways, in the case of your XPS-16 sharpener it is achieved by brush honing. The hone brush is bolted to the center of the diamond-grinding wheel. The bristles of the nylon brush are impregnated with silicon carbide crystals.

Optional Dia-

mond Hone available.

When the hone feature is selected and the drill has finished the sharpening cycle, the drill moves over into the honing position.

With the cutting edge perpendicular, the drill feeds into the honing brush, pausing as the bristles lap over the cutting edge, creating a radius. This method creates what is known as a waterfallshaped hone, the edge prep is skewed toward the topside of the tool. The main benefit of this type of hone is that the honing process leaves more tool material directly under the cutting edge, further strengthening the corner. The longer the cutting edge remains paused in the brush the larger the radius. To change the size of the radius, adjust the length of time the drill is in the hone cycle. Your options for the time in the hone range from .010 to 60.0, fo justment refer to information on page 53.

r Hone Time Ad-

WHY HONE?

A carbide cutting tool’s edge must withstand tremendous stress. It’s ability to handle the applied stress and wear in a slow predictable manner determines a tool’s life and wear rate. In certain applications, proper edge preparation known as “honing” has improved tool life 200 percent or more.

The primary purpose of honing is to establish an edge between the tool and the work piece. Chip flow, cutting speed, in-feed pressure and other machining variables are strongly impacted by the characteristics of this edge. The size and shape of the hone determine the amount of tool pressure required for a machining operation to be success-

ful. If the hone is too large for a given application, the excessive pressure required to cut will increase the amount of heat developed during machining. That shortens tool life. If the hone is too small, the cutting tool edge will be weak and unable to withstand cutting pressures. 0.001 to

0.003 is the size of most radius created by edge

honing.

BENEFITS TO HONING

CARBIDE

Longer Tool Life: improve the wear rate by re-

ducing the stress to the tools cutting edge. Greater Consistency: you can achieve predictable tool performance, increased productivity, reducing scrap and less rework. Better Finish: a smooth edge helps reduce the tendency of chipping on the cutting edge. These chips create an inconsistent edge that degrades the finish and shortens tool life.

*NOTE: If the edge hone is incorrectly sized or insufficiently smooth, small work piece particles can attach to the cutting edge. As this buildup continues, more and terial will attach to the tool, adversely affecting the surface finish.

more ma-

HONE ONLY feature

Use this feature when regrinding is not necessary or desired. This option allows you to use your XPS-16 as a honing machine. When HONE ONLY is selected the grind and split process will be disabled. The diameter of the drill will still be detected but from that point on it will move directly into the honing position and continue to hone the drill.

HONING BRUSH MAINTENANCE

Clean the hone brush each time you clean the diamond grinding wheel. Remove the hone brush from the grinding wheel and clean using hot soapy water.

Honing Information

HONING BRUSH PART #’S

PP12686NF – Brush 120 Grit – Silicon Carbide

PP12680NF – Brush 180 Grit – Silicon Carbide

PP12684NF – Brush 320 Grit – Silicon Carbide PP12688NF – Brush 240 Grit – Diamond

PP12682TF – Brush Retainer PP12252FF – Bolts 3 each (4mm .7x18 SHCS) SA12680NA – Brush, Retainer & Bolts

HOW TO CHANGE HONING

BRUSH

This can be done, leaving grinding wheel mounted.

1. Push the emergency stop button, unplug unit from power supply and use a “LOCK OUT” “TAG OUT” procedure.

2. Using a 2.5mm hex key, remove the top two 3mm button head cap screws from wheel guard cover.

3. Then, loosen, but do not remove the bottom two 3mm button head cap screw s. pull wheel guard cover away from wheel.

NOTE: Leave vacuum tube attached to wheel guard cover

4. Using a 3mm hex key wrench, remove the three 4mm 7x18 SHCS .

5. Remove retainer ring.

6. Remove brush from wheel.

To reinstall, reverse steps.

Vacuum System Information

VACUUM SYSTEM AND

INSTALLATION INSTRUCTIONS

Do not use sharpener until vacuum system is connected to machine. The

airflow from the vacuum system keeps the grinding wheel & motor cool while running. Damage to the motor may occur if vacuum is not running while sharpening on the XPS-16.

XPS-16 VACUUM SYSTEM

The XPS-16 sharpener comes equipped with an environmentally safe dust collection system. Hook up the vacuum to your sharpener before sharpening drills.

HOW TO HOOK UP VACUUM

SYSTEM

1. Connect plug from vacuum to the receptacle

on the electrical panel located at the back of the XPS-16 sharpener.

VACUUM SYSTEM DISASSEMBLY & MAINTENANCE

1. Using a ¼ hex key wrench, remove bolt and washer.

2. Remove top ½ cover of vacuum canister.

3. Remove and dispose of filter cartridge.

4. Unthread plastic nut retaining bottom ½ of

vacuum canister.

5. Remove bottom ½ of vacuum canister.

6. Clean out residual grinding dust from bottom

of canister.

To reassemble, reverse steps.

NOTE: When reassembling, make sure the rim of the top ½ of vacuum canister is seated into gasket channel on bottom ½ of vacuum canister.

2. Connect Vacuum hose to the vacuum adapter tube on the sharpener and to the intake tube on the vacuum.

Vacuum System Information

Vacuum parts list on page 83 & 84 exploded view on page 87

VACUUM SPECS

Weight: 30lbs (13.61kg) Diameter: 14” (35.56cm)

Height: 19” (48.26cm)

SA12070EA - 115V vac w/plug 3 SA12080EA - 230V vac w/ plug

Wheel Information

XPS-16 WHEEL INFORMATION

The Darex XPS-16 comes equipped with electroplated, 180 Grit CBN (Cubic Boron Nitride) and 220 Grit diamond grinding wheels. The CBN

wheel, ready to sharpen HSS and Cobalt drills has been calibrated to your sharpener. The diamond grinding wheel, for grinding carbide drills, has a honing brush mounted to it. You will find both the diamond and CBN wheel packaged in the tool kit.

Sharpening with an electroplated CBN (Cubic Boron Nitride) or diamond grinding wheel reduces grinding cost and improves quality of the finished product. These results are obtained because the grinding material is super abrasive. The CBN is second only to diamond in hardness. In fact, CBN has twice the hardness and four times the abrasion resistance of an aluminum oxide grinding wheel. The CBN and diamond wheel last longer; the grinding process is faster and less grinding time is lost due to wheel breakdown & maintenance.

INSTRUCTION FOR USE OF

CREPE STICK

TO CLEAN GRINDING WHEEL

The CREPE STICK (PP0001981), included in the tool kit can be used to clean the grinding wheel while on the machine. This procedure provides a convenient method that can be applied about once per hour. A more thorough wheel cleaning should be preformed at regular intervals as described in the user manual.

1. Be sure the machine in the home position.

2. The grinding wheel must be rotating.

3. Lightly press a corner of the crepe stick

against the surface of the grind wheel.

4. Sweep it across the face of the wheel.

5. Repeat several times.

WHEEL MAINTENANCE

These wheels are maintenance free from truing and dressing but will need to be cleaned periodically. After removing the wheel from the sharpener, saturate the wheel with any type of oil-less solvent, such as Automotive Brake Cleaner. It is helpful to use a soft bristle brush and lightly brush the saturated wheel loosening the impacted grinding particles. Re-saturate the wheel to flush out any loosened debris.

NOTE: If after cleaning wheel, the drills still discolor or burn, the wheel life may be exhausted and the wheel will need to be replaced.

WHEEL PART #’S

• PP12660GF – 180-grit CBN grinding wheel

• PP12666GF – 220-grit Diamond grinding wheel

• PP12675GF – 320-grit Diamond grinding wheel

(Not recommended for larger drills)

• PP12670TF – Wheel retainer bolt

Proprietary Wheel – Diameter is 4.500 - Width is

1.025. Contact Darex for special wheel configura-

tions.

*Darex Corporation does not re-plate or recommend re-plating the grinding wheels. For replacement wheels, contact your Darex distributor or Darex Corporation.

Caution: Wear Eye protection and firmly grip the crepe stick while performing this procedure.

Wheel Information

HOW TO CHANGE A WHEEL

1. Push the emergency stop button, unplug unit from

power supply and use a “LOCK OUT”

“TAG OUT” procedure.

2. Remove Guard door cover.

3. Remove thumbscrews from cover.

4. Pull the wheel guard cover away from wheel,

leaving the vacuum tube attached.

5. Insert spindle lock pin through access hole

located on top of wheel guard casting.

7. Using a ½ inch socket wrench, loosen wheel retainer bolt in the counterclockwise direction until wheel is free of the spindle.

8. Repeat steps in reverse to install new wheel. Tighten to 12 lbs/per foot.

When changing from a CBN to Diamond or vise versa, it’s a good idea to write the wheel offsets on the back of the wheel before adjusting the offsets to the new wheel.

6. Rotate spindle until spindle lock pin engages.

Recalibrate Material Take Off

• After a wheel change, verify and/or recalibrate

Material Take Off:

1. Use a 3/8 HSS standard twist drill, measure the length of drill before sharpening.

2. Using the Darex #1 File sharpen the drill.

3. After sharpening the drill, measure the drills

new length. MTO should be approximately .005-.007.

4. If incorrect, adjust using Grinding Wheel Offset Screen Selector Refer to information

on page 59.

Wheel Position Offset Adjustment

The calibration sheet shows all of the values stored in the machine when it left Darex. Normally, it is just reference information. If somehow the machine memory became corrupted then the data could be used to restore these parameters (very unlikely). These values are not changed when grind wheels are changed. The Wheel Offsets are the values that you should record and change when replacing grind wheels.

Here is the suggested process: When the machine comes to you from Darex the

offsets should be dialed in very close. Take a 3/8” diameter test drill, open the Darex file and sharpen the drill. Adjust the Center and Depth (using the Wheel Offsets) to give you a “perfect” split. Save these Wheel Offsets by going to the Safe icon on the second page.

Remember that these Wheel Offsets are only permanently saved if you save using the Safe icon. If the machine is turned off and back on, the Wheel Offsets from the last save will be loaded.

Now subsequent drills can be sharpened and Drill files saved knowing that the wheel is in the proper location. Use the Split Adjustment menu to adjust splits for these new drills.

Split Angle

Fan Angle

When the grind wheel is removed, record the Wheel Offsets on the backside with a permanent marker. Install the new grind wheel, open the Darex file, grind your test drill and adjust the Wheel Offsets to get your “perfect” splits. Safe (save) these offsets.

The grind wheel is now in the proper location and your Drill files should work the same as when they were originally saved. Note that Wheel Offsets are not saved with the Drill file just the Split Adjustments.

When this wheel is removed, record the Wheel Offsets on the backside with a permanent

marker.

If the first wheel is put back on the machine, then change the Wheel Offsets to the values recorded on the backside of the wheel and

Safe (save) these offsets.

Check the performance by opening the Darex file and grinding the test drill.

Helpful Hint: When getting ready to adjust new Wheel Offsets, it is best to back off the X and Z

axes a few thousandths in the negative direction

to keep from over-splitting the drill. It is not necessary to Safe these settings until after the final adjustment has been made.

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Sharpening Tips

1. Use MIN MTO when touching up your facet and conic ground drills.

2. Use MID MTO when sharpening chipped facet and conic ground drills.

3. Use MAX when changing point angles on conic ground drills only.

4. If your drill has a broken or highly misshaped geometry, you will want to rough grind on the XT3000 first.

5. If your drill has one cutting edge grossly longer that the other, when you insert the drill into the chuck, position the longest side down. The sensor will detect the most protruding edge and adjust its grind accordingly.

6. If you enter a drill diameter size outside the capability range of the sharpener, the setting will default to the closest MIN/MAX diameter size.

7. To make wheel changes faster, using a permanent marker, write the X & Z wheel offset values on the back of the wheel. After each wheel change, type in the offset from the back of that wheel.

8. To extend the life of and improve the performance of your wheel, clean each new wheel before using. For wheel cleaning instructions Re-

fer to information on page 57.

9. To adjust the paralle the cutting edge using the Advance button. For more information Refer to page 39.

10. Each time the XPS-16 is powered up, it defaults to the Darex File and reloads all default offset values.

11. Make sure each time you power down the XPS-16, you save your work, just as you

would on a PC. To save or create a file, Refer

to information on pages 23 & 24

lism of the facets, rotate

Wite-out. Because the fiber optic sensor works from reflectivity, the color of the drill may interfere with the alignment. Drills Black and Gold in color, are the biggest culprits. Painting just behind the cutting edge will help the sensor locate the cutting edge.

13. For a thick webbed drill, mark inside the flute using a black marker. Paint just under, and right up to, but not touching the cutting edge.

14. To increase the hone on the cutting edge of the drill, increase the length of time the drill is in the honing cycle.

15. If your drill has a thin web, we do not recommend sharpening it as a facet point style. The width of the primary facet produced will be very thin.

16. Be careful when chucking up carbide drills. Center the drill in the jaws as you tighten the chuck. It is helpful to rotate the drill as you tighten down the chuck. Be careful not to over tighten the chuck on small drills.

17. You can influence the size of

ated on an R-Split drill. Measure web of drill. Enter a web thickness value smaller than the drills actual web diameter. Watch the C Axis rotation, it will automatically advance the drill in the + direction and could nick the opposite cutting edge. Adjust the C Axis rotation in the minus direction. For more details see page 35.

the radius cre-

12. If the XPS is having trouble picking up the drills cutting edge, paint just behind the cutting lip, using white correction fluid such as Bic

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Trouble Shooting Section

Trouble Shooting Icons

Insert Drill Alarm

Remove Drill Alarm

chuck

Cutting Edge Detection Alarm

• If cutting edge is not detected

within one full revolution you will see this alarm. For more information see

page 65.

Material Take Off Alarm #1

• Drill not pushed up against the

stop.

• To trip the limit switch, reset drill,

pushing the tip into the stop while tightening the chuck.

• MTO sensor failed, contact factory.

• Use compressed air to clean.

• No drill has

been detected Insert drill or check to see if drill is loose and has pushed back in the chuck

• Drill has

been left in chuck during Self Test Initialization program and before machine goes into the Lube cycle. Remove the drill from the

Material Take Off Alarm #2

• Use compressed air to clean lens

• MTO sensor failed, contact factory.

grinding wheel.

Grind Motor Error

• The grind motor fuse is

blown.

• No grind motor current

sensed.

Time Out Error

• In the grinding process

too long. Clean or replace

Oil Lubrication Screen

• Self-lubrication cycle necessary

Refer to information on page 79 for

details.

Trouble Shooting Section

Wheel Change Reminder

• This re-

minder will prompt you to change the wheel as you select different drill material options.

The XPS-16 does not know what type of wheel you have mounted; you

must mount a CBN wheel for HSS or Cobalt drills and a Diamond wheel for Carbide drills. Failure to comply will damage or shorten the life of your grinding wheel.

Door Open error

A AXIS ALARM

• A axis has moved past

the limit switch.

• A axis sensor has failed.

X AXIS ALARM

• X axis has moved past

the limit switch. Call Darex

• X axis sensor has failed.

• May be caused by stopping

or powering down during the lube cycle. See page 69.

BAD CODE ERROR

• Bad controller code

stored in memory.

• Machine door must be closed when “Cycle

Start” button is pressed. After closing door, push cycle start to continue grinding.

Z AXIS ALARM

• Z axis has moved past

the limit switch. Refer to page 69 for details.

• Z axis sensor has failed.

C AXIS ALARM

• C axis sensor has failed.

• XPS-16 waited too

long before receiving a response from the computer.

Trouble Shooting—XPS-16

Symptom

Machine won’t power up

Cause

• No power at outlet

• Make sure power cord is plugged in to ma-

chine and outlet

• Release E-stop button

• E-stop nut is loose and stuck down in the

off position

• On/Off switch need replaced

• Wiring lead disconnected

Symptom

After powering up, Initialization screen does not come up

Cause

• RS232 cable is disconnected

Trouble Shooting Section

Symptom

Failed Initialization screen test

Cause

• Axis driver card failure

• Limit sensors bad

• Solenoid bad

• Machine has moved past the limit switches

Symptom

LCD screen too light or dark to read

Cause

• Contrast needs adjusted Refer to page 32

• LCD back light failure

• LCD bad

Symptom

LCD screen displays garbage or grossly inaccurate information.

Cause

• Machine temperature is too cold/hot – do not operate until machine temperature reaches above 7°C (45°F) but not more than 32°C (90° F)

• Restore calibrations from locked area

• LCD battery is dead

• LCD is bad

• Cutting edge is broken

• Cutting edge has shinny build up, such as

aluminum

• Surface finish too rough

• Calibration of fiber optic sensor is incorrect

and will need recalibrated

• Fiber optic lens is loose

• Fiber optic sensor needs replaced

• Fiber optic lens needs cleaned or replaced

• Fiber optic cable has been damaged

• Shank is larger than body of drill and cor-

rect diameter has not been manually input. Example: Step drill

Symptom

Auto diameter detect will not detect correct diameter

Cause

• Diameter detection rod is bent

• Diameter detection rod has been improp-

erly installed. Refer to page 47

• Incorrect diameter calibration

• Shank of drill may be larger/smaller than

actually body of drill

• Drill flutes are worn or damaged

• MTO #1 button excessively worn

Symptom

After pressing “Cycle Start” the machine does not move into the sharpening cycle

Cause

• Make sure drill has been loaded properly and sensor button has been depressed

• Close door

• Software has caused machine to hang up –

turn machine off and then on again

• Cycle start switch needs replacement

• Printed circuit board on

Symptom

Drill rotates in front of fiber optic sensor failing to locate cutting edge

Cause

• Old software installed

• Drill diameter is smaller than 3mm

• Drill diameter is of a smaller dimension

with a thick web

• Color of drill is interfering with cutting edge detection – typically gold or black drills Refer to page 61

• False diameter was input or detected in manual mode

• Fiberoptic Amplifier Baseline setting has changed. Contact Darex for instructions.

back of LCD is bad

Symptom

Auto web detection does not display correct web thickness

Cause

• Fiber optic sensor lens is dirty. Refer to

page 81

• Fiber optic sensor is not calibrated correctly

• Fiber optic sensor is bad

• Old software installed

Symptom

Cutting edge is not positioned correctly at 1:00

Cause

• Chip on cutting edge

• Burr on cutting edge

• The fiber optic sensor has detected the

split line as cutting edge

• Drill has a hook in the cutting edge – use the Advance Screen to compensate. Refer

to page 39

• Changing from extreme point angles. Example: Converting a 180° drill into a 118° point angle

• Material build up on cutting edge

• A value left in the Advance Screen

Trouble Shooting Section

Symptom

Drill incorrectly split

Cause

• Check offsets on the split point offset. Page. Refer to page 29

• Wheel calibration is off

• Check wheel edge offset on wheel offset

page. Refer to page 28 & 59

• Did not align correctly

Symptom

Material take off varies

Cause

• Check wheel face offset on wheel offset page. Refer to page 28 & 59

• Wheel calibration is off

• Spindle cartridge loose

Symptom

Drill incorrectly positioned in the honing process

Cause

• Check offsets on the Hone offset page.

Refer to page 31

• Honing brush calibration is off

Symptom

Drill stops in front of the grinding wheel and will not continue into the sharpening cycle

Cause

• Grinding wheel is not rotating – check fuses

• Machine has hung up – power down machine and restart

Symptom

Length of time drill is in the grind becomes excessive

Cause

• Material take off too excessive

• Grinding wheel needs cleaned. Refer to

page 57

• Grinding wheel needs replaced. Refer to

page 58

• GMC # is too sensitive, decrease GMC #.

• Grind material selection has been changed

from HSS to CARBIDE

Symptom

Unable to secure drill in or release drill from chuck

Cause

• Solenoid malfunction. Refer to Sect ion 24

• Chuck spindle insert needs cleaned. Refer

to page 47

• Drill is carbide and needs to be centered while closing the chuck

• Large drill diameter

• Drill has multiple diameters that are inter-

fering with jaws

• Drill has a taper in the shank or on the body of the drill

Symptom

During initialization chuck tries to rotate unsuccessfully while making a ratcheting/clicking noise

Cause

• Solenoid has malfunctioned and chucklocking pin will not retract. Refer to Section

• Solenoid fuse blown

• Driver chip blown

• Drive pulley loose

Symptom

• Unexplained motion

Cause

• Machine temperature is too cold/hot - do not operate until machine temperature reaches 7°C (45°F) but not more than 32° C (90° F)

• Software issues – restore settings from permanent memory. Refer to page 27

• Download new software. Refer to page 41

• Loss of calibration – Call Darex Corporation

• Machine has moved outside of the limit

switches

• Bad limit sensor

Trouble Shooting Section

Identifying and checking LED

and limit switches

Identification of LED sensors refer to page 87

1. MTO 2

2. MTO 1

3. Rotate

4. Swing

5. X Feed

6. In Feed

7. Align

8. -5V

9. +5V

10. X Axis board

11. Z Axis board

12. A Axis board

13. C Axis board

Trouble Shooting Vacuum

Symptom

Excessive grinding dust visible

Cause

• Vacuum not operational

• Dirty filter

• Hoses split

• Hoses not connected

• Filter top box or bottom not seated prop-

erly

Symptom

Vacuum not operational

Cause

• Blown fuse

• Not plugged into sharpener

• Bad control circuit on power supply

• Vacuum motor burned out

Solution

• Place Sloader files and folders directly off of root drive in a directory called Darex

• Call tech support for a newer Sloader program

• Download a newer Sloader program from the Darex web site

• Try a different computer with a different operating system

Symptom

General System error – Error Initializing Serial Port

Cause

• Serial port conflict

Solution

• Move cable to another available serial port

• Close program using current serial port

(Hot Sync is a typical culprit)

Symptom

Download doesn’t work

Cause

• Communication between computer and sharpener not working

Solution

• Choose a different serial port

• Replace cable between computer and

sharpener

• Use a regular serial cable instead of null modem cable

Trouble Shooting Software

Download

Symptom

Transfer error

Cause

• Software loader doesn’t like directory name or location

• Software loader doesn’t support operating system

Trouble Shooting Section

Solenoid Troubleshooting

-Turn the machine power off.

- Open the Electrical Panel and disconnect the solenoid cable (connector located in lower right corner of Power Supply with a yellow and brown conductor). Check the electrical resistance of the solenoid by probing on the side of the connector. The resistance should be about 33 +/-3 ohms. If the resistance is not correct, then remove the black cover on the Chuck Swing Assembly and recheck the resistance at the solenoid connector. If the resistance is still incorrect then replace the solenoid. If the resistance is correct then there is a wiring/connector failure.

- If the solenoid needs replacement, the fuse and driver IC will also need to be replaced. If the solenoid and wiring are OK, then the most common fix is a fuse/IC replacement. Location of the fuse and driver IC are on the lower right corner of the Power Supply.

-Replacement of the solenoid is pretty straightforward. It is held in place by 2 bolts accessed from the rear of the Chuck Swing Assembly. The 2 pin connector needs to be separated on the front side and the solenoid plunger needs to be depressed before the assembly can be removed. Installation is in the reverse order of the solenoid removal.

-To replace the fuse and IC follow these steps (Use an ESD grounding device to avoid damaging components). Remove the small yellow component from its connector. Test the electrical resistance of the fuse. The resistance should be about 1 ohm. If the fuse is open circuit, then it needs to be replaced with a new one. Remove the IC by inserting a small screwdriver between the device and its socket. Carefully replace with a new IC chip as shown in the photographs. The correct orientation is with the printing upside down. Make sure all of the leads are inside of the socket. Next, insert a new or tested fuse into its connector.

- Re-connect the solenoid cable. Power-up the unit to check operation. Press the “Check” icon and the solenoid should retract with a “snapping” sound.

All axes should go to their home positions and the solenoid should then release with a “click”.

- Replace the Chuck Swing Assembly cover and close the Electrical Panel (be sure not to pinch any wire while securing cover or closing the panel).

Note: the solenoid may need some minor adjustment. It has a little free-play in its mounting and can be positioned a little clockwise or counterclockwise. With the power off and the Chuck Swing Assembly cover removed, loosen the mounting screws a little and turn chuck knob a little each direction to find the center of its freeplay. Carefully tighten the mounting screws while the chuck knob is in this position. Replace cover.

Trouble Shooting Section

Z Axis Stage Behind the Limits

NOTE: This condition usually occurs when the machine goes into the lube cycle and the cycle is interrupted before it has completed its run. SYMPTOM: When the machine is powered-up and the “Check” icon is pressed, the Z axis tries to go to its home position by moving in the –Z direction. Under normal conditions the axis moves back until it trips the sensor and then steps forward into the home position. When the stage is already behind the sensor it will continue to follow the same program. It will now move all the way back and eventually into a hard stop and sit there with the motor stalled. Usually there is a squealing noise and the X axis error will usually appear. To verify this is the problem measure the front of the chuck Jaws to the face to MT01. With the chuck in the sharpening position, the distance between the 2 should be no more than 1” . The procedure to recover from this is as follows:

1. Remove drill from chuck

2. Open the chuck all the way

3. On the initialization screen, touch the screen just to the left of the D in “DAREX”

4. Press icon located at the end of

the third row on the maintenance screen. Immediately, the Z axis stage will move in the + direction about 1 inch.

5. Power off the machine, wait 5 seconds then power it back on.

6. Press the “Check” icon, another limit error may appear. Press :“Ok” and the machine will initialize and move into the home position.

If the above procedure does not correct the Problem repeat steps 3-6.

IMPORTANT: The stage will not stop until it has moved the entire 1” regardless of what is in its path. If you see interference between the chuck and any other part of the unit, press the E-Stop button right away.

If the above procedure does not correct the problem, contact Darex. 800-547-0222.

Trouble Shooting Section

X-Axis Loose

(Revised 012207)

Concerning the lost motion in the "X" axis, make sure the Motor End Plate is not loose The plate is secured by two M5 cap screws, PP12285FF. If this plate is OK, then the other possibilities are a loose Lead screw Nut or a loose Anchor Bearing Assembly (see attached photo). Both are difficult to check. It will take about 2 hours to do this work for the first time and much less after you come over for training (about 30 minutes). Most

likely, the Lead screw nut cap screws

(PP12252FF) are loose. Here is the procedure to check them.

- The "X" axis stage will need to be removed . With the machine ON and drill removed, press the "TOOLS" icon and then the "BELT CHANGE" icon. Power off and unplug unit after everything stops moving.

- The following steps require access under the machine so it needs to be safely raised on blocks about 15 cm above the bench. Remove the Door and Top Cover. Remove the Motor Access Cover in back, unplug motor leads, disconnect the vacuum hose on the Grind Motor Shroud and loosen the motor mounting screws. Hold the Grind Motor, remove the screws, slip the drive belt off and set the Grind Motor on bench.

- Disconnect the Step Motor lead and the Limit Sensor lead at their respective connectors.

- Disconnect the Fiber optic cable from the Amplifier by opening the cover, moving the lock lever to down position and pulling the Fiber optic connector out of the Amplifier. Remove the clamp screws that hold down the amplifier

electrical cable. Remove the two

screws that anchor the Amplifier to the Spindle Block. Take the Amplifier and hang it over the back of the machine.

- Remove the four M6 cap screws (PP12277FF) that hold the Rail Supports in the base of the machine. Lift the "X" axis

stage out of the machine and set it on some foam pads.

- Back-out but do not totally remove the ten M2 screws that hold the Bellows to the Guide Cover on the Step Motor end of the stage. Turn the screws with a ball-style driver and stop when the screw detaches from the Guide Cover. Leave the screws in the Bellows and metal Frame to maintain alignment.

- Push the Bellows back and look inside to determine the cause of the looseness.

- If the lead screw nut cap screws are loose then follow the remaining procedure. If the Lead screw nut cap screws are not the issue, then let us know what you have found.

- Remove one of the cap screws, apply a very small amount of thread lock compound to the thread and re-install but do not tighten. Repeat for the other two cap screws.

- Turn the Lead screw by hand to move the Linear Guide closer to the Step Motor end of the stage. Continue the motion until there is still enough room to access the cap screws (with a 90 degree wrench) while the Bellow is compressed. The purpose of this is to align the lead screw nut with the center of rotation of the Anchor Bearing assembly. Now tighten the cap screws until they just remove all of the clearance and then tighten another 30 degrees. Do not over tighten as it may distort the lead screw nut and cause jerky motion. Turn the Lead screw and re-center the Linear Guide.

- Replace the Bellow screws and re-install the stage in the machine (hold the black plastic dust shield back about 1 cm during insertion ). Install the Rail Support screws and tighten. Re-connect the Step Motor and Limit Sensor cables. Re-install the Fiber optic Amplifier and cable clamp screws. Re-insert the fiber optic cable into the Amplifier making sure that the single fiber leg is the one on top. Lift the locking lever and close the cover.

- Re-install the Grind Motor and Drive Belt. The proper belt tension is the amount created by the motor weight. With the motor mounting screws 1/4 turn loose, lift up slightly on the back of the

X-Axis Loose continued

Grind Motor. The motor will rotate to tension the belt. Holding the motor in that position, tighten the motor mounting crews. Connect the vacuum hose and motor leads. Re-install the Motor Access Cover.

Trouble Shooting Section

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DRILL NOMENCLATURE

Drill Nomenclature

FACET & CONIC DRILL STYLE

PICTURE AND

NOMENCLATURE

CONIC DRILL

CLEARANCE

POINT SPLIT & RELIEF DIAGRAMS

DEPTH OF SPLIT DIAGRAM

Past Center To Center Below Center

CENTER OF SPLIT DIAGRAM

Past Center

SPLIT ANGLE DIAGRAM

To Center Below Center

120° 130°

95° 105°

FACET

Pointed Flat

FACET DRILL

Past Center

(over facet)

RELIEF

To Center Below Center

(under facet)

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Sample Drill File Form

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Drill Style Recommender

HSS, Standard Helix, 135-degree split point

• Cast Iron - Soft and Medium

• Stainless steel

HSS, Parabolic Flute design, 135-degree split point

ing of depths 4 times the diameter of the drill.

• Aluminum alloys

• Low to Medium Tensile Strength materials

HSS, High Helix 118-degree point

gineered with a high helix angle and wide flute for improved chip ejection. High helix drills are often used on materials that form chips that tend to weld together and resist being carried up the flutes. Specially designed for drilling deep holes.

• Aluminum

• Aluminum alloys

• Aluminum magnesium

• Aluminum bronze

• Zinc

• Low Tensile Soft Steels

HSS, Low Helix 118-degree point

neered with a low helix angle and wide flute to reduce grabbing on entrance and breakthrough and to promote better chip ejection.

• Free Machining Brass

• Plastics

• Shallow holes in Aluminum

• High Tensile Bronze

HSS, Standard Helix, 118-degree point

• Bronze Soft and Medium

• Copper

• Copper alloys

• Carbon Steel Low and Medium Alloyed

– Effective in deep hole drill-

– En-

– Engi-

Cobalt HHS, Jobber length, 135-degree split point

tant and used for drilling tough, high tensile strength materials.

• PH stainless steel

• Titanium

• Inconel

• High temperature alloys - Cobalt base - Iron

base - Nickel Base

• Carbon Steel - low and medium alloyed

– These drills are heat resis-

Cobalt HSS, Jobber length, wide land Parabolic flute design, 135-degree split point

provides superior performance in a greater range of materials and applications. Especially effective in deep-hole drilling of depths 4 times the diameter of the drill. Flute form produces closer tolerances due to improved chip flow. 135-degree split point reduces thrust.

• High Alloy Steels

• Titanium

• Inconel

• PH stainless

– The wide land parabolic design

Carbide-tipped, Standard Helix, Jobber and Taper length 118-degree point

Features heavy-duty construction and heat-treated body for optimum wear resistance and support of the carbide tip. Taper length is particularly advantageous when length longer than a jobber length is required.

• Hard Cast Iron

• Non-ferrous metals

• Composites

*Not recommended for drilling Steel

–

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General Maintenance

GENERAL MAINTENANCE

To extend the life of your sharpener, we recommend a routine maintenance program be put in place. Every 200machine hours is suggested, or more often if necessary.

Vacuum system:

Check filter on a regular basis. Inspect all hoses for cuts or tears. Do not use machine if hoses are damaged.

• Unplug vacuum from power source.

• Using a ¼ hex key wrench remove bolt and

washer.

• Wearing protective gloves, remove top ½

cover of vacuum canister, remove filter cartridge. Appropriately dispose of used filter.

• Unthread plastic nut retaining bottom ½ of

vacuum canister, remove bottom ½ of vacuum canister.

• Clean out residual grinding dust from bottom

of canister.

• Replace with new filter cartridge.

NOTE: When reassembling, make sure the rim of the top ½ of vacuum canister is seated into gasket channel on bottom ½ of vacuum canister.

Lube cycle:

Oil Lubrication Screen

After 250 sharpening cycles, the “OIL LUBRICATION” screen will come up and your machine will need to go through the self-lubing process.

• Remove drill from chuck.

• Touch the “CHECK” Icon . This will begin

the self-lubing cycle. Keep hands free from machine, as it goes into the lubing process, the X, Z and A axis will begin to move. The lube cycle will last 45 seconds. Upon completion, the lubing screen will disappear and the original screen will return.

Do not interrupt or stop machine once the lubing cycle has begun. If cycle is

interrupted when the machine has moved beyond the limit switches, it will not be able to find the home position. If this occurs, call Darex, 800-547-0222.

Grinding motor belt change:

• Touch the “BELT CHANGE” Button on

the Tools, Offset & Maintenance screen. The X axis will move into position. The machine will go into an motors will shut down.

• Once the “RESTART” screen has

come up on the screen, you can proceed.

• For safety, power down machine and unplug

AC power from machine.

• To remove the

inspection plate located at the back of the machine, use a

2.5mm hex key wrench to remove the 4; 3mm BHS.

• Belt and pulley

will now be exposed. Using a 3/16 hex key wrench, loosen the 4; ¼-20 SHCS bolts located on the motor mount extrusion, enough to slide the motor/pulley assembly to the right, allowing the belt to slip off.

• After replacing belt and before tightening up

the 4; ¼-20 SHCS bolts, allow the weight of the motor to tension the belt.

• Once the motor/pulley is secure, replace in-

spection plate and screws.

• After changing or adjusting the belt, you must

power down the machine using the On/Off switch.

• Restart and run Self Test Initialization pro-

gram. Refer to page 19

on hold

mode and the

General Maintenance

Wheel cleaning:

Always clean a brand new wheel before using. Wheels are packaged in rust preventative oil and will load up

if not cleaned before grinding.

These wheels are maintenance free from truing and dressing but will need cleaned periodically.

• Remove the wheel from the unit.

• Saturate the wheel with any type of oil-less

solvent, such as Automotive Brake Cleaner.

• Use a soft bristle brush and lightly brush the

saturated wheel loosening the impacted grinding particles.

• Re-saturate the wheel to flush out any loos-

ened debris.

NOTE: If after cleaning the wheel, (page 57) the drills still discolor or burn, the wheel life may be exhausted and the wheel will need replaced. Refer to page 57 for wheel change instructions.

After a wheel change, verify and/or recalibrate Material Take Off (MTO):

1. Use a 3/8 HSS standard twist drill, measure the length of drill before sharpening.

2. Call up the Darex #1 file and sharpen a drill.

3. After sharpening the drill, measure the drills

new length. MTO should be approximately .005-.007.

4. If incorrect, adjust using Grinding

Wheel Adjustment Screen Selector

Refer to page 28 & 59

Chuck cleaning:

Push the emergency stop button, unplug unit from power supply and use a “LOCK OUT” “TAG OUT” procedure.

• Open chuck jaw assembly to its largest capac-

ity range. Use a 3mm hex key wrench to remove the 4; 4mm Allen head cap screws from the chuck knob.

• The chuck jaw

assembly can now be removed through the back of the chuck spindle assembly.

• Brush away any grinding residue.

DO NOT REMOVE JAWS FROM

SPRINGS OR SPRINGS FROM SPINDLE INSERT. JAWS ARE POSITIONED AND THEN GROUND TO MATCH THE SPINDLE CONE HOUSING. BY REMOVING, YOU MAY COMPROMISE THE PRECISION OF THE CHUCK!

TO REINSTALL:

• Reinstall in reverse order, making sure the di-

ameter detect rod is oriented in spindle cor-

rectly.

If diameter detector rod is reinstalled im-

properly, damage to rod will occur.

• After chuck jaw assembly is properly replaced

and before the 4mm bolts are in place, open or close the chuck knob until the bolt hole pat-

General Maintenance

tern on the chuck knob is in alignment with the bolt hole pattern on each of the chuck knob retainers. Contact Darex if you have a

single bevel retainer.

Chuck knob retainer showing bevel

Top

NOTE: The position of the chuck knob retainers may need to be rotated to meet the bolt hole pattern on the chuck knob. Carefully insert bolts and tighten.

Changing the Grind Motor &

Vacuum Fuses:

Unplug AC power. Located on the back of the machine, on the electrical box panel, you will find both sets of fuses. Fuse holder is spring loaded. Using a flat head screwdriver push in and turn counterclockwise until fuse holder backs out enough to hold on to, turn and remove. It’s a good idea to check continuity of new fuse before replacing. Replace both Vacuum fuses or both less of the appearance of the second fuse.

Grind motor fuses, regard-

Cleaning Fiber Optic Lens:

For good drill alignment function, keep the fiber optic lens clean. Normal service period is about every 14 days, depending on conditions, more often may be necessary. To service, lightly dust off lens with a soft bristled paint brush. Make sure lens is not loose. To remove any oily film, use a minimal amount of isopropyl alcohol on a cotton swab and lightly clean lens.

Material Take Off (MTO)

Sensors 1 & 2:

Using a soft bristle paint brush, lightly brush debris away.

Electronics Panel Fan Filter:

Turn the power off and remove the fan guard and filter. Clean the filter with soap and warm water and then blow dry. Reinstall filter and guard.

LCD Screen:

Clean LCD screen with a soft cloth and a small amount of mild glass cleaner.

Wheel Housing Cavity:

While grinding wheel is out of machine and before replacing wheel, vacuum out wheel housing and wipe off and around the hub area.

Removing and Replacing

Grind Motor Brushes:

1. Refer to removing and replacing grind motor assembly to remove and replace the motor.

Refer to Section 24

2. Once the motor is removed, note the slotted brush retaining screws on each side of the motor.

3. Unscrew and check brushes one at a time noting how they were oriented in the guide. Marking them is a good idea.

4. Check each brush for damage to the springs or for excessive wear. They should measure no less than .275 inches from the lowest point of the radius to the top of the brush.

5. If either one needs replacement you must replace both brushes with new ones. If not, carefully replace them the same way they came out.

F1, 2 & 3 Models only

General Maintenance

6. If you are replacing with new brushes, be sure to install them with the radius of the brush in line with the rotation of the motor.

7. After brushes are installed Refer to Section 24

Removing and Replacing Grind Motor Assembly Instructions to replace the motor.

Removing Chuck Spindle

Drive Belt:

1. Remove Chuck Jaw Assembly Refer to Section

Do not remove the jaws or springs from the assembly.

position for accuracy and are not to be removed. Now rotate the crescent shaped knob retainers and remove.

3. To loosen and remove belt, insert a flat blade screw driver in the slotted bearing screw.

4. On the back of the casting is a 4mm button head screw that locks the bearing in place. Loosen with a 2.5mm Allen wrench. Rotate the bearing screw counterclockwise and loosen the belt. Slip the belt off the sprockets and remove.

5. Replace the belt. Using two fingers on a flat blade screw driver, rotate slotted bearing screw clockwise until belt just pulls to a flat condition. in resistance past this point of rotation. Continue rotating another 1/16". Hold screw driver in this position and secure bearing lock screw.

There will be a noticeable

They are ground in

increase

TO ACCESS MODULAR

COMPONENTS INSIDE

SHARPENER:

To Remove Guard Door:

1. Remove PP12026TF - Guard Door Retaining Knob.

2. To clear base casting lip, lift door up and then off.

To Remove Left Side Top

Cover:

1. Using a 5mm hex wrench, remove the three

1.25 x 18 Allen head bolts on the top cover.

2. Lift top cover off.

To Open Right Side Top Cover:

1. Using a 5mm hex wrench, remove 1; 1.25 x 18 Allen head bolt on the top cover.

2. Top cover is hinged at the front and can-

not be totally removed. Lift from the back. Gently lift cover up until it touches the hard stop and is vertical. The top cover will stand open in this position.

External Machine Castings:

Wipe down external machine castings with a mild household cleaner.

Internal Machine Castings:

• Carefully vacuum and inspect the internal cavi-

ties of the machine.

• Check baffles for tears.

Exploded Views/Parts List

Serial Number—through F3 (See page 84 for V4 and newer)

Not Shown PP10035NF - Cooling Fan Filter -

Not Shown - SA12638NA - Brushes

Not Shown - PP12581LF - Nema Drive Gear

3 - SA12070EA - 115v Vacuum Blower /Plug

Not Shown - PP02705PF - Vacuum Hose

/08Revised 12 /08

CNC-XPS-16 PARTS LIST

1 - PP12003PF - Tool Tray Mat 16 - PP12074FF - 115v - 7A-250v SLO Fuse (Vacuum)

2 - PP12015EF - LCD Display 16 - PP12057FF - 230v - 1.6A-250v SLO Fuse (Vacuum)

3 - SA12048EA - Cycle Start Button Assembly 17 - SA12340MA - Step Motor w/ Coupling

4 - SA12049EA - Cycle Stop Button Assembly 18 - PP12645FF - 115v-3A - 250v SLO Fuse (Grind Motor)

5 - SA12040EA - Emergency Stop Button Assembly 18 - PP12648FF - 230v-3.15A - 250v SLO Fuse (Grind Motor)

6 - SA12365EA - Limit Switch Sensor Assembly 19 - SA12150EA - 115v Electrical Panel Complete

7 - SA12345MA - Step Motor Assembly Complete 19 - SA12155EA - 230v Electrical Panel Complete

8 - SA12460EA - C Axis Sensor Assembly

9 - SA12680NA - Hone Assembly (Brush, Retainer & Bolts)

Not Shown - PP12680NF - 180 Grit Hone Brush 20 - SA12090EA - Cooling Fan

Not Shown - PP12686NF - 120 Grit Hone Brush

Not Shown - SA12252FA - Brush Retainer & Bolts 3 ea. 21 - SA12465EA - A Axis Sensor Assembly - Harmonic Dr.

10 - PP12660GF - 150 Grit CBN Wheel (Standard) 22 - SA12640MA - Grind Motor Assembly

10 - PP12666GF - 220 Grit Diamond Wheel (Standard) Not Shown - PP12655LF - Grind Motor Belt

10 - PP12663GF - 260 Grit Diamond Wheel (Optional)

10 - PP12675GF - 320 Grit Diamond Wheel (Optional) Not Shown - PP12138NF - D.C. Motor Choke

Not Shown - PP12750BF - Spindle Lock Pin Not Shown - PP12565TF - Diameter Detect Rod

Not Shown - PP12670TF - Wheel Retainer Bolt Not Shown - PP12582 LF - Drive Belt

11 - PP12005PF - Floor Mat Not Shown - SA12517TA - Belt Idler Assembly

12 - SA12025PA - Guard Door Assembly Not Shown - SA12595EA - Solenoid Assembly Complete

13 - SA12380EA - X Axis Sensor Assembly Not Shown - PP12038EF - 115v Power Switch

14 - PP12610BF - Spindle Cartridge Block Not Shown - PP12039EF - 230v Power Switch

15 - SA12615TA - Spindle Cartridge Arbor Assembly CNC VACUUM EXPLODED VIEW PAGE 87

Not Shown - PP12050EA - Guard Door Interlocking Switch 1 - SA12075EA - 115v CNC Vacuum Complete

Not Shown - PP12026TF - Guard Door Retaining Knob 2 - SA12072EA - 230v CNC Vacuum Complete

MISC 4 - SA12080EA - 230v Vacuum Blower /Plug

Not Shown - PP10144EF - 115v Cord Set 5 - PP12088NF - Air Filter Gasket

Not Shown - PP10148EF - 230v Cord Set 6 - PP12080NF - Filter Box Bottom

Not Shown - PP12027EF - 6V lamp (Clear) 7 - PP12087NF - H-Gasket

Not Shown - PP12830NF - Machine Cover 8 - PP12091TF - Filter Box Mounting Ring Nut

Not Shown - PP12850KF - Manual 9 - PP12086NF - Filter

Not Shown - PP04896VF - Video 11 - SA12082SA - Filter Box Top Assembly

Not Shown - SA12800KA - 115v Tool Kit Not Shown - PP12077LF - Intermittent Hose (wheel Guard)

Not Shown - PP12860NF - Software Diskette 10 - PP12085TF - Filter Box Top Washer

Not Shown - SA12805KA - 230v Tool Kit Not Shown - PP12097PF - Siphon Hose

Parts list for Models V4 or newer

Not Shown - PP10035NF - Cooling Fan Filter

Not Shown - PP12651BF - BLDC Motor Mount

2 - SA12072EA - 230v CNC Vacuum Complete

Not Shown - PP12097PF - Siphon Hose

1 - PP12003PF - Tool Tray Mat 16 - PP12074FF - 115v - 7A-250v SLO Fuse (Vacuum)

2 - PP12015EF - LCD Display 16 - PP12057FF - 230v - 1.6A-250v SLO Fuse (Vacuum)

3 - SA12048EA - Cycle Start Button Assembly 17 - SA12340MA - Step Motor w/ Coupling

4 - SA12049EA - Cycle Stop Button Assembly 18 - PP12645FF - 115v-3A - 250v SLO Fuse (Grind Motor)

5 - SA12040EA - Emergency Stop Button Assembly 18 - PP12648FF - 230v-3.15A - 250v SLO Fuse (Grind Motor)

6 - SA12365EA - Limit Switch Sensor Assembly 19 - SA12151EA - 115v Electrical Panel Complete w/BLDC

7 - SA12345MA - Step Motor Assembly Complete 19 - SA12156EA - 230v Electrical Panel Complete w/BLDC

8 - SA12460EA - C Axis Sensor Assembly 20 - SA12090EA - Cooling Fan

9 - SA12680NA - Hone Assembly (Brush, Retainer & Bolts)

Not Shown - PP12680NF - 180 Grit Hone Brush 21 - SA12465EA - A Axis Sensor Assembly - Harmonic Dr.

Not Shown - PP12686NF - 120 Grit Hone Brush 22 - PP12641MF - BLDC 115V Grind Motor

Not Shown - SA12252FA - Brush Retainer & Bolts 3 ea. 22 - PP12639MF - BLDC 230V Grind Motor

10 - PP12660GF - 180 Grit CBN Wheel (Standard) Not Shown - PP12656LF - BLDC Grind Motor Belt

10 - PP12666GF - 220 Grit Diamond Wheel (Standard)

10 - PP12663GF - 260 Grit Diamond Wheel (Optional) Not Shown - PP12643SF - BLDC Grind Motor Shroud

10 - PP12675GF - 320 Grit Diamond Wheel (Optional) Not Shown - SA12641MA - BLDC 115V Motor Upgrade Kit

Not Shown - PP12750BF - Spindle Lock Pin Not Shown - SA12639MA - BLDC 230V Motor Upgrade Kit

Not Shown - PP12670TF - Wheel Retainer Bolt Not Shown - PP12565TF - Diameter Detect Rod

Not Shown - PP12582 LF - Drive Belt

12 - SA12025PA - Guard Door Assembly Not Shown - SA12517TA - Belt Idler Assembly

13 - SA12380EA - X Axis Sensor Assembly Not Shown - SA12595EA - Solenoid Assembly Complete

14 - PP12610BF - Spindle Cartridge Block Not Shown - PP12038EF - 115v Power Switch

15 - SA12615TA - Spindle Cartridge Arbor Assembly Not Shown - PP12039EF - 230v Power Switch

Not Shown - PP12050EA - Guard Door Interlocking Switch CNC VACUUM EXPLODED VIEW PAGE 87

Not Shown - PP12026TF - Guard Door Retaining Knob 1 - SA12075EA - 115v CNC Vacuum Complete

11 - Not Shown - PP12005PF - Floor Mat PP12581LF - Nema Drive Gear

MISC 3 - SA12070EA - 115v Vacuum Blower /Plug

Not Shown - PP10144EF - 115v Cord Set 4 - SA12080EA - 230v Vacuum Blower /Plug

Not Shown - PP10148EF - 230v Cord Set 5 - PP12088NF - Air Filter Gasket

Not Shown - PP12027EF - 6V lamp (Clear) 6 - PP12080NF - Filter Box Bottom

Not Shown - PP12830NF - Machine Cover 7 - PP12087NF - H-Gasket

Not Shown - PP12850KF - Manual 8 - PP12091TF - Filter Box Mounting Ring Nut

Not Shown - PP04896VF - Video 10 - PP12085TF - Filter Box Top Washer

Not Shown - SA12800KA - 115v Tool Kit 11 - SA12082SA - Filter Box Top Assembly

Not Shown - SA12805KA - 230v Tool Kit Not Shown - PP12077LF - Intermittent Hose (wheel Guard)

Not Shown - PP02705PF - Vacuum Hose

Not Shown - PP12860NF - Software Diskette 9 - PP12086NF - Filter

Revised 12/08/08

Grind Motor 115v & 230v

Exploded Views/Parts List

XPS-16

All Models

115 V & 230 V

Electronic Panel

SA12703BA ALIGNMENT ASSEMBLY

Exploded Views/Parts List

XPS-16 Vacuum Assembly

Wiring Diag

ram

ELECTRONIC PANEL ASSEMBLY

1. MTO2

2. MTO1

3. C Axis

4. A Axis

5. X Axis

6. Z Axis

7. Align

8. -5V

9. +5V

10. X Axis board

11. Z Axis board

12. A Axis board

13. C Axis board

SA12150EA & SA12155EA

AC LAMP

40V

-12V

-5V

+5V

+12V

JP1

GMC DETECT

LOGIC GRIND

X AXIS

DC Motor Controller – PP12147EF (Not used on V4 and Newer)

Z AXIS

A AXIS

LOGIC

VACUUM

SOLENOID FUSE

C AXIS

Wiring Diagram

(2) = Qu ick Disco nnect Termina ls

(1) = L ocking con nect or

(3) = Ring Term ina l

(2) = Qu ick Discon nect Terminals

Notes: Unless Specified

Cable DRS

(3) 1/16/03 Added Darex part # s for

(4) 11/14/06 Change Grind Motor

C lari ty. RJ

(1) 5 /1/02 Added more detail for clarity RJ

(2) 6/19/02 Added chassis ground wire. RJ

(4) Twisted Wire (1 twist per inch)

(1) = Locking connector

(3) = Ring Terminal

Notes: Unless Specified

(3) 1/16/03AddedDarex part #s for

Clarity. RJ

(2) 6/19/02 Added chassis ground wire. RJ

(1) 5/1/02 Added more detail for clarity RJ

ELECTRICAL WIRING

DIAGRAM

Revision Notes

PP12151EF

F/F3-Revision 3

V4-Revision 4

SC ALE

BY:

DATE:

TITLE:

XP S-1 6 P A NEL TO BA SE WIR ING DIA GRAM

TO STEPPER

MOTORS

FROM

G RIND M OT OR

PP1 2639MF &

PP1 2641MF

"C" AXIS

"Z" AXIS

TO CHASSIS GROUND

TO L C D PW R/E-S TOP

PP12154EF

TO S OLE NOID

grn/ yel

DAREX CORPORATION

220 HERSEY- P.O.BOX277 A SH LAND,OR.97520

Telephone # 541-488-2224 Fax # 541-488-2229

SHEET 1 OF 1

"X" AXIS

"A" AXIS

PP12172EF

PP12169EF

CONTROLLE R

Blk ( L)

Wht (N)

Grn ( Earth)

PP12100EF

J6J1

TO S ENSO RS

"Z" AXI S S ENSOR

"C" A XIS SENSOR

"X" A XIS SEN SOR

"A" A XIS SENS OR

MTD S ENSOR

EDGE SENSOR

SA12640EF

TO GRIND

ALIG N

SENSOR

RS232

PP12730EF

TO CHA SSIS GROUND

grn/ yel

Telepho ne # 541- 488-2224 Fax # 541- 488-2229

DAREX CORPORATION

220 HERSEY -P.O.B OX 277 ASHLAND,OR. 97520

TO L CD PWR/E-S TOP

SHEET 1 OF 1

PP12154EF

SCALE

TITLE:

XPS-16 PANEL TO BASE WIRING DIAGRAM

MOTOR

TO SO LENOID

PP12164EF

BY:

TO STEPPER

MOTORS

"X" AXIS

"C" AXIS

"A" AXIS

"Z" AXIS

PP12172EF

PP12169EF

CONTROLLER

PP121 00EF

blk (A-)

red (A+)

J6J1

TO SENSORS

"Z" AXIS SENSOR

"C" AX IS SENSOR

"X" AXIS SENSOR

"A" AXIS SENSOR

MTD SENSOR

EDGESENSOR

ALI GN

SENSOR

RS232

PP12730EF

DATE:

4/23/02

PART #

DWG. #

PP12151EF

12151

PRINT CHK BY

Revision

Panel Ground

PP12180EF

PP1 2182EF

To FanAssemblyAs

per W/ I CN C1209 0

To P P12 137EF

To J 6 o nP ower Supply

FILTER

PP12143EF

4/23 /02

PART #

DWG. #

PP12151EF

12151

PRINT CHK BY

Panel Ground

PP12180EF

PP12182EF

To Fan Assembly As

per W/I CNC12090

PP1211 0EF

To PP12147EF

To J 6 on P ower Supply

Revi sion

PP12143EF

Wiring Diagram

115 VAC

10 A (MIN.)

1 KVAOR230 VAC

5 A (MIN)

1 KVA

LINE 2

P.E.

PO WER

RECEP TACLE

PP12065EF

= LOCKING CONNECTOR

= "QUICK" DISCON NECT TERMINALS

DEPICT ACTUALPART LOCATIONSON PANEL.

NOT E: LOCATIONS OF ITEMSSHOWN DO NOT

SE E REFERENCENU MBER S: 1 ,2 , 3 ...X

36 VDC

SO LENOI D

PP12595EF

PP12042EF

24VDC FAN

PP12070EF

RED & RED

RED & BLK

1, 2, 3, & X

TYP

GRN ,

WH T,

BLK,

RED

TYP

LIMIT & FO CAB LES

GRN,

WH T,

BRN,

YEL

GRN /

YEL

BLU

GRN/ WHT

EMER GEN CY

STO P SWITC H

PP12040EF &

115 V OR

SIGN AL

230 V

BRN &yEL

LINE 1

GND

BRN

PP12038EF - 115V

PP12039EF - 230V

INPUT

FILTER

PP12135EF

OR 230V AC -

PP12075EF

PP12072EF

UNDER VOLTAGEDROP-OUT

WITH TH ERMAL BREAKER &

POWE R SWI TCH

VACUUM

115VAC -

MOTOR

= "QUICK" DISCONNECT TERMINALS

=LOCKINGCONNECTOR

BRN

VACUUM FUSE

115V - 7A SLO,PP 12074 FF X 2

230V - 1.6A SLO, PP 12057FF X 2

DEPICT ACTUAL PART LOCATIONS ON PANEL.

NOT E: LOCA TIONS O F ITEMS SHO WN DO N OT

SEE REFERENCE NUMBERS: 1 , 2 ,3 ...X

SOLENOID

PP12595EF

24VDC FAN

PP12070EF

1, 2, 3, & X

33 MHZ

PROCESSOR

GRN,

WHT,

BLK,

RED

BLU

TYP

115 VAC

10 A (MIN.)

1 KVAOR230 VAC

5 A (MIN)

1 KVA

LINE 1

LINE 2

P.E.

POWER

RECE PTACL E

PP12065EF

GRN /

YEL

GND

OR 230VAC -

PP12075EF

PP12072EF

VACUUM

115VAC -

MOTOR

ELECTRICAL WIRING DIAGRAM

SA12150EF

F/F3-Revision 6

36 VDC

GRN/ WHT

EMERGENCY

STOP SWITCH

PP12040EF &

PP12042EF

RED & RED

RED & BLK

BRN &yEL

GRN

BLU

BL UBLU/

115 V OR

SIGNAL

230 V

BRN

UNDERV OLTAGE DROP-OUT

WITH THERMAL BREAKER &

PP12038EF - 115V

PP12039EF - 230V

POWER SWITCH

INP UT

FILTER

PP12135EF

BRN

VACUUM F USE

115V - 7A SLO, PP12074FF X 2

230V - 1.6 ASLO, PP12057FF X 2

BLU

V4-Revision 7

VDC

±12

36 VDC STEPPER MOTORS

36 VDCS TE PPER M OTO RS

PP12340EF

RED & BLK

5 VDC

RS232 (9.6K BAU)

GRN & W HT

TITLE XPS-16 ELECTRICALDRAWING

220 HERSEY - P.O .B OX 277 A SHLAND,OR. 97520

Telephone # 541-488-2224 Fax # 541-488-2229

SCA LE

DAREX CORPORATION

SHEET 1 O F 2

BY RJI

DATE 7/12/01

PRIN T CHK BY

PART# P P12 150E F

DWG. # 1215 0

STE P MOTORDRIVERS

CONTROLLER PCB

PP 1210 0EF

SE NSO R PCB

PP12105EF

33MHZ

GRN/YEL

D riv e F ilt e r

PP12639MF - 230V

PP12641MF - 115V

MOTOR

SW IT CH-N O

ORG &

ORG

RED &

BLK

PP12137NF

WH T

BLDC

BLK

Removed

5 VDC

BLKWH T

SW IT CH- NO

GRN &

GRN

VDC

GNDGR N

BLK

BLU

MOTOR FU SE

115V - 3.0A SLO

PP12645FF X 2

230V - 3.15A SLO

PP12648FF X 2

5 VDC

RED & BLK

GRN & W HT &

BLK

SW IT CHE D

DC MOTOR

FILTER

PP12140NF

BLU

BLK

5-6

VDC

LAMP

BLK &

WH T

IN TE RF ACE

PP12122EF

PCB

PP12015EF

PO WER S UPPLY

PCB PP12110EF

SW IT CHE D

RED & BLK

24 VDC

SCALE

TITL E X PS-16 EL ECTRICAL DR AWING

220 HERSEY -P.O.BOX277 ASHLAND,OR.97520

Te leph one # 5 41- 488- 222 4 F ax # 5 41- 488 -222 9

DAREX CORPORATION

BY RJI

TOUCH

SCR EEN /

DISPLAY

DATE 7/12/01

PART # PP121 50EF

DWG . # 12 150

PP12340EF

CONTROLLER PCB

PP12100EF

SENSOR P CB

PP12105EF

33MHZ

GRN/YEL

BLK

ORG

5VDC

RED

RED & BLK

5 VDC

GRN & WHT

PP 12640E F

90 VDC

MOTOR

RS232 (9.6K BAU)

SHEET 1 OF 2

ORG &

5 VDC

ORG

CONTROLLER

DC MOTOR

PP12147EF

BLK

PP 12138N F

CHOKE

5 VDC

RED & BLK

Drive F ilter

PP 12137N F

GRN &

5 VDC

GRN

PRINT CHK BY

VDC

±12

VDC

GND

BLK

BLU

WHT

BL K

MOTOR FUSE

115V- 3.0A SLO

PP 12645F F X 2

230V- 3.15A SLO

PP 12648F F X 2

5 VDC

RED & BLK

GRN & WHT &

BLK

SWITCHED

DC MOTOR

FILTER

PP12140NF

BLKBLU

5-6 VDC

LAMP

BLK &

WHT

INTE RFACE

PP12122EF

PCB

PP12015EF

POWER SUPPLY

PCB PP1211 0EF

SWITCHED

RED & BLK

24 VDC

TOUCH

SCREEN /

DISPLAY

Revision

PP12054EF

RS232

PO RT

(57K BA UD)

Revision

LAMP

PP12054EF

CYCLE HOLD

SWITCH

PP12048EF,

OPERATOR

PP12045EF &

LAMP

PP12046EF

CYCLE START

SWITCH

PP12048EF,

OPERATOR

PP12045EF &

RS232 PORT

(57K BAUD)

CYC LE STA RT

SW IT CH

PP12048EF,

OP ERAT OR

PP12045EF &

LAMP

PP12046EF

CYCLE HOLD

SW IT CH

PP12048EF,

OP ERA TOR

PP12045EF &

LAMP

SERVICE P ARTS REPLACEMENT

SCHEMATICS & WORK INSTRUCTIONS

USER SECTION

CHUCK SWING CASTING ASSEMBLY EXPLODED VIEW: SA12500CA.... PAGE 1

CHUCK SPINDLE DRIVE BELT REPLACEMENT............................... PAGE 3

REMOVE/REPLACE C HUCK BELT IDLER ASSEMBLY...................... PAGE 6

REMOVE/REPLACE CHUCK LOCKING SOLENOID.......................... PAGE 7

REMOVE/REPLACE NEMA DRIVE GEAR......................................... PAGE 8

REMOVE/REPLACE ROTATE SENSOR ............................................ PAGE 9

REMOVE/REPLACE A-AXIS (SWING) SENSOR............................ PAGE 11

CHUCK ASSEMBLY EXPLODED VIEW: SA12520TA .............................. PAGE 13

REMOVE/REPLACE DIAMETER DETECT ROD .............................. PAGE 15

ELECTRICAL WIRING DIAGRAM: PP12150EF ....................................... PAGE 17

REMOVE/REPLACE COOLING FAN............................................... PAGE 19

REMOVE/REPLACE LCD DISPLAY................................................ PAGE 21

REMOVE/REPLACE SWITCHES

GRIND MOTOR ASSEMBLY EXPLODED VIEW: SA12640MA F1, 2 & 3. PAGE 25

REMOVE/REPLACE GR IND MOTOR ASSEMBLY F1, 2 & 3............ PAGE 27

REMOVE/REPLACE GRIND MOTOR BELTF .................................. PAGE 29

REMOVE/REPLACE GRIND MOTOR BRUSHES F1, 2 & 3.............. PAGE 30

SPINDLE CARTRIDGE ASSEMBLY EXPLODED VIEW: SA12615TA....... PAGE 31

REMOVE/REPLACE S PINDLE ARBOR CARTRIDGE ASSEMBLY.... PAGE 33

E-STOP,CYCLE START & FEED HOLD .. PAGE 23

PP12581LF

NEMA DRIVE GEAR

User Manual Page 1

CHUCK SWING CASTING

ASSEMBLY

SA12500CA

User Manual Page 3

Removing and Replacing the Chuck Spindle Drive Belt

1. Remove the three 3mm button head screws with a 2mm Allen wrench and remove the cover

3MM button head screws

plate.

2. Remove the four, 4mm cap screws from the chuck knob with a 3mm Allen wrench. Lift the chuck knob straight up. The jaw assembly and knob will come out together. Set aside.

4MM cap screws

3. Do not remove the jaws or springs

from the assembly. They are ground in

position for accuracy and are not to be removed.

Knob and jaw assembly

Now rotate the crescent shaped knob retainers and remove.

Knob retainers

cover

User Manual Page 4

4. To loosen and remove belt, insert a flat blade screw driver in the slotted bearing screw.

Loosen

5. On the back of the casting is a 4 mm button head screw that locks the bearing in place. Loosen with a 2.5mm Allen wrench. Rotate the bearing screw counterclockwise and loosen the belt. Slip the belt off the sprockets and remove.

6. Replace the belt. Using two fingers on a flat blade screw driver, rotate slotted bearing screw clockwise until belt just pulls to a flat condition. There will be a noticeable increase in resistance past this point of rotation. Continue rotating another 1/16". Hold screw driver in this position and secure bearing lock screw.

Tighten

4MM locking screw

User Manual Page 5

Diameter detect rod Not ch

Replace Chuck Spindle Drive Belt

1. Take the knob and jaw assembly and position all jaws in slots. Holding in your hand, align the black diameter detect rod in the corresponding notch in the spindle cone. (See drawing below). Make sure jaws are in spindle slots. Slide the assembly all the way in until it

3. Slip the knob retainer under the knob and locate threaded holes under counter bored holes in the knob. (Note the dotted lines). Hold in position with your finger and secure

Bevel side down

Top

with 2 cap screws. Rotate the chuck 180° and repeat the process. Replace the cover and secure with 3 button head screws.

stops.

2. With the solenoid engaged in the locking hole, rotate the chuck to the illustrated position.

Darex XPS-16 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual