Makino D200z Installation Manual

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Page 1

Original instructions

29F24D-2006EN

Page 2

Page 3

English

This manual should only be used by skilled maintenance personnel.

Japanese

Albanian

Bosnian

Brazilian

Portuguese

Bulgarian

Chinese

Croatian

Czech

Danish

このマニュアルは訓練された保守要員がご使用ください。

Ky manual duhet të përdoret vetëm nga personeli I trajnuar i mirëmbajtjes.

Ovo uputstvo bi trebalo koristiti samo osoblje obučeno za održavanje.

Este manual apenas deve ser utilizado por técnicos de manutenção qualificados.

За използване само от специално обучен персонал за поддръжка.

本手册仅供已经培训的维护人员使用。

Ovaj priručnik namijenjen je samo obučenom osoblju za održavanje.

Tato příručka může sloužit k použití pouze pro školený personál údržby.

Denne manual må kun anvendes af specielt uddannet servicepersonale.

Estonian

German

Hungarian

Indonesian

Dutch

Finnish

French

Greek

Italian

Dit handboek mag enkel door speciaal opgeleid onderhoudspersoneel gebruikt worden.

Manuaal on mõeldud kasutamiseks ainult vastavate oskustega hoolduspersonalile.

Vain koulutetut huoltohenkilöt saavat käyttää tätä ohjekirjaa.

Ce manuel ne doit être utilisé que par du personnel de maintenance compétent.

Dieses Handbuch darf nur duch speziell ausgebildetes Wartungspersonal verwendet werden.

Το παρόν εγχειρίδιο πρέπει να χρησιμοποιείται από ειδικά εκπαιδευμένο προσωπικό συντήρησης.

Ezt a kézikönyvet csak szakképzett karbantartó személyzet használhatja.

Manual ini harus digunakan hanya oleh petugas pemeliharaan yang berketerampilan.

Il presente manuale deve essere utilizzato solo da parte del personale di manutenzione appositamente addestrato.

Korean

이 작업지도서는 기술이 능수한 정비인원이 사용해 주십시요

Page 4

Latv

ian

Šo rokasgrāmatu drīkst izmantot tikai kvalificēts tehniskās apkopes personāls.

thuanian

acedonian

alaysian

orwegian

olish

ortuguese

omanian

ssian

bian (cyr)

Ser

Šį vadovą turėtų naudoti tik kompetentingi techninės priežiūros darbuotojai.

Овој прирачник треба да го користи само квалификуван персонал за одржување.

Manual ini hendaklah digunakan oleh kakitangan penyenggaraan yang mahir sahaja.

Denne håndboken skal kun brukes av autoriserte reparatører.

Ten podręcznik jest przeznaczony do użytku wyłącznie przez odpowiednio przeszkolony personel konserwacyjny.

Este manual apenas pode ser utilizado por técnicos de manutenção qualificados.

Acest manual trebuie utilizat numai de personal de întreţinere calificat.

Это руководство предназначено только для квалифицированного обслуживающего персонала.

Ово упутство би требало да користи само особље обучено за одржавање.

erbian (lat)

ovak

lovenian

panish

edish

hai

rkish

inian

Ukra

etnamese

Ovo uputstvo bi trebalo da koristi samo osoblje obučeno za održavanje.

Príručku môže používať len špeciálne vyškolený personál údržby.

Ta p ri ro čnik naj bi uporabljalo le osebje, usposobljeno za vzdrževalna dela.

Este manual sólo puede utilizarlo personal de mantenimiento especialmente cualificado.

Denna handbok får endast användas av speciellt utbildad underhållspersonal.



Bu kullanım kılavuzu sadece özel eğitim almış uzman bakım personeli tarafından kullanılmalıdır.

Ця настанова призначена лише для кваліфікованого обслуговуючого персоналу.

Tài liệu hướng dẫn này chỉ nên sử dụng bởi nhân viên bảo trì lành nghề.

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Important Information

General

• Do not attempt to modify the machine.

• Operation, maintenance, and inspection of this machine must be performed by staff who have received technical training for the machine, training in machine hazards and their prevention, and safety training.

• Observe the laws, regulations, and other rules of the relevant national and local administrative agencies.

• This machine, including technical data and software, may be subject to the Japanese Foreign Exchange and Foreign Trade Law. Prior to any resale, transfer or re-export of controlled items, contact Makino to obtain any required authorization or approval.

• The specifications and design are subject to change without prior notice.

This Manual

• This manual is prepared for usage by experienced operators. For this reason, it does not include safety precautions for operators who do not have mechanical or technical knowledge of machine operation, programming, and maintenance.

• If the machine is operated by persons who are not native speakers of the language in this manual, the customer must ensure that the operators receive complete safety training. Also, warning labels must be affixed in a language that the operators can understand.

• The copyright for the entire content of this manual belongs to Makino Milling Machine Co., Ltd. The copying, reproduction, or transfer of this manual, in whole or in part, without the express written permission of Makino Milling Machine Co., Ltd., is strictly prohibited.

• Illustrations and other details may differ from the actual machine due to the selected options, modified specifications, or other reasons.

• Store the manuals needed for operation, maintenance, and inspection of this machine in a location where they can be easily accessed by the operator.

• Be sure to perform periodic inspection and maintenance of the machine according to the periodic maintenance manual or the legend plate to prevent breakdown of the machine.

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Important Points for Work Safety

• Familiarize yourself with the safety precautions and functions before attempting to operate, maintain, or inspect the machine.

• The points that the operator must observe when performing machine operation and maintenance vary depending on the situation. All possible points cannot be covered in the content of this manual. Be sure to fully understand the machine, and remain constantly aware of safety and the potential hazards while doing work.

• If the safety devices or protective devices do not operate properly, stop operation of the machine and notify the supervisor or manager. The supervisor or manager must immediately notify your authorized Makino dealer or Makino service representative.

• When the machine is stopped due to an unknown cause, immediately contact the supervisor or manager, and wait for permission before restarting operation.

Keeping Machining Accuracy

After installing the machine, to keep machining accuracy, conduct periodic inspection such as performing level adjustment. If the level of the machine changes, high-accuracy machining cannot be performed. In addition, normal machining cannot be performed if the machine vibrates.

Especially, for approximately six months after installation, the level of the machine might change significantly until the foundation becomes stable.

Depending on the condition of the foundation or the machine usage frequency, conduct inspection and adjustment approximately every six months or every year.

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Manuals and How to Use Them

DANGER

WARNING

CAUTION

NOTENOTE

Manuals Belonging to This Machine

Name Description

Instruction Manual This manual includes the basic information (overview,

specifications) needed for operation, practical operating procedures (operation), and troubleshooting procedures.

Periodic Maintenance Manual This manual explains the intervals for periodic maintenance and

work that is required for maintaining optimum performance of this machine.

Peripheral Device Manual This manual describes the operating procedures for the peripheral

devices connected to the machine body.

Parts Manual This manual provides the machine component part names and

their order numbers.

Professional 6 Operation Manual

Professional 6 M Code List This manual describes the M codes of Professional 6.

FANUC Set of NC Manuals

Maintenance Manual (option) This manual describes the mechanisms of the machine and how to

Installation Manual (option) This manual describes the preparation, carry-in, and installation

Other manuals for options These manuals describe the operating procedures for the optional

This manual describes the operating procedures and various functions of the controller (Professional 6).

These manuals describe the operating procedures for FANUC equipment.

perform the maintenance and adjustment work.

procedures for setup of the machine.

devices.

Notation Used in This Manual

Indicates an imminent hazard which, if not avoided, will result in death or serious injury.

Indicates a potential hazard which, if not avoided, will result in death or serious injury.

NOTICE

29F24D-2006EN

Indicates a possible hazard which, if not avoided, may result in minor or moderate injury.

Indicates a potential situation which, if not avoided, may result in physical damage to the machine or adversely affect the work environment.

Indicates supplemental information for appropriate and efficient work or better understanding of the operation.

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Chap. 1 Safety

1 Safety Precautions .................................................................................. 1-1

1.1 Operator Checks .......................................................................................................... 1-2

1.2 Work Environment Checks ........................................................................................... 1-2

1.3 Precautions for Potential Fire Hazards ......................................................................... 1-3

1.4 Confirmation of Machine Status ................................................................................... 1-4

1.5 Pre-operation Checks ................................................................................................... 1-5

1.6 Implementing Lock-out and Tag-out ............................................................................. 1-7

1.7 During Work ................................................................................................................. 1-8

1.8 Handling of Hazardous and Toxic Materials ............................................................... 1-11

2 Warning Labels ..................................................................................... 1-12

2.1 Signal Word Definitions .............................................................................................. 1-12

2.2 Using Warning Labels ................................................................................................ 1-13

2.3 Information Contained in Warning Labels .................................................................. 1-14

2.3.1 Warning Labels with Warning Text ................................................................ 1-14

2.3.2 Warning Labels with Warning Marks Only .................................................... 1-14

2.4 Warning Label Locations ............................................................................................ 1-15

2.4.1 Area around Operator Door ........................................................................... 1-15

2.4.2 Area around Tool Magazine .......................................................................... 1-16

3 Safety Devices ...................................................................................... 1-17

3.1 "Emergency Stop" Switch ........................................................................................... 1-17

3.1.1 "Emergency Stop" Switch Installation Location (Machine Body) ................... 1-18

3.1.2 "Emergency Stop" Switch Installation Location

(Large Capacity Tool Magazine) ................................................................... 1-19

3.2 Door Switch ................................................................................................................ 1-20

3.2.1 Door Switch Installation Location (Machine Body) ........................................ 1-20

3.2.2 Door Switch Installation Location

(Disk Type Tool Magazine 21-tool/40-tool) ................................................... 1-21

3.2.3 Door Switch Installation Location (Large Capacity Tool Magazine) .............. 1-22

4 Work Hazards ....................................................................................... 1-23

4.1 Area Surrounding Machine ......................................................................................... 1-23

4.2 Electrical System ........................................................................................................ 1-24

4.3 Parameters ................................................................................................................. 1-24

4.4 Inside the Machining Chamber ................................................................................... 1-24

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Contents

4.5 Tool Magazine ............................................................................................................ 1-26

4.6 Cutting Fluid Supply Unit/Chip Disposal Device/

Cutting Fluid Temperature Controller/Dust Collector (Graphite Specifications) ......... 1-27

4.7 Temperature Controller .............................................................................................. 1-27

4.8 Hydraulic Unit ............................................................................................................. 1-28

4.9 Pneumatic Unit ........................................................................................................... 1-28

4.10 Splash Guard ............................................................................................................. 1-28

4.11 Other Peripheral Equipment ....................................................................................... 1-29

5 Occupational Health and Safety Management ..................................... 1-30

5.1 Safety Device Inspection ............................................................................................ 1-30

5.2 Noise .......................................................................................................................... 1-30

5.3 Personal Protective Equipment .................................................................................. 1-31

5.4 Disposal of Waste Products ....................................................................................... 1-32

5.4.1 Disposal of Waste Oil, Waste Fluids, and Waste Materials .......................... 1-32

5.4.2 Disposal of This Machine .............................................................................. 1-32

Chap. 2 Installation Preparation

1 Checking Installation Requirements ....................................................... 2-1

2 Allocation of Installation Area ................................................................. 2-2

3 Requirements for Carry-in Route ............................................................ 2-8

4 Installation Requirements ..................................................................... 2-15

5 Recommended Foundation Conditions ................................................ 2-16

6 Air and Power Sources ......................................................................... 2-19

7 Preparation of Equipment for Transfer/Installation ............................... 2-23

Chap. 3 Installation

1 Installation Work Flow ............................................................................. 3-1

2 Preparing Securing Fixtures for Shipment and Hoisting Attachment ...... 3-3

3 Hoisting the Machine Body ..................................................................... 3-5

3.1 Fixing Main Operation Panel ........................................................................................ 3-6

3.1.1 Fixing Main Operation Panel (When Transported on a Truck) ........................ 3-6

3.1.2 Fixing Main Operation Panel (When Transported in a Container) .................. 3-8

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Contents

3.2 Attaching Left Cover Securing Fixtures for Shipment ................................................ 3-10

3.3 Attaching Operator Door Securing Fixtures for Shipment .......................................... 3-12

3.4 Attaching Tool Magazine Door Securing Fixtures for Shipment ................................. 3-14

3.5 Hoisting ...................................................................................................................... 3-16

4 Hoisting the Peripheral Equipment ....................................................... 3-19

4.1 Hoisting the Cutting Fluid Supply Unit (Other than Graphite Specifications) ............. 3-20

4.2 Hoisting the Temperature Controller (Other than Graphite Specifications) ................ 3-21

4.3 Hoisting the Dust Collector (Graphite Specifications) ................................................ 3-22

5 Machine Setup ...................................................................................... 3-25

5.1 Setup of Machine Body .............................................................................................. 3-26

5.1.1 When Using Crane ........................................................................................ 3-26

5.1.2 When Using Forklift ....................................................................................... 3-28

5.2 Removing Hoisting Attachment .................................................................................. 3-30

5.3 Releasing Fixed Main Operation Panel ...................................................................... 3-32

5.3.1 Releasing Fixed Main Operation Panel (When Transported on a Truck) ...... 3-32

5.3.2 Releasing Fixed Main Operation Panel

(When Transported in a Container) ............................................................... 3-34

5.4 Removing Tool Magazine Door Securing Fixtures for Shipment ............................... 3-36

5.5 Removing Operator Door Securing Fixtures for Shipment ......................................... 3-37

5.6 Removing Left Cover Securing Fixture for Shipment ................................................. 3-38

5.7 Removing Machine Controller Securing Fixture for Shipment ................................... 3-39

5.8 Removing X-axis, Y-axis and Z-axis Securing Fixtures for Shipment ........................ 3-40

5.9 Releasing the Fixed Securing Bracket ....................................................................... 3-44

5.10 Adjusting the Height of the Tool Magazine ................................................................. 3-46

6 Setting Up the Peripheral Equipment and

Connecting the Piping and Wiring ........................................................ 3-47

6.1 Setting Up the Cutting Fluid Supply Unit and

Connecting the Piping and Wiring (Other than Graphite Specifications) .................... 3-48

6.2 Setting Up the Dust Collector and Connecting the Piping and Wiring (Graphite

Specifications) ............................................................................................................ 3-50

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Contents

7 Refilling Oil ............................................................................................ 3-51

7.1 Recommended Cooling Oil, Hydraulic Oil, and Lubricant .......................................... 3-51

7.2 Refilling Oil for the Temperature Controller ................................................................ 3-52

7.3 Refilling Oil for the Oil Air Supply Device ................................................................... 3-53

7.4 Refilling Oil for the Hydraulic Unit ............................................................................... 3-54

7.5 Refilling Oil for the Cutting Fluid Supply Unit

(Other than Graphite Specifications) .......................................................................... 3-56

8 Connecting the Power Supply and Air Source to the Machine ............. 3-59

8.1 Connecting the Power Supply to the Machine ........................................................... 3-59

8.2 Connecting the Air Source to the Machine ................................................................. 3-62

9 Work after Power Connection ............................................................... 3-63

9.1 Removing the Sleeper ................................................................................................ 3-63

9.2 Checking the Levelness of Installed Machine ............................................................ 3-64

9.3 Fixing the Leveling Block ............................................................................................ 3-65

9.4 Mounting Covers ........................................................................................................ 3-66

10 Operation Check ................................................................................... 3-67

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Chap. 1 Safety

1 Safety Precautions................................................................................... 1-1

1.1 Operator Checks ........................................................................................................... 1-2

1.2 Work Environment Checks............................................................................................ 1-2

1.3 Precautions for Potential Fire Hazards.......................................................................... 1-3

1.4 Confirmation of Machine Status ................................................................................... 1-4

1.5 Pre-operation Checks.................................................................................................... 1-5

1.6 Implementing Lock-out and Tag-out.............................................................................. 1-7

1.7 During Work .................................................................................................................. 1-8

1.8 Handling of Hazardous and Toxic Materials ............................................................... 1-11

2 Warning Labels...................................................................................... 1-12

2.1 Signal Word Definitions............................................................................................... 1-12

2.2 Using Warning Labels ................................................................................................. 1-13

2.3 Information Contained in Warning Labels ................................................................... 1-14

2.3.1 Warning Labels with Warning Text................................................................. 1-14

2.3.2 Warning Labels with Warning Marks Only ..................................................... 1-14

Safety

2.4 Warning Label Locations............................................................................................. 1-15

2.4.1 Area around Operator Door............................................................................ 1-15

2.4.2 Area around Tool Magazine .......................................................................... 1-16

3 Safety Devices ...................................................................................... 1-17

3.1 "Emergency Stop" Switch............................................................................................ 1-17

3.1.1 "Emergency Stop" Switch Installation Location (Machine Body).................... 1-18

3.1.2 "Emergency Stop" Switch Installation Location

(Large Capacity Tool Magazine) .................................................................... 1-19

3.2 Door Switch ................................................................................................................ 1-20

3.2.1 Door Switch Installation Location (Machine Body)......................................... 1-20

3.2.2 Door Switch Installation Location

(Disk Type Tool Magazine 21-tool/40-tool) .................................................... 1-21

3.2.3 Door Switch Installation Location (Large Capacity Tool Magazine) .............. 1-22

4 Work Hazards ....................................................................................... 1-23

4.1 Area Surrounding Machine.......................................................................................... 1-23

4.2 Electrical System......................................................................................................... 1-24

4.3 Parameters ................................................................................................................. 1-24

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4.4 Inside the Machining Chamber ................................................................................... 1-24

4.5 Tool Magazine............................................................................................................. 1-26

4.6 Cutting Fluid Supply Unit/Chip Disposal Device/

Cutting Fluid Temperature Controller/Dust Collector (Graphite Specifications) ......... 1-27

4.7 Temperature Controller ............................................................................................... 1-27

4.8 Hydraulic Unit .............................................................................................................. 1-28

4.9 Pneumatic Unit............................................................................................................ 1-28

4.10 Splash Guard .............................................................................................................. 1-28

4.11 Other Peripheral Equipment........................................................................................ 1-29

5 Occupational Health and Safety Management ...................................... 1-30

5.1 Safety Device Inspection ............................................................................................ 1-30

5.2 Noise ........................................................................................................................... 1-30

5.3 Personal Protective Equipment................................................................................... 1-31

5.4 Disposal of Waste Products ........................................................................................ 1-32

5.4.1 Disposal of Waste Oil, Waste Fluids, and Waste Materials ........................... 1-32

5.4.2 Disposal of This Machine ............................................................................... 1-32

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1 Safety Precautions

• Disregarding the specific instructions or precautions included in this manual may result in serious injury or death to the operators or surrounding workers, or damage to the machine.

• Never disable or remove any safety device. Operating the machine while the safety devices are disabled may result in serious injury, death, or damage to the machine.

• Observe the safety precautions provided in this manual at all times and fully implement safety measures.

• Inspect and maintain the machine regularly to keep it in optimum operating condition. Do not run the machine if it shows any signs of abnormal operation.

• The keys (release key for door switch, machine controller panel key, etc.) which are not necessary for regular operation and maintenance must be removed from the machine and managed by supervising personnel.

• The lubricating oil, cutting fluid, and other chemical substances used with the machine must be managed by supervising personnel.

Safety

• Workpiece materials such as magnesium and titanium may cause a fire if mishandled, so be particularly careful when machining workpieces and handling cutting chips made from these types of materials.

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1-1

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1 Safety Precautions

1.1 Operator Checks

• Only qualified personnel who have adequate mechanical and technical knowledge are allowed to operate and maintain the machine.

• Only qualified electrical engineers may perform electrical work.

• Only qualified personnel may use a crane or forklift.

• Wear suitable work clothes whenever operating or maintaining the machine. Do not operate the machine while wearing loose-fitting clothes, a necktie, jewelry, or any other clothing or objects which may become entangled with the moving parts of the machine.

• Tie up long hair, and wear a cap.

• Wear safety glasses, safety shoes, safety cap (including safety helmet), and safety gloves as needed.

• Protective gear should be worn to protect hearing when excessive noise may be generated during operation or maintenance.

• Never operate any machinery while under the influence of alcohol or drugs.

• The operator should be in proper physical condition. If the operator suffers from a condition that impairs judgment, it may result in serious injury or death.

1.2 Work Environment Checks

• Make sure the machine and surrounding area are fully lighted.

• Make sure the machine and surrounding area are tidy and clean at all times.

• Clean up any oil, cutting fluid, or chips scattered around the machine.

• When performing work at high locations, use a stable footstool or stepladder.

• Keep all flammable substances away from the work area.

• Maintain adequate working space.

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1 Safety Precautions

1.3 Precautions for Potential Fire Hazards

Use the machine by following the precautions below to protect the machine equipment, plant, and surrounding environment from the danger of fire and to ensure the safety of operators.

1 When using cutting fluid, be sure to use a water-soluble cutting fluid (type A1).

There is no fire hazard when using water-soluble cutting fluids (except when using them with special materials).

2 Oil-based cutting fluids present a potential fire hazard.

If an oil-based cutting fluid must be used due to unavoidable circumstances, be sure to observe the precautions below.

• Do not run the machine in an unmanned operation mode.

• Install the proper fire-extinguishing equipment near the machine.

• Provide alarm devices to detect a fire, automatic fire-extinguishing devices, and other equipment to the greatest extent possible.

• Do not create situations which may potentially start a fire.

• Machine under the proper cutting conditions.

• Perform proper tool management to prevent the occurrence of abnormal frictional heat and sparks.

• Do not allow chips to accumulate in the machining chamber.

• Check that a constant and full supply of cutting fluid is provided.

• Always clean up and organize the area around the machine, and do not place flammable objects in the area.

Safety

3 Precautions for machining of flammable solids, resins, wood, and other flammable materials.

When machining flammable solids or other special materials, be sure to fully implement safety measures after gaining a thorough understanding of the material properties. Be sure to also pay careful attention to safety when machining resins, wood, and other materials.

When machining materials that generate dust and powder, be sure to provide equipment that takes into account the danger of a dust explosion for certain material types.

4 Precautions for machining while blowing air.

Because air blowing has weak cooling performance, the chips that spray and fly out in the surrounding area are extremely hot. Do not place flammable objects in the machining chamber or in the area surrounding the machine.

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1 Safety Precautions

1.4 Confirmation of Machine Status

• Machine inspections and maintenance must be performed regularly to maintain optimum machining accuracy and long-term performance, and increase machine operating efficiency.

• Confirm that all safety devices are functioning normally.

• Make sure the operator knows the location of the "Emergency Stop" switches to enable easy access in the event of an abnormal or dangerous situation (Refer to 3.1 "Emergency Stop"

Switch).

• Check for any loose, damaged, or worn parts on the machine. Operating the machine in a condition in which any of the parts has an abnormality may cause abnormal noises or damage to the machine.

• Check for any damaged piping or wiring. Operating the machine with the piping or wiring left damaged may cause oil leakage, electrical shock, or fire.

• Use the most appropriate cutting tool, tool holder, retention knob, and workpiece, and make sure that they are all secured firmly in place. Otherwise, the workpiece may fall or the tool may fly out, and this may result in damage to the machine, serious injury, or death.

• Check that the tool numbers are registered correctly. Otherwise, the spindle may rotate at a speed outside the allowable range, the tool may fly out, and this may result in damage to the machine, serious injury, or death.

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1 Safety Precautions

1.5 Pre-operation Checks

• Be sure that you fully understand the work procedures and precautions before operating and maintaining the machine. Never operate any machinery if you are unsure about any points.

• Check that the clothes you are wearing are suitable for operation.

• Perform periodic maintenance.

• Confirm that all safety devices are functioning properly before operating and maintaining the machine.

• Periodically back up the parameters when the machine was shipped and the program and offset data that have been prepared by the customer. Makino is not liable for any program or offset data that is corrupted or lost.

• Makino does not accept responsibility for any trouble caused by apparatus or programs prepared by the customers, such as damage to workpieces or the machine.

• For details about replacement parts, contact your Makino service representative. Use of improper parts may result in reduced machine performance or safety, damage to the machine, or operator injuries.

Safety

• Before entering inside the machine to perform work, be sure to confirm the escape procedure in the event that you inadvertently become shut inside the machine.

• Perform the lock-out and tag-out procedures.

• Make sure the operator knows the location of the "Emergency Stop" switches for each device so that they can be easily operated in the event of an abnormal or dangerous situation.

• Be sure to observe the information on the warning labels. Contact your Makino service representative if a warning label comes off or becomes illegible.

• When handling a hazardous or toxic material (oils, cutting fluids, and other chemical substances), obtain the safety data sheet (SDS), and follow the instructions. The safety data sheet (SDS) contains information about the safe handling of hazardous and toxic materials, and emergency measures.

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1 Safety Precautions

1.5 Pre-operation Checks

• For the graphite specifications, do not let the dust collector collect anything other than graphite dust. Failure to observe this precaution may result in a dust explosion. Also, it may damage the filter or cause other malfunctions.

• For the graphite specifications, observe the following precautions to prevent health problems related to the inhalation of graphite dust.

• After machining the workpieces, wait for the dust collector to remove airborne dust particles before opening the operator door. If you open the operator door immediately after machining, the airborne dust will disperse throughout the machining room.

• Wear a high-performance dust-proof mask when doing the following (particle collection efficiency of 99.9% or more is recommended).

• Opening and closing the operator door

• Performing an operation with the operator door open

• Replacing a tool in the tool magazine

• Handling dust

• Do not remove the dust car and chip bucket while the dust collector is operating. Otherwise, dust will disperse in the surrounding area.

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1 Safety Precautions

1.6 Implementing Lock-out and Tag-out

Lock-out consists of shutting down the power source to the machine or devices and locking it.

Example: Set the main power switch to the "OFF" position and secure it using a padlock or a lockout device such as a cover.

Tag-out consists of placing a warning tag to prevent anyone from turning ON the power.

Example: Place a "Do Not Operate" or "Under Maintenance" sign with the operator's name and department and indicating that machine operation is prohibited on the main power switch and main operation panel.

Lock-out/tag-out should be performed to prevent inadvertent operation and ensure operator safety.

• Performing lock-out/tag-out alone does not completely ensure operator safety. The operator must read and thoroughly understand the work procedures and safety precautions, and always be aware of potential hazards.

Each operator should perform lock-out or tag-out by himself or herself. Perform this procedure before starting the work, and release the lock and remove warning tag yourself after finishing work. Never release a lock and remove a sign without confirming with the operator or without the presence of the operator himself or herself.

Be sure to clearly define and implement the lock-out and tag-out procedures of your company.

Safety

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OFF

Figure 1-1 Implementing Lock-out and Tag-out

DANGER

Under Maintenance/

Inspection

Operator's Name: xxxxx

Operator's Name: xxxxx Department: xxxxx

Department: xxxxx

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1 Safety Precautions

1.7 During Work

• Turn OFF the power before performing maintenance of the machine. When work must be performed with the machine power ON, confirm that all machine operations are completely stopped. Check that any residual energy in the machine is completely discharged.

• Never go near the moving parts of the machine. If you must approach moving parts to perform maintenance, be sure to take adequate safety precautions. Inadequate attention to safety may result in death or another serious accident.

• Always keep the doors and covers closed during operation. If you must work with the doors and covers open, be sure to take adequate safety precautions. Inadequate attention to safety may result in death or another serious accident.

• If an operator gets trapped inside the machine, press the "Emergency Stop" switch regardless of whether the machine power is ON or OFF.

• If the machine is stopped by a power failure or power supply fault, turn OFF the machine power. If the power is not turned OFF, the machine may start operating unexpectedly when the power is restored, and this may result in serious injury, death, or damage to the machine.

• If the machine is stopped by a power failure or power supply fault, check that the parameter, program, and offset data have not been corrupted. The machine may be damaged if it is operated using corrupted data.

• Be aware of the movement range of the machine and auxiliary components (each axis stroke, rotation range, etc.), and keep all body parts clear of moving components.

• When two or more people are required for maintenance work, be sure to maintain clear communication at all times to ensure operator safety. When performing work, be ready to press the "Emergency Stop" switch at any time.

• Be sure to always pay attention to the safety precautions listed on the warning labels affixed to the machine (Refer to 2 Warning Labels2 Warning Labels).

• Do not operate the switches or change the circuits except for adjustment purposes. In particular, operating the machine with the interlock(s) or other safety devices or functions disabled is extremely dangerous and may result in death or damage to the machine.

• If a circuit or other component needs to be changed for adjustment purposes, be sure to return it to the original setting after adjustment is completed.

• The optimum values for the NC parameters and machine parameters are set when the machine is shipped. Do not change any parameter setting unless it is described in the manual. Also, be sure that you fully understand the function of a parameter before attempting to change the parameter setting, and return the parameter to its original setting after the work is completed. If you try to operate the machine without the proper settings, the machine may operate unexpectedly, and this may result in serious injury, death, or damage to the machine.

• If the memory clear operation needs to be performed, be sure to contact your Makino service representative beforehand.

• If an alarm is triggered, eliminate the cause of the alarm using the appropriate procedure. If the remedy procedure is unclear, contact your Makino service representative.

• Never climb onto the covers. This may deform the covers or result in injury.

1-8

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1 Safety Precautions

1.7 During Work

• When using a stepladder or stool, it should be sturdy, safe, and have anti-slip surfaces.

• If any oils or cutting fluids get into your eyes, body, or on your skin surface, they may cause severe health problems. Wear safety gloves, mask, safety glasses, and other safety equipment.

• Wear safety gloves whenever handling chips, tools, and workpieces.

• Protective gear should be worn to protect hearing when excessive noise may be generated during operation or maintenance.

• If lubricating oil, grease, cutting fluid, or other substances are spilled on the floor, it may result in slippage, causing injury. Wipe up any spilled fluids as soon as possible.

• Never touch a switch, button, or key while your hands are wet. Failure to observe this precaution may result in electric shock.

• Some devices (motors, lighting equipment, valves, etc.) may become very hot while the machine is operating and remain hot soon after the power is turned OFF, so be careful to avoid burns.

• Do not subject the machine to sudden impact or jolts. This may cause the machine to perform an unexpected motion or result in damage to the machine.

• Do not use the machine for operation outside the specifications or exceeding the performance range. This may cause the machine to perform an unexpected motion or result in serious injury, death, or damage to the machine.

Safety

• Be careful that you do not leave objects such as tools or jigs inside the machine.

• Do not place the tools, workpiece, or other parts on an unstable location.

• When a lifting sling or attachment is necessary, verify that it is strong enough to support the weight of the parts. Confirm that no one is close to the machine and the parts are well balanced, and be careful not to hit to the machine.

• Never go under a load that is being lifted. While transferring the hoisted load, constantly pay careful attention to the hoisted load during the operation.

• Never insert hands or feet into the chip conveyor. They may be pulled in, and this may result in death or another serious accident.

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1-9

Page 24

1 Safety Precautions

1.7 During Work

• For the graphite specifications, observe the following precautions to prevent health problems related to the inhalation of graphite dust.

• Wear a high-performance dust-proof mask when doing the following (particle collection efficiency of 99.9% or more is recommended).

• Opening and closing the operator door

• Performing an operation with the operator door open

• Replacing a tool in the tool magazine

• Handling dust

• Do not remove the dust car and chip bucket while the dust collector is operating. Otherwise, dust will disperse in the surrounding area.

1-10

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1 Safety Precautions

1.8 Handling of Hazardous and Toxic Materials

Handlers of hazardous and toxic materials (such as oils and cutting fluid) must receive information, education, and training in accordance with the stipulations in JIS Z 7253 (revised March 2012)/ ISO 11014: 2009. Particular attention must be paid to the following points.

• Be sure that there is adequate ventilation in areas where hazardous and toxic materials are used.

• Hazardous and toxic materials must be handled and stored based on the handling procedures recommended by the manufacturer.

• Identify hazardous and toxic materials by affixing labels to their containers.

• Assign a person in charge to handle the hazardous and toxic materials, and provide education and training in emergency response procedures and handling procedures.

• Before handling any hazardous or toxic material, be sure to check the safety data sheet (SDS). The safety data sheet (SDS) contains detailed information on health and safety hazards, safe handling procedures, and responses to emergency situations.

Safety

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1-11

Page 26

2 Warning Labels

DANGER

WARNING

CAUTION

2.1 Signal Word Definitions

2 Warning Labels

Warning labels are affixed to machine parts that are potentially hazardous to warn operators about the hazard and its level of danger and ensure the safety of operators.

The warning labels include symbols to indicate the source of the danger, signal words to indicate the level of danger, and warning text to describe how to prevent the danger. When working at a location where a warning label is affixed, make sure that you fully understand the warning label information and definitions and follow the warning text that is provided. Failure to observe the information in the warning labels may result in death or another serious accident or damage to the machine.

2.1 Signal Word Definitions

Signal words are divided into four classes based on the degree of expected risk.

Signal Word Description

NOTICE

Indicates an imminent hazard which, if not avoided, will result in death or serious injury.

Indicates a potential hazard which, if not avoided, will result in death or serious injury.

Indicates a possible hazard which, if not avoided, may result in minor or moderate injury.

Indicates a potential situation which, if not avoided, may result in physical damage to the machine or adversely affect the work environment.

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2.2 Using Warning Labels

• Do not cover up or peel off the warning labels.

2 Warning Labels

2.2 Using Warning Labels

• Confirm that the operators and maintenance personnel are familiar with the language on the labels. If labels in other languages are required, contact your Makino service representative.

• Check that all the information in the warning label is legible. If any portion of the warning text or symbol is not visible, clean by wiping with a soft cloth dipped in water or household cleanser. Do not use organic solvents or gasoline. These may damage the surface of the warning label.

• Replace the warning label if the information in the warning label is no longer visible. To obtain new warning labels, contact your Makino service representative.

• If a part is replaced where a warning label was affixed, obtain a new warning label and affix it at the same position as before on the new part. To obtain new warning labels, contact your Makino service representative.

Safety

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2 Warning Labels

DANGER

CAUTION

2.3 Information Contained in Warning Labels

The two types of warning labels are shown below.

• Labels with warning text and a warning mark

• Labels with a warning mark only

2.3.1 Warning Labels with Warning Text

Signal Word Symbol Description

This warning label is affixed to areas where entry is prohibited.

This warning label is affixed to areas where there is a risk of getting pressed, being sucked in, stabbed, or falling down, resulting in a serious injury, accident, or death.

Maximum output 1mW, semiconductor laser Class 2 laser product Do not stare into the beam.

2.3.2 Warning Labels with Warning Marks Only

Symbol Description

This warning label is affixed to parts where touching the internal high-voltage components may result in electrical shock.

Workers who are not qualified electrical engineers must not access the parts where this warning label is affixed.

1-14

This warning label is affixed to parts that may become extremely hot. Do not touch parts where this warning label is affixed. Be particularly careful

immediately after operation because these parts are extremely hot at this time.

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2 Warning Labels

2.4 Warning Label Locations

The type of warning label and the location where the label is affixed to vary depending upon the machine model.

Warning labels with warning marks only are affixed to various locations on the machine, and all affixing locations are not shown in the figure.

2.4.1 Area around Operator Door

DANGER

危険

Serious Injury / Death

死傷に至る

Crush, Pinch, Stab,

Slip and Fall Hazard

押しつぶし、巻込み、突刺し、転倒、転落

Safety

DANGER

危険

DO NOT ENTER

機械内部立入禁止

Authorized Personnel Only

許可された者以外

CAUTION

注意

29F24D-2006EN

DONOT Stare into Beam

レーザー光を覗き込むな

Power 1mW Semiconductor laser Class2 laser product

最大出力１ｍＷ半導体レーザクラス２レーザ製品

(When an automatic non-contact type tool measurement device is

included)

Figure 2-1 Area around Operator Door

1-15

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2 Warning Labels

DANGER

危険

許可された者以外

機械内部立入禁止

DO NOT ENTER

Authorized Personnel Only

Serious Injury / Death

死傷に至る

押しつぶし、巻込み、突刺し、転倒、転落

Crush, Pinch, Stab,

Slip and Fall Hazard

DANGER

危険

2.4 Warning Label Locations

2.4.2 Area around Tool Magazine

Figure 2-2 Area around Tool Magazine

1-16

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3 Safety Devices

DANGER

WARNING

3.1 "Emergency Stop" Switch

3 Safety Devices

• Never disable or remove any safety device.

Safety devices are installed on the machine to protect operators and maintenance personnel. The safety devices also include ones that function on the condition that the operator observes the safety procedures.

3.1 "Emergency Stop" Switch

• Make sure operators know the locations of all the "Emergency Stop" switches prior to performing machine operation or maintenance to enable use in an abnormal or dangerous situation.

Safety

The machine goes to the following status when the "Emergency Stop" switch is pressed:

• Feeding of the axes is stopped immediately.

• Spindle rotation stops if it is rotating.

• The spindle is clamped if it has been unclamped.

• When orientation of the spindle has been performed, orientation is reset.

• When a tool is being changed or the tool magazine is operating, operation stops immediately (even during motion).

• The chip conveyor in operation comes to an immediate stop.

• The hydraulic unit is stopped.

• The cutting fluid supply is stopped.

• Supply of the air blow inside the machining chamber is stopped (graphite specifications).

• The dust collector stops collecting dust (graphite specifications).

• Energizing of all solenoid valves is reset.

• The NC is reset.

Once the "Emergency Stop" switch is pressed, it is locked in the pressed position. The lock can be released by turning the switch in the direction indicated by the arrow or pulling out the switch. Then, pressing the [CONTROL POWER ON] switch cancels the emergency stop state.

For details about recovery procedures following machine operation stopped by the "Emergency Stop" switch activation (Refer to Instruction Manual Chap. 7 Troubleshooting 2.1 Recovery from Emergency

Stop Status).

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3 Safety Devices

3.1 "Emergency Stop" Switch

3.1.1 "Emergency Stop" Switch Installation Location (Machine Body)

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Figure 3-1 "Emergency Stop" Switch Installation Location (Machine Body)

No. Name

1 "Emergency Stop" switch

X10 X100

X1000

AUX

OFF

ABS

MAC

REL

ORG

1-18

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3 Safety Devices

3.1 "Emergency Stop" Switch

3.1.2 "Emergency Stop" Switch Installation Location (Large Capacity Tool Magazine)

Safety

Figure 3-2 "Emergency Stop" Switch Installation Location (Large Capacity Tool Magazine)

No. Name

1 "Emergency Stop" switch

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1-19

Page 34

3 Safety Devices

3.2 Door Switch

The door switch is a device for detecting and controlling the status of doors.

3.2.1 Door Switch Installation Location (Machine Body)

Figure 3-3 Door Switch Installation Location (Machine Body)

No. Name

1 Door switch

1-20

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3 Safety Devices

3.2 Door Switch

3.2.2 Door Switch Installation Location (Disk Type Tool Magazine 21-tool/40-

tool)

Safety

Figure 3-4 Door Switch Installation Location (Disk Type Tool Magazine 21-tool/40-tool)

No. Name

1 Door switch

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1-21

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3 Safety Devices

3.2 Door Switch

3.2.3 Door Switch Installation Location (Large Capacity Tool Magazine)

Figure 3-5 Door Switch Installation Location (Large Capacity Tool Magazine)

No. Name

1-22

1 Door switch

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4 Work Hazards

4.1 Area Surrounding Machine

4 Work Hazards

The following tables list examples of hazardous actions and situations during machine operation and maintenance and examples of the resulting accidents and incidents that may occur.

The points that the operator must observe when performing machine operation and maintenance vary depending on the situation. All possible points cannot be covered in the content of this manual. Therefore, be sure to fully understand the machine, and remain constantly aware of safety and the potential hazards while doing work.

Improper operation may result in death or damage to the machine.

4.1 Area Surrounding Machine

Action/Situation Result

Safety

Tripping on piping/wiring Falling

Operator working on oily floor Fall, bone fracture, injury

Bringing an open flame into the area Fire, burn

Improper handling of chemical substances Skin lesions, eye injury, or respiratory

problems

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4 Work Hazards

NOTESNOTES

4.2 Electrical System

Action/Situation Result

Performing inspection or maintenance operation without turning OFF the power (Refer to NOTE)

Touching a device with residual voltage (Refer to NOTE) Electrical shock

Miswiring Breakdown of the machine, abnormal

Loose screw in terminal block or other location Breakdown of the machine, abnormal

Machine controller door or junction box cover is left open Electric leakage, breakdown of the

Touching switches with wet hands Electrical shock

Damage to wiring on floor Electric leakage, breakdown of the

Operation or maintenance by non-qualified personnel Breakdown of the machine

1 Prior to performing maintenance of the servo amplifiers, spindle amplifiers, and inverters, turn OFF the main power and

confirm that the LED which indicates charging (red) for each amplifier and inverter is off.

2 High voltage current flows through components inside the junction box.

3 High voltage current continues to flow on the primary side of the main power switch even after the main power is turned

OFF.

4 Electrical current continues to flow to lamps and outlets in the machine controller even after the main power is turned

OFF.

Electric shock, breakdown of the machine, abnormal operation, fire

operation, fire

machine, abnormal operation, fire

4.3 Parameters

Action/Situation Result

Changing NC/machine parameters not listed in manual Injury or death, workpiece damage,

breakdown of the machine

Forgetting to return the parameter to its original value after adjustment

Injury or death, workpiece damage, breakdown of the machine

4.4 Inside the Machining Chamber

Action/Situation Result

Working without performing lock-out and tag-out Injury or death, damage to the

machine

Operator entering machining chamber without turning OFF the power

Injury or death

1-24

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4 Work Hazards

4.4 Inside the Machining Chamber

Action/Situation Result

Operator entering machining chamber with safety devices or functions disabled

Getting near the operating range of an axis when the power is turned ON or during axis feeding

Replacing the gravity axis motor without using the fixing jig Injury or death, damage to the

Rotating spindle prior to cleaning of tapered section while operator door is open

Rotating unbalanced tool at high speed while operator door is open Injury or death, damage to the

Hand or other body part becomes wedged in operator door when it is opened or closed

Operator touching rotating spindle Hands or fingers cut off, body part

Touching a feed axis motor Burns

Workpiece has not been clamped Injury, bone fracture, bruises

Entering machining chamber when table is inclined Injury, bruises

Touching an operating ATC shutter Injury

Injury or death

Injury, bone fracture, bruises

machine

Injury or death, damage to the machine

machine

Injury, bone fracture, bruises

becomes entangled, or other serious injury or death

Safety

Operator becomes entangled in chip conveyor Body part pulled in, resulting in injury

or death

Climbing on top of covers Fall, bone fracture, injury

Climbing on top of the movable covers, inserting your hand into the gaps

Operator working on oily floor Fall, bone fracture, injury

Touching the wipers Cuts to hands

Operator touching bladed tools Cuts, injuries to hands

Holding a heavy tool Strained back, hands become

Operator being struck by chips, cutting fluid, or dust scattered during machining

Operator being splashed by cutting fluid dripping from ceiling in machining chamber

Operating machine while there is abnormal vibration or abnormal noise

Operating machine with a tool incorrectly clamped Injury or death, damage to the

Opening the operator door and entering the machining chamber while mist is not being collected

Injury, bruises

wedged between tool and object

Damage to eyes, cuts or burns to skin

Damage to eyes, skin irritation

Damage to the machine

machine

Respiratory problems

Cleaning without wearing protective gloves Cuts to hands

Opening the operator door or entering the machining chamber while dust is not being collected

Entering the machining chamber without wearing a dust-proof mask Respiratory problems

29F24D-2006EN

Respiratory problems

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4 Work Hazards

4.5 Tool Magazine

Action/Situation Result

Fastening tools or implementing other work during spindle orientation

Inhaling dust Respiratory problems

Injury, bone fracture, bruises

4.5 Tool Magazine

Action/Situation Result

Working without performing lock-out and tag-out Injury or death, damage to the

machine

Operator entering the tool magazine without turning OFF the power Injury or death

Operator entering the tool magazine with the safety devices and functions disabled

Manually changing tools by entering inside the tool magazine Injury or death

Performing T command or tool change while tool blade or tool is mounted incorrectly

Tool number is registered incorrectly Damage to the machine

Operator inserting hands into tool magazine during tool magazine operation

Injury or death

Injury or death, damage to the machine

Cuts, bone fracture of hands

Touching the tool magazine motor Burns

Operator working on oily floor Fall, bone fracture, injury

Operator touching bladed tools Cuts, injuries to hands

Holding a heavy tool Strained back, hands become wedged

between tool and object

Hand or other body part becomes wedged in tool magazine door when it is opened or closed.

Leaving a safety guard or maintenance cover opened or removed Injury

Holding or carrying a removed cover Injury or machine damage due to

Performing cleaning or maintenance while a tool is stored in the tool magazine

Cleaning without wearing protective gloves Cutting or stabbing of hand

Injury, bruises

dropping of cover

Cutting or stabbing of hand or body

1-26

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4 Work Hazards

4.6 Cutting Fluid Supply Unit/Chip Disposal Device/Cutting Fluid Temperature Controller/Dust Collector

4.6 Cutting Fluid Supply Unit/Chip Disposal Device/Cutting Fluid

Temperature Controller/Dust Collector (Graphite Specifications)

Action/Situation Result

Working without performing lock-out and tag-out Injury or death, damage to the

machine

Inserting hands or feet into conveyor or tank without turning OFF the power

Touching part or component immediately after operation Burns

Operator touching moving parts when chip discharge outlet cover is removed

Stepping on a tank that is not fixed Fall, bone fracture, injury

Operating with low levels of cutting fluid Fire, damage to the machine

Touching cutting fluid or chemical additives Skin irritation

Touching chips Cuts, injuries, burns to hands

Replacing the filter without prior cleaning Cuts, injuries to hands

Inhaling large quantities of cutting fluid mist Respiratory organ damage

Mixing different brands of oils Breakdown of the machine

Failing to properly clean or collect flammable cutting chips or sludge Fire

Mixing cutting chips made from different materials Fire

Performing operation without wearing protective gloves Cuts, injuries to hands

Inhaling dust Respiratory problems

Serious injury due to body part becoming entangled, or cuts to hands and feet

Serious injury due to body part becoming entangled

Safety

4.7 Temperature Controller

Action/Situation Result

Touching part or component immediately after operation Burns

Oil temperature exceeds flash point. Flash point of Makino Spindle Lubricant: 95C

Changing filters without reducing the internal pressure Injury or death, damage to the

Performing operations without safety gloves, mask, and other protective gear

Mixing different brands of oils Breakdown of the machine

Fire

machine

Damage to eyes, skin irritation, accidental ingestion, or respiratory organ damage

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4 Work Hazards

4.8 Hydraulic Unit

Action/Situation Result

Working without performing lock-out and tag-out Injury or death, damage to the

machine

Operator working on oily floor Fall, bone fracture, injury

Hand or other body part becomes wedged in tool magazine door when it is opened or closed.

Leaving a safety guard or maintenance cover opened or removed Injury

Touching part or component immediately after operation Burns

Oil temperature exceeds flash point. Flash point of standard hydraulic oil: Approximately 200C

Changing filters without reducing the internal pressure Injury or death, damage to the

Performing operations without safety gloves, mask, and other protective gear

Mixing different brands of oils Breakdown of the machine

Injury, bruises

Fire

machine

Damage to eyes, skin irritation, accidental ingestion, or respiratory organ damage

4.9 Pneumatic Unit

Action/Situation Result

Removing the pneumatic unit source piping on the machine side or disassembling the primary-side line filter without shutting of the air supply from the factory facilities

Injury due to flying off of parts or impact

Removing the pneumatic unit source piping on the machine side or disassembling the primary-side line filter without releasing the residual pressure in the air piping (inside the air circuit)

Injury due to flying off of parts or impact

4.10 Splash Guard

Action/Situation Result

Working without performing lock-out and tag-out Injury or death, damage to the machine

Operator entering splash guard with the safety devices and functions disabled

Operating the machine with the covers removed Injury or death

Holding or carrying a removed cover Injury or machine damage due to

Operator working on oily floor Fall, bone fracture, injury

Operator working at elevated locations Fall, bone fracture

1-28

Injury or death

dropping of cover

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4.11 Other Peripheral Equipment

4 Work Hazards

4.11 Other Peripheral Equipment

Action/Situation Result

Performing operation without turning OFF the power Injury or death, electric shock

Safety

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Page 44

5 Occupational Health and Safety Management

NOTE

CAUTION

5.1 Safety Device Inspection

5 Occupational Health and Safety Management

5.1 Safety Device Inspection

Perform periodic maintenance and inspection of the safety devices used on this machine in order to ensure that they continue to function normally. Make sure that all maintenance staff fully understand the types of safety devices, functions, and locations described in 3 Safety Devices before performing any maintenance work. Before starting operation or maintenance work, inspect the safety devices, and if any are not functioning properly, abort machine operation.

5.2 Noise

The noise level of the machine is shown below.

• Noise level: 80 dB maximum (A-weighted sound level)

These values are measured values at full operation (maximum rotation of the spindle without machining a workpiece) with the safety guards and covers correctly mounted and all doors closed.

• When a workpiece is machined, noise at 80 dB or higher may occur under certain customer cutting conditions. When performing work near the machine during machining, be sure to wear ear protection and other equipment to ensure that your health is not harmed. Performing work without wearing ear protection may lead to hearing loss.

NOTE

The above noise level is measured at a location that is a distance of 0.5 m from the machine and a height of 1.2 m above the floor.

1-30

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5 Occupational Health and Safety Management

WARNING

5.3 Personal Protective Equipment

When conducting installation, operation, and maintenance work on the machine, be sure to protect your body from the following potential hazards.

• Mechanical hazards

• Hazardous and toxic materials

•Heat

•Noise

Be sure to always use protective equipment to protect your body from these hazards. Some examples of protective equipment are shown below.

Protected Body Part

Head Bruises and cuts,

Eyes, nose, mouth, face

Eyes Laser beam Laser safety goggles • Work performed with the eyes

Ears Noise Earplugs • Work where the environment

Hands Cuts, burns, and

Feet Bruises Safety shoes • Handling and transporting of

Torso Falling from high

Hazard Type Protective Equipment Work Requiring Protective

Equipment

Work cap, Helmet • Work where parts or other falling from high locations

Flying out of dust, chips, chippings, and other substances

Splashing of mist, lubricants, grease, and other oils

adhesion of chemical substances

locations

Protective goggles,

dustproof mask

Protective gloves,

heat-resistant gloves,

chemical-resistant gloves

Safety belt

objects may fall on the head

• Work where the head may get hit

• Work at locations 2 m or higher

• Work where objects may spray or fly out

at around the same height as the laser beam

constantly generates noise above the stipulated level

• Work where the hands must be protected

heavy objects

• Work at locations 2 m or higher

Safety

29F24D-2006EN

• Even when wearing laser safety goggles, do not look directly into the laser beam or indirectly by reflecting the beam on a mirror surface. Use laser safety goggles to protect the eyes from the dangers of accidentally looking into the laser beam and scattered laser beams.

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Page 46

5 Occupational Health and Safety Management

5.4 Disposal of Waste Products

5.4.1 Disposal of Waste Oil, Waste Fluids, and Waste Materials

Dispose of any chips, graphite dust or liquids such as cutting fluid, grease, hydraulic oil and lubricant that are discharged during operation of this machine in accordance with the laws, regulations, and ordinances established in your country. Also, separate and dispose of recyclable materials properly.

5.4.2 Disposal of This Machine

When disposing of this machine or its parts, disassemble and dispose of them in accordance with the laws, regulations, and ordinances established in your country. Also, separate and dispose of recyclable materials properly.

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Chap. 2 Installation Preparation

1 Checking Installation Requirements ......................................................... 2-1

2 Allocation of Installation Area ................................................................... 2-2

3 Requirements for Carry-in Route.............................................................. 2-8

4 Installation Requirements ....................................................................... 2-15

5 Recommended Foundation Conditions .................................................. 2-16

6 Air and Power Sources ........................................................................... 2-19

7 Preparation of Equipment for Transfer/Installation ................................. 2-23

Installation Preparation

Page 48

Page 49

1 Checking Installation Requirements

Confirm that the requirements below are all satisfied before installing the machine.

• Allocation of installation area (Refer to 2 Allocation of Installation Area)

• Requirements for carry-in route (Refer to 3 Requirements for Carry-in Route)

• Installation requirements (Refer to 4 Installation Requirements)

• Preparation of foundation (Refer to 5 Recommended Foundation Conditions)

• Requirements for power supply (Refer to 6 Air and Power Sources)

• Requirements for air source (Refer to 6 Air and Power Sources)

• Preparation of equipment for transfer (Refer to 7 Preparation of Equipment for Transfer/

Installation)

Installation Preparation

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2-1

Page 50

2 Allocation of Installation Area

NOTE

2 Allocation of Installation Area

Be sure to provide an area for machine inspection and repair in addition to an area necessary to install the machine.

NOTE

The installation area varies depending on the machine model. For details, contact your Makino service representative.

2-2

29F24D-2006EN

Page 51

2 Allocation of Installation Area

Installation Preparation

29F24D-2006EN

Figure 2-1 Allocation of Installation Area (General View)

2-3

Page 52

2 Allocation of Installation Area

505

500

370 350

150

10701140(ATC100)

1150 900

TLSDOORCELING

OPENINGDEPTH

10(ATC100)

HYDRAULICOILSUUPY (H=535)

COOLANTTEMP.CONTROLLER (OPTION)

TRANSFORMERBOX

(OPTION)

MAINTENANCEAREA (PNEUMATIC)

AIRDRYER (OPTION)

AIRSUPPLYPORT(Rc1/2) H=350(WITHAIRDRYER)

AIRSUPPLYPORT(Rc1/2) H=1750(STANDARD)

POWERSUPPLYPORT(Ø60) (H=500)

415

ATC100(OPTION)

441

HYDRAULICUNIT

R645.5

128

517

660

MTC

R880

120

865

772

900(ATC100)

520

215

510

TLSDOOR OPENINGWIDTH

900

1800(WITHROBOTSHUTTER)

2710

3295

1250250

910150

400

355

205 395

600

OP.DOOR OPENINGWIDTH

510

600

190

Ø120

R440

368

3001500(STD.)

MAINTENANCEAREA (COOLANTTANK)

OILTEMP.CONTROLLER

LEVELINGPLATE

SPINDLECENTER

MISTCOLLECTORJINT

Ø100orØ125

105

140°

CONTROLPANEL

835265

OP.DOOR

CELING

OPENING

DEPTH

30 385

13402200

1030 310

3750

1640

560

210

2-4

Figure 2-2 Allocation of Installation Area (Layout: Large Capacity Tool Magazine)

(Other than Graphite Specifications)

29F24D-2006EN

Page 53

2 Allocation of Installation Area

1920

1050

745305

870

380

SHUTTER OPPENING HEIGHT

800 900

950

110 0

Z-STROKE

250

150 MIN

2300

875

1525

930495

Installation Preparation

Figure 2-3 Allocation of Installation Area (General View: Large Capacity Tool Magazine)

29F24D-2006EN

2-5

Page 54

2 Allocation of Installation Area

TRANSFORMER BOX

(PNEUMATIC)

MAINTENANCE AREA

(200V)

DUST COLLECTOR

AIR SUPPLY PORT(Rc1/2)

H=1470(WITH AIR DRYER)

H=1750(STANDARD)

160

815 800

350 840 960

150

660

500

150

1070

900

R645.5

500

520

R880

ATC100(OPTION)

(H=500)

POWER SUPPLY PORT(Ø60)

TLS DOOR CELING

OPENING DEPTH

1140(ATC100)

1150

441

215

415

120

(H=535)

HYDRAULIC OIL SUUPY

HYDRAULIC UNIT

10(ATC100)

865

128 772

R645.5

TLS DOOR OPENING WIDTH

355

205

900

510

CONTROL PANEL

OP.DOOR OPENING WIDTH

368

395

140°

R440

600

400

(OPTION)

AIR DRYER

LEVELING PLATE

OP.DOOR

CELING

OPENING

DEPTH

3750

1640

2200

Ø120

835265

30 385

210

560

OIL TEMP.CONTROLLER

1340

1000340

SPINDLE CENTER

MTC

(OPTION)

2-6

Figure 2-4 Allocation of Installation Area (Layout: Large Capacity Tool Magazine)

(Other than Graphite Specifications, Dust collector 200 V specifications)

29F24D-2006EN

Page 55

2 Allocation of Installation Area

(PNEUMATIC)

MAINTENANCE AREA

AIR SUPPLY PORT(Rc1/2)

H=1470(WITH AIR DRYER)

H=1750(STANDARD)

150

660

MTC

R645.5

500

150

1070

900

520

R880

(OPTION)

TRANSFORMER BOX

480

810

190

350

DUST COLLECTOR

(400/460V)

800

500

990

OIL TEMP.CONTROLLER

(OPTION)

AIR DRYER

LEVELING PLATE

SPINDLE CENTER

440 900

3750

1340

1640

Ø120

OP.DOOR

CELING

OPENING

DEPTH

2200

400

835265

215

30 385

415

210

560

R440

CONTROL PANEL

OP.DOOR OPENING WIDTH

2710

3295

1800(WITH ROBOT SHUTTER)

3001500(STD.)

368

395

140°

600

ATC100(OPTION)

TLS DOOR OPENING WIDTH

865

128 772

900(ATC100)

355

205

900

510

TLS DOOR CELING

OPENING DEPTH

(H=535)

HYDRAULIC OIL SUUPY

HYDRAULIC UNIT

1140(ATC100)

10(ATC100)

517

R645.5

1150

441

(H=500)

POWER SUPPLY PORT(Ø60)

120

29F24D-2006EN

Figure 2-5 Allocation of Installation Area (General View: Large Capacity Tool Magazine)

(Graphite Specifications and Dust Collector 400 V/460 V Specifications)

Installation Preparation

2-7

Page 56

3 Requirements for Carry-in Route

Determine the carry-in route of the machine by taking into account the machine dimensions during transfer. If the machine is to be hoisted with a crane, a hoisting allowance of 500 mm is required in addition to the height of the hoisting attachment.

Table 3-1 Machine Size When Being Transported

Item Height Height including

hoisting

attachments

Machine body 2300 mm 2599 mm 1500 mm 2200 mm

Lift-up chip conveyor (other than graphite specifications)

Cutting Fluid Temperature Controller (Other than Graphite Specifications) (option)

Large capacity tool magazine (option)

Dust collector (200 V specifications) (graphite specifications)

Dust collector (400 V specifications)

(graphite specifications)

1920 mm 1980 mm 1135 mm 1310 mm

1353 mm - 505 mm 596mm

2300 mm 2490 mm 900 mm 1140 mm

2843 mm 2950 mm 959 mm 997 mm

2782 mm 2870 mm 987 mm 897 mm

Width Depth

2-8

29F24D-2006EN

Page 57

3 Requirements for Carry-in Route

(mm)

2599

1500

Figure 3-1 Requirements for Carry-in Route 1 (Machine body)

Installation Preparation

29F24D-2006EN

2-9

Page 58

3 Requirements for Carry-in Route

2599

2200

(mm)

Figure 3-2 Requirements for Carry-in Route 2 (Machine Body)

2-10

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Page 59

3 Requirements for Carry-in Route

(mm)

1980

310 1000

1135 1310

Figure 3-3 Requirements for Carry-in Route 3 (Lift-up chip conveyor)

Installation Preparation

29F24D-2006EN

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Page 60

3 Requirements for Carry-in Route

596500

1353

(mm)

Figure 3-4 Requirements for Carry-in Route 4 (Cutting Fluid Temperature Controller)

(Other than Graphite Specifications) (option)

2-12

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Page 61

3 Requirements for Carry-in Route

(mm)

2843

959 997

Figure 3-5 Requirements for Carry-in Route 5 (Dust Collector) (200 V Specifications)

Installation Preparation

29F24D-2006EN

2-13

Page 62

3 Requirements for Carry-in Route

(mm)

2782

987 897

Figure 3-6 Requirements for Carry-in Route (Dust Collector) (400 V/460 V Specifications)

2-14

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4 Installation Requirements

Before installing the machine, make sure the following conditions are met.

Table 4-1 Installation Requirements

Setup Location and Environmental Conditions

Room temperature 10C to 40°C (optimum temperature 20 1C)

Ambient humidity RH 35% to 70% (no condensation)

Temperature

fluctuations

Sufficient illumination

No direct sunlight

No dust

Allocation of space for storing materials, machined products, tools, and other items

Allocation of enough space for maintenance

Allocation of space large enough to carry out work while the machine doors are open

Availability of necessary power sources

Level and solid enough to support the machine

No air flow from the opening of factory facilities hitting the machine

1C or less every 30 min (range that does not affect machining)

Installation Preparation

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2-15

Page 64

5 Recommended Foundation Conditions

NOTE

NOTES

5 Recommended Foundation Conditions

Carry out foundation work by referring to the foundation diagrams shown in Table 5-1 and Figure 5-1.

NOTE

Foundation diagram varies depending on the machine model. For details, contact your Makino service representative.

Table 5-1 Recommended Foundation Conditions

Item Description

Maximum mass on foundation concrete (machine mass) Approx. 4600 kg

Foundation concrete mass (specific gravity 2:3) Approx. 1800 kg

Average bearing pressure of foundation concrete

Approx. 2900 kg/m

underside

NOTES

1 These values are reference values.

2 Dimensions indicated on this foundation drawing are minimum requirements for a suitable solid installation foundation.

The foundation drawing shows only recommended values.

3 As this machine operates at high-speeds, vibration generated by machine operations may affect the surrounding area

depending upon the foundation and ground conditions. Consult a professional civil engineer to determine the final foundation dimension requirements as they vary according to actual ground conditions and possible influence on the surrounding area.

4 Adjust the level of the foundation surface so that it varies within a range of 0.005 mm/m when the maximum load is

loaded on the table surface and the Y-axis is moved. Doing so can maintain the machine accuracy for a long period of time.

2-16

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5 Recommended Foundation Conditions

865

1500

200

100

1600

750

1500

750

SPINDLE CENTER

BASE PLATE

1190

560

POWER SUPPLY

PORT(Ø60)

ATC LE G

H=500

1640

820

190

MTC LEG

H=1750 (STD.)

H=1470 (WITH AIR DRYER)

AIR SUPPLY PORT (Rc1/2)

150

350

400400

350

361

1033

106

70 195

1235

1460

150

Installation Preparation

105

FORM STYROL

265350

RUBBLE

1650

1750

1527

1475

1650

835

2200

ROD

REINFORCING

LEAN CONCRETE

200

450

ANGLE STEEL (50X50,t=6)

FRAME LEG

555

656 725

300

100

Figure 5-1 Recommended Foundation Conditions

COOLANT TANK LEG

(50)

150

140

PLATE STEEL (B=140,t=6)

*CAULK GAPS

WITH OIL PROOF SEAL.

(6)

(50)

FORM STYROL

SECTION

断面

(50)

(S=1：3)

A-A

29F24D-2006EN

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5 Recommended Foundation Conditions

MEMO

2-18

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Page 67

6 Air and Power Sources

Table 6-1 Air and Power Sources

Item Description

6 Air and Power Sources

Power source (Machine body)

Power source (Dust collector: 200 V)

Maximum power consumption (other than graphite specifications)

Maximum power consumption (graphite specifications)

Total power requirements (actual power requirements) (other than graphite specifications)

Total power requirements (actual power requirements) (graphite specifications)

400 VAC± 50 Hz±2 % three-phase or 460 VAC± 60 Hz±2 % three-phase

200 VAC± 50 Hz±2 % three-phase or

200 VAC± 60 Hz±2 % three-phase

35.0 kVA (standard specifications)

40.7 kVA (including options)

33.5 kVA (standard specifications)

36.5 kVA (including options)

35.0  0.6 = 21.0 kVA (standard specifications)

40.7  0.6 = 24.4 kVA (including options)

33.5 x 0.6 = 20.1 kVA (standard specifications)

36.5 x 0.6 = 21.9 kVA (including options)

Installation Preparation

Short circuit current rating (SCCR)

Circuit breaker Regions with input supply voltage of 240 VAC or less:175 A

Power cable

Ground Class C grounding work (ground resistance: 10  or less)

Ground cable Obtain cable A or B by referring to Table 6-2,Table 6-3.

2.5 kA/400VAC

Regions with input supply voltage of 380 VAC or more:90 V

Obtain cable A or B by referring to Table 6-2,Table 6-3. Obtain cable terminals in the sizes shown in Table 6-4,Table 6-5.

29F24D-2006EN

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Page 68

6 Air and Power Sources

NOTENOTE

NOTICE

Although the machine is provided with air filters, perform periodic maintenance and inspection for ensuring that the optimum air is always supplied. Failure to perform periodic maintenance of the filters can lead to filter contamination and damage.

NOTICE

To ensure that the required air flow is provided to the machine, pay careful attention to the piping (air hose) inner diameters for the air source.

Machine body (with scale)

With air blow 750

Air blow inside the machining chamber (graphite specifications)

400

Item Description

Air source Pressure: 0.4 to 0.8 MPa

Connection port: Rc1/2 Dew point temperature: -20C or less Air source piping inner diameter: 15 mm or more

Air quality specifications provided by customer: Compliant with class 2.5.2 specified by JIS B 8392-1 (equivalent to ISO 8573-1)

• Maximum number of particles per 1 m

0.001   0.005 mm: 100 or less

0.0005   0.001 mm: 6000 or less

0.0001   0.0005 mm: 400000 or less

• Dew point under pressurization: +7C or less (when the absolute pressure is

0.8 MPa)

• Total oil concentration: 0.1 mg/m

The air quality varies according to the factory environment. Use a particle counter or other measuring instrument to confirm that the air quality values within the factory satisfy the required values.

for particle diameter x:

or less

Required air flow (L/min: ANR)

Air dryer Mandatory (If the option is not selected, this must be provided by the customer.)

2-20

29F24D-2006EN

Page 69

Table 6-2 Power Cables

NOTE

6 Air and Power Sources

Customer power supply

240 V or less

380 V or more

Wiring location Recommended cable Q

From customer power supply to Makino step-up transformer (option) (200 V system)

From step-up transformer provided by customer to machine-side circuit breaker (400 V system)

From customer power supply to machineside circuit breaker (400 V system)

A 2PNCT 1C 38 mm

Single-core cabtyre for ground cable

25 sq

(Ex.) CFPE.250.01 (IGUS)

B 2PNCT 4C 60 mm

A 2PNCT 1C 14 mm

Single-core cabtyre for ground cable

10 sq

(Ex.) CFPE.100.01（IGUS）

B 2PNCT 4C 22 mm

A 2PNCT 1C 14 mm

Single-core cabtyre for ground cable

10 sq

(Ex.) CFPE.100.01（IGUS）

B 2PNCT 4C 22 mm

t' y

Installation Preparation

Table 6-3 Power Cables (graphite specifications)

Customer power supply

240 V or less

NOTE

Check that the power cable to be connected to the machine and the conduit tube for it conform to the electrical standard of

the region where the work is executed.

From customer power supply to dust collector

Wiring location Recommended cable Q

A 2PNCT 1C 3.5 mm

Single-core cabtyre for ground cable

3.5 sq

(Ex.) CFPE.100.01（IGUS）

B 2PNCT 4C 3.5 mm

t' y

29F24D-2006EN

2-21

Page 70

6 Air and Power Sources

Table 6-4 Cable Terminals

Connection location Cable end treatment

Machine main circuit breaker M8

Ground terminal in main circuit breaker box M8

Step-up transformer Primary side M8

Secondary side M6

Ground terminal for step-up transformer M6

Table 6-5 Cable Terminals (graphite specifications)

Connection location Cable end treatment

Dust collector breaker M5

Ground terminal in dust collector box M4

2-22

29F24D-2006EN

Page 71

7 Preparation of Equipment for Transfer/Installation

When moving the machine, provide a crane, forklift, or roller type carrier suitable for the size and weight of the machine.

If equipment to transfer the machine is necessary, contact your Makino service representative.

Table 7-1 Necessary Equipment and Tools

Parts/Tools to Be Prepared

Transfer equipment: Crane, forklift, hoisting attachment

Required tools: Items provided with the machine as standard

Measuring equipment: Precision level, indicator

Table 7-2 Machine Weight

Item Weight (kg)

Machine body 4600 kg

Lift-up chip conveyor (other than graphite specifications) 320 kg

Cutting Fluid Temperature Controller (Other than Graphite Specifications) (option)

Large capacity tool magazine (option) 600 kg

Dust collector (graphite specifications) 300 kg

147 kg

Installation Preparation

29F24D-2006EN

2-23

Page 72

7 Preparation of Equipment for Transfer/Installation

MEMO

2-24

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Page 73