makino EDGE2 Installation Guide

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Makino EDGE2

Ram Electrical Discharge Machine

with MGF Control

Pre-Installation Guide

This guide is intended for use by Makino customers and Makino employees and assigns for the safe operation and maintenance of Makino equipment.

This guide was developed through the combined efforts of: Makino Documentation Gro up - Mason USA MBS Associates (Lynne Hays) Makino Customer Support

Release Date: July 20, 2000

• No part of this manual may be reproduced or transmitted by any means or in any form to parties other than which it is intended, without the expressed written permission of Makino.

• All specifications and designs may change without notice.

Every attempt was made to ensure that the information in this publication was correct at the time of printing. As specifications and designs change, Makino is not responsible for information that becomes incorrect or inaccurate after publication.

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The following ic ons are used in this document. Safety and precau tionary statements are presented as shown below.

DANGER

A existin tions must be taken immediately to prevent personal injury or death.

WARNING

A potentially hazardous situation with some probability of death or serious injury. Precautions must be taken immediately to prevent personal injury.

CAUTION

A potentially hazardous situation with some probability of personal injury or dama the machine. Precautions must be taken immediately to prevent personal injury or machine dama

icon precedes each danger statement. A

hazardous condition with a high probability of death or severe injury. Precau-

icon proceeds each warning statement. A

icon proceeds each caution statement. A

DANGER

WARNING

CAUTION

icon indicates an

icon indicates a

e to

• Precautionary statements must be followed to prevent personal injury or damage to the machine.

• In addition, all safety requirements and guidelines found in Chapter 1 Safety, the ANSI safety guidelines the Makino Safety Manual, shipped with the machine, and established company safety requirements and regulations must be followed. Taking personal responsibility for safety will prevent most accidents.

Notes are presented using the following icon format

A NOTE icon indicates information that expands on information given or indicates where additional infromation can be found. Notes are presented immediately followin the applicable content.

A copy of the ANSI Safety Manual, ANSI document number ANSI B11.8 was shipped with the machine. If this manual was lost or misplaced, another copy can be obtained from Maki no at no charg e.

Write us at: Call or FAX us at: Makino

P.O. Box 8003 7680 Innovation Way Mason Ohio, 54040-8003 Attn: Information Services

Phone: (513) 573-7200 ask for Information Services FAX: (513) 573-7360 Attn: Information Services

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To contact Makino, for service after the sale:

Makino 7680 Innovation Way Mason, Ohio 45040 USA

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Technical Support Services

Mon.-Fri. 7:00 a.m. to 8:00 p.m. Sat. 8:00 a.m. to 2:00 p.m.

(Eastern Standard Time)

Parts Express

24 hours, 7 days a week

Tr aining Services

(888) Makino4 (625-4664) Fax: (513) 459-1825

(888) Makino1 (625-4661) Fax: (888)-881-9289 (888) Makino1 (625-4661)

The following acronyms and abbreviations are used in this document:

Term Meaning

APC Automatic Pallet Changer- work table (pallet) storage and exchange device ATC Automatic Tool Changer - tooling storage and exchange device ccw counterclockwise - direction of rotation CNC Computerized Numerical Control - control unit for machine tool system cw clockwise - direction of rotation DEC Deceleration - axis slow down for reference operations DI Dielectric (i.e. DI Fluid, DI unit) EOB End Of Block - program code at end of each block of data E-Stop Emergency Stop - machine condition halting all machine operation FPB Flexible Pendant Box - portable control and axis positioning device FSE Field Service Engineer - customer service technician LS Limit Switch - LS00 = limit switch 00 MDI Manual Data Input - operating mode for direct input of NC data MTC Machine Tool Cabinet - Cabinet housing main machine electrics/electronics NC Numerical Control - input data (i.e. NC program) PM Preventive Maintenance - routine maintenance items and checks S/G Splash Guard - machining area enclosure SOL Solenoid - SOL01 = Solenoid 01

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AVISO!

Las personas que no pueden leer o entender en Ingles deben mandar traducir este manual y solicitar entrenamiento antes de operar o mantener la maquina. Todos los que trabajen en esta maquina deberan saber como operarla con toda seguridad y en forma correcta para evitar un posible dano.

ATTENTION!

Les personnes ne sachant pas lire l'anglais devront se faire lire et expliquer le manuel avant d'utiliser ou de faire l'entretien de la machine. Toute personne travaillant sur la machine doit savoir comment l'utiliser sans danger et correctement afin d'eviter tout accident.

HINWEIS

Alle Personen die nur Teile des Handbuches oder kein Englisch verstenen, müssen sich dieses Handbuch erklären lassen, bevor sie die Maschine in Betrieb nehmen oder instandhalten. Alle Personen, die an der Maschine arbeiten, müssen zur Vermeidung von Verletzungen zur korrekten Handhabung angeleitet werden.

WARNING!

Persons unable to read English or do not understand any part of this guide, must have this guide read and explained to them before operating or maintaining the machine. Everyone working on the machine must know how to operate and maintain it safely and correctly to prevent possible serious injury.

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CONTENTS

Chapter 1 Safety Precautions Chapter 2 Specifications Chapter 3 Installation Process Overview Chapter 4 Pre-Delivery Preparations Chapter 5 Machine Delivery Appendix A Conversion Factors

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Chapter 1 Safety Precautions

For a Safe Working Environment

Makino EDGE2

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Ram Electrical Discharge Machine

with MGF Control

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Chapter 1

Safety Precautions

Contents

1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1

1.2 General Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1

1.2.1 Dan

1.2.2 Access to Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4

1.2.3 Point-of-operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 4

1.2.4 Lockout/Ta

1.3 Personal and Professional Safety. . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

1.4 Equipment and Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . .1 - 7

1.5 Environmental Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10

1.6 Liftin

1.6.1 Slin

1.6.2 Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 11

1.6.3 Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 12

1.6.4 Eye Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 12

1.6.5 Rin

1.6.6 Liftin

1.6.7 Liftin

1.7 Mechanical Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . .1 - 14

er, Warning, Caution Statements and Symbols . . . . . . 1 - 2

out Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 11

s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11

s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 12

the Machine or Components . . . . . . . . . . . . . . . . . . . 1 - 13

Workpieces and Fixtures . . . . . . . . . . . . . . . . . . . . . .1 - 13

1.8 Electrical Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 15

1.9 EDGE2 Ram Electrical Dischar

1.9.1 Fire Hazard and Prevention . . . . . . . . . . . . . . . . . . . . . . . . .1 - 16

1.9.1.1 EDM Fire Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 18

1.9.2 Machine Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 20

1.9.3 Location of Emer

1.9.4 Location of Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 21

1.10 EDGE2 Equipment and Operation Safety. . . . . . . . . . . . . . . . . 1 - 23

ency (E-Stop) Button . . . . . . . . . . . . . . . 1 - 20

e Machine Safety. . . . . . . . . . .1 - 16

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1.11 Installation Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 25

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KETCHES

1.1 Overview

This chapter provid es proven general safety guidelines t hat, if followed, promote a safer working environment. It also contains safety information specific to the EDGE2.

All machining centers have inherent haz ards the manufacturer either designs out, guards against, or warns about. Even though the manufacturer has this responsibility, the machine user has ultimate responsibility to ensure that a safe working environment is maintained in and about the machining center. This includes, but is not limited to, allowing only properly trained and technically qualified personnel program, operate, and maintain the machin in g cent er.

It is Makino’s po licy and respo nsibility to d esign, manu facture, and m arket machining centers that are as reasonably safe as possible for their intended use.

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1.2 General Safety

Safety precautions or requirements discus sed in Makino gu ides or manuals do not supersede any safety requirements imposed by local, state, or federal governments. All government-imposed guidelines, i.e. OSHA (Occupational Safety and Health Administration), NEC (National Electric Code), NFC (National Fire Code), ANSI (American National Standard Institute) standards, shall take precedence.

To protect against injury or damage operate the machining center within the guidelines described in the provided documentation. Consider Makino’s safety precautions supplemental to:

• Other Makino supplied guides or manuals related to programming, operation, and maintenance of this specific machining center.

• Your company’s safety rules and regulations.

• All local, state, and federal regulations.

Your particular application may require additional safety measures to ensure proper operator safety.

Additional copies of any guide or manual provided with your Makino machining center may be purchased from Makino.

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Prior To Installation, Operation, or Service,

Do NOT attempt to install, operate, or service this machining center until:

• You have read and under stand th e safety i nstru ctions containe d in th is guide.

• You have read and understand all Danger, Warning, and Caution safety labels attached to the machining center and its related equipment.

• You have read and understand all technical information, including the following sections of this safety chapter.

Questions Regard ing Safe Operation

Before you operate this machine – contact your Makino service group for answers to any questions about safety and your Makino machine.

1.2.1 Danger, Warning, Caution Statements and Symbols

It is important that all employees recognize each safety symbol on the machine and understand the meaning of Danger, Warning, and Caution.

These safety labels must never be removed, covered, or painted over, and must be replaced if they are damaged, defaced, or become unreadable.

Table 1-1

that all employees recognize and understand the meaning of the safety symbols shown in

The location of safety labels for specific hazards on the EDGE2 is described in

presents the meaning of each safety statement. It is important

Table 1-2

section 1.9.4

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DEFINITION OF DANGER, WARNING, AND CAUTION STATEMENTS

Statement Meaning

DANGER is the most severe safety statement. This statement means

DANGER

WARNING

CAUTION

ABLE

1-2

that either severe personal injury or death may result if the instruction(s) is not followed.

WARNING is the next level of safety statement. It indicates that if the instruction(s) is not followed severe personal injury could result.

A CAUTION is the least severe safety statement and indicates that if the instruction(s) is not followed damage to the equipment may result.

SAFETY SYMBOL SHAPES AND THEIR MEANING

Symbol Meaning

A triangle or diamond shaped safety symbol indicates a hazard exists in the area or behind the enclosure where the symbol is placed. The symbol at left indicates an electrical shock hazard exists.

A solid colored circle shaped safety symbol with an icon inside indicates the action shown by the icon is mandatory. The symbol at left indicates that safety glasses be worn.

A square shaped safety symbol is used to convey information relative to the area where the symbol is placed. The symbol at left indicates the area is hot.

A circle shaped safety symbol with a diagonal slash across the image indicates the action shown is prohibited in or around that area. The symbol at left indicates that smoking is not allowed in the area.

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1.2.2 Access to Information

We strongly recommend that a copy of these safety instructions and all provided guides , manuals, and technical information be kept near the machine. This infor matio n shou ld be o rgan ized for quick acce ss and u sed by operators, maintenance, and other personnel with duti es related to the machining center.

Access to this information:

• May save a life.

• W i l l prevent or reduce injury, mis-operation, and machining center damage.

In the event tha t parts of this information become damaged or unus able, replace them immediately.

1.2.3 Point-of-operation

“Point-of-operat ion” should be safeguarde d to the greate st extent po ssible for all machining operations.

In addition to panel locks, interlocks, and guarding, certain areas of the machining center ar e colo r coded f or safet y. It is important that the origina l color and vividness of these areas be maintained.

Different operations or applications may make the general purpose safeguards unsuitable and require additional safeguards. You and your company are required to use special safeguards in these situations.

To assist in designing point-of-o peration safeguards for specific machining center applications:

• OSHA has published a booklet called OSHA Publi cation No. 3067.

• Films regarding safety requirements for machine tools are available from ANSI and trade groups such as NMTBA (National Machine Tool Builders Association).

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1.2.4 Lockout/Tagout Procedure

The machining center is powered by high voltage and other energy sources that represent potential hazards. To reduce the risk of injury or death establish, define, and practice a Lockout/Tagout procedure for the equipment in your facility.

Lockout/Tagout defines a minimum safe procedure to be followed by persons who might be confronted with unexpected energizing, start-up, or release of stored energy that could cause injury or death. At a minimum, all Lockout/Tagout procedures should include:

Electrical Shock Hazards Exist - Work Safely

Failure to turn the Main Power disconnect to the Off position, lock it out, and tag it could result in severe personal injury or death.

1. Set the machine’s Main Power switch to the Off position.

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2. Affix a near the machine’s Main Power switch, until all repairs are complete.

3. Turn the Main Power disconnect to the Off position.

4. Install an industry approved lockout device through the Main Power disconnect handle.

5. Install a t amper-proof padlock onto the loc kout device. Al l persons performing maintenance on the machine at the same time shall install their own padlock onto the lockout device.

6. Disconnect the main power of all power sources (i.e. electrical, air, hydraulic, etc.).

Use the Lockout/Tagout policy and procedures defined by your company. If no Lockout/Tagout procedure has been communicated to you, please ask your supervisor to provide and explain one or obtain copies of standards to develop and implement Lockout/Tagout in your plant.

• A NSI has issued a standar d to a ssist in th e desig n and developme nt of

a Lockout/Tagout policy. It is written as a guide to follow when determining the spec ific p roced ures and trai ning n ecessar y and appr opria te to your plant operations.

DO NOT START

tag with your na m e and department at, on, or

- Copies of the ANSI standard are available from ANSI at 1430 Broadway, New York, NY 10018, ask for: Standard ANSI Z244.11982, or as modified, for personal protection - Lockout/Tagout Of Energy Sou rces - Minimum Safety Requirements.

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1.3 Personal and Pr ofessional Safety

General safety precautions should be practiced everyday, but never become common place. Safety is the responsibility of every person on the job site. In this regard, consider yourself responsible for safety in your workplace. No on e is better positioned to eliminat e or prevent unsafe conditions than you. Each employee should practice the following, regardless of their position, title, or labor grade:

• Approach and intercede anytime you witness unsafe procedures.

• Be prepared to report any condition which seems unsafe to your company’s safety department or any supervisory or management staff. It could save lives. In particular report such things as:

- Missing or defective guards and protective devices.

- Leaks and spills of cutting fluid, lubricants, or any liquids.

- Improperly stored chemicals or flammable materials and any

unusual fumes.

- Loose, worn, or broken flooring.

- Slippery, broken, or unstable platforms.

- Missing, broken, or unstable handrails.

• A v oid making sudd en movemen ts, loud noise s, engagi ng in horsep lay, or other activities that may prove distracting and result in an unsafe or dangerous work environment. Remember that around machinery, it only takes a second’s inattention to result in personal injury or death.

• Observe and obey all signs posted on the machinery and its components and sign s placed by your company, like:

- NO SMOKING

- SAFETY GLASSES MUST BE WORN WHILE OPERATING THIS

MACHINE

- DANGER - HIGH VOLTAGE, etc.

• Wear appropriate safety equipment as defined by OSHA, the equipment manufacturer, your company safety policy, or MSDS (Material Safety Data Sheet). Always wear approved eye protection and other safety equipment to meet the demands of current conditions while operating or working around the machining center.

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• Clean up any oil or other liquid spills immediately.

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• Obtain an MSDS for each chemical (such as cutti ng fluids, lubricating oils, greases, etc.) used on or around the machining center. Practice safe working ha bits and wear all protective equipment required. Know and understand the procedures to follow in the event:

- Your skin is exposed to the chemical.

- Your eyes are contacted by the chemical.

- You ingested or inhaled the chemical.

1.4 Equipment an d Op e ration Safety

We urge that all machining centers be operated, equipped, and cared for in strict compliance with all local, state, and federal safety regulations. The following safety requirements apply to all machinery and should be practiced in addition to machine specific safety guidelines.

• Do not neglect your responsibility to ensure that all machining centers are operated, mai ntain ed, and eq uipp ed with compl ete r egar d for o perator safety.

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Only qualified personnel, trained in safety and all machining center functions should be allowed to operate, maintain, or repair the machine.

To be considered qualified, all personnel whose duties are related to the operation, maintenance, or repair of the machining center should:

• Know the location and operation of t he [ ton.

• Study the related guides or manuals prior to attempting to operate, maintain, or repair the machine.

• Locate and understand all machining center and accessories.

Machining centers are designed for operation by one person at a time.

• P ersons other than the designa ted operato r should stay ou t of the area during operatio n.

• Unauthorized personnel may increase the potential for injury or damage due to inattentiveness.

Danger, Warning,

EMERGENCY

and

Caution

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labels on the

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Be sure to Always:

• Take steps to protect the machine tool and control cabinets from moisture and condensation. Moisture can damage electrical components, causing unwanted machine motion, leading to injury or machin e damage.

• Maintain the exact original color and vividness of any machine areas that are color coded as safety precautions.

• Ensure that all shields and gu ards are in place and all covers, cabinet doors, and terminal boxes are closed prior to operation.

• Avoid accidentally bumping any machine controls, as this may cause unintended machine motion causing injury or machine damage.

• Be alert for loose, damaged, or worn parts on the machine and associated equipment. Immediately correct or report any loose items, noticeable change in operating noise, or any unusual machine action.

• Be aware of the machine and auxiliary components’ moving members and range of movement which may create pinch points. Always be cautious of these areas. Avoid pinch points entirely during machine operation.

• Keep the machining center properly maintained. Perform maintenance at prescribed int ervals, as describe d in the Mechanical Editions. Machining center maintenance should be performed only by authorized individuals.

• Check the level of each fluid reservoir periodically. Add fluids, if needed, as described in the Mechanical Editions. Use only recommended lubricants.

• Keep the machining center clean. Keep the work area clear of chips, rags, etc. Clean up any spilled or splashed fluid on the floor immediately. Cleaning should be performed at least daily.

• Double check the set up and workpiece before power up.

• Check all clamp bolts for tightness and verify the accuracy of all set ups before restarting machining operation.

• U se caution when handli ng workpieces after machini ng. Machining can produce sharp edges and, at times, considerable heat.

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You should:

• N ever wear loose -fitt ing cl othing or acc essories tha t may be entan gled in machine components. In particular, never wear any of the following items when working in a shop environment:

- Jewelry (rings, bracelets, watches, or necklaces) and accessories

(necktie, scarf, or loose fitting belt)

- Long hair (tie back and contain it under a hair net or cap)

• Never operate any machinery after taking strong medication, using nonprescription drugs, or co nsuming alcoholic beverages.

• Do not make modifications to the machine or associated equipment that may reduce the operational safety of the device such as:

- Never paint, alter, deface, or remove any danger, warning, or cau-

tion label. (Rep lacement labels are available from Makino)

- Never change or by-pass the location of the stroke limit dogs, limit

switches, interlock circuitry, etc.

- Never operate the machine with any safety device disabled or

removed or any cover open or removed

• Do not allow yourself to become trapped or caught in pinch points:

- Always be aware of a safe exit, when in or around any type of

equipment. Know the travel limits of the machining center and always keep all body parts clear of moving components.

- Never enter an area restricted by a barrier without first properly

shutting down the equipment and locking out the power sources to prevent its restarting.

- Never perform any set up, check the set up, or reach into the work

area or across moving par ts while th e mach ine is in autom atic ope ration.

- Never change a workpiece or perform a manual operation on a

workpiece while the machine is in automatic operation.

• Never activate or press any button or other operating control unless you are trained on t he ope ration of that d evice, ma chine , or e quipm ent.

• Never use compressed air to clean or blow chips or dirt off the table, workpiece, or the machining center.

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1.5 Environmental Safety

Follow these specif ic practices when work ing at the machining center:

• T he area arou nd the machine shou ld be well lig hted, dry, and free from obstructions. Keep the area around the machine clean and in go od order at all times.

• Equipment should not be operated during severe thunderstorms or other electrical disturbances.

• In the event of a power failure, turn the Main Power switch Off immediately. Leave the switch in the Off position until the power is fully restored and no rmal operations can safely be resumed.

• Never step on machine covers as they can become slippery during normal operation and are not designed to support your weight.

• Never perform grinding operations in the vicinity of the machining center. The dust created by grinding can contaminate components, cause premature wear, and cause inaccuracies or component failure .

• Never weld on parts mounted on or in the machine. Electrical cu rrents associated with welding could cause bearing damage or explosions and result in serious injury or equipment damage.

• When a platform is placed around the machining center, it should be extremely sturdy, safe, and have anti-slip surfaces.

• Keep all flammable liquids away from the work area.

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1.6 Lifting Safety

These lifting safety precautions must be followed by all persons responsible for lifting. This includes, but is not limited to , lifting machinery, machine components, and workpieces:

• All lifting equipment must be properly rated for the weight being lifted.

• All lifting equipment must be inspected on a regularly scheduled basis.

• A ny lifting device fo und to be defe ctive must be repa ired in accord ance with industry standards.

• Any lifting device that cannot be repaired mus t be destroyed.

1.6.1 Slings

Use nylon slings when lifting irregularly shaped objects and:

• Never exceed the lifting capacity of any sling.

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• Protect slings with heavy padding when lifting objects with sharp edges.

1.6.2 Chains

Lifting chains must be stored prop erly to prevent da mage when not in use. When using chains:

• Never exceed the lifting capacity of any chain.

• Do not drag chains.

• Do not allow chains to become tangled or kinked.

• Never twist chains in an attempt to shorten their length. Use proper devices to shorten a chain’s length.

• Use chains equipped with enclosed lifting hooks.

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1.6.3 Hooks

When using hooks:

• Never exceed the lifting capacity of any lift hook.

• Do not repair lifting hooks.

• Destroy and discard bent lifting hooks.

1.6.4 Eye Bolts

To ensure a safe load carrying capacity:

• Never exceed the lifting capacity of any eye bolt.

• An eye bolt must be en gaged to at least 90 per c en t of its threaded portion.

• Never weld or heat an eye bolt to a temperature in excess of 480° C (900° F). Heat exposure can change the physical properties of the stock and create an unsafe eye bolt.

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• Never use an inch eye bolt in a metric thread or vice versa:

- Use inch series thread eye bolts in inch series threads.

- Use metric series thread eye bolts in metric series threads.

• Never use a painted or coated eye bolt as this may cover up defects.

• Discard and destroy any defective eye bolts.

1.6.5 Rings

When possible use a lifting ring or clevis instead of an eye bolt. Secure the lifting ring with the correct inch/metric series bolt.

• Never exceed the lifting capacity on any lifting ring or clevis.

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1.6.6 Lifting the Machine or Components

Use only a lifting dev ice and relate d equi pment t hat is capa city ra ted to li ft the total weight of the machining center (and shipping skid, if the skid is attached during lifting). Always follow the lifting instructions provided in the Pre-Installation Guid e.

Before lifting, refer to shipping documents to obtain the weight of the machine or component being lifted. If the necessary weights cannot be determined, consult Makino. In addition:

• Only qualified riggers should perform machine lifting operations.

• Never place any portion of your body beneath a suspended object.

• Lift the machining center only at the designated lifting points.

• Never lift the machine higher than necessary.

• Always maintain the center of gravity by properly adjusting the leg lengths of the lifting device.

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1.6.7 Lifting Workpieces and Fixtures

Always use a lifting device and related lifting equipment that is capacity rated for the workpiece or fixture being lifted.

• Never place hands, arms, feet, or any other portion of your body beneath a suspended workpiece fixture.

• Always maintain the center of gravity by properly adjusting the leg lengths of the lifting device.

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1.7 Mechanical Maintenance Safety

Mechanical maintenance procedures for Makino machining centers should be performed by properly trained and technically qualified personnel. They should ad here to the se specif ic pra ctices wh en wo rkin g wi th th e machining center:

• Always perform Lockout/Tagout before removing any safety guard, cover, barrier, or any basic component of the machining center. See

section 1.2.4

• Block vertical sliding members before disassembling any portion of their drive train.

• B e familiar with and adhere to safe lifting practices described in

before lifting the machine or components.

1.6

• Never return the machining center to production until all safety guards, covers, barriers, or other safety devices are reinstalled and confirmed operational.

section

Mechanical Maintenance Equipment

Mechanical maintenance personnel should:

• Keep all hand tools in good repair.

• Use each hand tool in a manner for which it is intended.

• Never use any hand tool that is defective, broken, or worn out.

• Keep alert with regard to nearby hazards.

• Do not use extenders in an effort to gain leverage; use a bigger tool.

1 - 14

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1.8 Electrical Maintenance Safety

Electrical maintenance procedures for Makino machining centers must be performed by properly trained and technically qualified personnel. They should adhere to these specific practices when working with the machining center:

• Always perform Lockout/Tagout before working on electrical circuits. See

section 1.2.4

• Use extreme care when troubleshooting with power On.

• With the power Off, identify and discharge any power retaining devices, such as capacitors, before starting any maintenance procedure within any electrical control cabinet.

Electrical Maintenance Equipment

Use only industry standard approved electrical testing equipment.

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• Volt/Ohm Meters.

• Oscilloscopes.

• Static Ground Wrist Straps.

Machine Grounding

All Makino machin ing centers must be properly grounded at the time of installation.

• JIS class 3 grounding (resistance of 100 Ohms or less) is recommended.

• Proper grounding requires an isolated earth ground.

• Ground the machine in accordance with local, state, and federal regulations.

Machine Electrical Devices

Always replace defective electrical components, such as fuses, shunts, overloads, etc., with components of the same capacity and rating as the original equipment. If you are unsure of the correct electrical component or part, refer to the machine’s electrical drawings or consult Makino.

01_20ed3a Safety.fm 1 - 15

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1.9 EDGE2 Ram Electrical Discharge Machine Safety

In addition to safety precautions for all machining operations, Become familiar with the machine specific safety features listed below.

1.9.1 Fire Hazard and Prevention

Fire Hazard

RAM type EDM uses a dielectric fluid in the machining process. This fluid is flammable and may i

All Makino RAM machines are provide d with the following fire related safety features:

1. Dielectric Temperature Detector – to immediately stops the machining process when the temperature of the dielectric fluid rises above a set value of 53°C.

nite, if improperly applied.

2. Dielectric Level Detector – to immediately stops the machining process when the dielectric level falls below the set level. The set level must be at least 50mm above the workpiece.

3. Abnormal Machining Detector – stops the machining process if an arc occurs for an extended duration. During an arc the head retracts to clear the problem. If the head retracts beyond a specified distance, machining stops and an “abnormal machining” alarm is generated.

4. Automatic Fire Extinguisher – If the dielectric fluid catches fire a sensor detects the temperature rise and discharges the extinguishing agent into the work area. Additionally, all machine functions stop and an audible alarm sounds. To resume machining operations, you must change filters and di electric fluid t o remove the exti nguishing age nt. Do NOT remove or chang e th e p ositi on s of the fire extinguishe r senso r (s) or jet nozzle(s).

1 - 16

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Be sure to Always:

• Keep all fire extinguishers fully maintained and operational and train all personnel in their proper use.

• Ensure the automatic fire extinguisher is f ully operational. Perform a functional test at the prescribed intervals. Never operate the machine with the fire extinguisher testing knob in the "LOCK" position.

• In stall addition al fire extinguisher s of a type for liquid app lications in the work area.

• Fully ventilate the work area at all times.

• Pay attention to the mounting method of the electrode, workpiece and fixture so that electrical discharge does not occur near the surface of the dielectric.

• Monitor the machining process. Never leave the machine totally unattended for extended periods of time. Allocate workers in such a manner that necessary measures can be taken if a problem occurs or if a fire arises.

• Use only approved dielectric fluids.

You Should Never:

• Never substitute any oth er flammable liquids, such as kerosene for dielectric fluid.

• Never use fire or heat sources such as heaters, welding machines or open flame, near the mach ine.

• Never machine with fluid only being jetted onto the workpiece.

• Never machine with less than 50mm of dielectric fluid covering the workpiece.

01_20ed3a Safety.fm 1 - 17

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1.9.1.1 EDM Fire Conditions

The following conditions may result in fire during machining operations (

Figure 1-1

1. Fire hazard caused by spray ing dielectr ic fluid onto workpiece. Workpiece shou ld be submerge d in the dielect r ic fluid to ensure safe bu rning.

2. Fire hazard from mach ining without e nough dielectri c fluid covering th e workpiece. Dielectric level must be 50mm above the top of the workpiece.

3. Fire hazard from machine platen contacting a clamp. Ensure mo ving machine members will clear clamps, work piece, and fixturing.

4. Fire hazard due to arcing between shank and electrode. This is caused if the electrode becomes loose or is im properly mounted.

5. Fire hazard due to carbon build up is caused by a combination of too little dielectric fluid covering the part and arcing.

6. Fire hazard can be caused by concave electrode shape (not shown), as gas can collect in cavity. Ensure a vent hole is drilled at the high point of the cavity.

1 - 18

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Legend

[1] Electrode [2] Jet Nozzle [3] Workpiece [4] Table [5] Dielectric [6] Clamp [7] Shank

IGURE

01_20ed3a Safety.fm 1 - 19

EDM FIRE CONDITIONS

1-1

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1.9.2 Machine Safety Fe atures

The EDGE2 provides the following safety features:

EMERGENCY

•[

] button, to immediately halt all machine functions.

• Automatic Fire Extinguisher and other fire related equipment, see

tion 1.9.1

Descriptions, operational detail, and precautions related to these safety features are described in the Operation Guide.

(pg 1-16)

1.9.3 Location of Emergency (E-Stop) Button

EMERGENCY

The [

] button [1] is on the Main operation panel (

sec-

Figure 1-2

MGF

1 - 20

IGURE

EMERGENCY BUTTON LOCATION

1-2

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1.9.4 Location of Safety Labels

Labels attached to the machine at specific areas, ident ify safety risks and provide important instructions that must be read and followed.

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• Machine safety labels (

• Oilmatic safety labels (

Figure 1-3

Figure 1-4

)

(pg. 1-22)

)

IGURE

01_20ed3a Safety.fm 1 - 21

MACHINE SAFETY LABELS

1-3

RIGHT VIEW

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OILMATIC SAFETY LABELS

1-4

1 - 22

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1.10 EDGE2 Equipment and Operation Safety

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In addition to the general safety precautions in specific practices when working with the EDGE2.

section 1.2

, adhere to these

Be sure to Always:

• Inspect all tool holders for nicks or other damage to ensure the accuracy of machining operations and prevent damage to the equipment.

• Check with the manufacturer to ensure proper and safe operat ion in a RAM EDM environment, of any accessory NOT specifically built, designed, or s upplied by Makino .

• Use extreme caution when changing electrodes. Make sure that all electrodes are properly loaded and secured and that they will not come into undesirable contact with items in the work ar ea during oper ation.

• Load or unload workpieces only when the machine is completely stopped and the control is in the STOP or RESET status.

• DRY RUN machining programs to verify that there is no chance of any interference be twee n an y mach ine pa rts, f ixtur ing, and wor kpie ce pr ior to unattended operation of the machine.

• Before moving the X, Y, or Z axes, make sure that there are no obstructions within the range of movement.

• Check the tightness of all clamping devices, fixture mounting, electrodes and tool holders prior to any machining operations. Be sure to verify the acc uracy of the set up prior to automatic operations.

You should Never:

• Never use any device NOT specifically designed for use in an EDM environment. The dielectric fluid and electrical energies will cause damage to improperly designed devices.

• N ever lay too ls on t he machi ne wher e they may i nter fere wi th machi ne movement or can become entangled with the work.

• Never exceed the machines specified maximum workpiece weight (500kg) or electrode weight (50kg).

• Never perform any set up work while the machine is in operation.

01_20ed3a Safety.fm 1 - 23

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Working Inside the Machine

When working inside the machine be aware that axes and work tank operation are hazards that could result in serious injury or death. Therefore:

• Enter the machining area only when all machine motion is completely stopped and the control is in the STOP or RESET state.

• Remember injury can occur if any body parts are caught between top of the work tank and the workpiece or fixture or between work tank bottom and a platform or steps set near the machine.

• Ensure the Flexible Pendant Box cable does not interfere with the workpiece or fixture.

• Always place the Flexible Pendant Box to prevent accidental key activation resulting in unexpected machine movement.

Prior to Machining

• Check with the manufacturer of any accessory not designed, built, or supplied by Makino to ensure the device will opera te properly and safely under the proposed operating conditions.

• P rio r to unatte nd ed op eratio n, p rove ou t p art p rogram s t o ensu re cl earance between machine parts, fixturing, and the workpiece.

• Before moving the axes, make sure there are no obstructions within the range of movement.

• Verify the accuracy of the set up prior to automatic operation. Check the tightness of all clamping devices, fixture mounting, etc.

Workpiece Handling Safety

These specific l if ti ng safe ty p r ecau ti on s must be followed by a ll personnel responsible for lifting workpieces. In addition to the general lifting precautions in

• The EDGE2 has a maximum allowable table capacity of 500kg. Never

• U se liftin g equi pmen t for heavy w orkpiec es an d other ma terial s. Never

section 1.6

exceed this weight limit.

attempt to lift anything beyond a reasonable weight without proper devices.

, adhere to these specific practices with the ED GE2:

1 - 24

• Use care not to place fingers or hands where they may be pinched by the table or lower head while loading/unloading workpieces.

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1.11 Installation Safety Instructions

The following information is related to installation of the machining center. Adhere strictly to the installation instructions provided in the Pre-Installation Guide:

('*(

• Review the general lifting safety rules in procedures in the Pre-Installation Guide, prior to moving the machine.

• Review the general electrical safety rules in procedures in the Pre-Installation Guide, prior to connecting power to the machining center.

section 1.6

section 1.8

and the specific

01_20ed3a Safety.fm 1 - 25

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OTES

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KETCHES

1 - 26

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Chapter 2 Specifications

Machine Unit and Control Specifications

Makino EDGE2

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Ram Electrical Discharge Machine

with MGF Control

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Chapter 2

Specifications

Contents

2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1

2.2 Installation Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1

2.2.1 Layout Drawin

2.2.2 Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5

2.3 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 6

2.3.1 Machine Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 6

2.3.2 Machine Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6

2.3.3 Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7

2.3.4 Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8

2.4 Unit Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9

2.4.1 Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9

2.4.1.1 C Axis (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 10

2.4.2 Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 11

2.4.3 Axis Components (Spindle, Ram, Saddle) . . . . . . . . . . . . .2 - 12

2.4.4 Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12

2.4.5 ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 14

2.4.5.1 Maximum Electrode Size. . . . . . . . . . . . . . . . . . . . . . . .2 - 14

2.4.6 Dielectric Fluid Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 15

2.4.6.1 Dielectric Fluid.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 16

s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2

2.4.7 Machinin

2.5 Makino MGF Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 18

2.5.1 Operation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 18

2.5.2 Machine Communications . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 18

2.5.3 Operational Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 19

2.5.4 Maintenance and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 20

2.5.5 Controlled Axes and Coordinate System . . . . . . . . . . . . . . .2 - 20

2.5.6 Auxiliary Functions and Machinin

2.5.7 Interpolation and Feeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 21

2.5.8 Pro

Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17

Conditions . . . . . . . . . . 2 - 21

ramming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 22

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2.1 Overview

Makino’s EDGE2 prov ides fully automated function al machine capabilities. Machine and MGF control specifications follow.

Information Subject to Change

Every effort was made to ensure the accuracy of the data presented in this chapter at the time of publication. Machine and control specifications are subject to chan prior notification.

2.2 Installation Specif ica tions

Dimensional and general arrangement drawings are included in this section to ensure proper machine site selection.

The machine tool sh ould be placed with sufficient clearance to:

• Access the rear of the machine and all auxiliary components.

('*(

e without

• Completely open all cabinet doors and panels.

• Prevent interference and pot ential pinch points of moving components with structural features (pillars, walls, etc.), other machines, their range of movement, or components.

02_20ed3a Specifications.fm 2 - 1

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2.2.1 Layou t Drawings

2 - 2

IGURE

2-1 EDGE2

Legend

[1] Work Table [5] NC Unit [2] ATC [6] Flexible Pendent Panel [3] Ram [7] Work Tank [4] Main Operation Panel

FRONT VIEW

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Legend

[1] Dielectric Unit [5] Air Filter Regulator [2] Oilmatic [6] Automatic Fire Extin [3] Ram [7] Work Ta nk [4] NC Unit [8] Work Table

IGURE

02_20ed3a Specifications.fm 2 - 3

2-2 EDGE2

LEFT AND RIGHT VIEWS

uisher

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2 - 4

IGURE

2-3 EDGE2

Legend

[1] Dielectric Unit [3] NC Unit [2] Oilmatic [4] Main Operation Panel

GENERAL ARRANGEMENT DRAWING

2.2.2 Foundations

The machine should be placed on a continuous concrete pad. The required floor space (including standard accessories) is 2225 for a standard m achine. The required floor space increases with ATC or booster options.

• The recommended concrete thickness is 300m m.

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2370mm

02_20ed3a Specifications.fm 2 - 5

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2.3 General Information

This section contains general information on EDGE2 environment, machine size, power, and air requirements.

2.3.1 Machine Environment

The EDGE2 performan ce is dire ctly af fected by t he env ironmen t. lists key environmental specifications.

ABLE

2-1 EDGE2

Item Specification

Ambient Temperature Range 10 – 35°C Optimum Temperature 20±1°C Maximum Relative Humidity 75% (no condensation) Maximum Vibration 0.7m/s EDGE2 Heat Release Rate 30A 5.3kW EDGE2 Heat Release Rate 60A 7.1kW

In addition, protect the EDGE2 from:

• Dust, like that from grinding or polishing machines.

• Direct sun light , excess air from ventilation systems, or any source that may affect the machine temperature.

2.3.2 Machine Size

ENVIRONMENTAL SPECIFICATIONS

Table 2-1

Machine dimensions are listed in plans are presented in

ABLE

2-2

Height 2290mm Width 1625mm Depth 1770mm Wei

ht (including NC unit and generator) 3000k

Required Floor Space 2225×2370mm

2 - 6

MACHINE DIMENSIONS

Item Specification

section 2.2.1

Table 2-2

. External dimensions and floor

2.3.3 Electrical Power

A 3-phase power source, with stable voltage regulation (±10%) and a JIS class 3 ground, of 10 ohms or less, must be provided.

The EDGE2 operates on 200/ 220VAC ±10%, 50/60Hz ±1% connec ted to a terminal in the machine tool cabinet.

• A standard machine operates on 9kVa. The customer must:

• Provide a properly sized service box for the machine. Use local code and

Table 2-3

machine kVa rating when calculating machine electrical consumption.

• Ensure the electrical service voltages meet all requirements.

• Install an additional automatic voltage regulator i f t he required voltage cannot be maintained within ±10%.

to assist in sizing the machine electrical service. Use the

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• Connect incoming electrical service at the Main Power switch.

• Provide a JIS class 3 ground of 100 ohms or less.

To convert kVa to amperage for service amperage:

kVa

1000/1.73

Voltage

amps

then take:

amps

ABLE

2-3

Machine kVa Rating Standard 30amp 9kVa Machine kVa Ratin Source Volta Operatin Cycle (±1%) 50/60Hz

MACHINE POWER REQUIREMENTS

Power Requirements

60amp 12kVa

e (±10%) 200-480VAC

Voltage (±10%) 200-220VAC

125% = Service

02_20ed3a Specifications.fm 2 - 7

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2.3.4 Air

Dry and clean compressed air at 0.6MPa must be available. The air supply line should be permanentl y piped.

• A pressure switch detects if air pressure drops below 0.3MPa and

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stops machine operation .

ABLE

2-4

Standard machines Pressure 0.6MPa

With MA Head Pressure 0.6MPa

With ATC Pressure 0.6MPa

AIR SPECIFICATIONS

Item Specification

Consumption 100 liter/min.

Consumption 200 liter/min.

2 - 8

2.4 Unit Specifications

Specifications for each machine component follow. These specifications are presented to serve as a quick reference.

2.4.1 Head

The head can be purchased in several configurations. On standard head s the electrode is bolted directly to the platen.

Figure 2-4

bolt pattern. Machines may also be pur-

chased with a C axis (option) which comes with a chuck adapter.

shows the platen

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• The C axis may be purchased with a 3R m acro or Erowa rapid action chuck system

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ABLE

2-5

Max Electrode Weight 3 Axis Orbiting 50k Max Weight Capacity of Chuck 40k

HEAD SPECIFICATIONS

Item Specification

2-4

Legend

[1] M10 × 1.50 TAP (4 Places) [2] M8 × 1.25 TAP (12 Places)

STANDARD PLATEN BOLT PATTERN

02_20ed3a Specifications.fm 2 - 9

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2.4.1.1 C Axis (option)

The C axis is available in a MA or MR configuration (

Table 2-6

). The C axis allows progra m ma ble indexing of th e h ea d for positioning the electrode to a specific angle. The MA and MR heads also provide a rotary function for rotating the electrode.

• Refer to your sales order to confirm the head provided on your

machine.

ABLE

2-6

Speed (Rotary Function Selected) 10~1000rpm 0~10rpm In Rotation (C-axis and Rotary Function) 30 amps 30 amps Fixed (C-axis and Rotary Function) 30 amps 60 amps Max. Electrode Wei Max. Electrode Weight Using C-axis Positioning10k Minimum Input Increment 0.001° 0.001° Toolin

Provisions Available Erowa ITS or 3R Macro

SPECIFICATIONS FOR MA AND MR HEADS

Specification

ht in a Fixed Position 5k

Head Type

MA MR

10k 15k

2 - 10

2.4.2 Table

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Figure 2-5

IGURE

ABLE

2-5

2-7

shows table detail and

TABLE AND T-SLOT DETAILS

TABLE SPECIFICATIONS

Item Specification

Table 2-7

lists table specifications.

Table Size 500x350mm Number of T-Slots / Size 10mm x 4 rows Maximum Workpiece Weight 500kg Table Surface Height 840mm

02_20ed3a Specifications.fm 2 - 11

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2.4.3 Axis Components (Spindle, Ram, Saddle)

Table 2-8

lists work zone and machine travel specifications.

shows axis configuration and work cube.

ABLE

2-8

X,Y Axis Travel 300×250mm Z Axis Travel 250mm Worktank Dimensions (WxDxH) 650×450×300mm Platen to Table Distance Bottom Point 250mm Chuck Face to Table Bottom Point 180mm Table Size 500×350mm

AXIS COMPONENT SPECIFICATIONS

2.4.4 Accuracy

Table 2-9

cies are checked at the factory and requir e proper instal lation, foun dation , environment, operation, and maintenance to be maintained or guaranteed.

lists standard machine accuracy specifications. These accura-

Item Specification

Figure 2-6

ABLE

2-9

Static Load Positioning ± 5 microns [0.005mm] Repeatability ± 2 microns [0.002mm] Dynamic Machining ± 5 microns [0.005mm] * Above accuracies can be guaranteed, when machine is installed, operated, and main-

tained under proper conditions.

ACCURACY SPECIFICATIONS

Item Specification

2 - 12

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Legend

[1] Machine Reference [2] Table

IGURE

02_20ed3a Specifications.fm 2 - 13

AXIS CONFIGURATION AND WORK CUBE

2-6

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2.4.5 ATC

An ATC (Automatic Tool Changer) provides several advantages in extending no or low-attendant machining, au tomatic multiple operations, and assigning spare tools for long job runs. The standard ATC is an A4 rack type with an A8, A16, or A24 carousel types available. specifications.

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Table 2-10

lists A TC

ABLE

2-10

ATC SPECIFICATIONS

Item Specification

Tool Selection Random or Sequential Tool Chan Max Electrode Wei

e Time Approximately 45 Seconds

ht by ATC 5k

2.4.5.1 Maximum Electrode Size

Maximum electrode length and diameter (

Figure 2-7

by ATC size, chuck type, and work tank positio n.

Maximum electrode diameter varies by ATC size. Maximum electrode length varies with chuck type and work tank position. See

Table 2-11

• M ax imu m lengt h is based on

work tank in full up position.

) are limited

IGURE

Legend

[A] 230mm [C] 60mm [B] 250mm [D] 80mm

ELECTRODE SIZE LIMITATIONS

2-7

ABLE

2-11

ATC Size

A16 230mm 250mm 60mm A24 230mm 250mm 60mm

Maximum length with work tank in full up position.

2 - 14

ELECTRODE LIMITATIONS BY

Maximum Length

3R Macro EROWA

A4 230mm 250mm 80mm A8 230mm 250mm 80mm

SIZE AND CHUCK TYPE

ATC

Maximum

Diameter

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The maximum e lectrod e l ength, show n in full up position and is also affected by chuck type.

Figure 2-7

, is for the work tank in

02_20ed3a Specifications.fm 2 - 15

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2.4.6 Dielectric Fluid Supply

The dielectric supply unit (DI unit) consists of an integrally designed tank, filters [1], and cooler unit.

This system filters machining sediments from the fluid and supplies clean fluid to the work tank for optimum machining. For increased accuracy, the cooler maintains fluid temperature within a set range of the machine temperature.

ABLE

2-12

Fire Extinguisher Automatic Worktank Vertical Slide System Number of Pumps 1 Filtration 8 Micron × 2 Filters Dielectric Refri Max Worktank Level 250mm Dielectric Reservoir Capacity 200 liter Flushin

DIELECTRIC SUPPLY

Item Specification

eration Standard and Adjustable to ± 20°C

- Pressure/ vacuum 2 Ports – 1.05kg/cm

IGURE

2-8 DI

UNIT

2 - 16

2.4.6.1 Dielectric Fluid

1. Always use a highly refined oil with a minimum of PAH’s. Use an oil similar to EDM244 or EDM-250 to minimize any health risks.

2. Never use a dielectric fluid with a flash point under 70°C.

Dielectric fluid is used in the machining process and is required at time of installation and start up.

• The dielectric tank holds 200 liters. There are three basic types of dielectric fluid, choose the type best suited

to your work

1. Mineral Fluid – provides a concentrated electrical discharge and a removal rate 10 to 20% faster than synthetic fluids.

2. Synthetic Fluid – is recommended for machining with graphite and when using hi gh current setti ngs. Synthe tics h ave le ss odo r an d be tter surface roughness than mineral fluids and promote longer filter life.

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Dielectric Fluids

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3. Intermediate Fluid – Provides performance characteristics between those of mineral and synthetic fluids.

2.4.7 Machining Power Source

Table 2-13

ABLE

Circuit Type Transistor Pulse Maximum Machinin Current Settin Volta OFF Intervals 256 Steps Power Stabilizin LL Generator Circuit Standard Power Unit Coolin Machinin

lists the machining power source specifications.

2-13

MACHINING POWER SOURCE SPECIFICATIONS

Item Specification

Current 30A (60A optional)

s 90 Steps

e Settings8 Steps

Circuit Standard

Power Source 9kVa

Forced Air

02_20ed3a Specifications.fm 2 - 17

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2.5 Makino MGF Control

Standard MGF control configuration is listed below.

2.5.1 Operation Panel

Feature Detail

Display

Panel

Routine

Functions

10.4 inch Color display MDI (Manual Data Input) Function Operation Record Display Run Hour Dynamic Graphic Display Automatic Reference Return Measurement Return To Workpiece Zero Position Stored Stroke Limit

2.5.2 Machine Communications

Feature Detail

I/O Communication Ports

3.5 type Floppy Disk Drive NC Tape EIA/ISO Recognition

RS-232C RS-227 2DD/2HD: 720kB/1.25MB, 1.44MB 1 inch, 8 bit EIA Automatic

2 - 18

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2.5.3 Operational Support

Feature Detail

Operational Support Functions

Automatic Operation Support

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Label Skip Single Bloc k Program Stop – M0 Optional Stop – M1 End of Program Block Skip - / Dry Run Machine Lock Auxiliary Function Lock XY Axes Exchange Manual Absolute Automatic Return Workpiece Edge Positioning Hole Centering Corner Edge Positioning Groove Width Centering Plate Width Centering Cylinder Center Measurement Work Parallelism Measurement Automatic Measuring and Machining Machining Time Estimation User Creation Screen Help Window Key Input Pl ayback Manual Interrupt Process Skip and Additional Machining Function Approach Function Noncontact Point Search Functio n Automatic Power Cut Off Function

02_20ed3a Specifications.fm 2 - 19

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2.5.4 Maintenance and Safety

Feature Detail

Emergency Stop Axis Overtravel Protection - 2 systems - Hard and

Stored Stroke Limit Work Limit Diagnostic Function

Maintenance and Safety

Regular Check Function Maintenance Function Parameter Output by Machine Number (G150) Machining Condition Output (G151) Machining Time Output (G152) Machining Status Record Output (G153) Data Backup (G154)

2.5.5 Controlled Axes and Coordina te System

Feature Detail

Controlled Axes

Coordinate Systems

5 Simultaneous Control – 4 Absolute or Incremental - G90, G91 Reference Point Return - Manual, G28 Return From Reference Point - G29 Return To 2nd – 4th Reference Point - G30 Coordinate System Setting - G92 Machine Co ordinate System Setting - G53 Work Coordinate System Group – G500 – G509 Work Coordinate System Selection - G54-G61 Work Coordinate System Preset – G92 Relative Coordinate System Preset

2 - 20

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2.5.6 Auxiliary Functions and Machining Conditions

Feature Detail

Auxiliary Functions

Machining Conditions

Machining (M17/M18) Work Tank Up/Down (M28/M29) Selection: E4 digit (E0001 – E9999) Registered area: 600

2.5.7 Interpolation an d Feeds

Feature Detail

Rapid Positioning – Manual G0 Linear Interpolation – Manual G1 Circular Interpolation – G2 (CW), G3 (CCW) Taper Interpolation – G51 (left), G52 (right), G50(can-

Interpolation

Feeds

Axis Motion Overrides

cel) Taper Corner Tangential Interpolation – G24 Spiral Interpolation – G2 5 Taper Top/Bottom Same Radius – G49 Vertical Irregular Shape Interpolation – G41/G42 P0,

P1, P2 Servo Feed by Machining Condition Setting F4 Digit Traverse Rapid Feed Jog Feed (High, Middle Low) Step Feed (Least Input Increment ×1, ×10 Incremental Feed Dwell – G4 Automatic Accele ra tio n/De cel erati on Override Cancel F4 Digit Feed Override 0 – 200%

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02_20ed3a Specifications.fm 2 - 21

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2.5.8 Programmin g

Feature Detail

Storage

Methods

Editing

Programming Support Functions

Memory – 369,000 characters (1000m of tape) Number of registrable programs – 9999 Standard CNC Language Minimum Input Increment – 0.001mm (0.0001mm)

Standard or High Resolution (Parameter Selectable) Control Unit – 0.00005mm Maximum Programmable Increment - ±99999.999mm Sub-Programming – Nesting level: 9 Programmable data input – G10 Custom Macro: 33 Local and 200 Common Variables Decimal Point Programming Diameter Compensation 10× precision (inch) Part Program editing Background editing Program Number Search Program Number Copy Program Number Division Program Number Collation Sequence Number Search Address and Word Search Error Search Execution Program Protection Inch/metric selection –G20-G21 Circular Interpolation – by radius programming Parameter Call Modal Call Pseudo Command Call Scaling Rotation Rotation Copy Model Plan Sub Model Programless Cut Off Program Master Conversion Built In Automatic Programming Z axis Position Management

2 - 22

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KETCHES

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Chapter 3 Installation Process

Overview

Makino EDGE2

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Ram Electrical Discharge Machine

with MGF Control

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Chapter 3

Installation Process Overview

Contents

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1

3.2 The Installation Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2

3.2.1 Customer Installation Duties . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2

3.2.2 FSE Installation and Set-up Duties . . . . . . . . . . . . . . . . . . . .3 - 3

3.2.2.1 Machine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3

3.2.2.2 On-site Trainin

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 5

3.1 Overview

This chapter describes Makino’s installation process and contains guidelines to prepare you for the delivery and installation of the EDGE2. It establishes clear expectations a nd responsibilities for all of us.

The success and ef ficienc y of you r inst allation rest s, in large p art, on you r participation and involvement in the installation process.

Sixty days before the delivery of your Makino machine take time to:

• Review the information and requirements related to pre-installation

• Establish a time-line for completion of these items

Makino’s installation process includes pre-installation duties to be performed by you. These duties are listed in

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Installation Process

chapter 4

and

chapter 5

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03_20ed3a Install Process.fm 3 - 1

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3.2 The Installation Process

Makino developed a thorough process to ensure a consistent and professional installation. This process is designed to provide the maximum benefit from our FSE ( F ie l d Ser vi ce Engineer) for set-up and al i gnment of the machine and proper training of your operator(s). Your participation and assistance are critical to an effective installation.

3.2.1 Customer Installation Duties

Makino asks that you be an active participant in the installation process. Your duties are listed below.

Makino recommends that you:

• Always use your unique RID (Request IDentification) number when contacting us, to encourage clear, efficient communication (with your sales order, Makino assigns a RID to track your machine installation).

• Read the pre-installation information in this Guide.

• Follow the instructions in provided in machining center.

• Complete each task in the Pre-Installatio n Checklist ( expedite the installation and ensure adequate time for training. Proper training during the installation provides the greatest return on your investment.

- Fax or mail your completed Pre-Installation Checklist to Makino.

This checklist is your request for installation services. The FSE reviews the checklist to confirm completion of customer tasks, prior to visiting your facility.

• C o nsider ha ving:

- Maintenance personnel available to the FSE during installation; this

opportunity for exposure to the machine before the covers are on should not be missed.

- Operators and Maintenance personnel (ideally two, maximum of

four people) attend the Operation training.

chapter 4

to prepare for delivery and inst allation of the

and

chapter 5

. Use the worksheets

chapter 4

), to

3 - 2

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3.2.2 FSE Installation and Set-up Duties

The Makino FSE is respo nsible for installi ng the machine a nd training your personnel. The FSE in stalla tion p rocess shou ld be comple ted in five wo rking days.

These duties have a log ical or der an d a bui lt-i n flexib ility al lowi ng the FS E to work around unexpected delays or problems and still complete the installation on time. The following steps may be completed in a different order.

• Some tasks duplicate items you already performed. This confirmation reduces the chance of error or accident.

3.2.2.1 Machine Installation

1. Initial Checks

('*(

- Check the founda tion and placement.

- Check the machine for damage or other unacceptable conditions.

- Confirm cleanliness of machine components (i.e. anti-corrosive

grease is removed). After start up the FSE assists in final cleaning.

- Verify receipt of all accessories.

2. Remove Shipping Locks

- Remove all a xes and other compo nent shipping locks and supports.

You keep all locking and support devices in case the machine needs to be moved.

- Check all motor connections.

3. Power, Air, and Lubrication

- Verify source voltage, transformer connections, and tap settings.

- Confirm air is supplied at the proper pressure and volume.

- Supervise filling of reservoirs with the proper fluids.

4. Machine Set-up

- Verify machine level and correct, if needed.

- Connect peripheral devices (i.e. Oilmatic).

- Install unit anchors, if needed.

03_20ed3a Install Process.fm 3 - 3

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5. Power On

- Ensure the machine is ready for power, BEFORE applying power.

- After applying power, verify phase and confirm voltages are within the allowable range.

6. Checks and Adjustments

- Install any required custom programs.

- Check and confirm proper operation of all machine systems and functions (i.e. overtravel switches, spindle unclamp, etc.).

- Verify operation of CNC (Computer Numeri cal Control) and machine parameters.

7. Finish Installation – Install any remaining covers and accessories.

8. On-site Training – Perform operation training, see

section 3.2.2.2

3 - 4

3.2.2.2 On-site Training

Traini ng is a major compon ent in th e prop er insta llation of any equ ipm ent. Our experience shows that incomplete training can cause:

• Increased down time and avoidable machine damage.

• Increased frustration during the learning curve.

• Reduced utility and return on investment. Makino partnered with local educational groups to develop an on-site

training pac kage to make your operator(s) comfortable, confident, and familiar with machine features and operation. This training is a “hands on, practical application, competency based,” educational model.

Training during set-up is broken into three categories (each training area is discussed below):

•Operator

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• Operator Maintenance

• Options Makino requests the following be considered, regarding on-site training:

• We strongly recommend that both the operator(s) and maintenance personnel are available for this training.

- The job of maintenance is to “fix the machine,” e ven if the problem

is not the “machine” itself. A working knowledge of machine operation and programming are powerful maintenance tools.

• To ensure consistency, have personnel from different shifts available so the material is covered once.

- If scheduling does not allow this, notify the FSE, so the training tim-

ing can be adjusted to accommodate your needs.

Additional Training

Makino strongly recommends:

1. Operators/Pro trainin

2. Maintenance personnel new to CNC or Makino machines and controls attend the appropriate trainin

3. Companies interested in increasin Makino’s formal learnin

classes at Makino.

rammers not familiar with this control model attend the appropriate

classes at Makino.

their capabilities and production should review

opportunities.

03_20ed3a Install Process.fm 3 - 5

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Operator Training

This training is co mpet ency ba sed an d han ds on wit h practi cal applica tion in mind. To e nsu re its usability, all the information covered is cross-referenced to the Operation Guide.

This process requir es machining a test part and involves basic programming, part set-up, pr ogram prove ou t, and operation . With assistance fr om the FSE, the part is developed in steps that reinforce earlier steps, and adds new ones. A final test part is given for the operators to complete by themselves.

The FSE covers:

• Machine Overview

- Major machine componen ts and control and function operat ions are

explained, including checks and PM (Preventive Maintenance).

- Proper procedures for power On and power Off, machine reference,

tool changing, and basic alarm recovery are demonstrated.

- Operation of the control panels and display are explained, demon-

strated, and practiced.

• Job Set-up

- Finding program zero and assigning work coordinate offsets is

practiced.

- Finding and assigning tool offsets is practiced.

- Tool assignment is practiced.

• Control Operation

- All scree ns and functions a re e x plai n ed a nd demonstrated. Al l co m-

mon screens and their operation are practiced.

- Program search, entr y, and editing are explained and practiced.

- MDI (Manual Data Input) operation is explained and performed.

- Program Restart is performed and practiced.

Operator Training

1. This training can be modified, to some extent, to suit the needs of your personnel.

2. Specific questions will be answered on the spot when possible or referred to the appropriate personnel at your distributor or Makino.

3. Althou The FSE can assist in preparin tions, or refer you to an applications en your manufacturin

h FSEs are familiar with programming, they are not programming experts.

programs for training, answer programming ques-

ineer, if needed. The FSE cannot set up

process.

3 - 6

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Operator Maintenance Training

This training is competency based and hands on with practical application in mind. To ensure its usability, all the information covered is cross-refer enced to the appropriate guides.

The FSE covers:

1. Maintenance and Operation manuals for:

- Safety precautions

- Flexible Pendant Box operation

- Machining precautions

- PM (Preventive Maintenance)

2. Parts Manual layout and use are reviewed.

Operator Maintenance Training

1. This training can be modified, to some extent, to suit the needs of your personnel.

2. Questions will be answered on the spot when possible or referred to the appropriate

personnel at your distributor or Makino.

Options Training

Machine options expand capability or provide additional utility , features, or functionality to the basic machine tool. Op tions training is left to the discretion of the FSE. Our experience shows that allowing the operator to become familiar with the basic machining center, prior to learning the options, is beneficial.

Due to the nature of available options, training is provided in different ways:

• Common options are trained at installation if the FSE is familiar with the option and believes your personnel can retain the additional training.

• Special or one of a kind options requiring additional or special training, are scheduled for a later date.

- If you purc hased a special o ptio n, check wi th you r distri butor to see

if special training requirements exist. If so, make these arrangements now.

03_20ed3a Install Process.fm 3 - 7

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KETCHES

3 - 8

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Chapter 4 Pre-Delivery Preparations

Makino EDGE2

Ram Electrical Discharge Machine

with MGF Control

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Chapter 4

Pre-Delivery Preparations

Contents

4.1 Pre-Installation Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1

4.2 Pre-Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4

4.2.1 Checklist Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4

4.2.2 Checklist Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4

4.2.3 Completed Checklist Distribution . . . . . . . . . . . . . . . . . . . . . .4 - 4

4.3 Selectin

4.3.1 Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 7

4.3.2 Manufacturin

4.3.3 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 8

4.3.4 Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9

4.4 Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9

4.5 Formal Trainin

4.5.1 Trainin

the Machine Location. . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 7

Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10

Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 10

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4.1 Pre-Instal l at io n Preparations

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The Pre-Installation worksheet ( preparing for machine delivery and installation. The items checked in the “required” column must be completed for an efficient machine installation.

Use this Guide to accomplish these pre-installation tasks:

• Selecting machine location.

- Access, environm ent, and foundation (

- Dimensional drawings for required floor space and clearances

(

chapter 2

• Providing electrical service, air, water, and drainage requirements, described in

• Unloading, moving, and leveling the machine (

• Preparing work holding devi ces for operator training and production start up (

chapter 2

section 4.4

and detailed in this chapter.

(pg 4-9)

Table 4-1

(pg. 4-2)

) outlines key tasks in

section 4.3

chapter 5

(pg 4-7)

04_20ed3a Pre Delivery Prep.fm 4 - 1

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ABLE

4-1

MACHINE REQUIREMENTS Select machine site Ensure proper foundation Check floor space requirements Check environment Ensure power, air, and water

DELIVERY REQUIREMENTS Provide clearance from truck to

machine location Plan for off loading

Determine rigging requirements Establish installation duties

PRE-INSTALLATION CHECK LIST

ACTION Required

Not

Required

Date

Scheduled

Date

Complete

MACHINING REQUIREMENTS Determine fixturing needs

Identify job and workpieces Identify inspection equipment PERSONNEL REQUIR EMENTS Select Operator(s) Select Programmer(s) and

Maintenance personnel

1. Special foundations or environmental arrangements (if required) have long lead times. Proper does not necessarily mean a special foundation. Normal requirements are described in

2. Environmental concerns related to machine location include temperature, humidity, and cleanliness. See

3. Fixture design and manufacture typically require long lead times.

section 4.3.4

section 4.3.3

4 - 2

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4.2 Pre-Installatio n Ch e ck lis t

The Pre-Installation Checklist (on the following pages) is a customer request for installation services. To help ensure a smooth installation this Checklist allows Makino and your sales representative to know the status of your preparations and provide additional support where needed.

• It is necessary for you to complete or address the items on the Checklist prior to the arrival of the FSE.

In special cases and with prior appro val, completion of all Checklist items is not mandatory; however, it is essential that Makino is informed of the status of your preparations prior to sending the FSE to your facility.

4.2.1 Check lis t Questions

For questions or problems with any of the requirements on the Pre-installation Checklist or to inform us of your current status or a delay:

• Contact your distributor sales or service representative.

• Contact Makino Customer Support. Please provide your RID number to simplify service.

4.2.2 Checklist Instructions

The first page of the Checklist serves as the cove r sheet. This information is required for us to serve you properly.

The Customer Contact is the individual our FSE should request at your facility. This person:

• Should be authorized to sign all installation paperwork.

• Should be available to arrange or coordinate any required assistance.

• Will become the first customer contact of record in our customer service database. Space is provided for additional contacts.

4.2.3 Completed Checklist Distribution

When the Checklist is complete:

4 - 4

• Retain the original for your records.

• Mail or fax a copy to your sales representative.

• Mail or fax a copy to Makino.

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CUSTOMER SUPPORT FAX: 513-459-1825 PRE-INSTALLATION CHECKLIST

TO: Customer Support RE: Customer Request For Installation Services

Request ID_______ ___

FROM:

COMPANY INFORMATION

Company name Phone ( ) - Fax ( ) Customer Contact Title Phone ( ) 2nd Contact Title Phone ( ) 3nd Contact Title Phone ( ) Shipping Address Please complete to confirm the data in our records Street P.O Box Suite # City State

Zip Code Billing Address Complete only if different from Shipping Address Street P.O. Box Suite # City State

Zip Code We will be ready on: Si

nature Date

Fax Cover Sheet Number of pages to follow: 1.

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Pre-Installation Checklist page 2

Request ID number

Machine Model: EDGE2 Control Type:

Please indicate the completion of the following items with a “Y” in the space provided. If there is a question or problem with any item listed below, it should be addressed immediately by contacting your distributor, sales representative, or Makino, installation of the machine.

1. Packing list checked. Check that all parts, manuals, keys, tool kit, schematics, etc., have been received (in addition to immediately contacting Makino, note any discrepancies on a separate sheet and include with this document. Take pictures of any shipping damage).

2. Machine condition checked. The condition of the machine proper and all system components has been inspected for damage or other unacceptable conditions (in addition to immediately contacting Makino, note any discrepancies on a separate sheet, send to the shipper, and include with this document).

3. Machine placed on proper foundation clear of all obstructions and rough leveled.

4. Machine is clean. The machine, components, and accessories are unpacked, inspected, and cleaned (corrosion preventative and dirt removed by wiping with a safe, clean solvent).

5. Power cables are installed. 3-phase 240-480 VAC source voltage has been routed and connected to the main disconnect. time (the FSE will verify proper wiring prior to power up).

6. Air is available. Permanent air lines should be run to the machine vicinity (if uncertain where to route the air line, please ensure that clean and dry air is available for a temporary connection for installation and train ing purpose s) .

before

a Field Service Engineer is scheduled to supervise

WARNING!

MGF

Do NOT apply power to the machine at this

Serial #

Cutting fluid is available. Always use a highly refined oil with a minimum of PAH’s. Do not fill the dielectric tank prior to the FSE’s request.

8. Proper Earth Ground is connected. Earth Ground should be routed via any convenient path and attached to the machine's ground buss, inside the MTC (Machine Tool Cabinet).

9. Maintenance personnel selected and scheduled to assist the FSE with the installation (this is an excellent opportunity for exposure and learning. If required, riggers and millwrights are scheduled or available on short notice).

10. A precision level (0.0005in./ft.) is available for set-up. If not available, contact your distributor or sales representative (this equipment is required for proper periodic maintenance. Makino recommends this equipment be acquired, if not currently owned).

11. 1. A part has been selected, and a part program is written and ready.

2. Proper fixturing is ready.

12. Operators and Maintenance personnel selected and available for training.

4 - 6

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4.3 Selecting the Machine Location

Key factors in selecting the machine location include:

• Access and required floor space.

• Your manufacturin g pr oce ss.

• Work and machine environment.

• Foundation. Proper environment and foundation are of the utmost importance and

more than any other factors, ensure machine accuracy and dependability. Remember to ensure a path from the truck to the machine site that pro-

vides sufficient width, height, and swing clearance to accommodate your machine rigging and moving equipment. Failure to ensure sufficient moving room could result in delays and additional charges.

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4.3.1 Access

The machine placement must have suf ficient room for safe access aroun d the machine and for all cab inet doors an d panels to swing comple tely, see

chapter 2

for machine floor plan and dimensional drawings.

4.3.2 Manufacturing Process

Ideally the machine should be placed closest to the process it supports. This placement reduces handling costs and improves communication between process steps.

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4.3.3 Enviro n m en t

A sub-standard e nvi ron me nt can ca use control, machine, and component failures of all types.

Do NOT locate the machine:

• In direct sunlight.

• Near a source of heat.

• In a place subject to large temperature variation.

• Near a source of severe vibration, which may affect accuracy and alignments.

- If the machine must be located in such an environment, we recom-

mend a separate fo undation with a 2 5mm exp ansion str ip to a bsorb the vibration.

• Near a source of extreme metallic dust, like grinding machines.

The machine location should meet or allow for the following conditions:

• Dust-free, well-lighted, and free of temperature changes

- Ambient temperature – 10 to 35°C, opti mum 20±1°C.

- Temperature fluctuation – less than 1°C/30 minutes.

- R elative humidity – 35 to 75% (no condensation).

• Freely flowing air

• Available floor and bench space for storing raw and finished workpieces, tooling, and inspection equipment

• Enough room for mainten ance w ork. Ad equat e spa ce aro und m achin e and clearance to fully open cabinet doors.

• Adequ ate and proper sized utilities are available: electrical power su pply, clean, dry air supply, and water.

• Drainage for the overflow and tank cleaning drains with provisions for disposal of the used dielectric fluid.

• A foundation fl at and strong en ough to support the weight of the machine without appreciable deflection.

4 - 8

4.3.4 Foundation

To ensure machine accuracy and performance, customers must comply with all installation and foundation requirements. Failure to comply may void the accuracy portion of the warranty. Consistent accuracy can only be foundation that meets the minimum specifications for the machine.

A reinforced, isolated, concrete floor is the best foundation to minimize vibration and defl ection (see and dimensional drawings).

• The concrete pad should be continuous, flat, and strong enough to support the weight of the machine without appreciable deflection.

• Do NOT place machine on s eparate sectio ns of concrete.

As a rule of thumb, the foundation must meet the following specifications:

• Minimum ground resistance of 5 Ton/M

• Minimum foundation thickness of 300mm

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uaranteed on a reinforced concrete

chapter 2

for detail on foundati ons, floorplans,

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• Foundation should extend 300mm beyond the machine base.

• Lev el within 3.2mm/m

If the floor does not meet these specifications, a special foundation is needed to maintain m achine level and alignmen t. If yo u ar e co nside ri n g a special foundation, contact Makino.

When locating the machine on an upper floor of a building, be sure to:

• Consult a structural engineer for load bearing capacity.

• Consult Makino for acceptance or stipulations on this arrangement.

4.4 Fixtures

Fixtures typically require a long lead time. Address this issue before the delivery of the machine tool.

Consider design and manufacturing time, and coordinate completion with the delivery of the machine for a smooth transiti on into your production schedule.

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4.5 Formal Training

In today’s compet itive marketplace it is go od busi n ess to incr ea se pr o ductivity in cost effective ways. Training is one o f th e b est a v en ue s to in cr easing productivity without increasing capacity.

Dollar for dollar your best investment is to properly train your people. Though often overlooked, training is most important after a major investment in new equipment or technology.

To assist our customers in getting the most out of their Makino machines, Makino provides formal classroom training at our facility in Mas on, Ohio.

This is the time to look ahead and determine and schedule your training needs. Some courses provide the best benefit when attended before the arrival of the ma chine, and others after the machine has been in oper ation and the operator or programmer has developed a familiarity with the machine. This information is provided in the prerequisite area of each course description.

Course offerings designed to support our EDM customer’s in:

• RAM Machine Operation and Applications

• WIRE Machine Operation and Applications

• Advanced EDM Applications Seminar We also offer courses to support our Milling machine customers in:

• Basic CNC, Advance d CNC, and Conversational Programming

• Machine Options

• Machine Tool System Maintenance

• Die/Mold Process Training on high-speed machining

4.5.1 Training Schedule

Makino issues a training sched ule througho ut the year. A copy is available from your sales representative, distributor, or from Makino.

• The training schedule includes ALL information necessary for enrolling students, class dates, and information on hotel accommodations.

• In addition, special training can be arranged in most instances.

4 - 10

Contact your distributor for descriptions of the formal training courses related to the EDGE2.

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KETCHES

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KETCHES

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Chapter 5 Machine Delivery

Makino EDGE2

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Ram Electrical Discharge Machine

with MGF Control

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Chapter 5

Machine Delivery

Contents

5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1

5.2 Inspect the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2

5.3 Unloadin

5.3.1 Liftin

5.4 Levelin

5.4.1 Check the Precision Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7

5.4.2 Levelin

5.5 Initial Cleanin

5.6 Air Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11

5.7 Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 13

5.7.1 Connectin

, Lifting, and Moving . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 3

and Moving the Machine . . . . . . . . . . . . . . . . . . . . . . . 5 - 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7

the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 10

Power to the Machine . . . . . . . . . . . . . . . . . . . .5 - 13

5.1 Overview

This chapter describ es how to receive, insp ect, unload, move to site, level, clean, and connect piping and electrical power to the machine.

Performance of these duties:

• Ensures the smoothest and sh ortest installation time.

• Provides maximum training ti me fo r op er at or an d ma i nte na nce pe rso nnel.

Makino’s Installation process includes Pre-Installation duties to be performed by you. These duties are described in this chapter and Makino customers must perform these duties to provide the maximum amount of time for proper machine setup and trainin an effective installation.

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The Installation Process

chapter 4

. Your participation and assistance are critical to

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5.2 Inspect the Machine

Inspection of the machine should begin when the driver removes the tarp and continue throughout the unpacking process.

To minimize the potential effects of shipping damage on your installation, follow these simple procedures.

Before Signing Shipper

1. Inspect the machine and all separate packages and containers for damage.

2. Check each item against the shipper and packing list for shortages.

When Signing Shipper

1. Write on the shipper –

damage.

investment.

2. Sign yo ur name.

Though rarely a factor, this precaution may protect your

Received subject to hidden and concealed

After Signing the Shipper

1. Inspect all items as soon as possible.

- Inspect each item in e very box, crate, and carton.

Damage or Shortage is Found

If damage is discovered after releasing the driver (damage within crates is considered hidden damage):

1. Contact the carrier immediately. A. File a claim with the carrier immediately. B. Leave damaged materi al exa ctl y as fo un d a nd ta ke p ho tographs of

the damage.

5 - 2

2. Contact Makino immediately with your name, company, machine type, and RID (Request IDentification) number.

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5.3 Unloading, Lifting, and Moving

Unloading and moving the machine and its ancillary components to their final site is the customer’s responsibility.

• Makino recommends that professio nal rigg ers unloa d the machine and ancillary components and move them to their final site.

After the initial checks for damage are complete:

1. Unload the machine and ancilla ry components from the truck.

• Use an overhead crane, boom truck, or fork lift of sufficient capacity to lift the machine packing case and ancillary components off the truck.

2. Move the machine and the ancillary components to their location.

• Verify there is adequate clear ance and turni ng room to safely mo ve the machine to its final site or the site where the packing case will be removed.

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• Use an overhead crane, boom truck, or fork lift of sufficient capacity to move the machine packing case and ancillary components.

• Dollie s, or rolling bars of sufficient capacity may also be used.

- If dollies or rolling bars are used, some type of lifting equipment will

be needed at the final site to lift the machine and remove the skid.

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5.3.1 Lifting and Moving the Mach ine

Lifting and Moving Hazard

When lifting or moving the machine:

1. Make sure machine is balanced. Keep the machine level and lift or move

2. Lift no hi

3. Prevent impact with any nearby objects.

4. Do Not remove axis locks or move any axis. Axis locks will be removed by the FSE.

1. Verify the machine moving members - X and Y axes and A TC are securely retained by the yellow or orange painted shipping locks (

A. Y axis shipping lock is

her than needed. Keep all body parts from under the machine.

Figure 5-1

located on the left behind access plate [2].

ently.

B. X axis shipping lock is

located on the back behind access plate [1].

C. ATC shipping lock is

viewed from the front.

2. Attach the lifting fixture to an overhead crane (

Figure 5-2

) and center it over the machine

3. Place the cable loops over the lifting bars, as shown in

Figure 5-2

4. Slowly raise the crane hook

IGURE

5-1

Legend

[1] X Axis Shipping Lock [2] Y Axis Shippin [3] ATC Shippin

SHIPPING LOCKS

Lock

to remove slack in the cables, checking for interference with machine components. Use heavy pads or wood blocks at interference points. .

Rigging Detail

Makino machines are designed to be lifted by overhead crane. The required rigging is shipped with the machine. If usin side (Not the NC side).

a fork lift BE SURE to approach from the machine

5 - 4

5. Lift the machine and move to installation site.

6. Set 300mm blocking under the machine, near each leveling point.

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7. Lower the machine onto blocking and install the NC unit leveling feet into the bottom of the cabinet. Run the leveling feet up to within 5mm of cabinet.

- Leveling feeet and machine leveling pads are shipped in t he accessories crate or attached to the machine pallet.

8. Lilft the machine and remove blocking.

9. Set the machine on the leveling bases.

10.Unhook the cables and move the crane away from the machine.

11. Rough level the machine.

Setting and Leveling Bases

1. When setting the machine, even temporarily, place leveling bases under the machine to prevent castin

2. If machine will sit for lon machine to 0.03mm/m (see

distortion.

er than 12 hours prior to its final setting, rough level the

section 5.4

(pg 5-6)).

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RIGGING AND LIFTING DETAIL

5-2

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5.4 Leveling

Makino builds a highly rigid machine tool, and it’s accuracy depends on machine level. The importance of setting and maintaining proper machine level cannot be over-emphasized.

Rough leveling prevents a twist or other distorti on from setting into the iron. Rough lev el the machi ne and le ave i t sit ov ernigh t to allow the iron to normalize before final leveling.

5.4.1 Check the Precision Level

1. Place the level on a clean fl at surface that is level enough to give a bubble reading that is not “bottomed” in the bezel.

2. Note the reading and rotate the level 180°.

- If the reading is the same as the first (bubble is in the same place, on the same side of the bezel, from your vie wing po sition), the level is accurate and repeatab le .

3. If the reading is different, the level needs calibration.

4. Use the adjustment screws to calibrate and recheck the level.

5 - 6

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5.4.2 Leveling the Machine

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The EDGE2 uses a three point leveling system ( The leveling procedure

described uses one level

1. Loosen the lock nut [1] on each leveling screw [2].

2. Set the level in the X axis plane, note the reading. Move to the Y axis plane, note the reading.

3. Adjust the leveling screws to obtain level.

4. Repeat the X and Y readings and level adjustments until the machine is level within 0.03mm.

5. Tighten the lock nut [1] on each leveling screw [2].

Figure 5-3

6. Run the NC leveling feet [4] down to touch the floor.

7. Double check X and Y axis plane readings.

8. Remove the level from the table.

IGURE

LEVELING POSITIONS

5-3

Legend

[1] Lock Nut [2] Levelin [3] Levelin [4] NC Levelin

Screw Plate

Feet

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5.5 Initial Cleaning

A corrosion preventat ive is applied to the machined and sl iding surfaces of the EDGE2 to prevent oxidation during shipping. This corrosion preventative must be removed prior to operating the machine.

• Use a clean, dry cloth and mineral spirits or another high flash-point, non-toxic solvent to remove the corrosion pr eventative. Clean only those areas of the machine you can reach without moving the axes.

• Wipe the machine surfaces dry with a clean, dry cloth. Do NOT us e an air hose to dry the solvent. Pressurized air drives grit and dirt between bearing surfaces and causes premature wear.

• Lightly coat machined surfaces with way lubricant, to protect against oxidation. Periodic oiling of these surfaces will increase machine life.

The FSE will assist in the final cleaning after machine start up.

5 - 8

5.6 Air Source

Makino considers it the customer’s responsibility to ensure that the air supply to the machine is both clean and dry. Supplied air must NOT exceed 40% relative humidity.

Connect the Air Supply

The air source is connected at the filter/regulator ( the machine.

1. Prepare an 8mm I.D. air supply hose with

2. Connect air supply hose to male inlet cou-

Figure 5-4

a female coupling.

pling.

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Incoming Air Supply

) located on the right rear of

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Setting Standard Air Regulator

Adjust the filter/regulator to obtain an output pressure of 0.6MPa.To set the pressure:

1. Pull up on adjusting cap [1].

2. Rotate adjusting cap [1] (cw to incr ease or ccw to decrease), until pressure gage [3] reads 0.6MPa.

3. Push adjusting ca p [1] down until it seats, locking the adjustment.

Legend

[1] Adjusting Cap [2] Output to Machine [3] Pressure Ga [4] Input to Machine

IGURE

5-4

STANDARD AIR ADJUSTMENT

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Setting Optional Air Booster

Adjust the filter/regulator to obtain an output pressure of

0.6MPa. To set the pressure:

1. Unlock adjusting cap [2] and [4], by pulling up on the knobs.

2. Turn adjusting cab [4], until the outlet pressure gage [5] reads 0.7MPa.

- Rotate adjusting cap cw to increase or ccw to decrease.

3. Turn adjusting caps [2] until pressure gage [1] reads

0.6MPa.

4. Push the adjusting caps down until they seats, locking the adjustment.

Legend

[1] Pressure Gage [2] Adjustin [3] Output to Machine [4] Adjustin [5] Outlet Pressure Ga [6] Input to Machine

Cap

5 - 10

IGURE

BOOSTER AIR ADJUSTMENT

5-5

5.7 Power Source

A 3-phase power source with stable voltage (±10%) must be provided. The EDGE2 runs on 200Vac at 60Hz. A step down transformer accepts incoming power from 480Vac down to 240Vac and regulates v oltage to 200Vac.

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See

chapter 2

for machine power re quirements (kVa ratings and calculat-

ing required service).

5.7.1 Connecting P ower to the Machine

When Making Connections Ensure:

1. The power BUSS or main disconnect is Off, Locked Out, and Tagged.

2. The machine’s Main Power switch is Off.

3. The proper size and type of cable is used (consult your electrical code).

4. The proper

To connect power from the shop power BUSS or disconnect to the machine Main Power switch:

1. Ensure the EDGE2 Main Power switch (CB1) is Off.

2. Ensure the facility power BUSS or disconnect is Off.

3. Perform Lockout/Tagout at the facility power BUSS or disconnect.

round is provided.

4. Ensure proper cable size and type are used (consult electrical code).

5. Ensure proper ground is provided (JIS class 3, 10 Ohm or less).

6. Open the NC door. Main Power switch (CB1) located in middle left.

7. Bring the power cable into NC through a cable inlet in the bottom and route the

IGURE

5-6

MAIN POWER SWITCH COVER

power cable to the top of CB1.

05_20ed3a Machine Delivery.fm 5 - 11

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8. Connect incoming power at the top of CB1, terminals R, S, and T (

Figure 5-7

9. Connect the facility ground wire to earth ground (

5-7

10.C lose the NC doors.

Do NOT Apply Power

Leave the power BUSS or disconnect Off, Locked Out and Ta FSE will confirm connections, incom-

voltage, and the transformer taps.

in Failure to observe this DANGER may result in serious dama injury.

11.Do Not apply power at this time. Leave the power disconnect turned Off, Locked Out, and Tagged until the FSE requests that power be turned On.

Figure

ed. The

e or personal

IGURE

Legend

[1] Ground [2] Main Power Switch

POWER CONNECTION TO

5-7

CB1

5 - 12

makino EDGE2 Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual