Page 1
OPTIMUM
MASCHINEN - GERMANY
Rebuilding instruction
Version 1.3.3
Add-on kit CNC lathe
D240/D280
© 2007
GB
30 / 11 / 2007 Page 1 Add-on kit D240/D280 ; Version 1.3.3
Keep for future reference!
Page 2
OPTIMUM
MASCHINEN - GERMANY
Inhaltsverzeichnis
1 Packing list D240/ D280; D240 Vario/ D280 Vario
2 Packing list CNC special rebuilding kit, Z-axis D240/D280
3 Safety warnings (warning notes)
3.1 Classification of hazards......................................................................................................... 7
3.1.1 Glossary of symbols ....................................................................................................7
3.2 Proper use .............................................................................................................................. 8
3.3 Required auxiliary material......................................................................................................8
4 Assembly
4.1 Assembly X-axis...................................................................................................................... 9
4.2 Assembly Z axis.................................................................................................................... 24
5 Wiring of step motors on the machine
5.1 Assembly X- / Z-axis............................................................................................................. 33
5.2 Wiring X- / Y- / Z-axis............................................... ... ..................................... ... ..................33
6 Mounting examples reference switch D240 and D280
7 Appendix
7.1 Copyright............................................................................................................................... 38
7.2 Terminology/Glossary...........................................................................................................38
7.3 Warranty................................................................................................................................ 39
7.4 Disposal................................................................................................................................39
7.5 Product follow-up .................................................................................................................. 40
© 2007
GB
30 / 11 / 2007Page 2 Add-on kit D240/D280 ; Version 1.3.3
Page 3
Packing list D240/ D280; D240 Vario/ D280 Vario
OPTIMUM
MASCHINEN - GERMANY
1 Packing list D240/ D280; D240 Vario/ D280 Vario
Maschinemodell
Machine type
Artikelnummer Komplettpaket
Item No complete package
Netto Gewicht
Net Weight
Brutto Gewicht
Gross Weight
Abmessung (Lx B x H)
Dimensions (L x W x H)
CNC - D240/ D280
357 0240
5,5 kg
6 kg
280 x 220 x 145 mm
Nr.NoBezeichnung
Description
Zahnriemenscheibe für Spindel Z-Achse
Toothed belt disk for shaft Z axis
1
Zahnriemenscheibe für Spindel Z-Achse
Toothed belt disk for shaft Z axis
Zahnriemenscheibe für Motor Z-Achse
2
Toothed belt disk for motor Z axis
Gehäuse für Z-Achse
3
Housing for Z axis
Schrittmotor für Z-Achse
4
Step motor Z axis
Artikelnummer
Item No
359 0221
359 02214
359 0223 CNC-03
359 0225 CNC-06 1
357 3307 CNC-11
Teile Nr.
Part No
D 240
CNC-01
D 280
CNC-01
Grösse
Size
40 Zähne,
HTD-40-3M-15
(40 teeth)
40 Zähne,
HTD-40-3M-15
(40 teeth)
26 Zähne,
HTD-26-3M-15F
(26 teeth)
34H280-01A
4,2 NM
6 A
40 V
Abbildung
Illustration
Stck.
Qty.
1
1
1
1
Abdeckplatte Antrieb Z-Achse
5
Cover plate drive Z axis 0 357 0240 08 CNC-08 1
Zahnriemen für Z-Achse
6
Gear belt for Z axis
3590210 CNC-09
3M-15
225 Zähne
(225 teeths)
© 2007
GB
30 / 11 / 2007 Page 3Packing list D240/ D280; D240 Vario/ D280 Vario Add-on kit D240/D280 ; Version 1.3.3
1
Page 4
OPTIMUM
MASCHINEN - GERMANY
Packing list D240/ D280; D240 Vario/ D280 Vario
Nr.NoBezeichnung
Description
7
Wellendichtring
Rotary shaft seal
Zahnriemenscheibe für Spindel X-Achse
8
Toothed belt disk for shaft X axis
Gehäuse für X-Achse
9
Housing for X axis
Abdeckplatte Antrieb X-Achse
10
Cover plate drive X axis
Artikelnummer
Item No
0 357 0240 10 24x40x7 1
359 0208 CNC-04
359 0224 CNC-05 1
0 357 0240 07 CNC-07 1
Teile Nr.
Part No
Grösse
Size
18 Zähne,
HTD-18-3M-9F
(18 teeth)
Abbildung
Illustration
Stck.
Qty.
1
Spindelverlängerung 1 X-Achse
11
Spindle extension 1, X-axis
Lager für X-Achse
12
Bearing for x axis
Zahnriemenscheibe für Motor X-Achse
13
Toothed belt disk for motor X axis
Zahnriemen für X-Achse
14
Gear belt for X axis
Schrittmotor für X-Achse
15
Step motor X axis
359 0222 CNC-02 1
0 357 0240 11 626-2RS 1
359 0208
359 0228 CNC-10
357 3304 CNC-12
BF 20
CNC-08
18 Zähne,
HTD-18-3M-9
(18 teeth)
3M-9
210 Zähne
(210 teeth)
23H280-01EA
2,2 NM
3 A
40 V
1
1
1
Spindelverlängerung 2 X-Achse
16
Spindle extension 2, X-axis
0 357 0210 13 CNC-13 1
© 2007
GB
30 / 11 / 2007Page 4 Packing list D240/ D280; D240 Vario/ D280 Vario Add-on kit D240/D280 ; Version 1.3.3
Page 5
Packing list D240/ D280; D240 Vario/ D280 Vario
OPTIMUM
MASCHINEN - GERMANY
Nr.NoBezeichnung
Description
Schraube
17
Screw
Schraube
18
Screw
Schraube
19
Screw
Schraube
20
Screw
Schraube
21
Screw
Schraube
22
Screw
Sechskantmutter
23
Hex. Nut
Kabel geschirmt
24
Cable wire protected
Prüfer:
Verified by:
Artikelnummer
Item No
359 0212
Teile Nr.
Part No
GB/T 79 M3 x 5 1
GB/T 70 M3 x 6 2
GB/T 79 M4 x 5 1
GB/T 70 M5 x 12 4
GB/T 70 M5 x 20 4
GB/T 70 M6 x 15 4
Datum:
Grösse
Size
M8 x 1 1
4-conductor x
0,75mm
Abbildung
Illustration
2
Date:
Stck.
Qty.
7m
© 2007
GB
30 / 11 / 2007 Page 5Packing list D240/ D280; D240 Vario/ D280 Vario Add-on kit D240/D280 ; Version 1.3.3
Page 6
OPTIMUM
Packing list CNC special rebuilding kit, Z-axis D240/D280
MASCHINEN - GERMANY
2 Packing list CNC special rebuilding kit, Z-axis D240/D280
Maschinemodell
Machine type
Artikelnummer Komplettpaket
Item No complete package
Netto Gewicht
Net Weight
Brutto Gewicht
Gross Weight
Abmessung (Lx B x H)
Dimensions (L x W x H)
Nr.NoBezeichnung
Description
Zahnriemenscheibe für Spindel Z-Achse
1
Toothed belt disk for shaft Z-Axis
Spindelverlängerung für Z-Achse
2
Spindel extension, Z-Axis
Mutter
3
Nut
CNC - D 240/D280
357 0241
0,3 kg
0,5 kg
140 x 90 x 80 mm
Artikelnummer
Item No
035702411 CNC-14
035702412 CNC-15 1
Teile Nr.
Part No
DIN EN
28675
Grösse
Size
40 Zähne,
HTD-40-3M-15
(40 teeth)
M8 x 1 1
Abbildung
Illustration
Stck.
Qty.
1
Prüfer:
Verified by:
Datum:
Date:
© 2007
GB
30 / 11 / 2007Page 6 Packing list CNC special rebuilding kit, Z-axis D240/D280 Anbausatz D240/D280 ; Version 1.3.3
Page 7
Safety warnings (warning notes)
3 Safety warnings (warning notes)
3.1 Classification of hazards
We classify the safety warnings into various levels. The table below gives an overview of the
classification of symbols (pictograms) and warnings for the specific danger and its (possible)
consequences.
OPTIMUM
MASCHINEN - GERMANY
Pictogram
In the case of specific dangers, we replace the pictogram by
Alarm expres-
sion
DANGER!
WARNING!
CAUTION!
ATTENTION!
INFORMATION
Definition/Consequences
Imminent danger that will cause serious injury or death to
personnel.
Risk: A danger that might cause serious injury or death to
personnel.
Danger or unsafe procedure that might cause injury to
personnel or damage to property.
Situation that could cause damage to the machine and
product and other types of damage.
No risk of injury to personnel.
Application tips and other important or useful information
and notes.
No dangerous or harmful consequences for personnel or
objects.
General danger
with a warning ofinjuries to
hands,
hazardous
electrical voltage,
3.1.1 Glossary of symbols
£ calls on you to act
gives additional indications
enumerations
© 2007
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30 / 11 / 2007 Page 7Safety warnings (warning notes) Add-on kit D240/D280 ; Version 1.3.3
or
rotating parts.
Page 8
OPTIMUM
MASCHINEN - GERMANY
3.2 Proper use
WARNING!
In the event of improper use of the add-on pieces
• will endanger personnel,
• will endanger the machine and other material property of the operator,
• may affect proper operation of the machine.
The add-on pieces as conversion kit are provided for the computer-aided - CNC, Computerised
Numerical Control - milling operations of your machine.
The drive of the step motors may also be performed manually with a control unit (potentiometer).
Safety warnings (warning notes)
Improper
use!
The milling machine with the adapter kit must only be placed and operated in dry and ventilated
rooms.
The handwheels need to be disassembled.
If the adapter kit is used in any way other than described above, modified without the authorisa-
tion of Optimum Maschinen Germany GmbH or operated with different process data, then it is
being used improperly.
We do not take any liability for damages caused by improper use.
We would like to stress that any modifications to the construction, or technical or technological
modifications that have not been authorised by Optimum Maschinen Germany GmbH will also
render the guarantee null and void.
3.3 Required auxiliary material
• Means of shaft lock-down device "Loctite 601, join the shaft"
• The designation of parts in the assembly description corresponds to the numbering of the
packing list.
• In order to degrease the shaft, a cleaner for brakes or a corresponding cleaning agent is
required.
• A tenacious grease e.g. Mobilux 2 or a corresponding lubrication grease serves to grease the
bearings.
• Lubricating oil for threading.
• Required tools: reamers 6 H7; twist drill 5mm, 5,8mm and 6,5mm;
• Countersink; plastic tip hammer; prick punch and scriber;
• A set of Allan keys; fork wrench; screw driver;
• Tongs and stripping tongs; cutter; screw tap M6;
• Manual drilling machine; shifting square; box wrench 13mm; chipping spanner
• Soldering iron; small chisel ; abrasive cloth; metal cutting saw
© 2007
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30 / 11 / 2007Page 8 Safety warnings (warning notes) Add-on kit D240/D280 ; Version 1.3.3
Page 9
Assembly
4 Assembly
CNC conversion kit MK D 24 PD / MK D 28 PD
4.1 Assembly X-axis
WARNING!
Before starting the work disconnect the machine from electrical power supply, only plug
it in upon expressive order if the rebuilding measures have not been termina ted.
£ Open the chuck protection of the
lathe chuck.
OPTIMUM
MASCHINEN - GERMANY
£ Unscrew the safety screw of the
lathe chuck protection.
£ Draw the lathe chuck protection off
the fixture.
Lathe chuck protec-
tion
Illustr.: 4-1: Lathe chuck protection
Safety screw
Illustr.: 4-2: Unscrew lathe chuck protection
Safety screw
Fixture lathe chuck
protection
© 2007
GB
30 / 11 / 2007 Page 9Assembly Add-on kit D240/D280 ; Version 1.3.3
Illustr.: 4-3: Fixture lathe chuck protection
Page 10
OPTIMUM
MASCHINEN - GERMANY
£ Unscrew the 3 fastening screws of
the splashboard on the headstock.
£ Unscrew the 2 fastening screws of
the splashboard of the engine bed.
£ Remove the splashboard of the
lathe in order to easily excess all
parts of the lathe.
Upper fastening
screws
Lower fastening
screws
Illustr.: 4-4: Fixture headstock
Engine bed
Assembly
CAUTION!
Danger by crushing.
The slide is very heavy!
£ Crank the compound slide with the
handwheel to the back.
£ Draw the compound slide backward
out of the guiding device.
Fastening screws
Illustr.: 4-5: Fixture engine bed
Compound slide
Illustr.: 4-6: Remove compound slide
© 2007
GB
30 / 11 / 2007Page 10 Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 11
Assembly
OPTIMUM
MASCHINEN - GERMANY
£ Measure the distance from the edge
of the spindle to the edge of the
lathe slide.
£ The measured distance of +42mm is
the total length of the shaft extension (part 11).
£ Measure the calculated length from the thread of the shaft elongation and cut the part into
lengths with the saw. Please also cut off the corresponding sleeve with the same length as
you have cut off the elongation and glue it onto the elongation with the shaft retention agent.
£ Unscrew the fastening screw of the
handwheel on the compound slide.
Edge spindle
Edge lathe slide
Illustr.: 4-7: Measure spindle distance
Handwheel com-
pound slide
£ Remove the handwheel of the com-
pound slide to the back off the spindle.
Unscrew the screw of
the handwheel
Illustr.: 4-8: Remove the screw of the handwheel
Pull off the hand-
wheel
Illustr.: 4-9: Remove handwheel
© 2007
GB
30 / 11 / 2007 Page 11Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 12
OPTIMUM
MASCHINEN - GERMANY
£ Pull off the feather key from the
spindle with tongs.
£ Pull off the first bearing of the spin-
dle completely.
Assembly
Tongs
Feather keys
Illustr.: 4-10: Remove the feather key
£ Unscrew the 3 fastening screws of
the graduated collar.
£ Pull off the graduated collar fro m the
spindle.
Spindle compound
Fastening screw
Graduated collar of
slide
1st bearing
Illustr.: 4-11: 1st bearing of the spindle
the X axis
Illustr.: 4-12: Pillow block X axis
© 2007
GB
30 / 11 / 2007Page 12 Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 13
Assembly
OPTIMUM
MASCHINEN - GERMANY
£ Pull off the 2nd bearing of the spin-
dle to the back.
Spindle X axis
Bearing of the spindle
Illustr.: 4-13: 2nd bearing of the spindle
£ Remove the spindle of the X axis
(compound slide) from the pillow
block.
£ If the spindle clamps, just turn it a lit-
tle when pulling it off.
£ Remount the fixture of the lathe
chuck protection on the machine.
Pillow block
Spindle X axis
Illustr.: 4-14: Spindle X axis
Fixture of lathe chuck
protection
Fastening screws
Illustr.: 4-15: Fixture lathe chuck protection
© 2007
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30 / 11 / 2007 Page 13Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 14
OPTIMUM
MASCHINEN - GERMANY
£ Assemble the lathe chuck protec-
tion.
Assembly
£ Tense the spindle of the X-axis with
the thread onto the lathe chuck. Do
not tense it too firm as otherwise the
thread might be damaged.
CAUTION!
Make sure that the shaft is running
true, as otherwise the shaft extension might be out of true which
might cause malfunctions.
Lathe chuck protec-
Illustr.: 4-16: Lathe chuck protection
Spindle X-axis
tion
Lathe chuck
Lathe chuck
Illustr.: 4-17: Spindle in lathe chuck
CAUTION!
For the following works the machine may be connected to the power supply.
© 2007
GB
30 / 11 / 2007Page 14 Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 15
Assembly
£ Drill about 15 mm deep into the
spindle with a 5.8 mm drill.
£ Deburr the hole with countersink.
£ Remove the dirt from the hole with
compressed air.
£ Ream the hole in the spindle with a
reamer 6 H7. Use oil as lubricant.
£ When reaming, make sure that the
reamer is being held at right angles.
£ Remove the chips from the reamed
hole with compressed air.
OPTIMUM
MASCHINEN - GERMANY
Lathe chuck
Drill 5,8 mm
Illustr.: 4-18: Hole in the spindle
Reamer 6 H7
Illustr.: 4-19: Reaming of 6H7
£ Check if the longer relief of the shaft
elongation (part 11) fits into the
reamed hole 6 H7.
Spindle X axis
Shaft elongation
Illustr.: 4-20: Check shaft relief
CAUTION!
Disconnect the machine in order that there is zero potential.
© 2007
GB
30 / 11 / 2007 Page 15Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 16
OPTIMUM
MASCHINEN - GERMANY
£ Remove the lathe chuck protection
from the lathe again.
£ Apply shaft retention agent onto the
longer relief of the shaft elongation
(part 11).
Fixture lathe chuck
protection
Fastening screws
Illustr.: 4-21: Disassemble lathe chuck protection
Assembly
£ Insert the shaft elongation (part 11)
into the reamed hole 6 H7 of the
spindle.
CAUTION!
Only reassemble the spindle when
the gluing agent has dried out.
Shaft retention agent
Illustr.: 4-22: Shaft retention agent
Spindle X axis
Shaft elongation
Illustr.: 4-23: Elongate the shaft
© 2007
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30 / 11 / 2007Page 16 Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 17
Assembly
OPTIMUM
MASCHINEN - GERMANY
£ Push the spindle with the glued spin-
dle elongation into guiding device
again.
Spindle X axis
£ Completely push the second bear-
ing on the spindle.
CAUTION!
The bearing needs to be lubricated
again with lubricant for bearings.
Make sure that the bearing is completely free from dirt.
£ Fasten the 3 fastening screws of the
graduated collar.
Guiding device of the
2nd bearing of the
Fastening screws
spindle
Illustr.: 4-24: Push the spindle into the guiding device
Spindle X axis
spindle
Illustr.: 4-25: 2nd bearing of the spindle
Graduated collar
Illustr.: 4-26: Graduated collar
© 2007
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30 / 11 / 2007 Page 17Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 18
OPTIMUM
MASCHINEN - GERMANY
£ Completely push the 1st bearing of
the spindle again.
Assembly
CAUTION!
The bearing needs to be lubricated
again with lubricant for bearings.
Make sure that the bearing is completely free from dirt.
£ Insert the feather key into the spin-
dle again - if required - slightly drive
it in with a hammer.
Spindle X axis
1st bearing of the
spindle
Illustr.: 4-27: 1st bearing of the spindle
Spindle X axis
Feather key
£ Mount the handwheel of the com-
pound slide onto the spindle.
£ Tighten the handwheel on the spin-
dle with the fastening screws.
Illustr.: 4-28: Feather key in the spindle
Handwheel com-
pound slide
Fastening screw
Illustr.: 4-29: Handwheel compound slide
© 2007
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30 / 11 / 2007Page 18 Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 19
Assembly
CAUTION!
Danger by crushing. The compound slide is very heavy!
£ Re-insert the compound slide from
the back into the guiding.
£ Make sure that the guiding is free
from dirt.
Compound slide
£ Crank the slide with the handwheel
into its normal position.
Guides
Illustr.: 4-30: Mount compound slide
£ Push the ball bearing (part 12) into
the housing (part 9).
£ Remove the crest which eventually
had been formed due to the opera-
Ball bearing
tion with an abrasive cloth.
OPTIMUM
MASCHINEN - GERMANY
£ Plug the housing (part 9) from the
backside onto the shaft extension
(part 11).
£ Aline at a rectangle to the engine
bed.
£ Mark out the holes for the fixture of
the housing with a pen.
Housing for X axis
Illustr.: 4-31: Bearing in the housing
Angle
Housing for X axis
Illustr.: 4-32: Apply housing
© 2007
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30 / 11 / 2007 Page 19Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 20
OPTIMUM
MASCHINEN - GERMANY
£ Center the marked out holes with a
center punch.
£ Drill with the 5mm drill, a hole of a
depth of 10mm into the lathe slide.
£ After drilling the hole needs to be
countersinked with a countersink in
order that the thread can be cut.
£ Blow out the holes with air in order
to remove the drill chips.
Assembly
Lathe slide
Center punch
Illustr.: 4-33: Mark the holes with the center punch
Drill 5mm
Spindle extension
£ Cut the thread into the lathe slide
with an M6 screw tap. Use oil for
threading.
£ When threading check the correct
cut of the thread with a 90° angle.
£ Cut thread M6 into the lathe slide.
Lathe slide
Illustr.: 4-34: Drilling for M6
90° angle
Screw tap M6
Illustr.: 4-35: Lathe slide
© 2007
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30 / 11 / 2007Page 20 Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 21
Assembly
£ Screw the nut (part 22) onto the
shaft elongation.
£ Screw the pulley (part 8) onto the
shaft elongation.
£ In order to be able to adjust the axis
distance more easily later on, screw
the nut and the pulley as much
inside as possible.
£ Counter the nut on the shaft elonga-
tion with a fork wrench.
£ To facilitate the countering to can
hold fast the handwheel of the compound slide.
OPTIMUM
MASCHINEN - GERMANY
Spindle elongation
Nut M8x1
Pulley
Illustr.: 4-36: Nut on shaft elongation
Fork wrench
SW 14
£ Measure the distance from the inner
edge of the pulley to the lathe slide.
£ Have the measured distance firmly
set on the calliper gauge.
Pulley
Illustr.: 4-37: Counter nut
Calliper gauge
Pulley
Lathe slide
Illustr.: 4-38: Measure distance
© 2007
GB
30 / 11 / 2007 Page 21Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 22
OPTIMUM
MASCHINEN - GERMANY
£ Place the pulley (part 13) with the
retention agent on the engine and
hold it in the housing (part 9) from
the back side.
£ Adjust the distance between the
edge of the housing and the first collar of the pulley (part 13) according
to the distance which you had determined with the calliper gauge.
£ Tighten the pulley with the hexagon
socket screw (part 18) (M4x5).
Assembly
Pulley
Housing for X axis
Illustr.: 4-39: Pulley on engine
£ Screw the step motor (part 15) with
the 4 screws (part 19) (M5x12) on
the housing (part 9).
Hexagon socket
Fastening screws
screw
Pulley
Illustr.: 4-40: Tighten pulley
Step motor
Illustr.: 4-41: Fasten step motor
© 2007
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30 / 11 / 2007Page 22 Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 23
Assembly
£ Insert the toothed belt (part 14) into
the housing.
£ Insert the cover plate (part 10) in the
housing.
£ Mount the housing with the toothed
belts as illustrated.
OPTIMUM
MASCHINEN - GERMANY
Housing for X axis
Toothed belt
Cover plate
Illustr.: 4-42: Insert parts in the housing
£ Tighten the housing (part 10) with
hexagon socket screws (part 21)
(M6x15).
CAUTION!
When fastening slightly turn the
handwheel of the compound slide.
The turning guarantees that the
housing will be fastened without offsetting the pinion.
Pulley spindle elon-
gation
Housing for X axis
Illustr.: 4-43: Add the housing
Housing X axis
Fastening screw
Illustr.: 4-44: Tighten housing
© 2007
GB
30 / 11 / 2007 Page 23Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 24
OPTIMUM
MASCHINEN - GERMANY
£ Unscrew the handle of the hand-
wheel of the compound slide with a
screw driver.
Assembly
£ The handle needs to be removed for
safety reasons.
CAUTION!
Danger due to rotating parts.
4.2 Assembly Z axis
£ Remove the information sign from
the lathe bed with a small chisel and
a hammer.
Handle compound
Information sign on
slide
Screw driver
Illustr.: 4-45: Unscrew handle
the lathe bed
£ Unscrew the first spindle nut of the Z
axis with a hook wrench.
£ By clamping the apron you can
clamp the spindle of the Z axis. This
facilitates the assembly.
Lathe bed
Illustr.: 4-46: Remove information sign
Spindle nut
Hook wrench
Illustr.: 4-47: Unscrew spindle nut
© 2007
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30 / 11 / 2007Page 24 Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 25
Assembly
£ Grease the shaft sealing ring part 7
with some oil and push it into the
housing of the Z axis (part 3) from
the outside.
£ Some remains may have gathered
in the holes due to the surface treatment of the housing which may
cause that the shaft sealing ring is
difficult to mount. If required regrind
the hole with a fine abrasive cloth.
£ Insert the pulley (part 1) into the
housing. Here some oil should be
applied on the shaft release of the
pulley in order that the sealing lips of
the shaft sealing ring will not be
damaged.
OPTIMUM
MASCHINEN - GERMANY
Shaft sealing ring
Housing Z axis
Illustr.: 4-48: Assemble shaft sealing ring
Pulley
£ Screw the pulley with the fork
wrench onto the spindle in order to
be able to mark out the hole to fix
the housing.
£ Mark out the holes with a pen on the
lathe back.
Housing Z axis
Illustr.: 4-49: Insert pulley
Fork wrench
SW 19
Z axis spindle
Illustr.: 4-50: Assembly on the spindle
© 2007
GB
30 / 11 / 2007 Page 25Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 26
OPTIMUM
MASCHINEN - GERMANY
£ Center punch the marked out hole
for the housing of the Z axis with a
center punch.
£ Disassemble the housing and the
pulley from the spindle of the Z axis.
£ Drill holes 5mm for thread M6 x
10mm deep into the lathe bed.
Counter sink the holes with a counter sink.
£ Cut the thread into the lathe bed
with a screw tap M6.
£ Implicitly use oil for threading.
£ Always make sure that the threads
are cut straight.
Assembly
Lathe bed
Center punch
Housing Z axis
Illustr.: 4-51: Mark out holes
Screw tap M6
£ Remove chips from the holes and
blow them out after threading.
£ Grease the spindle of the Z axis and
then apply the retention agent "join
the shaft".
90° angle
Lathe bed
Illustr.: 4-52: Cut threads
Spindle Z axis
Retention agent
"join the shaft"
Illustr.: 4-53: Prepare spindle
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30 / 11 / 2007Page 26 Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 27
Assembly
£ Push the pulley (part 1) into the
housing (part 3) again and mount it
on the Z-axis.
£ Screw the pulley with a fork wrench
as far to the rear until the end of the
pulley fits closely to the nut of the
spindle.
£ Screw the housing on the lathe bed
with the fixing screws (part 21) (M6 x
15).
OPTIMUM
MASCHINEN - GERMANY
Fork wrench
Housing Z axis
Illustr.: 4-54: Finish mounting of the housing
Housing
£ In some cases it may occur that
after screwing the housing is not
rectangular to the pulley. In such
cases you should put a spacer
between the housing and the lathe
bed in order to have a rectangular
alignment.
Fastening screw
Illustr.: 4-55: Fasten the housing
Rectangular to one
another
Spacer
Illustr.: 4-56: Align the housing
© 2007
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30 / 11 / 2007 Page 27Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 28
OPTIMUM
MASCHINEN - GERMANY
£ Measure the distance between the
outer edge of the pulley and the
edge of the housing. Have the
measured distance set on the calliper gauge.
Assembly
Outside edge of the
pulley
£ Plug the pulley (part 2) with retention
agent on the motor (part 4).
£ Adjust the determined distance on
the motor between the two surfaces.
£ Tighten the pulley (part 2) with the
hexagon socket screw (part 16).
Outside edge of the
Surface of the step
Outside edge pulley
housing
Illustr.: 4-57: Measure distance
motor (part 4)
Illustr.: 4-58: Pulley on the motor
Fastening screw
Pulley
Illustr.: 4-59: Tighten pulley
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30 / 11 / 2007Page 28 Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 29
Assembly
OPTIMUM
MASCHINEN - GERMANY
£ Put the toothed belt (part 6) on the
motor and mount it the housing as
displayed.
Housing Z-axis
Toothed belt (part 6)
Illustr.: 4-60: Put on belt
£ Screw the step motor with the fas-
tening screws (part 20) (M5 x 20) on
the housing.
£ Tighten the cover plate (part 5) with
the 2 fastening screws (part 17) (M3
x 6)
£ When tightening the screws make
sure that the PVC cover is not too
firmly fastened. The PVC cover
might get damaged.
Fastening screw
Step motor
Illustr.: 4-61: Tighten step motor
Step motor
Cover plate
Fastening screw
Illustr.: 4-62: Mount cover plate
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30 / 11 / 2007 Page 29Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 30
OPTIMUM
MASCHINEN - GERMANY
£ Open the terminal box on the spin-
dle head.
CAUTION!
Live parts.
Disconnect the machine.
£ In order to determine the position of
the new holes of the splash board,
apply the splash board in a way that
you can move the lathe saddle in
any direction without touching the
splash board.
Fastening screws
Terminal block on the
spindle head
Illustr.: 4-63: Open terminal block
Holes in the terminal
block
Assembly
£ Remove the old angle brackets on
the splash board and produce new
angle brackets.
Splash board
Illustr.: 4-64: Holes in the terminal block
New angle bracket
Splash board
Illustr.: 4-65: New angle bracket
© 2007
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30 / 11 / 2007Page 30 Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 31
Assembly
£ Screw the splash board with 2
screws on the terminal block.
£ Properly close the terminal block
after screwing the splash board.
£ Screw the splash board with two
screws to the lathe bed.
OPTIMUM
MASCHINEN - GERMANY
Fastening screws
Splash board
Illustr.: 4-66: Assembly splash protection
Splash board
£ Screw the support for the lathe
chuck protection to the spindle head
again.
Fastening screw
Illustr.: 4-67: Assembly splash protection
Support lathe chuck
protection
Fastening screw
Illustr.: 4-68: Support lathe chuck protection
© 2007
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30 / 11 / 2007 Page 31Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 32
OPTIMUM
MASCHINEN - GERMANY
£ Plug the lathe chuck protection to
the support again and tighten it with
the safety screw.
£ Disassemble the handle of the hand-
wheel of the lathe slide.
CAUTION!
Lathe chuck protec-
Illustr.: 4-69: Lathe chuck protection
Handle handwheel
tion
lathe slide
Assembly
Danger due to rotating parts.
Screw driver
Illustr.: 4-70: Disassembly handle
© 2007
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30 / 11 / 2007Page 32 Assembly Add-on kit D240/D280 ; Version 1.3.3
Page 33
Wiring of step motors on the machine
5 Wiring of step motors on the machine
5.1 Assembly X- / Z-axis
5.2 Wiring X- / Y- / Z-axis
£ Open the lid of the step engine with
a cross slot screwdriver.
Screw of the step
engine
Lid of the step engine
OPTIMUM
MASCHINEN - GERMANY
£ Remove the outer isolation of the
cable and make sure that the lower
isolation of the single conductor will
not be endangered.
£ The bare part should have a length
of about 6 cm.
£ Twist the fabric of the shielding.
Illustration: 5-1: Open the lid of the step engine
Outer isolation
Screening
Cut outer isolation
Illustration: 5-2: Remove outer isolation
Screening
Cable
Illustration: 5-3: Twist screening
INFORMATION!
© 2007
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30 / 11 / 2007 Page 33Wiring of step motors on the machine Add-on kit D240/D280 ; Version 1.3.3
The shielding will be connected to the terminal block of the engine on one side.
Page 34
OPTIMUM
MASCHINEN - GERMANY
£ The cables will be peeled off at a length of about 5 mm with insulation stripping tongs.
£ Plug and press wire terminations on the ends of the cable.
£ Plug the strain relief over the cable.
£ Insert the cable through the opening
of the cover plate of the step engine.
£ Connect the cable to the engine and
tighten the strain relief.
£ The twisted screening goes with the
clamping "GND" .
£ Fasten the lid of the step engine with
the cross slot screwdriver.
£ Then cut the cable to the length
which is required to connect it to the
CNC controller.
Wiring of step motors on the machine
Terminal block engine
Screening
Illustration: 5-4: Terminal block of the engine
Lid step engine
Illustration: 5-5: Screw the lid
£ Connect the cable to the CNC controller accordingly.
Motor Controller
A- auf A-
A+ auf A+
B- auf B-
B+ auf B+
GND
Terminal block
CNC Controller
Illustration: 5-6: Terminal block CNC Controller
INFORMATION!
Neither a shielding not an earth cable will be connected to the CNC Controller .
VI
© 2007
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30 / 11 / 2007Page 34 Wiring of step motors on the machine Add-on kit D240/D280 ; Version 1.3.3
Page 35
Wiring of step motors on the machine
INFORMATION!
If the turning direction of one - or several step motors with CNC operation via a CNC
software is being wrong, please exchange the corresponding connection on the step
motor or on the CNC controller.
Example:
Motor Controller
A- to B-
A+ to B+
B- to A-
B+ to A+
GND
OPTIMUM
MASCHINEN - GERMANY
© 2007
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30 / 11 / 2007 Page 35Wiring of step motors on the machine Add-on kit D240/D280 ; Version 1.3.3
Page 36
OPTIMUM
MASCHINEN - GERMANY
Mounting examples reference switch D240 and D280
6 Mounting examples reference switch D240 and D280
X-Achse
Z-Achse
© 2007
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30. November 2007Page 36 Universal mounting kit ; Version 1.3.3
Page 37
Appendix
7 Appendix
7.1 Copyright
© 2007
The documentation is copyright. All derived rights are also reserved, especially those of transla-
tion, re-printing, use of figures, broadcast, reproduction by photo-mechanical or similar means
and recording in data processing systems, neither partial or total.
The company reserves the right to make technical alternations without prior notice.
7.2 Terminology/Glossary
Term Explanation
CNC Computerised Numerical Control
Adapter kit Components
Movement rate Free, smooth mobility of components
OPTIMUM
MASCHINEN - GERMANY
Blow-back proof plastic tip hammer
Disassembly Remove, relieve
Toothed belt disc Disc with gearing to receive the toothed
A plastic tip hammer which is filled with
sand which does not prevent to spring
back when knocking.
belt.
© 2007
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30 / 11 / 2007 Page 38Appendix Add-on kit D240/D280 ; Version 1.3.3
Page 38
OPTIMUM
MASCHINEN - GERMANY
7.3 Warranty
Within the term of warranty, the company Optimum warrants for a perfect quality of its products
and will reimburse any cost for overhaul or exchange of defective parts in case of construction
error, fault in material and/or defect of fabrication.
The term of warranty for commercial use is 12 months and for use as an amateur it is 24
months. Condition for a warranty claim due to construction errors, faults in material and/or
defects of fabrication is:
• Proof of purchase and that the instructions for use had been followed.
In order to assert the claim of warranty, you have to present a typescript original receipt of
purchase. It must comprise the complete address, date of purchase and type designation o f
the product .
The instruction for use the corresponding device as well as the safety informa tion are to be
observed. Damages due to operator‘s mistakes may not be accepted as warranty claims.
• Correct use of the devices.
The products of the company Optimum had been designed and built for certain purposes.
They are listed in the operating manual.
The warranty claim may not be accepted if the operating manual is not being followed properly or if it is used for a purpose which has not been intended or with improper accessory.
• Maintenance work and cleaning.
It is absolutely necessary to maintain and clean the machine in regular intervals according to
the prescriptions of the instruction for use.
By intervention of a third party, any warranty claim will expire. Maintenance work and cleaning are usually not part of the claim of warranty.
• Original spare parts
Make sure to use only original spare parts and original accessory. This can be acquired from
authorised distributors of the machine.
When other than original parts are being used, consequential damages may occur and danger of accidents will increase. Disassembled or partially disassembled devices and devices
which are repaired with foreign parts are excluded from warranty claims.
• Wearing parts
Certain components are subject to wear out by time respectively a standard wear by use on
the corresponding machine.
Among these components are e.g. V-belts, ball bearing s, switches, main cables, gasket s an d
washers, etc. These wearing parts are not part of the wa rranty.
Appendix
7.4 Disposal
Disposal of used electrical and electronic machines
(Applicable in the countries of the European Union and other European countries with a separate collecting system for those devices).
The sign on the product or on its packing indicates that the product must not be handled as
common household waist, but that it needs to be delivered to a central collection point for recycling. Your contribution to the correct disposal of this product will protect the environment and
the health of your fellow men. The environment and the health are endangered by incorrect disposal. Recycling of material will help to reduce the consumption of raw materials. Your District
Office, the municipal waste collection station or the shop where you have bought the product will
inform you about the recycling of this product.
© 2007
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30 / 11 / 2007Page 39 Appendix Anbausatz D240/D280 ; Version 1.3.3
Page 39
Appendix
7.5 Product follow-up
We are required to perform a follow-up service for our products which extends beyond shipme nt.
We would be grateful if you could send us the following information:
• modified settings
• experiences with lathe machines, which could be important for other users
• recurring failures
OPTIMUM
MASCHINEN - GERMANY
Optimum Maschinen Germany GmbH
Dr.-Robert-P fleger-Str. 26
D-96103 Hallstadt
Phone +49 (0) 951 - 96 822 - 0
Fax +49 (0) 951 - 96 822 - 22
E-Mail: info@optimum-maschinen.de
© 2007
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30 / 11 / 2007 Page 40Appendix Add-on kit D240/D280 ; Version 1.3.3
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