prodigy GT-27 Maintenance Manual

Prodigy GT-27 Maintenance Manual

Maintenance Manual

Prodigy GT-27 Lathe

Release 04; April, 2007

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Prodigy GT-27 Maintenance Manual

Daily Checklist for Operators

In order to ensure safe operation and longevity of your Prodigy’s components it is critical that the Operator of this machine tool examine the Prodigy prior to power-up. The following items should be addressed:

∙Check the air system for proper lubrication. There are two bowls containing oil that lubricates the air system. The Prodigy’s collet closer will fail prematurely if it dries out! These bowls are to always contain a supply of Mobil DTE Oil Lite or equivalent.

∙Check the air system for proper filtration. (need to add details)See “Preventive Maintenance, Daily” section for details regarding air system lubrication and filtration.

∙Check the coolant tank; verify that sufficient coolant is available.

∙Verify that the floor and work area are clean and free of debris/oil.

∙Verify that the saddle/tool plate is clear of chips or debris. NEVER clean the work area with compressed air!

∙Verify that the two safety switch/magnets are clean and in good operating condition.

∙Verify that the window is in good operating condition.

Caution!

If your Prodigy lathe is newly installed or has sat idle for 30 or more days, the main spindle must be run at slow speeds and then ramp-up to allow the grease within the spindle to be properly distributed to the bearings. Failure to do so increases the risk of premature failure of the spindle.

See the “Spindle” section for details.

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Revision Record

Release	Description	Modified By	Date
01	New Release	M. Rogosienski	09/01/2006
02	Add spindle break-in procedure, add	M. Rogosienski	11/16/2006
	information regarding filtration of
	compressed air
03	Update axis motor parameters	M.Rogosienski	02/15/2007
04	Add axis lubrication procedures	M. Rogosienski	04/12/2007

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Index
Item		Page Number
Daily Checklist for Operators		2
Revision Record		3
Index		4
Introduction		7
Safety Cautions and Safety Switches		7
Lock out/Tag out Procedure		8
Machine Specifications		8
Axes of Motion		9
Dimensional Drawings		10
Installation		12
Electrical Requirements		12
Pneumatic (Compressed Air) Requirements		15
Leveling the machine		15
Spindle “break-in”		15
Fluids and Lubrication		16
Cutting fluids		16
Grease		16
Preventive Maintenance		17
Daily		17
Replacement of air filter; compressed air system		18
Weekly		20
Monthly		23
Annually		24
Safety switches and relay		30
Specifications		30
Replacement of switches/magnets		31
Replacement of relay		34
Wiring Diagram		35
Spindle Motor		36
Specifications		36
Replacement of Motor and Belt		36
Remove Belt		36
Remove Motor		38
Install Motor		40
Install Belt		40
Spindle		41
Specifications		41
Remove Spindle		42
Install Spindle		43
Spindle “Break-In” Procedure		46
Collet Closer		47
Specifications		47
Removal		47

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Remove Draw Tube		48
Install Draw Tube		48
Install Collet Closer		49
Axis Drive System		50
Specifications		50
Belts, Pulleys and Ball Screws		50
X-axis replacement of Belts, Pulleys and Screw		50
Remove X-Axis Belt and Pulley		50
Remove X-Axis Ball Screw		50
Install X-Axis Ball Screw		57
Install X-Axis Belt and Pulley		58
Z-axis replacement of Belts, Pulleys and Screw		59
Remove Z-Axis Belt and Pulley		59
Remove Z-Axis Ball Screw		62
Install Z-Axis Ball Screw		63
Install Z-Axis Belt and Pulley		64
Axis Drive Servo Motors		65
Specifications and Parameters		65
X-Axis replacement		65
Removal		66
Installation		70
Z-Axis replacement		71
Removal		71
Installation		74
Linear Guides		75
Specifications		75
X-Axis Replacement		75
Removal		76
Installation		83
Mount Rails to Tool Plate		85
Mount Tool Plate to Saddle		86
Z-Axis Replacement		87
Removal		87
Installation		91
Mount Rails to Base		91
Mount Saddle to Rails		92
Home Position		95
Re-Setting Home Positions		97
Parameter List		99
Pneumatic System (Compressed Air)		99
Live (Driven) Tools		99
Connecting air to a live tool		100
Coolant System		100
Specifications		100
Pump/Tank Installation		101

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Parameters		101
Accessing/Changing		101/102
Communications options		103
Flash Card Option		103
Parameters		103
Data Transfer		104
RS-232 Option		105
Parameters		105
Cable “pin-out” configuration		106
Data Transfer		106
Alarms		108
Machine Builder Alarm List / Trouble-shooting		109

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Prodigy GT-27 Maintenance Manual

Introduction

The Prodigy GT-27 is a high-speed, precision three-axis C.N.C. lathe manufactured by Somec Corporation in Maitland, Florida; a division of SNK (Shin Nippon Koki) of Osaka, Japan. This manual provides servicing and parts information for the Prodigy. Information contained herein is intended for use by maintenance personnel experienced in the servicing of C.N.C. machine tools and possessing advanced electro-mechanical knowledge. Many of the tasks described in this manual require specialized equipment to complete. We recommend that you verify that you have all that you need on-hand prior to beginning the tasks described in this manual.

Caution! – This symbol is used to call attention to a situation that could adversely affect related systems and/or negatively affect the performance of your machine tool.

Warning! – This symbol is used to call attention to a potentially dangerous situation that could result in serious injury or death.

Safety

Warning! - The Prodigy is a state of the art, automated machine tool capable of moving at very high rates of speed. Always operate the Prodigy with safety in mind and never alter or remove any warning or caution decals. When in close proximity to the Prodigy, always wear proper eye protection. Take time to study and understand the Operators’ Manual, Quick Reference and this Maintenance Manual prior to powering-up your Prodigy lathe.

Machine shops are dangerous environments, always ensure that the Prodigy’s work area is free of obstructions and that the floor surrounding the Prodigy is clean and dry. DO NOT operate the machine if it is in need of repair or service. If you are unsure how to operate the machine, do not attempt to operate it. Careless or uninformed operation of the Prodigy puts the operator at risk of serious or fatal injury

Safety Switches

Warning! The Prodigy lathe is equipped with safety rated switches on the chip hood and sliding door. At no time should these switches be tampered with or circumvented. Both doors must be closed to allow automatic operation. These switches are designed to trigger the following actions if either door is opened or ajar during automatic operation:

∙Motion of all three axes will cease

∙The spindle, when in turning mode, will come to a stop

∙The coolant pump shuts off ceasing the flow of cutting fluids

∙The spindle, when it is in rigid tapping mode will stop; the cycle is still active and will continue when the opened door is closed and “start” is pressed.

∙Live-tool rotation is stopped.

∙During threading, the tool will retract in X-axis and then the spindle will stop.

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Resumption of Automatic Operation

Ensure that both doors are fully closed, then press “start” to resume operation. The previously programmed spindle speed and coolant flow will resume.

LOCK OUTTAG OUT PROCEEDURE:

∙In the event the machine requires repair it is the responsibility of the user to comply with the OSHA requirements for a “Lock-Out/ Tag-Out” Safety System before beginning the repairs.

∙The main disconnect selector switch, located on the left side of the machine on the main electrical panel cover, is equipped with a spring retracted locking tab that is accessed by pulling the ear on the tab outward after selecting the “Off” position. A lock can then be placed through the hole in the tab insuring that the machine cannot be powered up during repairs until a qualified technician removes it.

Specifications

The table below lists the specifications of the Prodigy GT-27 lathe.

Description
Machine Dimensions L x D x H	34” x 34” x 47”	864 x 864 x 1194mm
X Axis Travel (max.)	12”	305mm
Z Axis Travel (max)	6.5”	165mm
C Axis Indexing, Least Increment		.01 Degrees
Axis Drives	Digital with Brushless Motors
Spindle Motor	5hp	3.75KW
Spindle RPM (Variable)		100 to 6,000 rpm
Spindle Bore	1-1/16”	27mm
Spindle Nose		5-C
Maximum Chuck Size	5”	127mm
Tool Plate Center Height	½”	12.7mm
Maximum Programmable Feed-rate	300 ipm	7.6 m/min
Maximum Rapid Travel rate	800 ipm	20.3 m/min
Power Requirement		7.5 KVA
Voltage	200 to 220V +/- 10%
Phase		3
Coolant Pump	1/4hp	0.2KW
Compressed Air (Clean, Dry)		5 SCFM
Machine Weight	3,240 lbs	1470 kg

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Prodigy GT-27 Maintenance Manual

Prodigy’s Programmable Axes of Motion.

The Prodigy is a three-axis C.N.C. machine tool that utilizes industry standards for identifying axis motions. The Prodigy can simultaneously move any axis, any two axes or all three axes in either absolute or incremental mode. Absolute and Incremental moves can be combined in a block together in a part program in any combination desired. The sketch below illustrates the three axes available. X and Z axes are programmed in linear distances, C or H are programmed in Degrees unless using the Polar Milling Function, then C axis moves are also linear distances.

+X or +U

-Z or -W		+Z or +W

-C or -H

-X or -U

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Prodigy GT-27 Dimensional Drawing

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Prodigy GT-27 Dimensional Drawing; Hole pattern on the top of the cast base.

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Prodigy GT-27 Maintenance Manual

Installation

Electrical Requirements

The Prodigy lathe is to be connected to incoming power using four (4) #10 AWG size wires, minimum. The Prodigy requires 220V three phase power. The Prodigy must be installed in compliance with electrical codes pertaining to your geographic area. Consult with local authorities to verify the requirements in effect at the time of your Prodigy’s installation. The Prodigy’s Electrical Requirements are:

Incoming power to be: 200 to 220 V +/- 10%, 50-60Hz, +/- 1Hz. 30 Amp. 7.2KVA Output voltage of the DC power supply to be: 24 to 24.4 Volts DC.

The Prodigy is a precision, computer-controlled automated machine tool. As with all computers, the Prodigy is vulnerable to power-related issues. The Prodigy must be grounded when installed. The Prodigy can be grounded inside the electrical cabinet. The picture below illustrates a Prodigy grounded inside the cabinet. The connection pictured is located directly behind the main circuit breaker.

24Volt DC Power Supply

The Prodigy has a 24 Volt DC power supply that has an adjustment used to compensate for fluctuations in incoming power. If the 24 Volt power supply is outputting less than

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24 Volts an over-current condition may occur that can cause damage to 24 Volt components.

The 24 Volt output must be checked with the Prodigy powered-up.

Warning! Only qualified personnel should perform maintenance or adjustments to this system. Use caution when working inside the electrical cabinet while powered-up! Hazardous voltages are present within the electrical cabinet during this adjustment.

With the Prodigy powered-down, open the electrical cabinet and then power-up the main breaker. Note: After opening the chrome door latch, pull up slightly on the black plastic lever normally used to power-up or down to release a safety catch on the door.

Illustrations and instructions regarding checking and adjusting the 24 Volt DC power supply are located on the next page of this manual.

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Check terminals PO to ON directly at the Power Supply. If a reading lower than 24 Volts DC, then adjust.

Adjust power supply ouput as shown.

Desired range: 24 to 24.4 Volts DC

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Prodigy GT-27 Maintenance Manual

Compressed Air

The Prodigy lathes are equipped with two pneumatic systems. One of them supports the Air Chuck, the other supports Live Tools. The supply of clean, dry air is required to ensure longevity of these systems. Connect incoming air to the input at the far-left of the lower filter/dryer mounted on the Air Box located next to the Electrical Cabinet. Compressed Air System Requirements:

Item	Detail
Air Pressure	58 P.S.I., minimum, 120 P.S.I. maximum
Air Volume	37 gallons per minute
Lubricating Oil	Mobil DTE Oil, Light (1/8 Gallon capacity)
Lube Drip	One drop of oil every minute, minimum
Machine Level

The Prodigy must be leveled during installation. The Prodigy is equipped with threaded adjustments located at the four corners of the machine. The lathe should be leveled to be within .0004” per foot, the drip plate located at the right end of the Prodigy must be positioned a minimum of 8” from the floor to accommodate the coolant tank. After leveling is completed, secure the lock-nuts in place.

Spindle “Break-in”

The Prodigy spindle’s grease must be evenly distributed around the bearings when installed. This is accomplished by running a program used for this purpose at the Factory. See the “Spindle” section for further details.

Caution!

If your Prodigy lathe is newly installed or has sat idle for 30 or more days, the main spindle must be run at slow speeds and then ramp-up to allow the grease within the spindle to be properly distributed to the bearings. Failure to do so increases the risk of premature failure of the spindle.

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Fluids and Lubrication

Air Line Lubrication

The Prodigy uses oil to lubricate the pneumatic systems. The table below documents the recommended oil used for this purpose. The Prodigy is shipped with this oil installed

Manufacturer	Description/Description
Mobil	DTE Oil, Light

Cutting fluids.

The Prodigy is built using seals designed to be chemically resistant. Cutting oils and water-soluble coolants may be used in the Prodigy. The coolant tank capacity is 16.5 gallons; 66 liters.

Greases

The Prodigy lathe uses linear guides and ball-screws to provide motion in the X and Z axes. These systems require the introduction of new grease every 2,000 hours of operation. See the Preventive Maintenance: Annually section of this manual for details. The greases are available from SNK. The table below contains ordering information.

Manufacturer	Description/Description
NSK	Grease for use in linear guides: NSK GRS AS2
NSK	Grease for use in ball screws: NSK GRS LR3

Grease guns designed for the Prodigy are available from the manufacturers. The table below contains ordering information.

Manufacturer	Description/Description
NSK	Grease gun : NSK HGP
MSC	Extension pipe and coupler for greasing L/M Guides: 48527394

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Prodigy GT-27 Maintenance Manual

Preventive Maintenance

The Prodigy, like any machine, requires maintenance to keep it in operable condition. The information in this section addresses preventive maintenance recommended by the factory.

1) Daily Maintenance

Proper daily maintenance will extend the life of your machine tool.

A. Air Supply

Visually check lubrication reservoirs of air lubricator(s) located on the side of the Air Panel which is mounted on the Electrical Cabinet. Adjust as needed to attain 1 to 1.5 drops per minute of oil flow. The pneumatic collet-closer requires constant lubrication. There are two sets of lubricators; one serves the collet closer and the other serves the four M-code controlled air outputs normally used to power pneumatic live tooling.

Warning! Servicing of the air supply systems should be done with the incoming air supply disconnected to prevent injury from escaping compressed air.

Do not fill above this line.

Fill before oil level drops below this line.

Visually check the lubrication system’s moisture separation systems. Left-hand bowls are moisture separators and have drains on the bottoms of them. Replace the filters when they become discolored.

To drain the left hand bowls: Rotate the fitting at the bottom of the bowl counterclockwise to open the drain. Rotate the fitting clockwise to close.

Filters:

The filters are located within the left-hand bowls of the two lubricator systems. These elements remove particulates from the incoming compressed air that can come from air lines or compressors. The filter elements will eventually become saturated with contaminants and turn darker in color. These elements will require periodic replacement to ensure optimum air-flow. The filters can be inspected for discoloration without removing them. The elements are pictured on the following page.

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Changing a Filter

Moisture Separator

Filter Installed

Pull down on spring-loaded latch, rotate bowl 45 degrees counter-clockwise and then pull down to remove bowl

Rotate counter clockwise and remove and then pull down on element to remove.

∙Disconnect the incoming compressed air supply.

∙Using instructions below the pictures, remove the filter element.

∙When installing the replacement filter, use caution to not over-tighten.

∙Replace the bowl; it will “snap” into place when rotated into position.

∙Connect the incoming air supply.

The picture below illustrates the three components of the filter assembly.

Replacement filter information
Manufacturer	Part Number
SMC	AC30-E3104

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B. Coolant supply

Check coolant level. Coolant level should be filled to 1/4 inches below bottom surface of Chip Pan every day. Maintaining proper coolant level reduces the possibility of running the coolant pump dry. Remove chips and debris from the chip pan every day at the beginning of machine use and continuously as coolant flow becomes restricted.

C.Machine Perimeter

∙Prior to machine use, walk around perimeter of the machine and remove any foreign materials.

∙Remove oil and debris from working area and around the entire perimeter of machine.

∙Check Splash Cover safety switch to make sure that it is operating properly. When Splash Cover is raised, feed hold button will turn on. If light does not turn on when door is raised, call your machine dealer for instructions on corrective action.

∙Make sure that all protective guards are in place.

∙Clean windows on Splash Cover.

D.Safety Switches

Remove any chips and/or debris from the door and chip hood safety switches and verify their functioning before beginning automatic operation.

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2) Weekly Maintenance

In addition to the Daily Maintenance items listed above in Section 1, the Prodigy GT-27 requires weekly inspection of the ventilation system of the electrical cabinet.

A. Electrical Cabinet Fan

Inspect the fan for dirt/oily build-up on it and/or the wire mesh guard covering the fan blades. Remove any greasy build-up/debris using a damp cloth. The picture below shows a properly cleaned fan.

B. Air Filter

Inspect the filter for debris/contaminates. If this filter becomes clogged, cooling of the interior components will be less effective.

∙Power-down the lathe if it is powered-up. Warning! Follow the “Lock out/tag out” procedure to avoid potentially fatal exposure to electric current.

∙Open the electrical cabinet.

∙Remove and inspect the filter element for dirt, debris or damage. Replace the filter element if it is damaged.

Air Filter

∙Clean the filter element in soapy water; use no solvents! Allow the filter to airdry.

∙Re-install the filter element.

∙Close the electrical cabinet and power-up to operate.

∙

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C. Coolant Return System

Cutting fluids and chips/debris commonly find their way through the spindle. The Prodigy lathe is equipped with a drip pan located at the end of the spindle that catches the cutting fluids and directs them back into the machine’s working area. A hose delivers the cutting fluids to a cavity in the base casting. If the hose or cavity is blocked by chips, the fluids will back up until the drip pan over-flows. The fluids can then drip into the electrical cabinet. This fluid return system should be inspected at weekly intervals and cleaned out as needed. The pictures below illustrate the cavity and drip pan/hose assembly.

Check here for chip and debris

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Check here for chip and debris. Also, check the hose below.

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3) Monthly Maintenance

Facility maintenance

A.Air Quality

Make sure that compressed air supplied to machine is free of moisture and particulates.

B.Power

Make sure that there is not a large voltage fluctuation in the power supplied to the machine. Voltage should be within the range of 200V to 220V +/-10%.

Warning! Exercise extreme caution when working in the electrical cabinet while the machine is under power. The Prodigy’s 220V system could cause serious or even fatal injury.

Machine Maintenance

C.Coolant Tank

Remove old coolant, chips and debris from Coolant Tank. Clean coolant tank with a degreasing agent to remove oil scum. Flush coolant pump and machine lines with clean water. Remove dirty water from coolant tank. Fill coolant tank with fresh coolant solution. Flush pump and machine lines with fresh coolant solution.

D.Air Lubricator

Check flow of lubricating oil to air supply. Adjust lubricating oil flow to a rate of one drop per minute. Make sure to tighten locking nut to insure consistent flow.

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Prodigy GT-27 Maintenance Manual

4) Annual Maintenance

In addition to the monthly tasks listed above, perform the tasks listed below once each year.

Caution! Do not use compressed air to clean exposed bearing units or other components that would normally be covered with a protective guard. Do not use oil thinning products to remove debris from components that contain precision bearings or that are normally covered by a protective guard. The use of de-greasing substances may cause premature failure of bearings that could void your machine tool’s factory warranty.

1) General

The following pictures were taken with sheet metal removed for clarity. Before removing any covers, remove all chips/debris from tool plate to avoid contaminating guarded components. Follow the instructions below to access the area under the tool plate. Chips and debris can accumulate in this area and should be removed to prevent damage to the X-axis ball screw and ensure unimpeded motion of the X-Axis.

∙Remove X-axis Slide Cover and the Z-axis Linear cover

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∙Remove X-axis Side Slide Cover and Z-axis Flex Cover

∙Remove the front X-axis wiper.

Cap Screws

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Prodigy GT-27 Maintenance Manual

∙Remove the rear X-axis wiper and the X axis Linear Cover. The picture below shows the rear wiper and Linear Cover after removal from the back end of the tool plate.

∙Remove the X-Axis Slide Cover. The picture below illustrates the Slide Cover after removal.

∙Remove all chips and debris from under tool plate and any remaining guards. Entire area under the tool plate must be free of anything that can interfere with, or damage guarded components.

∙While guards are off of the machine, complete annual maintenance on Ball Screws and Linear Motion Guides. If grease is removed from Ball Screws or Linear Motion Guides, these components must have fresh grease reapplied before reinstalling covers.

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Prodigy GT-27 Maintenance Manual

X-Axis Ball Screw Inspection and Cleaning

Use a clean shop towel to remove old grease and dirt/chips. Jog the X axis as required to access a section of ball screw. Remove old grease from the ball screws and surrounding areas. Repeat as needed. The picture below is the X-axis ball screw as viewed from the front of the Prodigy with the front wiper removed.

Z-Axis Ball Screw Inspection and Cleaning

Use a clean shop towel to remove old grease and dirt/chips. Jog the Z axis as required to access a section of ball screw. Remove old grease from the ball screw and surrounding areas. Repeat as needed. The picture below is the Z-axis ball screw as viewed from the end opposite of the spindle

Apply grease.

The Prodigy is equipped with a lubrication distribution system that feeds grease to the ball screws and linear guide/truck assemblies. The picture below shows the lubrication system mounted to the saddle.

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The Prodigy requires two types of greases; one for the ball screws and another for the linear motion guides/trucks. The distribution system is color coded: The two red plastic buttons cover fittings that feed grease to the ball screws. The four blue caps cover fittings that feed grease to the linear guides/trucks. Use the two guns pictured below to apply grease. The guns are labeled designating which one is which. Additionally, the fittings are uniquely designed for each intended gun to minimize confusion.

AS2 grease; linear guides/trucks

LR3 grease; ball screws.

∙Use a slow, even pumping motion when applying the grease

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Prodigy GT-27 Maintenance Manual

Move X and Z axis

Small pockets of air trapped inside the trucks during application of new grease can cause excessive pressure to build up inside the trucks. This can lead to premature failure of components. Before returning the lathe to production status, jog both the X and Z axes to allow the grease to distribute itself along the ball screws. This procedure will also allow the small air pockets to work their way out of the system.

Recommended Grease for Linear Motion Guides and Ball Screws

The greases listed are shipped in a “bellows tube”.

Manufacturer of all items listed: NSK

Description	Part Number
Grease for ball screws	NSK GRS LR3
Grease for linear guides (trucks)	NSK GRS AS2

∙After greasing is completed, replace all previously removed guards, wipers and covers.

X and Z-Axis Belts and Pulleys

It is recommended that the X and Z-Axis drive belts be inspected on an annual basis to maintain maximum repeatability. While changing belts, inspect the pulleys for wear/imbedded debris and chips. If the pulleys show signs of wear, replacement is advised

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Safety Switches and Relay

The Prodigy is equipped with a safety system that is designed to prevent automatic operation if the operator access door or window is opened or ajar.

Specifications

The safety system is comprised of a Gate Monitoring Safety Module (relay) that is mounted inside of the Prodigy’s electrical cabinet. The relay is hard wired to a pair of switches mounted to the chip hood of the Prodigy. The magnets are mounted to moving components that allow access to the machining area. The “door” lifts vertically and the “window” slides horizontally within the door. All of these components are supplied by Banner Engineering Corp.

Re-setting the relay

If either of these access points is not securely closed, the feed-hold button located on the operator’s pendant will be lit. This indicates that Alarm #2031; “feed hold button is pressed” has been triggered. The relay must be reset by opening the door or window far enough to disengage the magnet from the switch and then closing the window or door completely. The feed hold light will go dark when the relay reports safe operating state to the control. Normal operation can then continue.

Replacement of Switches and Magnets

The two pictures below show the switches and magnets mounted in place; the switches are the components with wires connected to them.

Switch and Magnet; Door

Switch and Magnet; Window

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