smithy 622 Operator Manual

SMITHYCNC 622 BED MILL

OPERATOR’S MANUAL

VERSION 1.1

2008

SmithyCNC 622 BED MILL Operator’s Manual

SmithyCNC (Smithy Co.)

170 Aprill Dr., Ann Arbor, Michigan
USA 48103

Toll Free Hotline: [phone]
Fax: [phone]

International: 734-913-6700
International Fax: [phone]

www.smithycnc.com

Copyright © 2008 SmithyCNC & Smithy Co.

All rights reserved. No part of this manual may be reproduced or transmitted in any form
by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior
written permission of Smithy Co.

For information on getting permission for reprints and excerpts, comments, or suggestions,
contact [e-mail]

While every precaution has been taken in the preparation of this manual, Smithy Co. shall
have any liability to any person or entity with respect to any loss or damage caused or
alleged to be caused directly or indirectly by the instructions contained in this manual or
by the computer software and hardware products described in it. Please see section on
warranty and safety precautions before operating the machine.

Printed and bound in the United States of America

TABLE OF CONTENTS

1 | INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Thank You . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Important Reminder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Suggestions or Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Customer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 | SMITHYCNC SYSTEM WARRANTY . . . . . . . . . . . . . . . . . . . . . . . 3

3 | GENERAL SAFETY GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Symbols Used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Basic Points of Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Clothing & Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety Aspects Related to Tools Work Holding

Safety Aspects Related to Maintenance . . . . . . . . . . . . . . . . . . . 9

Safety Aspects Related to Workpiece . . . . . . . . . . . . . . . . . . . . . 10

Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

. . . . . . . . . . . . . . 8

4 | INSTALLATION & SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Set-up Clearances & Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 11

Power Requirments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Stand Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Moving from Pallet to Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Attaching the Machine to the Stand. . . . . . . . . . . . . . . . . . . . . . . 15

Installing Your Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5 | MECHANICAL COMPONENT IDENTIFICATION

& FUNCTIONS

6 | MECHANICAL MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 21

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Ballscrews & Guidewats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Headstock & Spindle Bearings . . . . . . . . . . . . . . . . . . . . . . . 24

Period Maintenance Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Axis Bearing Adjustments/ Axis Backlash . . . . . . . . . . . . . . 24

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

X-Axis Ballscrew End Bearing Adjustment

& Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Y-Axis Ballscrew End Bearing Adjustment . . . . . . . . . . . . . 25

Z-Axis Ballscrew End Bearing Adjustment . . . . . . . . . . . . . 26

Adjustmet of Gibs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

X-Axis Gibs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Y-Axis Gibs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Z-Axis Gibs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7 | TOOL HOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Tool Holding Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Installing the Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

8 | CNC-622 BED MILL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 31

9 | MACHINE PARTS DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Diagram 1: Z-Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Diagram 2: Column & Junction Box . . . . . . . . . . . . . . . . . . . . . . . 37

Diagram 3: X-Axis Table & Saddle

Diagram 3A: Coolant Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Diagram 4: Y-Axis & Machine Base . . . . . . . . . . . . . . . . . . . . . . . 45

Diagram 5: Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

. . . . . . . . . . . . . . . . . . . . . . . . 41

10 | ELECTRICAL DIAGRAM & PIN OUTS. . . . . . . . . . . . . . . . . . . . . 49

1

INTRODUCTION

THANK YOU FOR YOUR ORDER

Congratulations on your purchase of a SmithyCNC bed mill. With proper setup and
maintenance, your machine should provide many years of quality work and enjoyment.

This manual covers general instructions regarding machine set-up, operation,maintenance
and troubleshooting for SmithyCNC 622 Bed Mills.

IMPORTANT REMINDER

Before operating any SmithyCNC Bed Mill, this instruction manual and any accompanying
instruction manuals must be read carefully
place where they are always easily accessible for reference during the operation of the
machine.

. Instruction manuals should be kept in a safe

While this manual has been compiled to give the general description and usage
of the SmithyCNC 1240 Bed Mills, changes are possible due to continuous design and
development efforts.

Remember safety comes above all else. Carefully, read, follow and understand the safety
information outline in chapter 3 of this manual and always let common sense be your
guide.

SUGGESTIONS OR COMMENTS

e are interested in any suggestions you might have to improve our products and

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services. Feel free to contact us with your suggestions by phone or in writing.

If you have comments about this operator’s manual, or if you have a project you’d like to
share with other SmithyCNC owners, contact the SmithyCNC Company, P.O. Box 1517,
Ann Arbor

, MI 48106-1517. Y

ou can also e-mail [e-mail] 24 hours a day.

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QUESTIONS

If you have questions not covered in the manual, please call our toll-free number:

Our friendly service technicians are available Monday through Friday from 8:00 a.m. to
5:00 p.m. Eastern Standard Time. You can also e-mail your questions 24 hours a day to

[e-mail]. If you are calling from outside the United States, please dial 1-734­913-6700

Don’t forget to check our website periodically, where we will post updates and revisions
to this manual as well troubleshooting techniques and technical advice.

CUSTOMER INFORMATION

Please record the information below about your SmithyCNC Bed Mill. Having this
information readily available will save time if you need to contact Smithy for questions,
service, accessories, or replacement parts.

1-800-476-4849

. You can also fax your questions to 734-913- 6663.

Model number: _____________________________________________

Serial Number: _____________________________________________

chase Date: _____________________________________________

Pur

Deliver

We look forward to a long working relationship with you, and thank you again for putting
your trust in SmithyCNC.

y Date: ______________________________________________

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WARRANTY INFORMATION

SMITHYCNC SYSTEM WARRANTY

30 Day Trial Offer

ry a Smithy for 30 days. If, for any reason within that time, you decide to return your

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Smithy, just call our Customer Service department at 1-800-476-4849. We will help you
arrange shipping back to us. When we receive the machine back, we’ll refund your full
purchase price. Please note: return shipping charges and any shipping damage from
improper repacking is your responsibility.

Smithy Warranty

Smithy 3-in-1 and Dedicated Machines are warranted for two years (unless otherwise
noted)to the original purchaser against defects in materials and workmanship. During that
time, Smithy will replace any defective parts that are returned to our warehouse, free of
charge. Upon receipt of the defective parts, Smithy technicians will arrange with you to
send replacement parts immediately. This warranty does not cover parts that are worn out
through the negligence on the part of the operator nor does it cover consequential
damages resulting from defects in material or workmanship.

SmithyCNC warrants its machines and control systems for a period of one (1) year to the
original purchaser from the date of purchase. If within one (1) year form the date of
purchase a SmithyCNC machine and/or control system fails due to defect in material or
workmanship, SmithyCNC will at their choice repair and/or replace components with new
or remanufactured parts free of charge.

(Some have asked why SmithyCNC machines have a shorter warranty period than Smithy
manual machines. There are several reasons, but the greatest factor is that, on average,
CNC automated machine tools, are operated a significantly greater number of hours
per day than the average manual machine. Also, by comparison, most of our competitors
selling benchtop CNC machines only offer a six (6) months warranty
machine have a full one (1) year warranty

Most warranty repairs and/or replacements are handled routinely, but sometimes request
for warranty service many not be appropriate. This warranty does not apply to defects due
directly or indirectly to misuse, abuse, negligence, accidents, repairs, or lack of routine
maintenance. This warranty is also void if the serial number of the machine or SmithyCNC
control system has been removed or has been altered or modified.

.)

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n no event shall Smithy be liable for indirect, incidental or consequential damages for the

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ale or use of the product. This disclaimer applies to both during and after the term of this

warranty.

We do not warrant or represent that the merchandise complies with the provisions of any
law or acts unless Smithy Company so warrants. In no event shall Smithy's liability under
this warranty exceed the purchase price paid for the product. Legal actions brought
against Smithy Co. shall be tried in the State of Michigan, County of Washtenaw.

Smithy Co. shall in no event be liable for death, injuries to persons or property for
incidental, contingent, special or consequential damages arising from the use of our
products.

This is Smithy Co.’s sole warranty and any and all warranties that may be implied by law,
including any merchantability or fitness, for any particular purpose, are hereby limited to
the duration of this written warranty.

This warranty gives you specific legal rights, and you may also have other rights, which
vary from state to state. Some states do not allow the exclusion or limitation of inciden­tal or consequential damages, so the above limitation or exclusions may not apply to you.

Telephone Support (Service engineers are available 8 am to 5 pm EST):

Service and Parts

Tel No. 1-800-476-4849
Fax No. 1-734-913-6663
Email Address: [e-mail]

Software and Programming Consultancy Services

In addition to our customary technical support for the machines and controls, we also pro
vide technical consulting support to our customers by providing engineering and G-code
programming services. The standard rate for these services is $28.00 per hour. Our princi­pal objective is to support you and to increase your productivity while reducing the
machining cost. Give us a call for such support as and when required.

el No. 1-800-476-4849

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Fax No. 1-734-913-6663
Email Address: [e-mail]

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GENERAL SAFETY GUIDELINES

OVERVIEW

General operational techniques and safety procedures will be outlined in this manual. You
will note, for example, that all rotating parts, wherever feasible, are protected by
specially designed covers and shields. If the machine is operated in accordance with the
manufacturers instructions, it will provide you with reliable service. However, with
machines of this nature, serious accidents may occur due to improper or careless
operation. It is strongly recommended that you read this manual and accompanying
manuals and understand thoroughly the contents of the manuals. Not every example of
improper operation or unauthorized usage which may lead to malfunction or an accident
can be anticipated. If a particular operation is not documented in this manual as an
authorized usage of the equipment, it should be assumed that it is an unauthorized or
improper usage with potential danger and should be avoided or the manufacturer should
be consulted before the actual use.

SAFETY

This machine is provided with various safely devices to protect the operator and the
machine. However, these cannot cover all aspects of safety. Therefore, the operator must
thoroughly read and understand the content of this manual before the machine is turned
on and operated. The operator should also take into consideration these and other aspects
of safety related to his/her particular environmental conditions, materials and tools.

Safety Symbols Used in this Manual

Three categories of safety guidelines have been used throughout this manual. Please take
note of these symbols and understand their meanings.

If this action is not avoided, it will cause permanent harm

DANGER

WARNING

to your health, such as death or serious injury, and it may
also cause permanent damage to your machine.

If this action is not avoided, it can cause potential
harm to your health, resulting serious injury, and has
potential to cause serious harm to your machine.

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Always observe the safety instructions inscribed on the safety nameplate fixed to the
machine.

DO NOT remove or damage these name plates.

DO NOT attempt to operate or turn on the machine until you have read and understood

the manuals supplied with the machine .

BASIC POINTS OF SAFETY

CAUTION

DANGER

I

f this action is not avoided, it may cause potential harm

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o your health, such as minor to moderate injury, and may

also cause moderate harm to your machine.

•There are high voltage terminals on the electrical control panel, motors, junction boxes
and other equipment. DO NOT touch any of these components under any circumstances,
when the power supply is ON.

•Make sure that all safety covers are fitted and electrical boxes are closed and secured
before the power is switched to ON.

•If any components or safety covers are to be removed, first switch off or disconnect the
main plug.

WARNING

•Memorize the position of the EMERGENCY STOP BUTTON on the machine so that you
can press it immediately from any position in case of emergencies.

•

DO NOT touch any of the switches accidently while the machine is in operations.

•

DO NOT touch the tool holder while the machine is running.

•Under no circumstances, should you touch a rotating tool holder or workpiece while the
machine is in operation mode.

•To prevent incorrect operation of the machine, carefully check the position of the
switches before operation.

•If in doubt, consult this manual or a SmithyCNC technician for advise and suggestions.

•Always unplug the main plug when the machine is not in use.

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General Safety Guidelines

•

If more than one person is operating the machine, DO NOT proceed to the next step

w

ithout informing the other operator(s) that you are about to do so.

•DO NOT modify the machine in any way that will affect safety.

CAUTION

•

DO NOT subject the machine,control box, operator panel, or the electrical control panel

to high voltage surge.

•DO NOT change the parameters or electrical setting values without good reason. If it is
becomes necessary to change the parameters or settings, first check with a Smithy
technician to assue that it is safe to do so, then make a note of the original values so that
it can be reset to that value, if necessary.

•

DO NOT paint, soil, damage, modify, or remove any fo the safety nameplate. If the details
become illegible or if the nameplate is lost, obtain a replacement from SmithyCNC and
mount it in the original position.

•

DO NOT remove any safety covers while the machine is in automatic operation mode.

•STOP all machine operations before cleaning the machine or any of the peripheral
equipment. After a job has been completed, set up each part of the machine so that it is
ready to be used for the next series of operations.

CLOTHING & SAFETY

DANGER

•Tie back long hair to prevent entangling with rotary tools.

ear safety equipment whenever possible.

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•Always wear a protective mask when machining Magnesium alloys.

•Never wear loose or baggy clothes.

•

DO NOT operate the machine while under the influence of drugs or alcohol.

DO NOT operate the machine if you suffer from dizziness.

•

•Always use gloves when loading or unloading workpieces or tools and when removing
chips from the work area to protect your hands from sharp chips and burns caused by heat
generated during machining.

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•Close all covers and junction boxes before running the machine.

•Check all electrical cables for damage to prevent electrical shock.

•

DO NOT handle coolant with bare hands to avoid irritation.

•Always use wire rope or slings as per standards, suitable for the load to be supported.

•

DO NOT remove or adjust switches to increase axis travel beyond the machine

specifications.

•DO NOT wipe the workpiece or clear away chips with your hand or with a rag while the
spindle is in operation.

WARNING

CAUTION

•

DO NOT allow chips to accumulate in the work envelope.

•Warm up the spindle and axis motion before running the machine in automatic mode.

•DO NOT operate the keyboard or operation panel switches when wearing gloves.

•DO NOT disconnect the main power cable without switching off the CNC and PC
connections.

SAFETY ASPECTS RELATED TO TOOLS & WORK HOLDING

WARNING

•Always use proper cutting tools and work holding clamps suitable for the work and
within the specifications of the machine.

•

DO NOT stall the machine during cutting due to improper feed and depth of cut suitable

for the workpiece material.

DO NOT operate the spindle above the rated speed of the accessories mounted in it such

•
as tool holders.

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General Safety Guidelines

•

Replace worn tools as soon as they are identified.

•Take care not to place any part of your bocy in the machine pinching areas.

CAUTION

•Make sure that the tool length to diameter ratio is proper to minimize vibration due to
excessive overhang conditions.

•Make sure the drawbar and the tool holders are tightened to the proper cutting conditions
before actual cutting operations.

SAFETY ASPECTS RELATED TO MAINTENANCE

DANGER

• Always disconnect the power to the machine before carrying out any maintenance work.

•After the power has been switched off for a minimum of 60 minutes, check voltage with
a multimeter or equivalent to make sure that there is no residual voltage.

WARNING

•Maintenance of electrical and mechanical components should only be carried out by
individuals with working knowledge of the machine tool.

•

DO NOT remove or modify switches.

•Clean the machine areas after the maintenance is completed.

CAUTION

•

DO NOT use compressed air to clean the machines.

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SAFETY ASPECTS RELATED TO THE WORKPLACE

•Always provide sufficient work space around the machine and peripheral equipment.

•Protect all cables from being damaged by cutting chips.

SAFETY EQUIPMENT

This machine is provided with various mechanical and electiracl safety devices to protect
the operator and the machine. The safety devices include interlock devices and emergency
stop switches. However
familiarizes himself with the instruction manual of the machine before operating the
machine. The manufacturer emphasizes that it is the sole responsibility of the operator to
ensure that all operations using the SmithyCNC bed mill are carried out in completely safe
manner.

WARNING

, it is absolutely recommended and necessary that the operator

Neither the manufacturer nor its representative or dealers can assume responsibility for
any mishaps, damage or personal injury which may occur as a result of improper
operation or from failure to observe the safety precautions mentioned in this manual.

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INSTALLATION & SET-UP

SET-UP CLEARANCES & CONDITIONS

When considering the permanent location for your SmithyCNC bed mill the following
should be taken into consideration:

•The machine should be installed on a flat surface so that the machine does not rock or
slide during operation.

•This location should be considered the machine’s permanent location for your machine.
If you need to move it, remove it from the stand first.

•Make sure your stand is level prior to placing the machine on the stand. Improper
installation and an unleveled machine can cause both numerical error and loss of precision
in your machining operation.

•The maximum temperature of your shop or working environment should not exceed
125 ºF.

•Humidity levels should not exceed 80%.

•Set up the bed mill stand so you have plenty of working space. Leave at least 3 to 4 feet
of clearance on the operating side of the machine. Note the suggested clearances of the
other sides of the machine in table 4.1.

Figure 4.1 Set-up Clearances

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A Dimension B Dimension C Dimension D Dimension

CNC 622 Mill

60 in

1524 mm

Table 4.1 Clearance Dimensions

18 in

457 mm

30 in

762 mm

44 in

1524 mm

POWER REQUIREMENTS

Voltage Amps Amps

CNC 622 Mill 110 15 Single

Table 4-2. Power Requirements

STAND REQUIREMENTS

You will need a stand that is capable of supporting the weight of your machine plus the
maximum allowable workpiece depending on your bed mill. (Please refer to the
specifications chart for the bed mill that you ordered to obtain this specification.) You will
also need to add into this figure additional weight for work holding devices, cutters and
coolant. A good rule is to build a stand that can support 5 to 6 times the weight of the
machine without any appreciable, permanent deformation. The benchtop should be rigid,
level and well-supported. If you purchased one of the optional bed mill stands available
from Smithy, these stands have been designed to support the weight of the specified
machine.

Your work bench should be located in a vibration-free area with a floor that is designed to
support the full weight of the bench, machine, accessories, and materials.

Now that your machine is in place, it is important to properly secure it to your machine
stand. If you purchased a stand from SmithyCNC, the holes in the stand are pre-drilled and
tapped. If you make your own stand, please refer to the bolt pattern following this section.
These instructions assume that you have assembled your stand per the manufacturers
instructions. (The SmithyCNC-622 stand is pre-assembled.) If you purchased the optional
Smithy Stand (Item 80-060) then the holes for mounting your machine are pre-drilled and
tapped. If you are making your own stand use the bolt pattern below.

NOTE: The mounting holes in the base of the machine are 12 mm.

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Installation & Set-up

NOTE: Hole position in
castings can vary +/- 5 mm.
Before fabricating a stand
check these dimensions on
your machine.

NOTE: Bolt hole is M12

Figure 4.2 Bolt Hole Pattern

DANGER

SmithyCNC strongly discourages the use of casters or wheels on metalworking machine stands.
The weight of the machine could result in the stand tipping while being moved. Once the machine
is mounted, consider your work bench to be permanent. If you must move the machine, first
remove it from the bench.

MOVING FROM PALLET TO STAND

Once you have removed the crate per the instructions in the set-up guide. Y
remove the machine from the pallet onto the stand.

There are four bolts securing the machine to the base of the crate, use an adjustable
wrench to remove the nuts located on the machine base. Once the nuts have been
removed, tap the screws through the casting and pallet if they didn’t fall through when
removing the nuts.

ou will need to

If possible, use a forklift to remove the SmithyCNC-622 from the pallet which is the method
that we have elected to use and is the method illustrated below. If a forklift is not available,
we suggest using an engine hoist and chains to remove your bed mill from the pallet.

Step 1: Thread one strap under the machine towards the back and one strap under the
machine near the front of the machine.

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