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 . . . . . . . . . . . . . .	8
	Safety Aspects Related to Maintenance . . . . . . . . . . . . . . . . . . .	9
	Safety Aspects Related to Workpiece . . . . . . . . . . . . . . . . . . . . .	10
	Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
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

	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 . . . . . . . . . . . . . . . . . . . . . . . .	41
	Diagram 3A: Coolant Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	44
	Diagram 4: Y-Axis & Machine Base . . . . . . . . . . . . . . . . . . . . . . .	45
	Diagram 5: Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	47
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. Instruction manuals should be kept in a safe place where they are always easily accessible for reference during the operation of the machine.

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

We are interested in any suggestions you might have to improve our products and 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. You can also e-mail [e-mail] 24 hours a day.

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SmithyCNC 622 Operator’s Manual

QUESTIONS

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

1-800-476-4849

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 1-734- 913-6700. You can also fax your questions to 734-913- 6663.

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.

Model number: _____________________________________________

Serial Number: _____________________________________________

Purchase Date: _____________________________________________

Delivery Date: ______________________________________________

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

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WARRANTY INFORMATION

SMITHYCNC SYSTEM WARRANTY

30 Day Trial Offer

Try a Smithy for 30 days. If, for any reason within that time, you decide to return your 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. Whereas SmithyCNC 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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SmithyCNC 622 Operator’s Manual

In no event shall Smithy be liable for indirect, incidental or consequential damages for the sale 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 provide 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.

Tel No. 1-800-476-4849

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 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 WARNING harm to your health, resulting serious injury, and has

potential to cause serious harm to your machine.

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SmithyCNC 622 Operator’s Manual

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

CAUTION to your health, such as minor to moderate injury, and may also cause moderate harm to your machine.

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

DANGER

•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 without 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.

•Wear safety equipment whenever possible.

•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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SmithyCNC 622 Operator’s Manual

WARNING

•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.

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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SmithyCNC 622 Operator’s Manual

SAFETY ASPECTS RELATED TO THE WORKPLACE

WARNING

•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, it is absolutely recommended and necessary that the operator 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.

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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4

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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SmithyCNC 622 Operator’s Manual

		A Dimension	B Dimension	C Dimension	D Dimension
	CNC 622 Mill	60 in	18 in	30 in	44 in
		1524 mm	457 mm	762 mm	1524 mm
		Table 4.1 Clearance Dimensions

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. You will need to 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.

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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