XYZ Machine Tools ProtoTRAK KMX CNC Safety And Quick Start Manual
XYZ Machine Tools Ltd.
Woodlands Business Park
Burlescombe, Tiverton, Devon EX16 7LL
T: 01823 674200 F: 01823 674201
www.xyzmachinetools.com
XYZ Machine Tools
Part Number: 17640
Version: 180619
ProtoTRAK® KMX CNC
Safety and Quick Start Guide
Covers all XYZ KMX Turret Mills
Copyright 2019, XYZ Machine Tools Ltd. All rights are reserved. No part of this publication may be reproduced,
stored in a retrieval system, or transmitted, in any form or by any means, mechanical, photocopying, recording or
otherwise, without the prior written permission of XYZ Machine Tools Ltd.
While every effort has been made to include all the information required for the purposes of this guide, XYZ Machine
Tools Ltd. assumes no responsibility for inaccuracies or omission and accepts no liability for damages resulting from
All brand names and products are trademarks or registered trademarks of their respective holders.
the use of the information contained in this guide.
1
Introduction
This guide provides important safety Information and a very brief description of the operation of the
CNC control.
Full safety and operating information is provided in the ProtoTRAK KMX Safety, Programming,
Operating, and Care Manual. Please take time to read and understand this manual before using the
machine. This manual can be downloaded from the support pages of our website
https://www.xyzmachinetools.com/customer-support/downloads-manuals/
Safety
This machine is designed for the machining of cold metal within the stated capacity of the machine
with axes movement occurring by manual use of handwheels or CNC control.
This machine must not be used for machining flammable materials (e.g. magnesium) without
undertaking a risk assessment and incorporating any additional safety measures identified.
It is designed to be used in a standard workshop environment only.
It is the responsibility of the employer, machine owner or controller to ensure that this machine is
installed, operated and maintained in accordance with the Provision and Use of Work Equipment
Regulations (1998) or equivalent local regulations.
In particular, the responsible person must:
1. Undertake a Risk Assessment on the use of this machine, paying particular attention to the
unique characteristics of the Prototrak control system (for example, operating mode selection
and access to the work zone)
2. Generate and apply Safe Operating Procedures for the use of the Prototrak machine
3. Provide any additional training, safeguarding and PPE identified by the risk assessment.
This machine must only be operated by trained and experienced operators.
The following Safety Features must be checked on a regular basis (e.g. at the start of every shift):
1. E-stop
a. In DRO mode, press the E-stop button and ensure that the control flags up critical error
0055 (machine disabled) and that the axes and spindle cannot be started.
2. Table Guard Interlock
a. Start the spindle and then open each door guard in turn. Check that the spindle stops
quickly (less than 3 seconds) and that the spindle brake is on. Check that the spindle
(and powered knee on SLV) cannot be started.
b. With the table guard open, check that the feedrate is limited to 2m/min (78 ipm). The
DRO display will not change and will still show 2540mm/min, so check that the feedrate
drops/increases as you jog the axes and open/close the guard (X axis is the best).
c. Go into DRO mode, open the table guards and then turn off or remove the air supply.
Close the table guards and check the Door open message stays on the screen and that
the spindle cannot be started.
3. Safety Speed Monitoring – If you have manual handwheels, move the table in any mode
other than DRO, RUN or TOOL TABLE. Check for a fault 232 or 233, depending on which
axes was jogging (unintended motion).
4. Guards: Inspect the guards for signs of damage (especially the transparent panels). Replace
if any part of the guard is damaged. Replace the transparent panels in accordance with the
stated schedule, regardless of their apparent condition (see the FAQ on our website for why
this is important).
Notes on the E-stop and Table Guard critical safety functions:
• E-stop:
• This is provided by a safety rated, hard-wired E-stop system controlled by the E-stop
XYZ Machine Tools
ProtoTRAK KMX CNC control, Safety and Quick Start Guide
2
• Air pressure (for the spindle brake and optional air powered drawbar) is NOT released in
• To reset the E-stop, twist to release the E-stop button and then press the blue POWER
• Releasing the E-stop button and pressing the POWER ON button, will always take the
• The hardware E-stop also disables the auto lube pump, so always leave the machine in
• Table Guards:
• With either (or both) of the table guards open, it is not possible to run the spindle or
• If the air pressure to the machine is less than about 50psi, it will not be possible to start
• If pressure is lost whilst the table guards are closed. It will be possible to continue to
button on the pendant. When the machine is E-stopped (button pressed in), the axes,
spindle and other potentially hazardous machine functions are disabled by removal of
power.
E-stop. To remove air pressure; disconnect the air supply at the quick release coupling.
ON button (for about 1 second). When the button is released, the machine will come
out of E-stop.
machine out of the hardware E-stop condition (unless there is a fault with the safety
circuits). However, the machine may still be disabled because of the current machine
mode, or on the results of software safety checks undertaken by the control (e.g. fault
232). This an “NC Not ready” state; and should not be confused with the hardware Estop condition.
this condition if not being used for a while, to avoid emptying the oil tank unnecessarily.
operate the powered knee (SLV model).
the spindle, even with the table guards closed.. This interlock has been provided to
ensure there is sufficient air pressure to stop the spindle quickly when the table guards
are opened.
run the spindle until the guards are opened. Once opened, you will not be able to restart the spindle again, even if the guards are closed.
When operating this machine, always observe the following safety precautions
• Do not operate this machine without knowing the function of every control key, button, knob,
or handle.
• Always wear the appropriate personal protective equipment, including safety glasses and
safety shoes.
• Do not wear loose fitting gloves whilst operating this machine as they could easily get caught
in moving parts.
• Never wear rings, watches, long sleeves, neckties, jewelry, or other loose items when
operating the machine.
• Keep your hair away from moving parts. Wear adequate safety head gear.
• Never operate any machine tool after consuming alcoholic beverages, or taking strong
medications, or while using non-prescription drugs.
• Carry out a COSHH risk assessment and use the correct protection equipment, e.g. barrier
cream/latex gloves, to prevent harm from items such as cutting fluid, lubrication oil and other
substances used on the machine.
• Do not use compressed air to remove swarf or clean the machine. This can damage the
slideway seals and create coolant mist which can be harmful. XYZ recommend the use of
BioConcept cutting fluids which do not present a risk to the respiratory tract.
• Always ensure the appropriate guarding is in place for the machinery operation being
undertaken. Never reach around a guard to gain access to the part, tool, or fixture.
• Observe and understand the warning and safety information labels affixed to this machine.
• Do not attempt to tamper with or override any guarding/safety device fitted to the machine.
• Stop the machine spindle, open the table guards and take the CNC control out of an active
mode (DRO, RUN, TOOL TABLE):
o Before changing tools.
o Before changing parts.
o Before you clear away the Swarf, oil or coolant. Always use a chip scraper or brush.
o Before you make an adjustment to the part, vice, coolant nozzle or take measurements.
XYZ Machine Tools
ProtoTRAK KMX CNC control, Safety and Quick Start Guide
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