TEL STANDARD : +33 5 63 38 34 40

TEL CUSTOMERS SERVICE : +33 5 63 38 54 18

FAX : +33 5 63 54 24.76
E.MAIL : [email protected]
MECANUMERIC S.A. – ZI de Fonlabour – 81000 ALBI – France

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 CONTENTS

Chapter 1 – Safety instructions 5

1.1 BASIC SAFETY INSTRUCTIONS 5

1.2 EQUIPMENTS AND SAFETY PROTECTIONS OF THE STAFF 6
1.3 SECURITY FOR THE USING 6
1.4 SAFETY FOR THE PIECES AND THE TOOLING 7
1.5 SAFETY INSTRUCTIONS FOR CLAMPING AND PROJECTION RISKS 8
1.6 SAFETY FOR THE RISK OF SENDING OUT OF MACHINING
CHIPS AND DUST 8
1.7 SAFETY FOR THE EQUI¨MENT DRIVING 8
1.8 SAFETY FOR THE EQUIPMENT AND ITS ENVIRONMENT 9
1.9 SAFETY INSTRUCTIONS REGARDING THE MAINTENANCE 9
1.10 SAFETY FOR THE WORKING AREA 9
1.11 DESCRIPTION OF SAFETY DEVICES 10
1.12 SITUATION OF THE SAFETY DEVICES 12
1.13 SIGNALISATION SELF-ADHESIVES 13
1.14 DESCRIPTION PLATE 14
1.15 NOISE DECLARATION 15

Chapter 2 - Equipment presentation 16

2.1 CUTTING TABLE AND AXIS 17

2.2 AXIS DEFINITION 17
2.3 FUNCTIONAL UNITS 18
2.3.1 Electric cabinet 18
2.3.2 Multifonction remote control 18
2.3.3 High frequency spindle 18
2.3.4 Spindle cooling unit 18
2.3.5 Cooling with ventilator 18
2.3.6 Air blast cooling 19
2.3.7 Water cooling 19
2.3.8 Cooling liquid 19
2.3.9 Lubrication unit with oil spraying (Option) 19
2.3.10 Static or rotative tool shop (Option) 20
2.3.11 Tool shop protection (Option) 20
2.3.12 Chip suction system (Option) 20
2.3.13 Vacuum plate (Option) 20
2.3.14 Indicator light – Defect 21

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 2.4 PHYSICAL DATAS 22
2.4.1 Measurement and weight 22
2.4.2 Installation constraints 23

Chapter 3 – Equipment Acceptance 27

3.1 SETTING ON SITE 27

3.2 UNPACKING 27
3.3 POSITION OF THE TRANSPORT ANVIL STAKES 27
3.4 UNLOADING 28
3.5 TRUEING OF THE EQUIPMENT 29
3.6 CONNECTIONS 31
3.7 PROTECTION OF THE SITE AND SAFETIES 31

Chapter 4 – Equipment starting up 32

4.1 CHECKING 32
4.2 TENSIONING 33
4.3 PRESENTATION OF REMOTE CONTROL 34
4.4 DISPLAY DESCRIPTION 40
4.5 MENU OF THE SPECIAL FUNCTIONS 43
4.5.1 Different kind of display mode 43
4.5.2 Zero setting on X, Y and Z axis 44
4.5.3 Saving/Recovery 0 XYZ 45
4.5.4 Inside programmes 46
4.5.5 Axis running in 52
4.5.6 Rewind on traject 53
4.5.7 Tool measuring 54
4.6 CONNECTION TO COMPUTER SYSTEM 56
4.7 MACHINE PARAMETER SETTING 57
4.8 MACHINE LANGUAGE 60
4.9 STARTING UP OF THE EQUIPMENT 62

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Chapter 5 – Work preparation 65

5.1 MATERIAL PREPARATION 65

5.2 TOOL PREPARATION 67
5.2.1 Tool choice 67
5.2.2 Determination of the cutting parameters 68
5.2.3 Tool setting 76
5.2.4 Using of the option : Tool and/or material cooling 78
5.3 PREPARATION OF THE TOOL SHOP (option) 79
5.3.1 Type of tool shop 79
5.3.2 Operating mode 82
5.3.3 Precautions and advices 82
5.4 POSITIONING OF ZERO POINT OF A WORK 83
5.4.1 First way to take a starting point of a work in X, in Y, in Z 83
5.4.2 Second way to take a starting point of a work in X, in Y, in Z 84
5.5 SPINDLE WITH ELECTRONIC REGULATING NOZZLE 85
5.6 SPINDLE WITH KCF OPTION (SEMI CUTTING KIT) 85
5.7 STARTING OF THE CUTTING 86
5.7.1 Operating mode 86
5.7.2 Parameter modifications during the cutting 86
5.7.3 Tool breakage during the cutting 87
5.7.4 Cutting end 88
5.7.5 Repetitive startings of the same programme 88
5.8 OTHER FUNCTIONS 89
5.8.1 Using of the “suction nozzle” 89
5.8.2 Using of the option flatness measuring device 89

Chapter 6 – General maintenance of the equipment 90

6.1 DAILY MAINTENANCE 90

6.2 MONTHLY MAINTENANCE 90
6.3 FROM TIME TO TIME 91

Chapter 7 – Electrospindle characteristics 93

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 Chapter 1 – Safety instructions

Safety instructions are of prime necessity for the good running of the machine
and to avoid the corporal injuries. Please respect these instructions.

This section describes the precautions to be taken to guarantee the good running of the
machine under total safety. Do not use the machine before having correctly assimilated these
precautions which must be observed for the running methods and conditions. Of course, some
situations may occur on site which request unexpected running operations and / or conditions.
During the daily working of the machine, the operator will therefore have to pay particular
attention to his own security and he will have to observe the precautions described underneath.

1.1 BASIC SAFETY INSTRUCTIONS

Before the machine runs, read thoroughly the installation and using manual.

WARNING : DANGER

Make sure that all the doors and safety hoods are placed before tensioning the machine. The high
tension electric cabinet, the transformers, the electric motors, the junction boxes, etc. , are equipped
with high tension terminals indicated by the marking of the Jupiter triangle . Never paint,
modify, remove, damage the safety markings, open a door or a safety hood when the machine
tensioned ; never put the CN equipment (Numerical Control), the remote control or the electric
cabinet through important shocks.

Before any handling of your new equipment, identify the location of all emergency stops, and get
used to the remote control and all the buttons of the machine.

When there is an operator change, always think to indicate the situation of the current work and the
potential dangers related.

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1.2 EQUIPMENTS AND SAFETY PROTECTIONS OF THE STAFF

Always wear a safety equipment : earset for noise attenuation, goggles against the risk of chip
and dust projection, anti-perforating gloves (except for the using of the buttons which could
cause a false manœuvre), safety shoes. You must avoid to wear wide clothes and tie up long hair.
Do not use the machine after having taken medicine which could cause sleepiness effects or alcohol.
The using of the machine is forbidden to persons subject to dizziness or faintings.
The opening of the covers or protection bellows can cause serious corporal injuries during the
running of the machine in automatic or in manual. A tool or a piece in rotation must never be
touched with hands or with anything else.

1.3 SECURITY FOR THE USING

Always use origin parts for the change of any defective component

Before the equipment using, close the doors and covers of the CN equipment, of the electric cabinet
and of the distributing boxes on the machine to prevent damages caused by water, chips or dust.
Check that the electric wires are not damaged in order to avoid an accident due to current leaks or an
electrocution.
Regularly check the state of the safety covers. Repair or immediately replace all the covers and
safety parts which have been damaged by origin pieces.
Never make any adjustment during the running of the machine.
During the loading of the pieces on the machine or the product unloading, make sure that the tool is
located as far as possible from the working area and that it does not rotate any more.
Take the suitable measures against any fire risk in case you are using inflamable materials or fluids.
Touching or disadjusting the safety devices such as thrust blocks, the origin sensors of the machine
or the locking devices of the CN equipment in order to increase the axial travel would compromise
the running of the machine as well as its guarantee.
We attract your attention on the risks of dameges related to the use of the equipment during
storms. Any damages generated in this situation will not be taken into guarantee.
Before any using of the machine, preheat the spindle as well as all the axis mechanisms. Check that
the machine or the electrospindle do not make any abnormal noises.
Chips gathering around the tool could warm up and cause a fire. The operator will have to prevent
this kind of situation by checking that all suction device are maintained and run correctly.
The using of inflamable materials to lubricate the tool is not recommended at all. If by any chance
you cannot avoid this using, it is necessary to take all the necessary precautions. In case of a fire, the
user would bear the sole responsability.

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1.4 SAFETY FOR THE PIECES AND THE TOOLING

Always use the tool suitable for the work to be done and which is in conformity with the
characteristics of the machine. It is important to always respect the restrictions stipulated in
the specifications regarding the weight and the maximum diameter of the tool as indicated in
Chapter 5.
For an equipment with automatic tool changer, it is imperious to check the total height (cone +
tool) do not present a height difference over 1 cm when mounting the tools on the tool holder
cones. This is to allow the tool protector suction nozzle to fill in its function of chip and dust
suction, confining of varied projections and protection of the operator.

The longest tool must not be longer than the brush of the suction nozzle as shown on the
drawing hereunder.

This adjustment is entirely under the operator responsibility.

Quickly replace the worn tools which may cause accidents or deteriorations.
Make sure that the piece is solidly fixed and that it cannot be torn out through the cutting efforts
generated during the machining.
Whatever is the tool changing system, check that the tool is well tightened in the tool holder
(Spindle with tool change.).

Check that the tools do not collide with the clampings or others, that the material to be machined is
completely flattened against the table and that it is not warped.

It is important that the tools are correctly stored in the tool shop in accordance with the cutting
software parameters.

Never leave cones in the spindle when the machine is stopped in order to avoid any binding risk.
It is important to check regularly the cleanness of the tool holder cones in order to prevent any
abnormal vibration that may generate an abnormal wear of the spindle bearings. They must have no
chip or dust on.

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1.5 SAFETY INSTRUCTIONS FOR CLAMPING AND PROJECTION
RISKS

Your equipment has a grooved table to clamp mechanically the material plates to be cut. The
system of mechanical clamping is a safety device to be used even if your equipment has a
vacuum table.

The plates have to be fixed with the mechanical clamps delivered with the machine. The vacuum
table (if your machine has this option) has to be considered as a help to the perfect fixation of the
plate to be machined on the table (absorption of deformations), it also reduces the vibrations during
the machining to have a better machining quality.
As far as the pieces are concerned, as soon sa the machining is not finished, the piece is linked to the
plate by the non machined part. When the machining on the piece is over, the tool is not any more in
contact with the piece.
In those conditions, the risk of piece projection is limited.
Besides, the suction nozzle in low position confine the projections inside the nozzle.
It is also possible for the operator to plan micro-links between the piece and the plate.

1.6 SAFETY FOR THE RISK OF SENDING OUT OF MACHINING

CHIP AND DUST

Your machine has a tool protector suction nozzle, this system is a safety element.

The chip suction device has always to be running while machining. Before sending a work, you have
to check that the inside part of the suction nozzle is clean. You have imperiously to do this operation
without tool in the spindle.
You have also to make sure that your chip and dust suction device is not plugged. Regularly clean
the filters and empty the tank if there is one.

For your safety, the automatic tool ptrotector suction nozzle is always locked in low position. The
spindle can rotate only if the nozzle is in this low position.
In case of suction nozzle with manual adjustment, the adjustment of the nozzle height compared to
the piece to be cut is under the operator responsibility (refer to 1.4). The height, which guarantee an
optimal safety, must not exceed 1 cm between the piece to be cut and the lower part of the suction
nozzle.

1.7 SAFETY FOR THE EQUIPMENT DRIVING

Before taking any action to put in service a function of your equipment, make sure that
nobody is close to a part of the equipment that can move.
To drive your equipmetn with 2 operators at the same time (for example one at the command and
one realising a task on the machine) is completely forbidden, as reminded by signs on the
equipment.

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1.8 SAFETY FOR THE EQUIPMETN AND ITS ENVIRONMENT
While machining, the equipment has to be all the time under the control of an operator
trained to its using or to react in case of emergency situation.

1.9 SAFETY INSTRUCTIONS REGARDING THE MAINTENANCE

For any maintenance intervention, follow instructions detailed in Chapter VI.

Always proceed to a general power cut and lock the disconnecting switch with a padlock before
realizing any maintenance operation. This will prevent the machine from being tensioned by mistake
or by somebody else.
To proceed to a general power cut of the machine, you have to :
First press on the red button « 0 »
Turn the disconnecting switch on the position « 0FF »
Padlock the disconnecting switch to avoid an untimely re-tensioning.
Cut off the circuit breaker upper the machine.
The maintenance works on the electric or mechanical units must be realized only by qualified staff
trained at the machine delivery or able to follow the maintenance instructions detailed in
Chapter VI.

Nota : If you open the doors of the electric cabinet, the power supply is not automatically cut off.
Any intervention in the electric cabinet requires a general power cut off of the machine.

1.10 SAFETY FOR THE WORKING AREA

Wipe up any liquid spread on the floor, avoid any thing which could cause a false movement or a
fall.
Keep the combustible materials far away from the working area and from the chip projections.
Check that the working space is big enough and free to easily reach the machine, check that the
lighting of the working area is sufficient without prejudicing the visibility of the indicator lights and
the display.

Always clean the tools, store them away after using and sort them out to machine the same material.
Never put a thing on the gantry and on the Z axis, which could make it fall down or could cause the
deterioration of the machine.

The power supply cable at the front of the junction circuit breaker of the machine must have a
sufficient section compared to the maximum consumption of the equipment.
All the cables must be equipped with a mechanical protection.

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1.11 DESCRIPTION OF SAFETY DEVICES

This machine is equipped with various safety devices in order to protect the operator and the
machine. The safety equipments include the emergency stop buttons (Red on yellow background) as
well as the anti-shock protections with sensitive safety edge on the gantry (Option).

If these safety devices are put « out of order », this could cause
a serious corporal accident.

Never invalidate their functions.

N° Designation Functions
Enables the insulation of the machine from the electric
General network.
1 disconnecting
switch Does not allow to directly cut off the power. You must
first press onto the red button (0).
The machine is fitted out with emergency stops equipped
with safety vizors in order to avoid any acccidental
leaning in a normal operating situation. They are
generally located at every machine end as well as on the
2 Emergency stops gantry.

If an emergency stop is operated, the axis moving and the

spindle are stopped, independently from the operating
mode (Automatic or manual).
The protections with safety buffers which can be
delivered in option allow to protect the operator against
3 Safetypads the gantry movings.

To stop the machine, just press onto a safetypad.

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 Important

The machine is equipped with two signal indicators located on the head :

Spindle in rotation
This green indicator light allows to visualize the spindle state.
Indicator light is off : Spindle stopped.
Indicator light is on : Spindle in rotation.

This red indicator light allows to indicate an irregular running of the machine to the
operator. The defect can be more precisely located according to the state of the relays which
are in the electric cabinet.

This defect can be of different natures :

- Lack of compressed air comprimé (pressure inferior to 4 bars) (according to the spindle)
- Lack of cooling liquid (according to the spindle)
- Defect on the axis variators
- Defect on the spindle variator
- Excessive temperature of the spindle

When the defect occurs, the machine finishes the block being machined and switches over to
the manual mode. The spindle stops and the message "Machine defect" appears on the
display screen of the multifunctions remote control.

To go back to the work in progress, the operator must locate the problem and correct it.
Press onto the key The message « Machine defect » will disappear.
Then, press onto the key (Auto/Manu), the machine will resume the work exactly where it
stopped.

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 1.12 SITUATION OF THE SAFETY DEVICES

4 2

1
2

N° Designation
1 General disconnecting switch
2 Emergency stops
3 Safety pads
4 Signal indicator lights

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1.13 SIGNALISATION SELF-ADHESIVES

On the machine and in the electric cabinet, self-adhesives for explanations and warnings are located
at the suitable places. They are intended for informations which must be absolutely respected in
order to guarantee the operator safety during the running of the machine.

These self-adhesives must not be painted, stained, damaged, modified or removed.

WARNING : Electric
danger

WARNING :
Danger : Tool in rotation

WARNING :
Protection goggles and anti
noise hearset are compulsory

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1.14 DESCRIPTION PLATE

The machine is equipped with a metal description plate located on the frame - left side at the back of
the machine - (See fig. Situation of the description plate).

Indications on the plate :

- Type of machine
- Serial number
- Manufacturing date
- Electric and pneumatic consumptions

Description plate :

IMPORTANT
Please give us the precise serial number of the machine
in any correspondence with MECANUMERIC.

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1.15 NOISE DECLARATION

The noise generated by the equipment is measured according to the following conditions :

- The noise sensor is located near the operator in regular situation of waiting, that is
horizontally at 1.50 m and vertically at 1.60 m, in front of the command position of the
equipment.
- The spindle is in rotation at 12000 rpm, equipped with a cylinder tool of 10 mm diameter
and a length out of collet of 50 mm.
- The suction nozzle is down in working position
- The vacuum table is on with all pumps running
- The chip suction device is on and at minimum 10 m from the measuring point
- The machine is in machining cycle up in the air (no real machining) and moves on 2 axis

In those conditions, the noise level is under 83 dBA* at the measuring point and in our
premises.

* NB : Noise measuring in dBA = the measure is done on a frequency range from 500 Hz to
10 000 Hz, which is representative of human ears.

We recommend the operator to wear individual protection equipment insuring a reducing higher
than 20 dB at 1000 Hz.

“The given values are issuing levels and not necessarily levels allowing to work in security.
Although it exists correlations between the issuing levels and the exposing levels, those can
be used as a base to define if additional precautions are necessary. The parameters which
influence the real level of exposing include :
- machining conditions (clamping, tool, worked materials, cutting parameters)
- worlshop features
- other noise sources, etc…, that is the number of machines and manufacturing procedure
around.
Besides, the admissible exposing levels can be different from a country to another. However,
this information allows the machine operator to better evaluate the risks.”

Wearing individual protection equipments adapted is highly recommended.

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 Chapter 2 - Equipment presentation
The machine is equipped with the following main units :

3
7
10
9 8
11
1 5
2

N° Designation N° Designation
1 Cutting table 7 Lubrication unit (Option)
Suction nozzle coaxial to the spindle with
2 Gantry 8
watering system (Option)
Tool shop with measuring unit of the tool
3 Head 9
length (Option)
Selection valves of the vacuum table
4 Electric cabinet 10
(Option)
5 High frequency spindle 11 Vacuum table
6 Spindle cooling unit

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2.1 CUTTING TABLE AND AXIS

The strong base, made out of high inertia welded steel, bears a sliding gantry on tempered and
rectified slides.
Four Brushless servomotors allow to drive the machine. This characteristic allows to suppress the
main sources of the motor wear (Brush) and therefore to increase the life time. A position encoder
integrated to each servomotor allows to precisely determine its position.

X1 and X2 axis
The gantry moves to the front part (X-) and to the back part of the machine (X+), driven from both
sides together by the servomotor/ballscrews.
The double motorization allows to keep the Y axis quite perpendicular to the X axis in order to
obtain a good cutting quality.

Y axis
The head moves to the left (Y+) and to the right (Y-), driven together by the servomotor/ballscrews.

Z axis
The head moves upwards (Z+) and downwards (Z-), driven together by the servomotor/ballscrews.

A periodic maintenance (cleaning, lubrications, etc.) must be made.

See section Maintenance.

2.2 AXIS DEFINITION

In the manuals delivered together with the machine, the axis moving is defined as described
hereunder.

REMARK :
The axis moving is defined when the operator is standing in front of the machine.

The gantry travels forwards and backwards

X Axis Positive direction (+) : The gantry travels backwards

Negative direction (-) : The gantry travels forwards

The head travels towards the left and toward the right

Y Axis. Positive direction (+) : The head travels toward the left

Negative direction (-) : The head travels toward the right

The spindle travels upwards and downwards

Z Axis Positive direction (+) : The spindle travels upwards

Negative direction (-) : The spindle travels downwards

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2.3 FUNCTIONAL UNITS

2.3.1 Electric cabinet

The electric cabinet regroups the electric and electronic parts in the style of numerical control, speed
variators, interface cards, etc.
Calories generated by the elements of the electric cabinet are extracted through side holes of the
cabinet.
It is absolutely necessary not to obstruct these holes, this could cause irreversible damages.

2.3.2 Multifonction remote control

The remote control regroups all the command functions of the machine, the spindle, the manual
travelling on the three axis, the special functions, etc.
It is equipped with a display screen to visualize the coordinates, the linear speed of the axis, the
rotation speed of the spindle and the error messages in case of anomaly.
Always put the remote control back onto its support located at the front part of the electric cabinet
when it is not used.

2.3.3 High frequency spindle

The high frequency electrospindle is a asynchronous motor with variable speed thanks to a
frequency electronic variator located in the electric cabinet.
According to the spindle, the tool change can be done manually (clamping keys delivered with the
machine) or automatically (tool shop with automatic change).

A green light located on the head enables to visualize the state of

the spindle. When the light is on, the spindle rotates

2.3.4 Spindle cooling unit

There are several processes according to the spindle to dissipate the heat generated by the spindle.

2.3.5 Cooling with ventilator

A ventilator located on the top of the spindle allows to permanently temper the external casing of t
he spindle.

2.3.6 Air blast cooling

This process consists in sending dry and deoiled air by pressure directly inside the spindle in a
circuit provided for that purpose. The warmed-up air is extracted through a discharge nozzle located
on the spindle.

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2.3.7 Water cooling
Cooling liquid or air circulate around the electrospindle casing in order to limit the temperature
increase of the spindle. A tank with the cooling liquid is located under the machine table and is
equipped with a pump which allows to create a closed circuit between the spindle and the tank. This
one can be cooled down by natural convection or by a cooling unnit according to the spindle power.
The strongly built construction together with the spindle power enable the cutting in the main
materials used in the industry (Plexiglas, aluminium, wood, brass, etc.).

A periodic maintenance must be made in order to avoid any untimely

ageing of the spindle. See « maintenance » section.

2.3.8 Cooling liquid

A cooling liquid tank located under the table of the machine is equipped with a pump which allows
to create a closed circuit between the spindle and the tank. The latter can be cooled by a natural
convection or by a refrigerating group according to the spindle power.

2.3.9 Lubrication unit with OIL spraying (Option)

Like all milling machines, the MECAPRO can be equipped with a
lubrication system of the tool with oil spraying.
As a matter of fact, if you add a lubricant, while cutting in resistant
materials, this will allow to save time in the machining, the wear
will appear less rapidly, the tool will warm up less quickly and you
will get a higher cutting quality.
This system works according to the Venturi principle (Suction through vacuum). It includes a
lubrication tank set off on the gantry and a flexible hose allows to canalize the spray from the tank to
the watering nozzle (Watering system).
To have this unit runs, the spindle must have reached its ordered speed. As soon as this condition is
realized, you just have to press onto the remote control key.
The lubricant and compressed air flow can be modified thanks to the manual valves located on the
hood of the lubrication tank (See « STEIDLE « manufacturer’s documentation ).

2.3.10 Static or rotative tool shop (Option)

This unit is made of a 6 tool shop with automatic tool change as well as a measurement system of
the tool length (Measurement unit of the tool length).
The tool measurement device is equipped with a micro blowing device which allows to clean the
surface of the tool measurement device. This process allows to take off all the chips which would
remain on the surface of the tool measurement device and could cause a wrong tool measurement.
This unit allows to release the operator time and to maintain a good diving precision on the Z axis.

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2.3.11 Tool shop protection (Option)

The tool shop can be equipped with a protection hood of the present
tools.
This system allows to avoid that the tools are wrongly taken by the
spindle beacuse of chips which could be laid on the cones.
A push button located on the right side, on the electric cabinet, for
the static tool changer and on the plate of the rotative tool changer
allows to open and close the protection hood in manual mode.

2.3.12 Chip suction system (Option)

The MECAPRO machine can be equipped with a chip suction
system which includes two subassemblies :
- A suction nozzle coaxial to the spindle with automatic or manual
up / down according to the type of spindle. In the case of the
automatic model, pressing on the remote ocntrol key allows in the
manual mode to let the suction nozzle go up or go down in order
to reach the collet of the spindle or in the automatic mode with
the software.

- An industrial suction cleaner external to the machine with chip

recovery tank, filter and cleaning system of the filter.
The key on the remote control allows to activate / deactivate this
unit in the manual mode and with the software in the automatic
mode.

2.3.13 Vacuum plate (Option)

The machine can be equipped with a vacuum plate system allowing
to obtain a clamping help for the pieces to be machined.
This plate is divided into 11 or 22 areas (according to the option)
which can be selected by manual rotating valves (¼).
The suction plate can be efficient only if the area is covered at 90%
of its surface. It is recommended to add a mechanical clamping to
avoid a moving of the material during the machining.
The plate is constituted of aluminium laths which allow to clamp
the plates to be cut with angle bevels or with classic clamps thanks
to its T slots. Each aluminium lath is covered by a glued base plate
in expanded PVC.
A program in the numerical control allows to surface the « consumable » plate to get rid of the
asperities (See section « Plate surfacing »).

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Do not obstruct the rear part of the machine, this allows to extract the warm air coming out of the
suction pumps of the plate.
Excessive temperatures under the machine could damage the pumps.

The efficiency of this vacuum plate regarding the clamping depends therefore on
the covered surface per area, on the cleanliness of the plate, on the material to be
machined and on the cutting effort and on the state of the consumable plate.

2.3.14 Indicator light - Defect

This red indicator light allows to show the operator an irregular

running of the machine. The defect can be more precisely located
according to the state of the identified relays « KA » which are in
the electric cabinet

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2.4 PHYSICAL DATAS

2.4.1 Measurement and weight

Summary chart of the overall dimensions and weights - MECAPRO 3015

Length : 4200 mm
Width without rotative tool changer : 2400 mm
Width with rotative tool changer : 2600 mm
Maximum height : 2300 mm
Weight in basic version : 3500 kg
Weight with all options : 3750kg

Summary chart of the overall dimensions and weights - MECAPRO 3020

Length : 4200 mm
Weight in basic version : 2500 mm
Width with rotative tool changer : mm
Maximum height : 2300 mm
Weight in basic version : kg
Weight with all options : 4350kg

Summary chart of the overall dimensions and weight - MECAPRO 4020

Length : 5750 mm
Weight in basic version : 2500 mm
Width with rotative tool changer : mm
Maximum height : 2300 mm
Weight in basic version : kg
Weight with all options : 5000kg

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2.4.2 Installation constraints

MECANUMERIC would not bear any responsability if the unpacking and the installation of the
machine were made by non qualified staff.
Before starting the installation, please read section A. "SAFETY INSTRUCTIONS" and make sure
that you understood the informations indicated in this section.

The floor must be completely dry and free from oil spots to prevent operators from slipping or
falling during the transport and the installation of the machine, during the electric installation, during
the machine adjustments or any other operation.
The staff must wear a safety equipment (helmet, safety shoes, etc.) and clothes suitable for the work
to be carried out.

Use metal cables or slings which can bear the weight to be lifted and check their good state.
Devices to help for the hoisting, such as metal cables and slings must be put at the places planned
for that purpose, and the hoisting angle must be correct.
The travelling of the machine till its definitive location must be completely free in order to facilitate
its passage.
The place planned for the machine must be completely free and big enough to facilitate the loading
or the unloading of the materials to be cut.

Prepare an electric power supply source corresponding to section II.2.3.

"Setting on site. / Electric connection" as well as an air source corresponding to "Setting on site. /
Pneumatic connection".

During the adjustment operations of the machine, check that all safety devices are correctly working.

Version 22/07/03 23

Requirements regarding the environment of the machine

Premises
Avoid to install the machine in following places :
- Under direct exposure to the sun, near a heat source or excessive temperature variations.
- At places where humidity is excessively high.
- At dusty places.
- Near devices generating vibrations.
- At places where the floor is not solid enough to bear the weight of the machine.

Ambient tempeature
Temperature range accepted during the using of the machine : +5 to +40 °C.(The average
temperature during a period of time superior to 24 hours must not exceed 35°C)

Humidity
Accepted relative humidity rate :
- Less than 90 % for an ambient temperature of 20 °C.
- Less than 50 % for an ambient temperature of 40 °C.

Remark: The humidity increase reduces the insulation and accelerates the deterioration
of the electric components. Although it is not necessary to take special precautions
regarding dehumidification, you must avoid to install the machine in places with high
humidity concentration.

Atmosphere
Avoid to install the machine in dusty places or under high concentration of organic or corrosive
gases. Therefore, should the machine run in such an environment, please consult Mécanuméric to
take the suitable measures.

Fundamental requirements
Requirements to keep the machine precision
The machine must be installed on a stable floor and avoid the proximity with devices generating
vibrations.

Requirements regarding the conditioned air

Ambient temperature : 20°C ± 2°C
Temperature variation : 1°C / 30 min or inferior
Relative humidity : 75 % or inferior
Dusts and other foreign bodies : 0.3 mg / m³ or inferior

Version 22/07/03 24

Supply and evacuation constraints

Requirements regarding the electric power supply

To connect the power supply cable to the machine, an earth connection of grade D (former grade
3*) or higher is requested.

Earth connection of grade D :

The resistance of the earth connection is inferior or equal to 3 Ω.
15 m of cable adapted to the machine are supplied with the machine. If this cable is too short, use
cable conductors with a section superior or equal to the supplied cable :
Supplied cable : Three phases + earth
Reference HO7 RN-F of 4 G 2.5 to 4G 4 mm²

Install a circuit breaker with leak current to the earth (differential circuit breaker) defined for the
machine at the front part in the electric cabinet of the workshop.
Characteristics of the differential circuit breaker : Nominal tripping current 300 mA

The section of the cable of the earth connection must be similar or superior to
the section of the other power supply conductors

Caliber superior to the maximum intensity absorbed by the machine (Value indicated on the
description plate).
The machine has an equipment driven by tension and frequency converters. This appliance is
equipped with filters with strong leak currents to the earth. For that reason, it is strongly
recommended NOT to use a differential circuit breaker with a nominal tripping current of 30 mA
because this could cause a defect running of the machine.

Important : The following values are also indicated on the identification plate. In case of a
difference between the values given in the manual and those indicated on the description plate, you
will have to take into account only the values indicated on the description plate.

400 VAC threephase+

Tension of the supply source :
earth
Admitted fluctuation : ± 10 %
Network frequency : 50 Hz
Admitted fluctuation : ±1%
Maximum absorbed intensity : From 9 to 32 A per phase
Maximum absorbed power : 6000 to 22000 W

Remark : These values correspond to the consumption of the machine and of all elements
delivered with the machine.

Version 22/07/03 25
Requirements regarding the pneumatic supply source

The power supply source in compressed air must be in conformity with the pressure and the flow
recommended by Mécanuméric at the machine inlet.

The compressed air which supplies the machine, must be dried and deoiled in order to eliminate all
the water and oil particules.

If these two recommendations are not respected, the command parts and the equipment operating
with air could be severely damaged.

5 m of pneumatic flexible are delivered together with the machine.

Important : The following values are also indicated on the identification plate. In case of a
difference between the values of the manual and those of the description plate, you will have to
consider only the values indicated on the description plate.

Type of pneumatic power supply : Dry and deoiled air

Pressure at the machine inlet : 7 bars
Consumed flow : 15 to 60 m³ / hour

Remark : These values correspond to the machine consumption and all the
elements delivered with the machine.

Requirements regarding the evacuations :

Recovery of the lubrication liquid

Important : It is necessary to recover the lubrication liquid in order to avoid that it does not run on
certain parts of the machine (Electric gutter, suction plate pumps, etc.).
Two nozzles allow to recover the lubrication liquid, see picture : "Situation of the fluid inlet".
Use a flexible hose of 21 mm diameter.

It is absolutely forbidden to use again the lubrication liquid ; chips could damage
the lubrication system

Version 22/07/03 26
 Chapter 3 – Equipment Acceptance

WARNING
All the feet of the machine must be lifted and
put on the floor at the same time

3.1 SETTING ON SITE

Vital surfaces and constraints

Choice of the positioning area :

The working area must allow the loading and the unloading of the materials to be cut without any
difficulty for the operator.
The lighting must be sufficient, about 300 lux at one meter from the floor.
You must check that the lighting does not prejudice the legibility of the indicator lights and the
Display screens.
The premises must allow the access to the maintenance and keeping up material (You must provide
plugs near at hand).

3.2 UNPACKING

When the machine has been definitively installed on site, you can unpack it. Cut the plastic film
with a cutting blade while avoiding the following areas :

Cable path
Electric cables or pneumatic flexibles
Protection bellows
Chip suction hose
Protections with safety pads

Take off the cardboard protections at the corners of the machine.

Take off the wooden clamping block located between the spindle and the table.

3.3 POSITION OF THE TRANSPORT ANVIL STAKES

During the transportation, the units of the machine are maintained through two anvil stakes so that
they will not move during the transportation. Please refer to the picture underneath. Position of the
anvil stakes.
Once the machine is installed, take off the anvil stakes. Keep them with the bolts in a suitable place
so that you will be able to use them again during a further moving of the machine or during a further
transportation of the machine.

Version 22/07/03 27
3.4 UNLOADING
Procedure to follow up :

Dismount the anvil stakes of the gantry

Blocking anvil stakes

of the gantry

Position of the anvil stakes on the machine

Version 22/07/03 28
3.5 TRUEING OF THE EQUIPMENT

Due to the transport, to the unloading and the temperature variations, the machine geometry can
change more or less. For that reason the machine must be trued after any moving (Unloading,
moving till the positioning area, moving to a new premises, etc.). This will ensure its optimum
cutting precision.

Operating mode :

- Check that the 6 adjustable feet of the

machine are present and not damaged.
- Use a machinist mete stick and make
sure that it has been recently calibrated
CONTRE ECROU
(Precision of 0,5 mm/m)
- Let the mete stick slide on the whole
length of the guidance rails on the X axis
and the Y axis to check the horizontality ECROU DU PIED
of the machine, see picture "Positioning
of the level.on the machine ".
- Unscrew the counter nuts. See picture
underneath.
- Turn the screw of the foot in order to Adjustment : foot of the
true the machine. machine
- Screw again the counter nuts.

Positioning of the level on the machine on the X axis

Left rail of the X axis

Version 22/07/03 29
Positioning of the level on the machine on the Y axis

Rail of the Y axis

Version 22/07/03 30
3.6 CONNECTIONS

Electric
This operation must be realized by a qualified electrician. The electrician must take the precautions
relative to an intervention under tension

Important
Do not connect the power supply cable to the electric switch board in the
workshop as long as the installation of the machine is not completely finished

Make sure that the differential circuit breaker, in the electric cabinet in the workshop, associated to
the ligne of the machine is out of orderest hors service.
Make sure that the general sectionneur général of the machine is on the position 0FF.
Relier the power supply cable provided with the machine to the suitable disjoncteur in the electric
cabinet in the workshop, taking into account the section I.2"Requirements regarding the electric
power supply".
Connect the plug of the chip suction device to the cabinet (Option).
Plug in the plug of the remote control to the cabinet.

Pneumatic
For machines equipped with a general stop valve, make sure that it is closed.
Connect the pneumatic supply flexible delivered together with the machine to the compressed air
network (Dry and deoiled air) taking into account the section. "Requirements regarding the
pneumatic supply".
Connect the plug to the pneumatic network.

Evacuations
Check that the chip suction hose is well tied up and that it can follow all the movements of the
machine (Suction nose, gantry) and connect it to the chip suction device.
Connect the flexible hoses (Diameter 21) for the recovery of the lubrication liquid, to a reception
tank, see section "Requirements regarding the evacuations".

3.7 PROTECTION OF THE SITE AND SAFETIES

The machine must be installed on a perfectly limited and closed location

This location must have a selective entrance in order to ensure the
maximum protection of the operator.

Version 22/07/03 31
 Chapter 4 – Equipment starting up

4.1 CHECKING

Electric
Check the presence of the correct voltage, of the earth plug, and the neutral if necessary.
Control the presence and the caliber of the differential protection upstream.
Make sure of the correct cable section at the front of the machine
See that the protections through safety pads have not been damaged during the transport or the
unpacking as well as the emergency stops.

Mechanical
Make sure that the fastening anvil stakes of the machine units have been removed.
Close all the protection bellows
Make sure that the wooden blocking cale located between the spindle and the table have been
removed.
Control that no element encroaches on the volume of the machine.

Pneumatic
Check visually that the flexible hoses for the pneumatic supply have not been cut off or deteriorated
during the transport.
Open the general stop valve.
Make sure that the pressure indicated by the manometer filter does correspond to the pressure
indicated on the description plate and, if necessary, adjust it thanks to the blue adjustment valve
(Situated on the top of the manometer filter.)

Security
Check all the emergency stop buttons and make sure that none of them has been engaged or
deteriorated during the transport or the unpacking.
If an emergency stop has been operated, turn the red button clockwise in order to set it to its initial
position.
Make sure that the protections through safety pads have not been damaged during the transport or
the unpacking.

Version 22/07/03 32
4.2 TENSIONING

Operating mode
Chech that all the hoisting devices and the delivery accessories (Anvil stakes, blocking pieces,
etc....) have been removed.
Make sure that no piece or accessory are missing.
For the machines equipped with water cooled spindles, check the level of the cooling liquid in the
tank.

Procedure for the machine starting

STEP ACTION EFFECT
1 Turn the general disconnecting switch Tensioning of the driving box (Defect indicator light and
onto position "1". display are lighted).
The display screen indicates the procedure to follow :
"Press onto 1 then onto RAZ".
2 Press onto the green push button "1" The green indicator lights up.
(Just beneath the general disconnecting The defect indicator light switches off
switch). Tensioning of the whole power part of the machine.

3 Press onto the RAZ key The axis move till their origin machine setting (P.O.M).

Possible anomalies and corrections

Symptom Probable cause Measures to be taken
The multifonction General power supply
remdote control oes not Check the general power supply
switch on

Remote control cable Check that the cable of the remote control is
connected to the electric cabinet
Current 24 Volt not present
See if the ventilators in the cabinet are running.
Check the fuse 24Volts
The green button "ON" Emergency stop operated.
does not switch on. Check that all the emergency stops are released.

Safety pads are engaged

Check that a safety pad is not compressed

Current 24 Volt not present

See if the ventilators in the cabinet are running.
Check the fuse 24Volts
The error message Machine defect Check through the relays (KA) in the electric
"Machine defect" cabinet the defect causing the message.
appears following the Suppress the defect.
origin machine setting (See maintenance section)
and the red light on the
head remains ON.

Version 22/07/03 33
4.3 PRESENTATION OF REMOTE CONTROL

Physical presentation

Version 22/07/03 34
 Key Function Led
F1 : Allows to move in special functions.
Go back to previous function

F1
F2 : Allows to move in special functions.
Allows to change from a subprogramme to

F2 the next one

F3 : Allows to move in special functions.

Allows to change from a subprogramme to

F3 the previous one

F4 : Allows to move in special functions.

Go to next function

F4
F5 : Allows to take the reference points for Led ON : the Z axis current position is
the measuring flatness device option. under the safety position (zero table)

F5 HS+F5 : Pressing on the HS + F5 keys

together allows to save the current position of
Z axis as the zero table position.
Led OFF : the Z axis current position is
above the safety position (zero table)

F6 : Not used Not used

F6
F7 : Access to special functions (only in Led ON : the special functions menu is
manual mode) displayed

F7
F8 : Choice of the different kind of display Led ON : possible choice with F1-F4
of the axis positions (Machine Origin, Piece keys

F8 Origin, Following Error, Information on the

receiving buffer)

F9 : Short way to take the references on the Led ON : reference taking possible with
axis (Ref X, Ref Y, Ref Z, Zmin) F1-F4 keys

F9

Version 22/07/03 35
 Key Function Led
ARRUS (Machining stop) – Red key Led ON : the cycle has been stopped
To press on this key generates a cycle stop.
This key is valid in the 2 working modes of
the machine (manual and automatic)

The led is ON, the Z axis goes back up

by 10 mm, then the axis and the spindle
stop. It is then possible to move the Z
axis at low speed using the moving keys.

To restart the work, press on the « DCY»

key, the « ARRUS » led goes off and the
« DCY » goes on. If the Z axis position
has been modified, the machine position
again the axis before starting the spidle.
Then, the spindle starts and once the
programmed spindle rotation speed has
been reached, the Z axis goes down by
10 mm to go back to the working
position and the axis move to go on the
work.
DCY (Cycle start) – Green key Led ON : Work in process
This key is valid only in automatic mode,
it allows to start a work.
HS + DCY :
Resending the previous work.
Auto / Manu : This key allows to go from a Led ON : manual mode
working mode to the other one. Led OFF : automatic mode

In automatic mode, the moving keys

are not active and the machine carries
out the commands sent by the
computer.

Version 22/07/03 36
 Key Function Led
Oil spraying : Confirms the working of the Led ON : Oil spraying system workingt
oil spraying system when the spindle is Led OFF : Stop of oil spraying system
rotating at steady speed.
Key valid only in manual
mode.
Chip suction : Allows to start or stop the Led ON : Suction device on
chip suction device. Led OFF : Suction device off
Key valid only in manual
mode.
Suction nozzle up / down : Allows to put Led ON : Suction nozzle in up position
the nozzle in up or down position Led OFF : Suction nozzle in down
Key valid only in manual position
mode.
Spindle : Allows to stop the spindle Led ON : Spindle in rotation
Key valid only in manual mode Led OFF : Spindle stopped

Valid : This key allows to validate the

different choices

Minus : This key allows to correct the Z axis

-
position of the work zero point by 1/100 mm
towards down every time you press on the
key.

Operating mode : when carrying out a work,

go in manual mode with the « # » key and
make the correction with the minus key.
Then press on the « # » key to go in
automatic mode and press on « DCY » to go
on the work.
Plus : This key allows to correct the Z axis

+
position of the work zero point by 1/100 mm
towards up every time you press on the key.

Operating mode : when carrying out a work,

go in manual mode with the « # » key and
make the correction with the minus key.
Then press on the « # » key to go in
automatic mode and press on « DCY » to go
on the work.
RAZ : This command is active in
manual mode, it allows to empty the
receiving buffer. In case of an error
displayed, pressing on "RAZ" suppress it
once the fault has been corrected.

Pressing on "HS", and on "RAZ" at the

same time allows to move the gantry
towards the machine end.
(the actions order is essential in order
not to loose any data)

Version 22/07/03 37
 Key Function
HS : This command is active in manual mode. To combine this command
together with a moving key allows to make a high speed movement in the way
and on the axis selected.
To press on the “HS” key and on the "RAZ" key allows to move the gantry
towards the machine back part to have an easier access to a work (the actions
order is essential in order not to loose any data)
X+ : Allows to move the gantry towards the machine back part

X+
X- : Allows to move the gantry towards the machine front part

X-
Y+ : Allows to move the Y carriage towards left

Y+
Y- : Allows to move the Y carriage towards right
Y-
Z+ : Allows to move the Z axis towards down

Z+
Z- : Allows to move the Z axis towards up

Z-
Not used

A+
Not used
A-
Not used

C+
Not used
C-

Version 22/07/03 38

Potentiometer functions
Two potentiometers are located on the front side of the remote control, one is to adjust the linear
speed and the other one is to adjust the spindle rotation speed.

Potentiometer to adjust the linear speed of the axis

The linear speed can be adjusted from 0 up to the maximum speed.

Potentiometer to adjust the spindle rotation speed

The rot ation speed can be adjusted precisely from 4000 rpm up to 24000, 30000 or 40000 rpm
according to the spindle model.

IMPORTANT
Procedure to follow in the case the spindle had been stopped
for more than 8 hours
Tension the machine and start rotating the spindle at 4000 rpm
for about 5 minutes.
Increase progressively the speed until reaching half of the nominal speed
and leave it rotating for about 5 minutes.
Then increase up to the nominal speed.

Version 22/07/03 39
 4.4 DISPLAY DESCRIPTION

Line 1 2 5 . 4 : V O M 3 0 5 0 . 0 0 : X
Line 2 4 0 . 0 : B P 1 1 5 0 0 . 0 0 : Y
Line 3 M A N : T 1 1 9 5 . 0 0 : Z
Line 4 D E F A U T M A C H I N E

The display has 4 lines of 20 characters each.

Description of the first line of the display

Line 1 2 5 . 4 : V O M 3 0 5 0 . 0 0 : X

2 5 . 4 : V
Linear speed
This value is the axis moving speed when they are activated by pressing the « HS » key in manual
mode or the axis moving speed in automatic mode. This value can be modified with the linear speeed
potentiometer.

O M
Display mode
To modify the display mode, you only have to enter in the special functions by pressing on the « # »
key.
Using the moving keys « F1 and F4 », look for the display mode which will be indicated as follow :
« Position display ».
With the « F2 and F3 » keys, select the display mode you want :
- « Display position / Zero machine »(OM) : the displayed value is the position compared to the
machine origin point in mm
- « Display position / Zero piece »(OP) : the displayed value is the axis position compared to the
memorised position as being the work origin point in mm
- « Display measured position » (PM) : the displayed value is the value of the encoder position
- « Display following error » (EP) : the displayed value is the difference between the theoretical
position and the real position of the axis
- « Display info buffer » (IN) : in this display mode, the displayed value on the X axis is the
number of bites received and on the Y axis the value is the number of bites processed by the
numerical control
- « Display working time » (HR) : In this display mode, the value displayed on the X axis is the
time for the running of the programme in process. This value is indicated in seconds. On the Y axis,
the value is the number of hours of rotation of the spindle. On the Z axis, the value is the number the
number of hours when the powered part of the machine has been supplied.

3 0 5 0 . 0 0 : X
Display of relative value of X axis

Version 22/07/03 40
Description of the second line of the display
Line 2 4 0 . 0 : B P 1 1 5 0 0 . 0 0 : Y

4 0 . 0 : B
Spindle rotation speed

This information indicates the spindle rotation speed in 1000 rpm

Minimum speed 4000 rpm (4.0)
Maximum speed from 21900 to 40000 rpm (21.9-40.0)
(according to the spindle model)

P 1
N° of the programme partition

This information gives the number of the programme partition in process

1 5 0 0 . 0 0 : Y
Display of relative value of Y axis

Description of the third line of the display

Line 3 M A N : T 1 1 9 5 . 0 0 : Z

M A N :
Manual or Automatic mode

Indicates the working mode of the machine

MAN : for manual mode
AUT : for automatic mode

T 1
N° of tool in spindle

This information gives the number of the tool in the spindle.

1 9 5 . 0 0 : Z
Display of relative value of Z axis

Version 22/07/03 41
Description of the fourth line of the display
Line 4 D E F A U T M A C H I N E
Fault message

Any anomaly detected generates the machine stop (go to manual mode) and displays the kind of fault
detected. The machine shows the last fault occured.

X Y Z X2 AXIS FAULT
The following error, on the selected axis, has overpassed the accepted error fixed by the parametre. This
fault generates the cut off of the motor power supply.

LINK DEFECT
A fault has been detected on the RS232 serial link (Presence of a parasitre character).

MACHINE FAULT
This fault can have various causes :
- Lack of compressed air (pressure lower than 5 bar according to the spindle)
- Lack of cooling liquid (according to the spindle)
- Fault on the axis inverters
- Fault on the spindle inverter
- Too high temperature of the spindle

POSITION OCCUPIED
The operator has asked for a tool position in the tool shop where there is already a tool.

TOOL REQUESTED OUT

The requested tool is not in the tool shop.

CONE NOT PUT DOWN

During a tool change, the spindle has not put the cone in position before going back up or the cone has
fallen down and its position is empty.

PROGRAMME NOT COMPLETE

This message is displayed when the operator sends again a programme with the « HS » and « DCY »
keys or in the special functions in the menu rewind of traject if the numerical control cannot read the
programme heading.

FAULT PROGRAM. ARC

The datas of a circle arc to be executed by the machine are not coherent.
(EX : The final point of the arc is not positionned at the correct place)

OUT OF RANGE X AXIS

The size of the work to be carried out are bigger than the table size for the X axis or the reference / origin
point of the work is not correctly positionned compared to the work size.

OUT OF RANGE X AXIS

The size of the work to be carried out are bigger than the table size for the X axis or the
reference / origin point of the work is not correctly positionned compared to the work size.

OUT OF RANGE X AXIS

The size of the work to be carried out are bigger than the table size for the X axis or the reference / origin
point of the work is not correctly positionned compared to the work size.

Version 22/07/03 42
4.5 MENU OF THE SPECIAL FUNCTIONS

To enter the various special functions, the machine has to work in MANUAL mode (led of the # key
ON) and you only have to press on the « F7 » key.
The « F1 and F4 » or « X+ and X-» keys allow to move in the functions and the « F2 and F3 » or « Y+
and Y-» keys allow to move in the sub-functions.

The functions are as follow :

- Different kind of display mode
- Zero setting on X axis
- Zero setting on Y axis
- Zero setting on Z axis
- Save/Recover 0 XYZ
- Inside programmes :
- Table surfacing
- Table drilling (as per option)
- Table webbing (as per option)
- Table grooving (as per option)
- V grooving (as per option)
- Spindle rotation test
- Axis running-in
- Programme selection
- Rewind on traject
- Tool measuring
Every function will be detailed separately.

4.5.1 Different kind of display mode

- « Display position / Zero machine »(OM) : the displayed value is the position compared to the
machine origin point in mm
- « Display position / Zero piece »(OP) : the displayed value is the axis position compared to the
memorised position as being the work origin point in mm
- « Display measured position » (PM) : the displayed value is the value of the encoder position
- « Display following error » (EP) : the displayed value is the difference between the theoretical
position and the real position of the axis
- « Display info buffer » (IN) : in this display mode, the displayed value on the X axis is the
number of bites received and on the Y axis the value is the number of bites processed by the
numerical control
- « Display working time » (HR) : In this display mode, the value displayed on the X axis is the
time for the running of the programme in process. This value is indicated in seconds. On the Y axis,
the value is the number of hours of rotation of the spindle. On the Z axis, the value is the number the
number of hours when the powered part of the machine has been supplied.

To select a display mode, there are 2 possibilities :

- Press on the « F8 » key : a choice of the 4 most used display mode is shown on the bottom line of the
display
You only have to select the display mode you want using the « F1 - F4 » keys.

- Press on the « F7 » key to enter in the special functions : using the « F1 and F4 » or « X+ and X- » keys.
Then move to the display mode list using the « F2 and F3 » or « Y+ and Y- » keys and select the display
mode you want.
The display mode you have selected will be memorised when you go out of the special functions.

Version 22/07/03 43
4.5.2 Zero setting on X, Y and Z axis

Several cases may occur :

1/ The spindle is located at the position where the user wants to do his new origin point :

- The user must go into the special functions by pressing onto the « F7 » key
- Then the user must position on the function « 0 setting X axis» and / or « 0 setting Y axis»
and / or « 0 setting Z axis »
- If the spindle position does correspond to the requested position, the user must only press
onto the « F5 » key in order to memorize the current position as being the zero piece in X, Y
and Z
- To come out again of the special functions, you just have to press onto the « # » key.
- The new 0 point is registered.

A faster way of doing it :

Press on the « F9 » key, a list is shown on the display bottom line.
Then press on the « F1 » key, this will allow you to make the work zero point on X axis at the current
position.
The « F2 » key, this will allow you to make the work zero point on Y axis.
And the « F3 » key, this will allow you to make the work zero point on Z axis as the zero point of the
material.

2/ The user has the possibility to move the position of the zero piece of a real precise value. Please proceed as
follows :

- The user must go into the special functions by pressing onto the « F7 » key
- Then the user must move into position on the mode « 0 setting X axis » and/or « 0 setting Y
axis » and/or « 0 setting Z axis » with « F1 » or « F4 » or « X+ » or « X- »
- The « HS » key allows to choose the increment which will be added to or substracted from
the current position. Increment grade : 0.1mm, 1mm or 10mm
- Pressing onto the « F2 » and « F3 » or « Y+ » and « Y- » keys allows to adjust the position
by adding or substracting the value of an increment at each impulse
- To come out again from the special functions, you just have to press onto the « F7 » key.

Version 22/07/03 44
4.5.3 Saving/Recovery 0 XYZ

The user has the possibility to safeguard and recover up to 5 different zero points.
These safeguards are meant for following numbers 1 – 2 – 3 – 4 – 5. The safeguard of the 0 number cannot be
modified by the user. It only allows to register the last zero point of the last job which has been done. But the
recovery of this point is possible, for example, in the case of a power cut.

Memorization :

- The user must enter into the special functions by pressing onto the « F7 » key.
- Then the user must move into position on the mode « saving / recovery 0 X Y Z axis ».
- The the « F2 » and « F3 » or « Y+ » and « Y- » keys allow to increment or decrement the
zero number.
- The « F5 » key allows to register the current position of the axis in the safeguard of the
number indicated on the display screen.
- To come out of the special functions, you just have to press on the « F7 » key.

Recovery :

- The user must enter into the special functions by pressing onto the « F7 » key.
- Then the user must move into position on the mode « saving / recovery 0 X Y Z axis ».
- The the « F2 » and « F3 » or « Y+ » and « Y- » keys allow to increment or decrement the
zero number.
- The « HS » key allows to recover the zero registered in the displayed number.
- To come out again of the special functions, you just have to press onto the « F7 » key.

Version 22/07/03 45
4.5.4 Inside programmes

Table surfacing

This procedure enables the surfacing of the machine P.V.C. platform in the factory or after a change of the
PVC profiles by the customer. The operator can start this procedure by selecting the "SURFACING" option
in the special functions.
The cutting parameters are invariable but the operator can always modulate the linear or rotation speeds of
the spindle by using the potentiometers on the remote control.
- depth of the pass 1 mm
- linear speed 5 m/min
- rotation speed 24000 RPM
- milling tool diameter 20 mm

Before the surfacing operation, the operator must set the zero of the milling tool compared to the consumable
plate, like before any milling operation.

Do not suck up the chips while surfacing

IF THE MACHINE HAS A REGULATING FLATNESS DEVICE, IT IS ABSOLUTELY
NECESSARY TO DEVALIDATE IT IN THE SPECIAL FUNCTIONS BEFORE STARTING A
TABLE SURFACING

USING :

- Put on a milling tool with a 20 mm diameter in the spindle nose

- Tangent the consumable plate
- Press onto the « F9 » key to enter into the function of the work zero setting on Z axis
- Validate the setting of the work zero point on Z with the « F3 » key
- Press on « F7 » key to enter the special functions.
- With the « F4 » key, look for the menu « TABLE SURFACING »
- Pressing onto the « Valid » allows to load the programme in memory
- Come out of the special functions « F7 »
- Go up with the Z axis
- Press onto « # » to change the machine working mode (go in AUTO mode)
- Press on « DCY » to start the programme

Version 22/07/03 46
 Table drilling

The drilling is done with holes of diameter 3.

When you replace the PVC profiles, pay attention to the neopren sticking which must be made according to
the professional rules. The PVC drilling must be 3 mm deeper to be sure that you really drill through the glue
coat.
This procedure allows to drill the table top in the factory or after a replacement of the PVC profiles by the
customer. The operator can start this procedure by selecting the option "PLATFORM DRILLING" in the
special functions.

The cutting parameters are invariable but the operator can always modulate the linear or rotation speeds of
the spindle by using the potentiometers on the remote control.
- depth of the pass 18 mm
- rotation speed 40000 RPM
- linear speed 4 m/mm
- drill or milling tool diameter 3 mm

Before the drilling operation, the operator must set the zero of the drill compared to the consumable plate,
like before any milling operation.

Do not suck up the chips while surfacing

IF THE MACHINE HAS A REGULATING FLATNESS DEVICE, IT IS ABSOLUTELY
NECESSARY TO DEVALIDATE IT IN THE SPECIAL FUNCTIONS BEFORE STARTING A
TABLE DRILLING

USING :

- Put on a milling tool with a 3 mm diameter in the spindle nose

- Tangent the consumable plate
- Press onto the « F9 » key to enter into the function of the work zero setting on Z axis
- Validate the setting of the work zero point on Z with the « F3 » key
- Press on « F7 » key to enter the special functions.
- With the « F4 » key, look for the menu « TABLE DRILLING »
- Pressing onto the « Valid » allows to load the programme in memory
- Come out of the special functions « F7 »
- Go up with the Z axis
- Press onto « # » to change the machine working mode (go in AUTO mode)
- Press on « DCY » to start the programme

Version 22/07/03 47
 Resin table drilling (as per option)

The drilling of the resin table allows to select the vacuum zone by removing only the plugs located into the
zone selected with the sealing joint in the grooves. The drilling is made through several passes of different
diameters in order to be able to sink the plug in the table.

This drilling procedure allows to drill the complete table top. The operator can start this procedure by
selecting the option "PLATFORM DRILLING" in the special functions.

The cutting parameters are invariable but the operator can always modulate the linear or rotation speeds of
the spindle by using the potentiometers on the remote control.
- depth of the pass 5 mm
- rotation speed 40000 RPM
- linear speed 4 m/mm
- drill or milling tool diameter 6 mm

Before the drilling operation, the operator must set the zero of the drill compared to the consumable plate,
like before any milling operation.

Do not suck up the chips while surfacing

IF THE MACHINE HAS A REGULATING FLATNESS DEVICE, IT IS ABSOLUTELY
NECESSARY TO DEVALIDATE IT IN THE SPECIAL FUNCTIONS BEFORE STARTING A
TABLE DRILLING

USING :

- Put on a milling tool with a 6 mm diameter in the spindle nose

- Tangent the consumable plate
- Press onto the « F9 » key to enter into the function of the work zero setting on Z axis
- Validate the setting of the work zero point on Z with the « F3 » key
- Press on « F7 » key to enter the special functions.
- With the « F4 » key, look for the menu « TABLE DRILLING »
- Pressing onto the « Valid » allows to load the programme in memory
- Come out of the special functions « F7 »
- Go up with the Z axis
- Press onto « # » to change the machine working mode (go in AUTO mode)
- Press on « DCY » to start the programme

Version 22/07/03 48
Table webbing

The webbing has a diameter of 18 mm and a depth of 2.5 mm. The webbing is done with a BELIN milling
tool of diameter 8 by turning in order to get a diameter of 18 mm.

This procedure enables a webbing around the drillling in order to obtain a high efficiency of the machine
vacuum plate, in the factory or after a change of the PVC profiles by the customer. The operator can start this
procedure by selecting the "WEBBING" option in the special functions.
The cutting parameters are invariable but the operator can always modulate the linear or rotation speeds of
the spindle by using the potentiometers on the remote control.
- depth of the pass 2.5 mm
- rotation speed 40000 RPM
- linear speed 4 m/mm
- milling tool diameter 8 mm

Before the webbing operation, the operator must set the zero of the milling tool compared to the consumable
plate, like before any milling operation.

Do not suck up the chips while surfacing

IF THE MACHINE HAS A REGULATING FLATNESS DEVICE, IT IS ABSOLUTELY
NECESSARY TO DEVALIDATE IT IN THE SPECIAL FUNCTIONS BEFORE STARTING A
TABLE WEBBING

USING :

- Put on a milling tool with a 8 mm diameter in the spindle nose

- Tangent the consumable plate
- Press onto the « F9 » key to enter into the function of the work zero setting on Z axis
- Validate the setting of the work zero point on Z with the « F3 » key
- Press on « F7 » key to enter the special functions.
- With the « F4 » key, look for the menu « TABLE WEBBING »
- Pressing onto the « Valid » allows to load the programme in memory
- Come out of the special functions « F7 »
- Go up with the Z axis
- Press onto « # » to change the machine working mode (go in AUTO mode)
- Press on « DCY » to start the programme

Version 22/07/03 49
Table grooving (as per option)

The table grooving allows to limit the vacuum to the working zone.

This procedure allows to groove the complete table top. The operator can start this procedure by selecting the
option "GROOVING" in the special functions.

The cutting parameters are invariable but the operator can always modulate the linear or rotation speeds of
the spindle by using the potentiometers on the remote control.
- depth of the pass 5 mm
- rotation speed 40000 RPM
- linear speed 10 m/mm
- milling tool diameter 6 mm

Before the grooving operation, the operator must set the zero of the milling tool compared to the consumable
plate, like before any milling operation.

Do not suck up the chips while surfacing

IF THE MACHINE HAS A REGULATING FLATNESS DEVICE, IT IS ABSOLUTELY
NECESSARY TO DEVALIDATE IT IN THE SPECIAL FUNCTIONS BEFORE STARTING A
TABLE GROOVING

USING :

- Put on a milling tool with a 6 mm diameter in the spindle nose

- Tangent the consumable plate
- Press onto the « F9 » key to enter into the function of the work zero setting on Z axis
- Validate the setting of the work zero point on Z with the « F3 » key
- Press on « F7 » key to enter the special functions.
- With the « F4 » key, look for the menu « TABLE WEBBING »
- Pressing onto the « Valid » allows to load the programme in memory
- Come out of the special functions « F7 »
- Go up with the Z axis
- Press onto « # » to change the machine working mode (go in AUTO mode)
- Press on « DCY » to start the programme

Version 22/07/03 50
Table V grooving (as per option)

The table V grooving allows to have a vacuum surface more important at the level of the material to be hold.
This procedure allows to groove the complete table top. The operator can start this procedure by selecting the
option "V GROOVING" in the special functions.

The cutting parameters are invariable but the operator can always modulate the linear or rotation speeds of
the spindle by using the potentiometers on the remote control.
- depth of the pass 2.5 mm
- rotation speed 40000 RPM
- linear speed 10 m/mm
- milling tool 90 °

Before the grooving operation, the operator must set the zero of the milling tool compared to the consumable
plate, like before any milling operation.

Do not suck up the chips while surfacing

IF THE MACHINE HAS A REGULATING FLATNESS DEVICE, IT IS ABSOLUTELY
NECESSARY TO DEVALIDATE IT IN THE SPECIAL FUNCTIONS BEFORE STARTING A
TABLE GROOVING

USING :
- Put on a milling tool with a 6 mm diameter in the spindle nose
- Tangent the consumable plate
- Press onto the « F9 » key to enter into the function of the work zero setting on Z axis
- Validate the setting of the work zero point on Z with the « F3 » key
- Press on « F7 » key to enter the special functions.
- With the « F4 » key, look for the menu « TABLE WEBBING »
- Pressing onto the « Valid » allows to load the programme in memory
- Come out of the special functions « F7 »
- Go up with the Z axis
- Press onto « # » to change the machine working mode (go in AUTO mode)
- Press on « DCY » to start the programme

Spindle rotation test

This procedure allows to start the spindle. But the operator can also use this option to pre-heat the spindle at
the day beginning.

USING :
- Press on « F7 » key to enter the special functions.
- Using the « F1 » and « F4 » keys, look for the “table surfacing” function
- Using the « F2 » and « F3 » keys, look for the “spindle rotation test” programme
- Pressing onto the « Valid » key allows to start the running-in programme in memory
- Come out of the special functions by pressing on « F7 »
- Press onto « # » to change the machine working mode (go in AUTO mode)
- Press on « DCY » to start the programme (that is to start the spindle)
- The spindle starts and the machine goes back to manual mode
- To stop the spindle, go back to automatic mode pressing onto « # », then on « DCY ».
A second solution can be used :
Pressing TWICE on the « RAZ » key (1st : to stop the spindle – 2nd : empty the buffer).

Version 22/07/03 51
4.5.5 Axis running in

This procedure allows to run in the axis in the factory. But the operator can use this option.

Please proceed as follows :

- The user must enter into the special functions by pressing onto the « F7 » key
- With the « F1 and F4 » keys, look for the menu « TABLE SURFACING »
- With the « F2 and F3 » keys, look for the menu « AXIS RUNNING IN »
- Pressing onto the « Valid » allows to load the programme in memory
- Press onto « # » to stop the running in programme

The linear speed can be adjusted thanks to the potentiometer of the remote control.

Programme selection

This procedure allows to share the receiving buffer of the machine in 5 parts, which allows to store 5 different
cutting files.

WARNING :
The files stored in every one of the buffer part are not safeguarded following a power supply cut of the
machine. Pressing on RAZ allows to emprty only the selected part.

The using procedure is as follow :

- The user must enter into the special functions by pressing onto the « F7 » key
- With the « F1 and F4 » keys, look for the menu « PROGRAMME SELECTION »
- With the « F2 and F3 » keys, the user can modify the number of the selected part
- Press on « F7 » key to enter the special functions.
- Pressing onto the « Valid » allows to load the programme in memory
- Press onto « # » to stop the running in programme
- Send the file stored in the selected part with the computer
- It can from now on be processedone or several time using the “Rewind on traject” function

WARNING :
To press on the RAZ key will delete the part content.

Version 22/07/03 52
4.5.6 Rewind on traject

This procedure allows to go backward in the work which is being done or to restart a program execution if the
latter could be completely stored in the buffer. Therefore the maximum size of the whole program which
must be completely restarted must not exceed the 7 Mega-Octets of the buffer (memory not divided in parts).

The user may find two cases :

1/ The user wants to go backward on the machined trajectory :

- The user must go back to the manual mode by pressing onto the « # » key. The machine
carries on working until the end of the curve or of the straight line. Then he must go into the
special functions by pressing onto the« F7 » key
- With the « F1 » and « F4 » keys, he must look for the mode « rewind on traject »
- The « Y- » key allows now to go backward of one straight line segment or a curve
- The « Y+ » key allows to advance from one block in the buffer
- When you come out by pressing onto the « F7 » key and when you restart the execution by
pressing onto the « # » key followed by the « DCY » key, it allows to return to the work
from the point which has been defined

2/ The user has just machined a piece in automatic with a program which size is lower than 7 Mega-octets. If
the user wants to execute it again without restarting it from the PC, he can use the following procedure :

- At the end of the programme, the user must go back to the manual mode by pressing onto
the « # » key
- The user must not do a RAZ otherwise the work cannot be recovered. The user must press
onto the « F7 » key to enter into the special functions
- With the « F1 » and « F4 » keys, he must look for the mode « rewind on traject »
- Pressing onto the « RAZ » key allows to reload the programme which has been executed in
memory
- The user must come out of the special functions again by pressing onto the « F7 » key
- Pressing onto the « # » key followed by the « DCY » key allows to restart the work.

A short cut allows to do this operation faster :

Being in manual mode, you just have to press onto the « HS » and « DCY » key.

Version 22/07/03 53
4.5.7 Tool measuring

In order to avoid a measurement at each tool change, all the tools used in the work must have been measured.

When pressing onto the RAZ key or during a power cut due to an emergency stop or even during a general
power cut, the measure will not be lost.

The using procedure is the following :

- Press onto the « F7 » key to enter into the special functions

- With the « F1 » and « F4 » keys, look for the « TOOL MEASUREMENT » menu
- With the « F2 » and « F3 » keys, select the tool number to select
- Pressing on the « DCY » key allows to send the measure of the requested tool
- Select the number of the tool to be measured with the « Y+ » or « Y- » keys
- Pressing onto the « GV » key allows to start the requested tool measurement
- The machine moves to make the tool measurement or to do the change according to the
requested tool number
- With the « F2 » and « F3 » keys choose the tool number to measure and do again the above-
mentioned handlings
- If all the tools have been measured, press onto the « F7 » key to come out of the special
functions

WARNING :

Any change of the tool location in the tool shop or any change of the tool length in the tool shop without
a new tool measurement may irremediably damage the tool changer, the spindle, the working area or
the part you are machining. Every morning you must make a measurement after the preheating.

Version 22/07/03 54
 DESCRIPTION OF THE MANUAL COMMANDS
F7

Pos display/zero piece

Assignment of the
F5 current axis position F2
to the zéro.
F1 Measure.position display
For increment change
HS

zero X adjustment Add an increment to the

F2 F2
current zero

zero Y adjustment F3 Withdraw an increment to Travel distance display

the current zero

zero Z adjustment To change N°of the zero

F2 piece to recover or
F2
memorize.
SAVE / RECOVER
Recovery of the selected Buffer.info display
HS zero

F1 Memorization of the
F5 current position in the F2 Pos display/ Zero machine
selected N°

Table drilling Table webbing Axis running in

Table surfacing F2

Valid
F1
Y- Block return
To load the resident program

Rewind on traject
chemin

F1 RAZ Backward move on the

complete program

Tool measurement F2 Choice of tool N° to measure

F1 DCY Validate the tool measurement

55
 4.6 CONNECTION TO COMPUTER SYSTEM

Connection type

The commands are ASCII codes that can be sent to the machine through a serial connection - e RS232
type – from a computer.

transmission format:
19200 bauds
8 bits
1 stop bit
no parity

Control of the entry buffer, either :

by return of the XON and XOFF characters (h11 and h13)
or :
by RTS control (7 of the Sub'D 9 points – machine side

Detail of the cord wiring :

Capot

2 BLANC VERT 2

3 VERT BLANC 3
Coté machine

Coté PC
5 BLEU 5

7 ROUGE 6-8

8 BLANC / NOIR 7

Parameter setting for « PLATEFORME » software

Effective length of the table in mm (X axis) 3050

1520
Effective width of the table in mm (Y axis)

Number of steps on X for 1 mm 1

Number of steps on Y for 1 mm 1

Number of steps on Z for 1 mm 1

Inter letter speed in mm/min 25000

4.7 MACHINE PARAMETER SETTING

List of the machine parameters

p1 Gain on X axis
p2 Gain on Y axis
p3 Gain on Z axis

p6 X axis multiplicator coefficient

p7 Y axis multiplicator coefficient
p8 Z axis multiplicator coefficient

p11 X axis divisor coefficient

p12 Y axis divisor coefficient
p13 Z axis divisor coefficient

p16 X axis travel in µm

p17 Y axis travel in µm
p18 Z axis travel in µm

p21 X axis POM position in µm (POM = Machine origin point)

p22 Y axis POM position in µm (POM = Machine origin point)
p23 Z axis POM position in µm (POM = Machine origin point)

p26 X axis maximum travelling distance

p27 Y axis maximum travelling distance
p28 Z axis maximum travelling distance

57
p40 Acceleration in mm / s²
p41 Max. speed X and Y
p42 Max. speed max. Z
p43 Spindle maxi speed in RPM

p44 Message language

0 French
1 Italian
2 English
3 Spanish
4 German
5 Dutch
6 Swedish
7 Portuguese
8
p45 Temporizing for vacuum table stop 500 = 1s
p48 Temporizing for collet opening

p49 Position in Z on the tool changer

p50 Position in X of the measurement device
p51 Position in Y of the measurement device

p52 Z Position at the beginning of the measurement

p53 Z Position at the end of the measurement

p54 Tool changer position on index

p55 Tool changer position on Y

p56 Distance between tools in rotation

p57 Z Position of tool deposit

p58 Z Position of tool collection
p59 Y Position in front of tool changer

p60 Position number of the tool changer

p150 Tool number in the spindle

58

Parameters modified by the NCduring the working

p151 Zero piece in X (PREF)

p152 Zero piece in Y (PREF)
p153 Zero piece in Z (PREF)

p156 Zero piece 1 in X

p157 Zero piece 1 in Y
p158 Zero piece 1 in Z

p161 Zero piece 2 in X

p162 Zero piece 2 in Y
p163 Zero piece 2 in Z

p166 Zero piece 3 in X

p167 Zero piece 3 in Y
p168 Zero piece 3 in Z

p171 Zero piece 4 in X

p172 Zero piece 4 in Y
p173 Zero piece 4 in Z

p176 Zero piece 5 in X

p177 Zero piece 5 in Y
p178 Zero piece 5 in Z

p181 Measuring tool n°1

p182 Measuring tool n°2
p183 Measuring tool n°3
p184 Measuring tool n°4
p185 Measuring tool n°5
p186 Measuring tool n°6
p187 Measuring tool n°7
p188 Measuring tool n°8
p189 Measuring tool n°9
p190 Measuring tool n°10
p191 Measuring tool n°11
p192 Measuring tool n°12

p199 Display Mode (0 – 4)

59
4.8 MACHINE LANGUAGE

List of software known for driving the machine directly

Editor MECANUMERIC
PLATFORM (NUM FRAISAGE)

Manufacturer VISION NUMERIC

MECATYPE AND TYPE3 (NUM1060/760)

Distributor FICAM
MASTERCAM
ART CAM

Manufacturer SCANVEC
EN ROUTE 3D

Description of the programming mode of the machine

Internal commands

These commands must be used ONLY by

MECANUMERIC technical or maintenance departments.
They are given here only for indication purposes.

p[n°] Visualization of a parameter on the remote control.

This command allows to display the value of the parameter number [n°] on the remotre control

q[n°] Visualization of a parameter on the series link

This command allows to display the value of the parameter number [n°] on the series link.

w n°,val Parameter writing if p0 = 555

Writing safeguard of 550 in p0
This command allows to enter the value [val] of one parameter number [n°]

? Display of the software version on the remote control

60

Description of the programming code of the machine

The numerical control accepts and interprets the normalized reduced ISO code :

Preliminary functions :

G0 High speed moving

G1 Moving under programmed speed
G2 Anti-trigonometric direction arc under programmed speed
G3 Trigonometric direction arc under programmed speed
G4 Temporizing

M Functions

M0 Programmed stop
M2 Programm end
M3 Spindle start
M5 Spindle stop
M50 Chips suction nozzle UP
M51 Chips suction nozzle DOWN
M200 Starting of the vacuum plate
M201 Stop of the vacuum plate
M202 Starting of chips suction
M203 Stop of the chips suction

Addresses :
X X axis absolute coordinates (mm)
Y Y axis absolute coordinates (mm)
Z Z axis absolute coordinates (mm)
I Absolute coordinates of a circle centre in X
J Absolute coordinates of a circle centre in Y
R Arc of a circle ray
F Travel speed (mm/mn) or temporizing value (G4)
S Spindle rotation speed (rpm)
T n° Tool change

Others

%n° Program number

$XXX Comment Insertion

61
4.9 STARTING UP OF THE EQUIPMENT

Operating mode

Switch off the machine and turn the disconnecting switch onto position « 0 ».
Switch off the computer system.
Connect the plug 9 points on the serial port 1 (com1) or on the serial port 2 (com 2) of the
computer and the plug 9 points to the machine
(Connector located on the right side of the electric cabinet.)
Start the computer system.

Start the machine by turning the disconnecting switch onto position ON :

It shows off on the screen of the remote control Connection defect ?

Then :

Then :

Press onto the green button marked with 1 below the disconnecting switch.

Then press onto the RAZ key.

The three axis move in order to come to the origin point of the machine.
Once the machine has reached its origin points, the machine is then ready to carry out a work.

Possible anomalies and corrections

If the power of the machine is not engaged :

Check that the emergency stop is not engaged.

If the defect red light located on the head is switched on, check that the air pressure is
sufficient.
Check the running of the cooling pump, if it is a water cooled spindle.

In order to facilitate the locating of the defect of the safety chain, you will find some relays
called KA1, KA2, etc… in the electric cabinet, as well as a label indicating the defect
corresponding to the relay which is switched off.

62
Once you have checked the air and the water, etc...if everything seems to be correct, then
please contact MECANUMERIC’s Customers Service while indicating the type and the serial
number of your machine.

Computer / machine connection test

Look for the program «MS-Dos Command» on the computer and start it.

RS232 cable connected on the serial port 1 (com1) of the central unit of the computer.
The machine must have made its origin points and must be in automatic mode.
On the screen, you must see DOS displayed C:\> then type the following text while respecting
the small letters, the capital letters, the spaces and the punctuation:

MODE COM1 :19200,n,8,1,p then press onto enter.

The following message is displayed on the computer screen :
« Resident portion of MODE is loaded »
« COM1 :19200,n,8,1,p »

Then type :
ECHO ?>com1 then, press onto enter.

On the screen of the remote control, appears the version of the internal HARD of the
numerical control.
However, if there is no information displayed on the screen of the remote control, check that
the serial connection cable is connected to the correct serial port at the rear part of the central
unit of the computer and check that the connectors are correctly fixed.

RS232 cable connected on the serial port 2 (com2) of the central unit of the computer.
The machine must have made its origin points and must be in automatic mode.
On the screen, you must see DOS displayed C:\> then, type the following text while
respecting the small letters, the capital letters, the spaces and the punctuation:

MODE COM2 :19200,n,8,1,p then, press onto enter.

The following message is displayed on the screen of the computer :
« Resident portion of MODE is loaded »
« COM2 :19200,n,8,1,p »

Then, type :
ECHO ?>com2 then, press onto enter.

On the screen of the remote control, appears the version of the internal HARD of the
numerical control.
However, if there is no information displayed on the screen of the remote control, check that
the serial connection cable is correctly connected to the correct serial port at the rear part of
the central unit of the computer and check that the connectors are correctly fixed.

If you send the information onto the wrong serial port, the computer will get blocked.

63

Electrospindle preheating

It is absolutely necessary to proceed to a preheating of the spindle before starting a work by

following the preheating procedure described below :

Once the machine has made its origin points, start the spindle at its minimum speed and set
the axis in running in at about 6 meters minute.

Let it run for about 5 minutes and increase the rotation speed of the spindle and the axis linear
speed of 25% until stabilizing at 100% (time of the running in about 20 mn)

64
 Chapter 5 – Work preparation

5.1 MATERIAL PREPARATION

Setting and clamping

Your equipment has a table grooved to clamp mechanically the material plates to be cut. The
system of mechanical clamping is a sefety element to be used also if your equipment has
the vacuum plate option.

1. Tension the machine and make its origin points.

2. Position the material to be machined and start the vacuum plate (if your machine has one).

Nota : the vacuum table is a system to help a perfect clamping of the material plate to be machined
(absorb deformations) and reduces the vibrations during milling to have a better machining quality. It
is not in any case a clamping system.

In order to get an efficient help for the clamping through vacuum plate, the used area(s) must be
covered at 90 %. If the material to be machined does not fulfill this condition, you must settle the
problem either by selecting the profiles through the manual valves provided for this purpose or
complete the lack of materials in relation to the vacuum area, with eventually a rather thin PVC plate.

3. Set up the clamps delivered with the equipment, in the grooves designed for this on the table and fix
the material plate on the cutting table, so as the plate will not move while machining.

Important : Be very careful when positionning the clamps, so as they are not in the tool trajectory
once the work started or cannot be in contact with the suction nozzle.

65

First Cutting

Switch on your computer.

Open your software.
Prepare your cutting file.

Tension the machine by switching the disconnecting switch onto position

« ON ».

When the remote control shows, press onto the

green button « 1 » on the left side of the electric cabinet.

Then, press onto the « // » key of the remote control.

The machine will make its origin settings (P.O.M.).

Release the gantry at the bottom of the table by pressing onto the keys “HS” + “//”

Correctly place and clamp the material to be machined on the table.

Position the « X », « Y » axis at the starting point of the work to be carried out.

Tangent the material with the « Z » axis.

WARNING : For the Z axis, the starting point of the work will be made either on the
material to be machined or on the consumable plate according to the software.

Enter into the short functions of the referecne taking with the “F9” key.
With the “F1” and “F4” keys take the references on the selected axis.

Check that the rotation speed potentiometer is at the maximum.

Lower the linear speed to zero.

Send the work prepared on the computer towards the machine (See the software using).

Press onto the « # » key and then on the “DCY” key.

The indicator light of this key switches off, the signal indicator of the spindle rotation
located on the head switches on.

Slowly increase the linear speed until the maximum while checking there is no anomaly.
5.2 TOOL PREPARATION

5.2.1 Tool choice

- Cutting in plastic :
left cutting tool (conventional) one tooth
BELIN type ref : EG 12020.12030.12040
HAM type ref : 413

- Cutting in plastic :
right cutting tool (climb mill) one tooth
BELIN type ref : EG 13020.13030.13040

- Engraving in plastic
BELIN cutting tool ref : 91XXX
right cutting tool one tooth : HAM type ref : 420
right cutting tool two teeth : HAM type ref : 410
form cutting tool : HAM type series : 461

- Cutting or engraving in non ferrous materials

two edges right cutting tool
HAM type ref : 410.421

- High efficiency cutting or engraving in aluminium

one edge right cutting tool
HAM type ref : 490

WARNING
Do not mix up the screw shape direction with the cutting tool direction.
On MECANUMERIC’s machines, the cutting direction is « right cutting ».
If the cutting direction is not correct, the cutting tool turns in the opposite
direction and cannot cut.

67
5.2.2 Determination of the cutting parameters

Technological calculation
Notations :
Cutting speed V in m/min
Advance per tooth a in m/tooth
Cutting tool diameter D in mm
Teeth number Z
Rotation speed N in rpm

Normally, the « V » cutting speed is known and depends on the cutting tools
and on the materials to cut (see chart).

Spindle rotation speed « N »

N = 1000 V / π D
Numerical example 1 :
Case AU4G aluminium cutting with a 4 mm tool in carbide and 3 mm depth of pass
The chart 1 indicates : V=320 m/min
Hence : N=1000x320/3.14x4=25478 rpm
We can rotate at : 25500 rpm

Linear speed Va
Va = a Z N in mm/min

Numerical example 2 :
Case of AU4G aluminium as previously with a 2 teeth tool
The chart 1 indicates : a=0.02 mm
Hence : Va=0.02x2x25500=1020 mm/min
We can rotate at : 1 mm/min
Diving speed Vp

For soft materials : aluminium, zinc

Diving speed Vp=0.5Va

Numerical example 3 :
In the previous case
Vp=0.5x1000=500 mm/min=0.5 m/min

For hard non ferrous metals : brass, bronze

Diving speed Vp=0.3Va

For plastics
In order to avoid material overheatings and burnings when the tool is going down, you
must increase the diving speed. The appropriate speed is to be determined by
experimentation. However, you can use following starting base : Vp=0.6 to 0.8Va

68

Using advices
Checking of the input power :
For safety reasons, the input power must always be equal to 50% maximum of the power supplied by
the spindle.

Calculation of the rate of the removed material Q (en cm3/min)

Q = D p Va / 1000
D = tool diameter
p = depth of pass
Va = linear speed
Numerical application : same example as above

Q=4x5x1000/1000=12 cm3/min

Calculation of the input power

P=QK
P = power in watts
Q = chips rate in cm3/min
K = coefficient to determine in the chart 2
Numerical application : same example as above
P=12x17=204 W
K=17 determined on the chart 2 regarding aluminium

If the input power is superior to 50% of the supplied power :

Make the ratio : 2 Pabsorbée / Pfournie = R
(2 Input power / Supplied power = R)
Then, start the calculations again from the beginning by using the following
cutting speed :
V2 = V1 / 0.9 R V1 being the first cutting speed determined in the chart 1.

Numerical example : Case of a spindle supplying only 300 W

In this case R=2x204/300=1.36
In this case V2=320/0.9x1.36=261 m/min
Hence : N=20800 tr/min
Va=832 mm/min rounded to 800 mm/min
Q=9.6
P=163 W it means about 54% of the supplied power
In this case, these values can be used.

In order to reduce the input power, we can also reduce the depth of the pass. In this case, the new
depth will be given with following formula :
R = 2 Pabsorbée / Pfournie et P2 = P1 / R
(R = 2 Input power / Supplied power and P2 = P1/R
P1 being the old value of the depth of pass.

Numerical example : in the case of the spindle 300 W

R=1.36
P2=3/1.36=2.2 mm We will use 2 passes : One of 2.2 mm, the other one of 1 mm.

Important reminder
In the case of a worn out tool, the input power increases of 30%
(Take this into account while checking the available power)

69

Tool manufacture and geometry

Materials

Three types of material are generally used for the tool manufacture.
High speed steels (ARS) (HSS) without cobalt or supercarbide with cobalt.
High speed cemented steels : the wear resistance is improved. Below chart regarding the choice of
shades for high speed steels.

Type of high speed steel Hardness HRC Machined Using

cold material
steel R<70daN/mm²
without cobalt 65 to 62 cast iron, light alloys Very general use
cuprous alloys
with cobalt 65 to 62 steel Higher output
5% 70<R<120daN/mm² Good heat resistance
with cobalt steel Difficult works
8% 69 to 65 R>120daN/mm² Abrasion resistance
Titanium alloys Good heat resistance
steel Difficult works
supercarbide 67 to 64 R<120daN/mm² Abrasion resistance
with cobalt < 5% Abrasive materials Grinding difficulty
Good heat resistance

The recommended type of tool for a MECANUMERIC’s table is a steel tool with a high cobalt
percentage (5 à 8%).

Cemented metal carbides :

Tungsten, titanium, tantalum carbides, etc... bound with cobalt.

Several shades are available (according to NFE 66 304 norms) :

- P SERIES (P01.P10.P20.P30.P40.P50)
Used for the machining of ferrous metals with long chips (steel, MB cast iron).

- M SERIES (M10.M20.M30.M40)
Used for the machining of ferrous metals with long or short chips (steel, MB cast iron, grey pig iron).

- K SERIES (K01.K10.K20.K30.K40)
Used for all metal types
- grey pig iron K10, annealed cast iron, tempered steel, alloys
- aluminium/silicon , copper base alloys, plastic materials, hard cardboard.
- K20 : non ferrous metals, copper, brass, aluminium
- K40 : soft or hard wood, non ferrous metals
- For a MECANUMERIC’s table, use following shade : K20 (otherwise, if not available, use K10).

70
Type of carbide K01 K10 K20 K30 K40
Wear resistance + -
Toughness - +
Advance - +
Speeds + -

The cutting operation used on MECANUMERIC’s machines, is an operation technically called

« Milling with end cutter ». Tools suitable for our equipment are end cutter tools and side cutters (two
size milling tool). Moreover, these tools require, a cutting tooth in the middle in order to make
« diving » works (otherwise a stuffing or a breaking risk may occur). Generally speaking, there is a
type of tool suitable for each material to cut. According to the cutting material and the cutting quality,
you must choose the number of teeth, the screw direction (right or left) and the screw angle). For
engraving works, you will find form milling tools (conical, with round end, with flat end with cone,...).
In most cases, the milling tools do not have any screw angle (the cutting edge is parallel to the axis of
the milling tool).

Example : two size milling tools

High speed steel Carbide

Material to be machined An Gn Ls An Gn Ls
Aluminium alloys 13° 15° to 25° 30° to 45° 13° 5° to 8° 25°
Brass 13° 12° to 20° 30° to 45° 13° 5° to 8° 25°
Bronze 13° 0 30° to 45° 13° 0 25°
Plastic materials 13° 5° to 8° 30° to 45° 13° 0 to 3° 0

A n : Normal backing off of the tool

G n : Normal cutting angle
L s : Inclination angle of the tool edge

Right handed milling tool

- lifts up the plate to cut from its support
- extracts the chip from the hole and throws it all around
- can make some burrs on the top edge of the material
- tends to slide in the collet, if the tightening is not sufficient

Left handed milling tool

- flattens the material on its support (less vibrations)
- stuffs the hole with the chip
- does not make any burrs on the top edge of the material

71

Practical advices

Defects on the cut pieces

Defect Suggestions
Burrs and notches Decrease the advance per tooth
Adapt the angles of the tool – (reduce the direction angle)
Decrease the advance per tooth
Roughness defects Increase the cutting speed
Check the « out of center » of the tool and minimize it
Chip sticking on the part Increase the cutting speed (soft materials)
Increase the cutting angle on the tool
Adapt the rotation speed.
Cold hammering of the Increase the cutting angle and check the sharpening of the tool
machined surface Increase the advacne per tooth

Defects on the tool

Defects Suggestions
Choose a more resistant shade
Wear in backing off is too Decrease the cutting speed
quick Increase the advance
Increase the backing off angle
Lubricate
Wear in crater is too quick Choose a more resistant shade
Decrease the advance
Lubricate
Chafing of the cutting edges Choose a tougher shade
Decrease the advance per tooth
Reduce the backing off angle or the cutting angle
Edge burning Decrease the cutting speed or lubricate
Decrease the advance per tooth
Increase the cutting speed (soft materials)
Chip stuffing Lubricate plentifully
Choose a tool : bigger screw angle, less teeth
Check the tool fastening
Control and limit the « out of center »
Limit the wear and the chafing
Decrease the cutting conditions
Tool breaking Supervise the chip evacuation (stuffing)
Look for a stiffer and shorter tool, or a tool with a bigger core diameter, or a
tool with a more resistant tooth type.
Preferably use a tool with positive cutting (the chip goes up) rather than a tool
with negative cutting (the chip goes down)

72

Life time of cutting tools

A too long life time usually corresponds to weak cutting conditions and furthermore to a long using of
the machi. Therefore, this occurs a high cutting cost. A too weak life time shows an important tool
consumption and an increase of the incident risks. The economic life time is a compromise between
these two tendencies. It corresponds to a minimal machining cost and can be calculated with the
Taylor’s formula.

T = 60 ( (1/n) - 1 ) (Co/Cm)

Where :
T is the economic life time in cutting minute
n= Taylor’s exponent
Cm= machine hourly cost including :
. machine depreciation plus financial costs
. working costs : energy, premises, maintenance
. labour costs
Co=represents the global tool cost for a life time and includes :
. the tool cost
. the cost of the tool changing on the machine which is worth changing
time and adjusting time.

As example, please find below a chart representing the economic life time of some tools.

Diameter
Type of tool 3 4 5 6
High speed steel grooving cutter 100 min 120 min 130 min 140 min
Monobloc carbide grooving cutter 150 min 160 min 175 min 180 min

73

Chart of linear speed per tooth - (CHART 1)

Depth Advance per tooth Cutting speed

Material of pass Tool diameter Carbide tool Lubric.
mm 2mm 3mm 4mm 6mm m/min
Aluminium 1 0.01 0.02 0.02 0.04 390 yes
A4, A5, A9
AG3, AM4 3 0.01 0.01 0.02 0.03 320 yes
AU4G, AU4N
AU10G 5 0.02 0.02 280 yes
Aluminium 1 0.01 0.02 0.03 0.04 230 yes
ASZU
AS4G 3 0.01 0.01 0.02 0.03 220 yes
AS7G
AS10 5 0.02 0.02 190 yes
Aluminium 1 0.01 0.01 0.03 0.04 180 yes
AS12, AS13
AS20, AS22 3 0.02 0.03 150 yes
Bronze 1 0.01 0.02 0.03 200 yes
3 0.02 0.02 180 yes
1 0.01 0.02 0.03 0.04 180 yes
Brass 2 0.01 0.02 0.03 160 yes
5 0.01 0.03 130 yes
Copper 1 0.02 0.03 150 yes
3 0.02 0.02 130 yes
Zinc 1 0.03 0.04 0.06 0.08 420 no
3 0.02 0.03 0.05 0.07 390 no
1 0.05 0.08 0.10 0.12 450 no
Plastics 3 0.04 0.07 0.08 0.10 380 no
5 0.03 0.06 0.08 300 no

This chart of advances per teeth is given for indicative purposes according to the tests and could not
contractually bind us. The stated performances can vary within a ratio of 0.3 to 1.5 according to the :
- plate clamping
- plate stiffness
- exact constitution of the plates (material, thermic treatments)
- tool wear state
- tool type (material, geometry, sharpening angles)
- lubrication (nature, flow)

74

Power factor - (CHART 2)

Reminder : P = Q in cm3/min x K / 1000 P in kW

General remarks :

- The power required for the cutting is higher with a weak advance per tooth than with a
strong advance (with a similar chip flow).
- The decrease of the cutting speed makes the required power decrease quicker than the
decrease of the linear speed.
- For a worn out tool, the required power is about 30% superior to the one of a new tool

Material to be machined K Coefficient

Magnesium alloys 9
Aluminium alloys 17
Copper alloys
Brass and lead bronze 18
German silver or copper 18
Tin bronze 36
High resistance brass 36
Cupro aluminium 38
Plastics
P.V.C. 7
P.M.M.A. 5
Polypropylene 4
P.C. 5
Zinc alloys 10

75
5.2.3 Tool setting

Assemble only collets, nuts, cones and equilibrated tools, recommended and
distributed by MÉCANUMÉRIC, otherwise the cutting quality and the
spindle running will not be guaranted.

Precautions

Spindle with manual tool change

- Clean the tool, the collet, the nut and the spindle nose with an oil soaked rag.
- Mount the collet in the spindle nut (the lower part of the collet must be flush with the
lower part of the nut). Start to screw the nut on the spindle nose without tightening it too
much.
- Let the tool slide into the collet and leave 2 to 3 mm between the screw and the lower part
of the collet without inserting it till the bottom of the cone.
- Tighten the nut with the keys delivered together with the spindle.

Spindle with automatic tool change

- Clean the tool, the collet, the nut and the spindle nose with an oil soaked rag
- Mount the collet in the cone nut (the lower part of the collet must be flush with the lower
part of the nut). Start to screw the nut on the cone without tightening it too much.
- Let the tool slide into the collet and leave 2 to 3 mm between the screw and the lower part
of the collet without inserting it till the bottom of the cone.
- Tighten the nut with the keys delivered together with the spindle.
- Do the same with all the cones.
- Position the cones in the automatic tool changer by checking the tool disposition as it is
specified in the file you are going to carry out.
- Pay attention to the right tool N° in the spindle such as the one indicated on the remote
control with the number which follows the T letter on the display screen.
- Proceed to the measuring of every tool : go into the special functions and in the command
“tool measuring” (using F1 or F4 keys) and then select the tool number (using F2 or F3
keys), and validate with the key “DCY”.
- Measure all the tools by entering into the special functions and into the menu ‘’tool
measure’’ while shifting with X+ or X- and by selecting the number of the tool with the
Y+ or Y- keys and validate with the GV (HS) key.
- Start the procedure again for all the tools.

76

Anomalies

Defect Cause Suggestions

The collet is not adapted to the Change the collet.

tool you want to mount.
The tool slides in spite of a The tool is inserted till the Unscrew the nut and let the tool
correct tightening of the nut bottom of the cone. slightly go down.

Chips hinders the optimal Clean the tool, the collet, the nut
tightening. and the spindle nose.

The collet is not correctly Take off the tool and insert the
mounted in the nut. collet in the nut.

Chips are located between the

Out of center during the tool collet and the spindle nose,
manual rotation between the nut and the collet,
between the collet and the
miiling tool or between the cone
and the spindle nose.

77
5.2.4 Using of the option : Tool and/or material cooling

Spraying system - Lub 1 and Lub 6

Fill in the lubrication tank located on the gantry to the half with 95% water and 5 % soluble oil
« BIOMETAL » type. Do not use cutting oil to lubricate the tool.
Place the magnetic support of the watering nozzle as close as possible to the spindle nose on the hood
and direct the nozzles towards the cutting tool.

REMARK
THE LUBRICATION SYSTEM RUNS ONLY WHEN
THE SPINDLE IS IN ROTATION

Keep the “HS” key pressed on, and press on the “Spindle” key on the remote control.

Press on the “Oil spraying” key to engage the lubrication unit. The indicator light must switch on.
Adjust the lubricant and air flow with the wheels located on the lubrication tank hood. (See
documentation lubrication unit « STEIDLE. »)

The presence of a compressed air curtain called spindle overpressure

(according to the spindle) protects the front bearing of the spindle against
inauspicious raisings of droplets, dusts or chips.
Before lubricating, the user must ensure that the compressed air is
connected to the machine and that its flow is sufficient. For the machines
which are not equipped with such a system, the fact of adding a lubrication
unit through another source can irrevocably damage the spindle.

Frozen jet stream system

Place the magnetic support of the frozen jet stream as close as possible to the spindle nose on the hood
and direct the delivery nozzle towards the cutting tool.

Press onto the luminous push button located on the right side on the electric cabinet in order to
switch on the cooling unit. The indicator light must switch on when the spindle rotation is starting.

To stop the frozen air unit, uou just have to press again onto the button

Remark
The cooling system only runs when the spindle is rotating and
requests a very strong air flow (400 l / mn).

78
5.3 PREPARATION OF THE TOOL SHOP (option)

5.3.1 Type of tool shop

Static tool shop

MICRO BLOWER
COLLETS - CONE
SUPPORT

MEASURE UNIT OF THE

SAFETIES - CONES
TOOL LENGTH
PRESENCE

The static tool changer consists of a 6 tool shop with automatic tool change as well as an automatic
measuring system of the milling tool length.
The flatness measurement device is equipped with a micro blower which allows to clean the surface of
the flatness measurement device. This process allows to remove the chips which will remain on the
surface of the flatness measurement device and could cause a wrong tool measure.
This unit allows to release the operator working time and to maintain a good diving precision on the Z
axis. The tool changer can be equipped with a protection hood to be protected against the chips which
could be laid on the cones.

Safety – cones presence

A sensor placed under each collet allows to inform the numerical control of the presence of a cone or
not. This safety allows the machine not to put down a cone at a place where a cone is already laid.

79
Type of cones

Spindle Type of cones

IBAG HF 80 SKI 20
SC 62 ISO 16
PRECISE SC 4084 SHSK 25
RC 90 ISO 25
COLOMBO RC 110 ISO 30

Type of tool holder collets

Spindle Type of tool holders

IBAG HF 80 EX 16
SC 62 SRP 6
PRECISE SC 4084 EX 16
RC 90 ER 25
COLOMBO RC 110 ER 32

Automatic measure of the relative tool length

Precision +/- 1/10 mm

Maximum tool length 80mm
Limits Maximum tool diameter 24 mm

80

Rotating tool shop

The rotating tool changer consists of a 6 tool shop with automatic tool change as well as an automatic
measuring system of the tool length.
The flatness measurement device is equipped with a micro blower which allows to clean the surface of
the flatness measurement device. This process allows to remove the chips which will remain on the
surface of the flatness measurement device and could cause a wrong tool measure.
This unit allows to release the operator working time and to maintain a good diving precision on the Z
axis. The tool changer can be equipped with a protection hood to be protected against the chips which
could be laid on the cones.

Type of cones

Spindle Type of cones

IBAG HF 80 SKI 20
SC 62 ISO 16
PRECISE SC 4084 SHSK 25
RC 90 ISO 25
COLOMBO RC 110 ISO 30

Type tool holder collets

Spindle Type of tool holder
IBAG HF 80 EX 16
SC 62 SRP 6
PRECISE SC 4084 EX 16
RC 90 ER 25
COLOMBO RC 110 ER 32

Automatic measure of the relative tool length

Precision +/- 1/10 mm
Maximum tool length without collet 80mm
Limits Maximum tool diameter 24 mm

81
5.3.2 Operating mode

Tool mounting in the cones

- Clean the tool, the collet, the nut and the spindle nose with an oil soaked rag
- Mount the collet in the cone nut (the lower part of the collet must be flush with the lower
part of the nut). Start to screw the nut on the cone without tightening it too much.
- Let the tool slide into the collet and leave 2 to 3 mm between the screw and the lower part
of the collet without inserting it till the bottom of the cone.
- Tighten the nut with the keys delivered together with the spindle.
- Do the same with all the cones.
- Position the cones in the automatic tool changer by checking the tool disposition as it is
specified in the file you are going to carry out.
- Pay attention to indicate the right tool N° in the spindle such as the one indicated on the
remote control with the number which follows the T letter on the display screen.

Measure of a tool relative length

- Press onto the « # » key to enter into the special functions.

- Look for the menu « Tool measure » with the keys “F1” or “F4”.
- Look for the tool number to measure with the keys “F2” or “F3”
- Validate the request with the “DCY” key.

5.3.3 Precautions and advices

- Never change over two tools in the tool changer during an automatic running.
- Do not start the cutting program without having made the measure of all the tools.
- Do not add a tool in a free location during a running in automatic mode.
- Make sure that the cones, collets and safeties of the cone presence are thoroughly cleaned and that
the tool shop is cleared of chips.
- If the operator requests a tool measure when there is no tool in the spindle, the machine works as
if a tool is present in the spindle nose.
The machine will put the tool in the location indicated on the remote control and then stops.
Press onto a direction key, as you wish, to release the cycle and carry on with the tool measure :

While a program is being carried out in automatic mode, the error message relative to the tool changer
can appear :
The requested tool is absent
The location is busy
The cone is not placed

Pay attention to the position of the lubrication nozzle or

of the frozen air nozzle.

82
5.4 POSITIONING OF ZERO POINT OF A WORK

In this section, we will consider the positioning of the starting point of your work for each axis. There
are two ways to take a starting point of a work for each axis and 5 possibilities to safeguard the
starting point of a work.

5.4.1 First way to take a starting point of a work in X, in Y, in Z

X axis :
- Position the spindle where you want to situate your work origin point.
- Enter into the special functions to set the zero point by pressing onto the « F9 » key.
- If the position does correspond to the requested position, press onto the « F1 » key in order to
memorize the current position as being the zero of the work to carry out in the X axis.

Y axis :
- Enter into the special functions to set the zero point by pressing onto the « F9 » key.
- Press onto the « F2 » key in order to memorize the current position as being the zero of the work
to carry out in the Y axis.

Z axis :
Regarding the Z axis, there are two ways to take the zero as being the starting point of a work on this
axis.
These two ways depend on the used software. According to the software, we work on the Z axis in
positive or negative.

- Software working in negative Z :

In order to carry out the starting point of a work on the Z axis with a software working in negative, it
is necessary to touch lightly the material beofre before any further procedures.
After this operation, in order to memorize the starting point of a work on the Z axis, you just have to
proceed as for the two other axis.

- Soft working in positive Z :

In order to carry out the starting point of a work on the Z axis with a software working in positive, it is
necessary to touch lightly the consumable plate of the machine before any further procedures.
After this operation, in order to memorize the starting point of a work on the Z axis, you just have to
proceed as for the two other axis.

Warning
Do not make confusion between :
- starting point
- origin point
- zero of the work which indicate the same thing

83
5.4.2 Second way to take a starting point of a work in X, in Y, in Z
This second way consists in shifting the zero point of the three axis for a precise value. To carry out
this shifting, proceed as follows :

- Enter into the special functions by pressing onto the « F7 » key

- Then, look for the menu « Adjustment zero X », and/or « Adjustment zero Y » and /or
« Adjustment zero Z ».
- Pressing onto the «HS » key allows to choose the increment which will be added or substracted
to/from the current position.
This increment is expressed in : 0.1 mm, 1 mm, or 10 mm.
- Pressing onto the « F2 » or « F3 » keys allows to adjust the position by adding or substracting the
value of an increment at each impulse.
- Once the position is selected, memorize with the « F1. » key
- Carry out this operation for each of the three axis and come out again from the special functions
by pressing again onto the « F7 » key.

Safeguard of the work origin points

The operator has the possibility to safeguard and recover up to five different origin points of the work.

These are the safeguards of the numbers 1- 2 –3 –4 –5 in the menu Save/Recover 0 X, Y and Z axis.
The safeguard of the 0 number cannnot be modified. It only allows to register the last origin point of
the last work carried out. But the recovery of this point is possible.

Safeguard :
- Enter into the special functions by pressing onto the « F7 » key
- Look for the menu « SAFEGUARD/RECOVER 0 XYZ » with the « F1 » or « F4 » keys.
- The « F2 » or « F3 » keys allow you to increment or decrement the number of the safeguard. This
safeguard number is indicated with Z0, Z1, Z2, Z3, Z4, Z5. This indication is shown on the first
line of the display screen on the remote control, right after the indication of the linear speed of the
axis.
- Pressing onto the « F5 » key allows to register the actual position in the selected safeguard
number.
- To come out again from the special functions, press onto the « F7 » key.

Recovery :
- Enter into the special functions by pressing onto the « F7 » key
- Look for the menu « SAFEGUARD/RECOVER 0 XYZ » witht the « F1 » or « F4 » keys.
- The « F2 » or « F3 » keys allow to increment or decrement the number of the registration to find.
This safeguard number is indicated with Z0, Z1, Z2, Z3, Z4, Z5. This indication is shown on the
first line of the display screen on the remote control, right after the indication of the linear speed of
the axis.
- Pressing onto the « VALID » key allows to recover your work origin point in the selected
registration number.
- To come out again from the special functions, press onto the « F7 » key.

The safeguard of the 0 number is not possible. It only allows to

automatically register the last origin point of the work carried out. The
recovery of this point is possible with the above procedure.

WARNING : Regarding the Z axis, the safeguard is made by considering

the tool length. Therefore, it will be valid only if it is the same tool.

84
5.5 SPINDLE WITH ELECTRONIC REGULATING NOZZLE

This option allows to have a profile floow up of the material to be machined which allows a correction
of the flatness defect.

To machine by using the option « Profile follow up » :

- Slightly touch the material with the milling tool.

- Let the regulating nose go down in contact with the material.
- Press onto the « F5 » key.
- Enter into the special functions by pressing onto the « F7 » key.
- Look for the menu « profile follow up » and validate with the « F2 » key (to devalidate the
“profile follow up” function, press on the F3 key)
- Come out from the special functions by pressing onto the « F7 » key.
- Then, start the work.

Warning
Make sure that the nozzle can remain in contact with
the material during the whole travel except when passing in the air.

5.6 SPINDLE WITH KCF OPTION (SEMI CUTTING KIT)

This option allows the cutting of film stuck on a flat rigid plate (the flatness tolerance is ±
0.5 mm)

The « KCF » kit is composed of a blade holder and a kit storage holder fixed on the machine.

The blade holder must be positioned in the spindle like a normal tool in a collet of diameter 8.

The absence of the blade holder in its storage location cancels the spindle rotation.

USING PROCEDURE :

- Mount the blade holder in the spindle.

- Let the Z axis go down in order to come and tangent the plastic film.
- Make a slight moving of the X or Y axis to check the cutting depth. Adjust this cutting
depth with the Z axis.
- Enter into the special functions and make the ZERO adjustment of the three axis.
- Let the Z axis go up and start your work.

85
5.7 STARTING OF THE CUTTING

5.7.1 Operating mode

After you have prepared the material, as described in the corresponding chapter, and after you have
prepared the cutting file, proceed as follows :

- Measure all the tools used during the work

- Make the origin points of the work, and, register them, if necessary
- Check that the speed potentiometer of the spindle rotation is at the maximum
- Place the linear speed potentiometer at 0
- Send your cutting file to the machine
- Press onto the « # » key. The indicator light corresponding to this key switches off,
press on the “DCY” key, the indicator light corresponding to this key switches on.
- Gradually increase the linear speed potentiometer to check the good performance of
the work
- The spindle starts turning till it reaches its programmed speed
- As soon as the spindle reaches its programmed rotation speed, the axis move and
carry out the file which has been sent

5.7.2 Parameter modifications during the cutting

Linear speed
Two solutions are given to modify the linear speed during the cutting.

1° solution :
With this solution you can only decrease the linear speed by modifying with the potentiometer.

2° solution :
This solution implies following : stop the work, empty the buffer and modify the advance parameter in
the file and start the work.

To stop the work in progress :

- Set again the machine in the manual mode by pressing onto the « Auto/Manu. » or « F2 » key.
- The machine will finish the segment or the curve in progress; the axis will stop but the spindle
carries on its rotation.
- Press onto the « R.A.Z. » key. The spindle will stop and the buffer will become empty.

WARNING
If the file of the work sent to the machine is important and is not
contained at once in the buffer, it will be necessary to press several
times on the « R.A.Z. » key until the total cancellation of the data in
the buffer (except if the transmission is stopped before)

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Spindle rotation speed

Two solutions are given to modify the spindle rotation speed during the cutting.

1° solution :
With this solution, you can only decrease the spindle rotation speed by modifying the potentiometer.

2° solution :
This solution implies following : stop the work, empty the buffer and modify the linear speed
parameter in the file and start the work again.

To stop the work in progress :

- Reset the machine in the manual mode by pressing onto the « # » or « ARRUS » key.
- The machine will finish the segment or the curve in progress. The Z axis will go up again and the
axis will stop. But the spindle carries on its rotation.
- Press onto the « // » key. The spindle will stop and the buffer will empty.

WARNING
If the file of the work sent to the machine is important and is not
contained at once in the buffer, it will be necessary to press several
times onto the « R.A.Z. » key until the total cancellation of the data in
the buffer (except if the transmission is stopped before)

5.7.3 Tool breakage during the cutting

Programme stop
If a tool breaks during the work, you must proceed to a cycle stop.
To make a cycle stop :
- go back to the manual mode by pressing onto the « # » key. The segment or the curve in progress
will terminate. The X and Y axis will stop. The spindle will carry on rotating.
Now, the machine must be in the manual mode.
- Press onto the « Spindle » to stop the rotation of the electrospindle.

Tool change
Replace the broken tool. Then, to the adjustment of the zero « Z ».
If your machine is equipped with the option « static or rotative tool », make a tool measure. Then,
make a rewind on traject.

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Rewind on traject

- Press onto the « F7 » key to enter into the special functions.

- With the « F1 » and « F4 » keys, look for the mode « rewind on traject »
- The « F2 » key allows to come back behind a segment of a straight line or a curve.
- The « F3 » key allows to go forward from one block in the buffer.
- Coming out again by pressing onto the « F7 » key and restart the execution by pressing onto the
« # » key allows to resume the work from the point which has been defined.

5.7.4 Cutting end

At the end of the cutting, if the machine is equipped with the option « table suction », the pumps
intended for the vacuum table will stop after a temporizing of 30 minutes according to the end of the
work or by the software. This temporizing can be modified in the parameters of the numerical control.
For this purpose, please contact the CUSTOMERS SERVICE.

5.7.5 Repetitive startings of the same programme

The user has machined a piece in automatic mode with a program which size is inferior to 7 Méga-
octets. If he wants to execute it again, without restarting it from the PC, he can use the following
procedure :
- At the end of the program, the user must go back to the manual mode by pressing
onto the key « # »
- The user must not make a « RAZ » otherwise the work cannot be recovered
- Place the material on the table
- The user must press onto the « # » key to enter into the special functions
- With the « F1 » et « F4 » keys, he must look for the mode « rewind on traject »
- Pressing onto the « // » key allows to reload the program which has just been
executed in memory
- The user must come out from the special functions by pressing onto the « F7 » key
- Pressing onto the « # » key and then on the “DCY” key allows to restart the work

A short cut allows to carry out this function :

Being in manual mode, you just have to press onto the « HS » key and keeping it pressed, then press
on the “DCY” key.

88
5.8 OTHER FUNCTIONS

5.8.1 Using of the “suction nozzle”

Manual
To use the suction nose in manual moving, just press onto the nozzle key on the remote control.

Automatic
To use the suction nose in automatic moving.

Let the nozzle go down by pressing onto the nozzle up/down key on the remote control. After that, the
numerical control runs the nozzle automatically.

5.8.2 Using of the option flatness measuring device

Using of flatness measuring device :

- Moving on 2 points on the diagonal of the zone to measure.

- Press on F5 on the 2 points. Display of “Point 0” then “Point 1”.
- Loading of the programme of plotting in the special functions (after the “rewind on
traject”).
- Selection of the meshes by the F2 or F3 keys, and loading with ths HS key (meshes of 5,
10, 20, 40 mm).
The mesh 0 is used o delete a measure, tha it to cut without any flatness correction.
- Starting of the measuring process by going to automatic mode (the zero point in X and Y
must not be changed before starting the measuring).
Working condition :
The user must have defined the zone on which he wants to make the plotting and the
buffer must be empty.
- Put the sensor again in its place, and mount an engraving or cutting tool in the spindle.
- Adjust the zero point in X and Y axis (if you have not done it yet), the zero point in Z
must be taken compared to the material surface.
- Carry out normally the work.

General remarks :
The correction is made only at the points between the different blocks and is interpolated
between those different points.
If the blocks are long, they will have to be decomposed with the CAD software.
The correction is the same in a square zone around the measuring point, and has the same size
than the value of the mesh.
The zero point in Z must be taken compared to the material surface.

The parameter p63 allows to define the maximum travel during the plotting.
Example : for a plotting of maximum 4 mm, p63 = 4000.

This system will work correctly only if the correction to be made is low (correction of flatness
defects of the material, but not of peaks and holes).

89
 Chapter 6 – General maintenance
of the equipment
The maintenance of your machine is very important for its long life.

The spindle is the most fragile part of the machine. Its reliability and its life time are highly depending
on its using and on the care taken for its maintenance.
- Always use equilibrated tools according to the rotation speed of your spindle.
- Avoid to knock the spindle nose.
- Always proceed to the preheating of your electrospindle.
- Do not use damaged collets and tool holders

Respect the items mentioned below.

6.1 DAILY MAINTENANCE

The cleaning of the machine must be done every day through chip or dust suction of the materials to
be machined during the day.
Clean all the bellows in order to remove all the chips which could damage and limit their life time.

WARNING
Never use the blower to clean the machine or the spindle. The use of the
blower could let chips enter into some parts of the machine or some parts of
the spindle and this would be irremediable for your equipment.
Every night, empty the chip suction tank, take out and clean the filter. In case of very expanding chips,
do this operation again as much as it is necessary.

Check the lubrication level of the tool. Fill in half of the tank located on the gantry of the machine
with 95% water and 5% soluble oil ( BIOMETAL)

The lubrication tank must be filled in through the end cap located on the top of the tank cover.
In the filling hole, you will find a thin filter to stop the impurities which could be mixed up with the
liquid during the filling. Regularly clean this thin filter by putting it under the water. The filter must be
regularly replaced according to the dirtying.

Regarding the filter supply, please contact MECANUMERIC’s CUSTOMERS SERVICE.

6.2 MONTHLY MAINTENANCE

Greasing
- Lubricate the nut of the ball screw X, X1, Y and Z.
- Lubricate the ball slides of the guidances for all axis.
- The greasing must be done every 500 hours or minimum once a month.
- Use a grease with a lithium base – consistency grade NLGI 2 DIN 51818.
- Check the tension of the driving belts of the ball screws.

90
6.3 FROM TIME TO TIME

Spindle cooling liquid

The cooling tank is filled in with water plus a biocompatible additive.

The biocompatible additive develops bacteria in the form of a thin skin which take shape at the
surface of the contents of the cooling tank. It is absolutely necessary to regularly evacuate this bacteria
thin skin, because it causes a dirtying of the cooling circuit and of the electrospindle.
This dirtying would create stoppers in the circuit and would modify the electrospindle cooling.

WARNING
A bad cooling could generate irremediable electrospindle damages

Check the level and the state of the cooling liquid twice a month and complete, if necessary, by adding
water and 3 to 4 % additive according to the additional water quantity.

WARNING
When it is very hot, bacteria develop much quicker. Therefore it will be
necessary to proceed to the evacuation of the thin skin more often, and, at
the minimum, once a week.

Draining of the spindle cooling liquid

The draining of the cooling circuit must be made every 500 hours.

Before draining the circuit, it is recommended to bring an additional system cleaner TST.

Using condition of the system cleaner TST :

Clean and disinfect the cooling tank from the present bacteria, before renewing the cooling water, add
1% of the system cleaner (1 litre for 100 litres water).
It must act and circulate at least during 24 hours. You can carry on working normally. Hence, there
will not have any production loss.

After the 24 hours circulation of the system cleaner, completely drain the cooling tank and fill it in
with clean water by adding 3% to 4% of refrigerating liquid « FRIGOSOL MOTOREX »

91

Maintenance of the tool holders

Periodicity :

Once a week, if you are in a region with a saline air it will be necessary to proceed to a more
frequent maintenance.

For the machines with automatic tool change, it is necessary to clean the inside part of the spindle with
a clean and slightly oiled rag. Never use a small blower for the cleaning.

The tool holder cones and collets will be soaked in oil. This oil must have a minimum viscosity like oil
for weapons.

Also check that the cones are in excellent state and only use cones supplied by MÉCANUMÉRIC with
tools, nuts and equilibrated tools.

Any accessories, products and maintenance materials can be supplied by

Mécanuméric’s customers service.

92
 Chapter 7 – Electrospindle
characteristics

Spindle Power Speed Cooling Overpressure Type of cone

VS 60 4000 W 21900 rpm Autoventilated No No cone
HEN 40 800 W 24000 rpm Ventilated 0.4 bar No cone
ZEN 40 2500 W 24000 rpm Ventilated 0.4 bar No cone
RS 90 5500 W 24000 rpm Ventilated No No cone
RC 90 4000 W 24000 rpm Air No ISO 25
RC 110 7400 W 30000 rpm Air No ISO 30
HF 80 2.7 – 3.2 KW 40000 rpm Water 1.2 bar SKI 20
SC 62 1100 W 60000 rpm Water
SC 4084 2800W 40000 rpm Water

TOOL MAXI DIAMETER (mm) TOOL MAXI LENGTH (mm)

USED With tool Without tool With tool Without tool TOOL MAXI
SPINDLE changer option changer option changer option changer option WEIGHT (g)
VS 60 No tool changer 35 No tool changer 12 x diameter 100
HEN 40 No tool changer 30 No tool changer 12 x diameter 80
ZEN 40 No tool changer 30 No tool changer 12 x diameter 90
RS 90 No tool changer 35 No tool changer 12 x diameter 100
RC 90 24 35 80 12 x diameter 100
RC 110 24 80 12 x diameter
IB 80 24 25 80 12 x diameter 90
SC 62 24 80 12 x diameter
SC 4084 24 80 12 x diameter

Perske VS60 Spindle

- Electric characteristics
Voltage : 380 volts - Maxi frequency : 360 Hz - RPM : 21900 - Power : 4.4 Kw

- Accessories : collets – nuts

The spindle is delivered together with :
1 nut M27 1,5 right - 1 flat key of 24mm -1 featherhead key ref : 125A-50
1 set of basic tool holder collets ref. OZ1833

The spindle can accept tools till an end diameter of 12 mm maxi.

Non equilibrated, higher sized tools, cones or collets which are not referenced by MECANUMERIC
would seriously damage the spindle. We also recommend to use quality tools in order to get better
results.

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 Fischer HEN40 Spindle

- Electric characteristics
Voltage : 380 volts - Maxi frequency : 700 Hz
RPM : 42000 - Power : 0.800 Kw

- Accessories : collets – nuts

The spindle is delivered together with :
1 nut 61-16720
2 keys 1 E16 SCHAUBLIN and 1 JR 40-50
1 set of basic tool holder collets ref. EX16 UP

The spindle can accept tools till an end diameter of 10 mm maxi.

Non equilibrated, higher sized tools, cones or collets which are not referenced by MECANUMERIC
would seriously damage the spindle.
We also recommend to use quality tools in order to get better results.

Fischer ZEN 40 Spindle

- Electric characteristics
Voltage : 380 volts
Maxi frequency : 400 Hz
RPM : 24000
Power :2.700Kw

- Accessories : collets – nuts

The spindle is delivered together with :
1 nut 61-16720
2 keys 1 E16 SCHAUBLIN and 1 JR 40-50
1 set of basic tool holder collets ref. EX16 UP

The spindle can accept tools till an end diameter of 10.mm maxi.
Non equilibrated, higher sized tools, cones or collets which are not referenced by MECANUMERIC
would seriously damage the spindle.
We also recommend to use quality tools in order to get better results.

94
 Colombo RS90 Spindle

- Electric characteristics

Voltage : 380 volts

Maxi frequency : 300/400 Hz
RPM : 18000/24000
Power : 5.5 Kw

- Speed – power diagram

V
kW

380 5.5

190 2.75

0 Hz
150 300 400

RPM
0 9000 18000 24000

- Accessories : collets – nuts

The spindle is delivered together with :
1 nut GST25
1 flat key of 27 mm
1 featherhead key ref : 125A-50
1 set of basic tool holder collets ref. ER25

The spindle can accept tools till an end diameter of 13 mm maxi.

Non equilibrated, higher sized tools, cones or collets which are not referenced by
MECANUMERIC would seriously damage the spindle.
We also recommend to use quality tools in order to get better results.

95
 Colombo RC 90 Spindle

- Electric characteristics
Voltage : 380 volts
Maxi frequency : 500 Hz
RPM : 30000
Power : 4 Kw

- Speed – power diagram

V
kW

380 4

190 2

0 Hz
200 400 500

RPM
0 12000 24000 30000

- Accessories : collets – nuts – cones

The spindle is delivered together with :

1 flat key of 27 mm
1 featherhead key ref : 125A-50
6 tool holder cones ISO 25 Ref : ER25 with nuts Ref : CP25 as per option
1 set of basic tool holder collets ref. ER25

The spindle can accept tools till an end diameter of 13 mm maxi.

Non equilibrated, higher sized tools, cones or collets which are not referenced by
MECANUMERIC would seriously damage the spindle.
We also recommend to use quality tools in order to get better results.

96
 Colombo RC 110 Spindle

- Electric characteristics

Voltage : 380 volts

Maxi frequency : 500 Hz
RPM : 30000
Power : 7.4 Kw

- Speed – power diagram

V kW

380 7.4

190 3.7

0 200 400 500 Hz

0 12000 24000 30000 RPM

- Accessories : collets – nuts – cones

The spindle is delivered together with :
1 flat key of 36 mm
1 featherhead key ref : 125A-50
6 tool holder cones ISO 30 Ref : ER30 with nuts Ref : CP30 as per option
1 set of basic tool holder collets ref. ER30

The spindle can accept tools till an end diameter of 16 mm maxi.

Non equilibrated, higher sized tools, cones or collets which are not referenced by
MECANUMERIC would seriously damage the spindle.
We also recommend to use quality tools in order to get better results.

97
 Ibag HF 80 Spindle

- Electric characteristics

Voltage : 380 volts

Maxi frequency : 1300Hz
RPM : 40000
Power : 3.2 Kw

- Speed – power diagram

3.5

2.5

2
[KW]

1.5

0.5

0
0 5 30 35
10 15 20 25 40

[x1000 rpm]

- Couple diagram
0.8

0.7

0.6

0.5
[Nm]

0.4

0.3

0.2

0.1

0
0 5 30 35
10 15 20 25 40

[x1000 rpm]

- Accessories : collets – nuts – cones

The spindle is delivered together with :
1 flat key of 18 mm
1 flat key of 22 mm
6 tool holder cones SKI 20 Ref : SKI 20 with nuts Ref : 61-16721 as per option
1 set of basic tool holder collets

The spindle can accept tools till an end diameter of 10 mm maxi.

Non equilibrated, higher sized tools, cones or collets which are not referenced by
MECANUMERIC would seriously damage the spindle.
We also recommend to use quality tools in order to get better results.

98
 Précise SC 62 Spindle

- Electric characteristics

Voltage : 380 volts

Maxi frequency : 1000Hz
RPM : 60000
Power : 1.1Kw

- Accessories : collets– cones

The spindle is delivered together with :
1 eye key Précise Ref : 152508
1 flat key of 9 mm
6 collet holder cones Ref : ISO16 with nuts as per option
1 set of basic tool holder collets

The spindle can accept tools till an end diameter of 8 mm maxi.

Non equilibrated, higher sized tools, cones or collets which are not referenced by
MECANUMERIC would seriously damage the spindle.
We also recommend to use quality tools in order to get better results.

Précise SC 4084 Spindle

- Electric characteristics

Voltage : 380 volts

Maxi frequency : 1300Hz
RPM : 40000
Power : 2.8 Kw

- Accessories : collets – nuts – cones

The spindle is delivered together with :

1 flat key of 24mm
1 square key of 18 mm
6 collet holder cones Ref : SHSK25 ATC4-25.16 with nuts (as per option)
1 set of basic tool holder collets

The spindle can accept tools till an end diameter of 10 mm maxi.

Non equilibrated, higher sized tools, cones or collets which are not referenced by
MECANUMERIC would seriously damage the spindle.
We also recommend to use quality tools in order to get better results.

99