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User’s Handbook

I.M.00 User’s Handbook


versions
B1200 smart
B1200 smart S

N°: M.U. B1200 ST - Date: 10/07/2006 - Cod: T140-00325_0


T140-00325_0

General Instructions
Index

1.1 Safety regulations and precautionary measures . . . . . . . . . . . . . . 1


1.2 Expected Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Electromagnetic fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Symbols, signs and typographic conventions. . . . . . . . . . . . . . . . 4

Machine description
2.1 Main components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Elements of control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Axes of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Control board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 HSK 63 tool connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.6 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.8 Signal devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.8.1 Information and warning . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.8.2 Warning plates and signs. . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.9 Hazardous points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.10 Residual Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.11 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Technical Specifications
3.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Power diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.1 Main Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.2 Sub-spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2.3 Motor-driven headstock . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3 Axes stroke scheme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.4 Specifications of HSK 63 tool taper . . . . . . . . . . . . . . . . . . . . . 24
3.5 Noise level and vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Transportation
4.1 General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2 Transportation equipments . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.3 Arranging the transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4.1 Swarf conveyor lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.5 Transportation with package . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Machine installation
5.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2 Installation environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3 Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4 Rests and machine positioning . . . . . . . . . . . . . . . . . . . . . . . 38
5.5 Positioning the swarf conveyor . . . . . . . . . . . . . . . . . . . . . . . . . 41
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Connections

Index
6.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.2 Electric cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.2.1 Power supply and protection . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.2.2 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.2.3 Connection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.3 Compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.4 Swarf conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.5 Control pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.6 Tank positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.7 Final controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Controls
7.1 Safety and reliability of control systems. . . . . . . . . . . . . . . . . . . . 53
7.2 Machine switching on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.3 Machine switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.4 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.4.1 Restarting after EMERGENCY . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.5 Front sliding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Tool magazine – ATC (Automatic Tool Change)


8.1 Machine description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.2 Magazine description and tool data on NC . . . . . . . . . . . . . . . . . 61
8.2.1 Tool data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.2.2 Tool magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.3 Manually loading tools in the chain . . . . . . . . . . . . . . . . . . . . . . . 68
8.4 “ARCHIVE” and “LIFE” Management . . . . . . . . . . . . . . . . . . . . . . . 69
8.4.1 Initialization of tool table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.5 Tool loading (rear side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.6 Tool setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.6.1 General remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.6.2 Tool setting by tool-setter arm . . . . . . . . . . . . . . . . . . . . . . . 72
8.7 Usefulness concerning the ATC (Automatic Tool Change). . . . . . . 74
8.7.1 Tool table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.7.2 Menu of ATC manual commands. . . . . . . . . . . . . . . . . . . . . . 76
8.7.3 Operational notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.7.4 Diagnosis of ATC phases . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.7.5 Inclined manual movement. . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.7.6 List of “M” functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.8 Tool phase advancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Main Spindle, Tailstock and Subspindle


9.1 Main Spindle (Smart version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.1.1 Main spindle - hole Ø 95 mm ASA 8” . . . . . . . . . . . . . . . . . . 87
9.1.2 Main spindle - hole Ø 102.5 mm ASA 8” . . . . . . . . . . . . . . . . 88
9.2 Main spindle with electrospindle (Smart S version) . . . . . . . . . . . . 89
9.3 Overall dimensions for bar feeder assembly . . . . . . . . . . . . . . . . 90
T140-00325_0

9.3.1 Bar guides for Smart lathe and Smart S electrospindle . . . . 91


Index

9.3.2 Bar guides for version with hole for bar passage 102.5 . . . . . 92
9.4 Spindle of sub-spindle (Smart S) . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.5 Chuck machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.5.1 Assembling chucks and collets on the main spindle
Ø 315/95 Chuck on spindle – hole Ø 95 ASA 8” . . . . . . . . . . 95
9.5.2 Assembling chucks and collets on counterspindle
ø 250/77 Chuck on spindle – hole ø 67,5 ASA 6” . . . . . . . . . 97
9.6 Tailstock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
9.6.1 Adjusting thrust pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . 99
9.6.2 Setting sleeve feed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
9.6.3 Adjusting sleeve micro limit switches . . . . . . . . . . . . . . . . . . 100
9.6.4 M.T. fixed bushing (Standard) . . . . . . . . . . . . . . . . . . . . . . . 101
9.6.5 Bushing with concentricity adjusting and lock ring
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.6.6 Tailstock with integral rotating head (Optional) Dis.
10.27.50.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.7 Steady-rest (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9.7.1 Shift in the working position . . . . . . . . . . . . . . . . . . . . . . . . 106
9.7.2 Adjusting the locking pressure by the pressure switch . . . . . 107

Maintenance
10.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.2 Characteristics of consumables . . . . . . . . . . . . . . . . . . . . . . . . . 110
10.2.1 Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
10.2.2 Lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
10.2.3 Oils for coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
10.2.4 Oils for hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
10.2.5 Liquid for cooling assembly . . . . . . . . . . . . . . . . . . . . . . . . 112
10.3 Checks to be done before starting the machine up . . . . . . . . . . 112
10.3.1 Chuck jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
10.3.2 Machine conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
10.3.3 Lubrification system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
10.3.4 Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
10.3.5 Procedure of electropump topping-up . . . . . . . . . . . . . . . . 117
10.3.6 Hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
10.3.7 Air treatment unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
10.3.8 Cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
10.4 Checks to be done after machine switching on . . . . . . . . . . . . . 120
10.5 Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
10.5.1 Disassembling oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
10.6 Cleaning the coolant unloading area (for machines with
unloader, only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
10.7 Covering, axes and guideways . . . . . . . . . . . . . . . . . . . . . . . . . 123
10.8 Tool magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
10.9 Maintenance program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
T140-00325_0

Operational personal

Index
11.1 Professional profiles of machine operators. . . . . . . . . . . . . . . . . 126
11.1.1 Unskilled operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
11.1.2 Tooling-up operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
11.1.3 Maintenance man . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
T140-00325_0
Index

Page intentionally left blank


T140-00325_0

General Instructions

Generals Instructions
1.1 Safety regulations and precautionary measures
Biglia lathes are built in accordance with the current technological
situation, with the safety regulations and with the European directive
98/37/CE, and according to the most modern designing criteria.
To have the lathe work in safety conditions and with optimum
performances, it is necessary for it to be carried in the appropriate
conditions, that it is perfectly installed and started up and that all this
is made by a well-trained and expert staff, that it is used according to
the guidelines provided by Biglia, and that it undergoes an accurate
and recurrent maintenance.
To this purpose, it is fundamental to follow the instructions contained
in the following documents:
• operating manual;
• user’s manual;
• maintenance manual;
• programming manual;
It is possible that your machine differs in some details from the
illustrations present in this manual: these differences do not influence,
in any way, the commands of the machine.
This user’s manual is absolutely necessary to use the machine in
complete safety and it has to be always kept by the machine, together
with the safety manual.
1.2 Expected Usage
This multifunction milling-turning centre with 5-axes and its accessory
parts are designed for the machining of a wide range of ferrous and
plastic materials having dimensions compatible with the work area, with
the powers available to the spindle, to the axes and to the clamping
equipments.
The fields in which they can be used are turning, threading and
milling.
This turning-milling centre can operate, for example, in the fields of
aeronautics, aerospace, medicine, automotive, hydraulics and general
mechanics.

The firm Biglia forbids:


• any use different from the one provided and indicated in this
manual;
• using this machine in technical conditions which are not perfect,

 1.1 Safety regulations and precautionary measures


T140-00325_0

or without taking into consideration (in part or completely) the


Generals Instructions

instructions for safety and for the prevention of dangers;


• using the machine without observing the instructions given in
the user’s manual, in the maintenance one and in the safety
one;
• ordinarily using the machine before eliminating those troubles
that can compromise safety;
• any change and decommissioning of the safety devices which
are on the machine, either if they are useful for it to work
properly, either if they are of use for its active and passive
safety.
Because of these behaviours, some unexpected dangers can occur
and they can damage either people’s life, the machine and other
patrimonial estates of the firm and of the operator.
_____________________________________________
Warning
! The regulations/behaviours listed above are to be
considered as not consonant to the machine use and they
exclude any responsibility of the manufacturer.
_____________________________________________

_____________________________________________
Warning
! This machine has NOT been designed to machine:
• ceramic materials;
• plywood with synthetic resins;
• materials that can easily trigger a fire or an explosion
(magnesium, silicon, etc.) without the appropriate
safety measures.
____________________________________________
Important
! If the machined material produces volatile substances
(fumes, dust, aerosol, etc.), a suction system
equipped with special filters to hold back the noxious
substances will be installed. The machines by Biglia
can be equipped with particular supplementary
equipments (automatic steady rest in cycle, kit for
bar machining, tool load monitoring) which are able
to accurately widen their field of application.

1.2 Expected Usage 


T140-00325_0

1.3 Staff

Generals Instructions
Only a reliable staff, who has been duly authorized and who has gained
a specific expertise in this field, shall be employed on Biglia lathes.
Without the necessary training, none can work on the machine, even
not for short intervals or under an external control.
__________________________________________

i Note
The specific skills needed to perform the various
activities safely and with optimum outputs have to
be exhaustively and certainly defined by the user
company, which takes the responsibility to control
their conformity.
__________________________________________

The company using the Biglia turning-milling center will have the task
to check if the user’s manual has been read and fully understood by
the personnel who will use the machine.
Moreover, the end-user company has the duty to constantly observe
the general technical conditions of the machine.
By general technical conditions, we mean those defects and damages
that can be externally recognized and the changes in the machine
working conduct.
Fixing and maintenance need to be carried out only by the staff who
has been specifically trained and qualified for their respective technical
abilities (electric, electronic and hydraulic sectors, CNC, etc.) and who
observes all the instructions contained in this manual.

1.4 Environment
The machine described in this manual can machine and produce
substances noxious for the health of the environment, in accordance
with what is contained in the European directives concerning this
subject and with the respective national laws.
Therefore, during daily activities, such as the dismantling and
decommissioning of the machine, official regulations concerning
environment protection shall be observed by the user.

 1.3 Staff
T140-00325_0

1.5 Electromagnetic fields


Generals Instructions

On Biglia turning-milling centres, there are some devices (electric


motors, transformers, etc.) that generate magnetic fields, sometimes
even of a high intensity.
Any person carrying a pacemaker or metal implantations and pregnant
women must not stay within a ray of 70 cm from the machine.
In the same way, objects that could be damaged by its magnetic field
(such as watches, data platforms, smart cards) should not be taken
within the interference ray of the machine.

1.6 Symbols, signs and typographic conventions


A hierarchy organization of the manual, reminding the concepts of
the Directive on Machines 98/37/CE, has been adopted inside the
Biglia manuals in order to keep the exposition of contents as much
clear as possible.
The adopted coding form provides for a subdivision of contents
according to thematic chapters, which are then divided into paragraphs
and sub-paragraphs, identified according to a progressive numerical
code.

Example
The information 5.4.2 placed at the top of a text means that you are
consulting the sub-paragraph 2 of the paragraph 4 included in chapter
5.
In order to go through easily in the manual, the identification of the
manual, the progressive number of the page, and the headings of
the chapter and the paragraph have been reported on the margins of
each page.

1.5 Electromagnetic fields 


T140-00325_0

To make clearer the safety instructions, the warnings for dangers and
the suggestions for an optimum usage, the following symbols are
used in this manual:

i Note
Special uses and applications for an advantageous and
economic employment of the lathe

Specific instructions and recommendations for the

! Important execution of commands, the reactions and the optimum


uses of the lathe

!
Special instructions, orders and prohibitions for the
Warning prevention of dangers

Sequence of operations to be carried out, keys to be


Procedure pressed, safety devices to be activated in order to
perform an action

The communication with this symbol by contain some


Environment warnings about environment.

 1.6 Symbols, signs and typographic conventions


T140-00325_0

Machine description
Machine description

2.1 Main components

A
O

Q C

B D

I
F
M
G

P
L

A Two-sector tower light H Cover of the bar guide


B Main switch M CE marking
C Sliding doors N Switch for door closing
D Movable console O Automatic opening and
E Swarf conveyor belt closing device
F Tailstock pressure gauge P Pedal connections
G Pressure gauge of jaws locking Q Electric cabinet

2.1 Main components 


T140-00325_0

Machine description
C

A B

E
M

D
H

A Topping-up point of the coolant G Key selector switch for the tool
B Indicator of the level of the liquid in magazine door
the cooling assembly H Hand drives for the rotation of tool
C Thermal conditioning assembly of magazine
the electric cabinet I Emergency stop push-button
D Ventilation of the spindle – engine L Button for the electric cabinet door
assembly unlocking
E Heat exchanger of the electric M Electrical rating of the electric
cabinet cabinet
F Couple of buffer batteries of the NC N Connection of the bar-feeder

 2.1 Main components


Machine description T140-00325_0

B N
A L
O

P H

B
G

C
F
D E

A Swarf conveyor belt drive H Panel accessing the unit


B Indicator of the coolant level I Rear panel accessing the tool
C Topping-up point of the coolant magazine
D Connection of the swarf conveyor L Sliding door on tool magazine
belt M Removable tank
E Filter of coolant at low pressure (4,5 Q Air treatment unit and slide greasing
bar) unit
F Indicator of the oil level in the N High pressure pump (18 bar)
hydraulic unit O Low pressure pump (4 bar)
G Topping-up point of the oil in the unit P Swarf unloading

2.1 Main components 


T140-00325_0

2.2 Elements of control

Machine description
The elements of control that are on the machine are listed below.
• Main switch
• Sliding window of the tool magazine
• Emergency stop in the area of the tool magazine
• Door of the work zone
• Control board with drive and emergency stop button
• Pedal to control tailstock forward/backward
• Pedal to control chuck opening/closing

2.3 Axes of the machine


Names and directions of the movement of machine axes, accord-
ing to the machine related movements along the X, Y, Z, B, C axes
(electronic).

 2.2 Elements of control


T140-00325_0

2.4 Control board


Machine description

B
I
C

E
H

G
F

A PCMCIA Slot G Key selector switch for safety devices


B 10.4” Monitor H Biglia control board
C Soft keys I Fanuc control board
D Emergency stop push-button L Socket RS232 and 220V (on the board
E Key selector switch of the operating side)
modes M Luminous LEDs
F Indicator of tool releasing

The elements of control of the machine and the way in which the
keys and buttons, present on the board, work are described on the
Operating Manual, Section A, of the machine, to which you should
refer.

2.5 HSK 63 tool connection


The tool changer unit uses an approved conical connection of HSK
63-A type, in compliance with the Standard ISO 12164 Part 1, as a
link between the spindle and the tool. For the turning tools, we use,
as a reference, the standard ICTM with a closer tolerance on the
small key at the bottom of the conical seat.

2.4 Control board 10


T140-00325_0

Machine description
ø 120

ø 90

43
18
8
25

ø 12

Inside the HSK 63 connection, there are two pneumatic systems:


• Blower for cone-cleaning, performed during the tool unloading
and the loading of the new tool;
• Checking of the tool presence P.E.L.

2.6 Safety devices


In compliance with the instructions of the directives on machines
and with the international regulations, in order to avoid any possible
accident, the machine is equipped with a series of safety devices
which eliminate any risk and danger for the operator and any damage
for the machine.
The essential safety components can be grouped in four macro
categories:
1. protection guards against chippings, sprinklings and high
temperatures; SAFETY

2. mode key selector switch for bi-manual drive;


ON OFF

3. magneto-thermic and electrical devices;


4. guarded doors.

11 2.6 Safety devices


T140-00325_0

The machine protection guards completely wrap up the machine


Machine description

and so they prevent fluids and swarfs from being thrown against the
operator or even they prevent the operator from entering into contact
with high temperature areas.
The machine guards are fixed to the frame through screws or locks
requiring tools of different shapes to be removed.

_________________________________________

! Important
Since the machine guards are not connected to
electromechanical devices which block the working
of the machine if they are not assembled, make sure
that all fastening screws are at their place and that
the guards are firmly installed, after carrying out a
maintenance intervention.
_________________________________________

An integral part of the guard are the glass panels of the front sliding
doors and of the rear tool-magazine window.
It is a toughened and multilaminated glass which protects the operator
from the throwing of objects in normal working conditions.
On the movable control board and in the rear area of the machine
(tool magazine), there is a two-position key selector switch with spring
return.
When in mode ON, all the safety devices of the machine are on, the
machine works normally with its standard characteristics and in safe
conditions (guards closed during working).
When in mode OFF, the machine can work with neutralized safety
devices (open guards), but at the following conditions:
• presence of only one operator;
• it is not possible to carry out movements in automatic or
semiautomatic way;
• the movements of the actuating components and of the turret
are executed at low speed and can be implemented only through the
simultaneous control of the their respective push-buttons and of the
key in OFF (two-hand control devices at continuous motion).
Passing from the ON condition to the OFF condition causes the
RESET of all machine functions.

2.6 Safety devices 12


T140-00325_0

_________________________________________

Machine description
! Important
The key of the selector switch shall be kept by the
operator responsible for the machine. Only expert,
qualified and authorized personnel shall be allowed
to use the machine with neutralized safety devices
_________________________________________

2.7 Lighting
In the machining room, there is a device (A) for auxiliary lighting (neon)
which supplements the one in the work area.

They are lamps for specific use in the sector of tool machines, but they
can be easily bought by any dealer of electrical material, in conformity
with the specifications contained in the spare part catalogue.
Even though set in the upper part of the machining room, in a quite
protected area, they are subject to the sparkling of the coolant and
to the throwing of swarfs and so to breakings: in order to guarantee
an optimum lighting, they have to be cleaned regularly and their
functioning has to be checked every day.

13 2.7 Lighting
T140-00325_0

2.8 Signal devices


Machine description

2.8.1 Information and warning


The CN control and the machine communicate with the operator
through video graphic interfaces.

The communication terminals are the 10,4” color monitor, which is


placed on the mobile control station, and a bi-color lamp (red and
green), put on the roof of the machine.
The tower light is made up of two sectors:
• fixed green sector: it signals the condition of ongoing cycle.
• flashing red sector: it signals the condition of stopped
machine.

2.8.2 Warning plates and signs


The adhesive or metal plates stuck on the machine are just warnings
about residual risks. They are an important part for the preservation
of safety conditions for the operator and of integrity for the machine;
therefore, they don’t have to be removed or displaced.
For some components which have not been directly manufactured
by Biglia, the original plates, applied by the manufacturer, have been
kept.
The applied warning plates refer to the European Directive 92/58/CEE
which acts according to the logic of colors that has been synthetically
described in the preceding paragraph.

2.8 Signal devices 14


T140-00325_0

2.9 Hazardous points

Machine description
The concept of hazardous point let us locate those areas which are
exposed to risk.
According to the “Directive on Machine” 98/37/CE, a hazardous point
is any area within and/or near a machine where the presence of an
exposed person (any person who is completely or partly within the
hazardous point) constitutes a risk for the safety and health of this
same person.
By exposed person, we intend any person that can be (entirely or
partly) in the immediate vicinity of the machine, without being the
operators or the qualified personnel in charge of its maintenance.
So, exposed people can also be other people who work in the company
or visitors.
In light of these concepts, Biglia thinks that the hazardous point can be
located inside a perimeter area having the following dimensions:
• L x P = 7.150 x 4.250 mm
• L x P = 7.500 x 4.400 mm (subjects who are sensitive to
electro-magnetic emissions).
The space included within this rectangle will have to be free from
obstacles, clean and sufficiently lit up (at least 300 lux).

B
B
50
4.2
A 7.1
50

A Movement area of the machine operator


B Area destined to the maintenance-man or to the unloading of
the swarf truck.

2.10 Residual Risks


While designing and drafting this manual, Biglia company took into
account the risks that can be encountered during a normal use of
the machine and it has weighed the abnormal conditions that can be
reasonably expected.

15 2.9 Hazardous point


T140-00325_0

Nevertheless, in spite of the solutions adopted, some particular risk


Machine description

situations remain, and they can be safely managed by the user by


following the related instructions given below.
• Protection guards. As described in the paragraph 2.6, the
protection guards which prevent from accessing the openings of the
machine do not have any electro-mechanical devices which disable
the functions of the machine or which stop its functioning, when they
are not installed or correctly fixed.
Therefore, it is very important that the unskilled operator, the
maintenance-man and the person in charge of the machine check
the presence and the correct installation of protection panels, since
the machine do not have to work without them.
• Swarf conveyor. The area of the swarf conveyor is uncovered in
its terminal part so as to allow swarf unloading in the waste container.
The transport mechanism is composed by moving components and,
so, there is the risk that it clasps parts of the body and/or clothes: in
order to reduce this risk factor, you have to use specific containers for
swarfs that can be perfectly coupled to the conveyor. It is absolutely
forbidden to perform any maintenance operation while mechanical
organs are moving.
• Bar billet machining. The machine is suitable to machine bar
billets that can be inserted into the spindle hole: there is the risk that,
if the bar juts out too much, people in transit within the working area
can be damaged. In order to eliminate this risk, don’t let the bars
project out of the machine protection cover.
• Chuck machining. When machining with chuck, there is the
risk that a wrong selection of jaws can cause damages to the machine
and to the operator. Carefully select the jaws to use on the basis of
the machining you are going to execute.
• Front protection glass panel. There is the risk that the glass
panel, though toughened, may not bear an extremely violent stress
by a very large-sized object. Always carefully weigh the instructions
on this manual about the dimensions of the objects that can be
machined and the respective rotation speeds of the spindle.
• Throwing and falling of objects. It has been considered the
possibility that the presence of objects on the machine can cause
wounds to the operators present in the operating area of the machine.
An adhesive warns that you cannot put objects of any nature on the
machine.

2.10 Residual risk 16


T140-00325_0

• Presence of residual energy. It exists the risk that in the machine

Machine description
circuits (electric, pneumatic, hydraulic) there are some residual
energies in the accumulation devices even after switching off power to
the machine. Always carry out an operation of plant unloading before
starting any maintenance and tooling intervention.
• High temperatures. Machining frictions engender a high
temperature of objects and of coolants. To eliminate this risk, always
use your IPDs (Individual Protection Devices), such as protective
gloves, goggles and suitable clothing.
• Noise. Materials and machining parameters produces very
strong stresses to the hearing. This risk is taken back within acceptable
physical parameters if operators always use oto-protective devices.
• Gas and dust emission. When machined, some materials can
produce gases/dusts which are noxious for man’s health. If necessary,
install appropriate air filtering systems and regularly check their
efficacy.
• Using the machine in the manual mode/fitting out. In the operating
“manual” mode, even though the machine working parameters are
very low and there is the bond of the continuous double control, there
is the risk that objects/fluids (i.e. swarfs and coolant) may be thrown
against the operator, with open door. Always wear your IPDs, pay your
greatest attention and control that no other people, a part from the
operator, are within the machine operating area.
• Managing tools in the automatic magazine. Loading the tool
magazine and/or replacing tools which are already in represents a
residual risk if the operator doesn’t update the tool chart or if he does
it in an incorrect way. Always accurately check the correspondence
between the chart and the tools inserted in the tool magazine.
• EMC – Electromagnetic emissions. The present electric
components (engines, transformers, etc.) produce a magnetic field,
sometimes of high intensity. For particular subjects (for example people
carrying a pacemaker, or metal implantations, pregnant women) there
is the risk of health damages. To avoid this risk, a safety area of 70
cm around the perimeter of the machine has been provided for these
people.
• Coolant dripping. After machining, the walls of the machining
room are covered with coolant. There is the residual risk that a certain
quantity of drops may fall down on the operator during the phase of
piece loading/unloading.

17 2.10 Residual Risk


T140-00325_0

• Allergies to materials. For some categories of particularly


Machine description

sensitive people, an allergic reaction to some products, used


during the machining of the material, could occur. Together with the
company’s doctor and your personal doctor, consider very carefully
the instructions contained in the product safety cards and perform all
the preventive actions that you think appropriate.
• Environmental conditions. Evaluate with attention the working
environmental conditions: in very heavy environmental conditions
(beside what indicated in this manual), some components could not
work as expected.

2.11 CE marking
Below the movable control board, in a highly visible place, a metal
plate, fixed through rivets, is stuck on each machine, and it identifies
the machine according to what required by the directives on machines
98/37/CE,.

On each plate there is at least the following minimum information,


written with indelible characters:
• identification of the manufacturer and address;
• the EC marking (according to annex III of the European
Directive 98/37/CE);
• designation of model;
• serial number;
• year of manufacture;
• total weight of the machine.

2.11 EC marking 18
T140-00325_0

Technical Specifications

Technical Specifications
3.1 Technical Data
Unit Technical specification SMART SMART S
Overall Height (mm) 2.450
dimensions
Depth (mm) 2.250
Length with swarf conveyor (mm) 5.550
Weigth Empty weight (kg) 8.400 9.000
Power supply Voltage and mains frequency 400 V, 50 Hz
Installed Power (kW) 40 55
power
Noise level Empty noise emission level/turning (dBA) 76/79
Machining Maxi. turning diameter (mm) 500 400
range
Maxi. swing (mm) 700
Maxi. swing on chariot X (mm) 580
Maxi. lathable length with self-centering 1.250 1.200
chuck
Maxi. lathable diameter with bar 93 (100) 93
Pipe hole for bar passing (mm) 95 (102,5) 95
Spindle Maxi. revolutions (rev./min.) 2.800 3.000
Spindle nose (mm) ASA 8”
Spindle shaft bore (mm) 111 106
Internal diameter of the three front bearings 150 150
(mm)
Spindle motor power (kW) 30 25
Maximum torque (N*m) 776 795
Max. applicable chuck diameter (mm) 315/400 315
Tailstock Positioning stroke (mm) 1.100 -
Sleeve stroke (mm) 150 -
Sleeve diameter (mm) 115 -
Cylinder section (mm2) 4.400 -
Bush for revolving tailstock CM5 -
Sub-spindle Maxi. Revolutions (rev./min) - 3.500
Spindle nose (mm) - ASA 6”
Spindle shaft bore (mm) - 76
Pipe hole for bar passing (mm) - 67
Torque to 100%/50% (N*m) - 334
Max. applicable chuck diameter (mm) - 250
Motor-driven
headstock
of the Connection type HSK-63
electrospindle
Maxi. Revolutions (rev./min) 6.000
Electrospindle motor power (kW) 9
Maximum torque (N*m) 86
Angular position of the spindle blocked in every 7,5 °
turning

19 3.1 Technical Data


T140-00325_0
Technical Specifications

Unit Technical specification SMART SMART S


Cross slide Z-axis of the longitudinal slide
Maxi. stroke (mm) 1.300
Screw diameter (mm) 40
Max. fast mode speed (m/min) 24 20
X-axis of the transverse slide
Maxi. stroke (mm) 520
Screw diameter (mm) 32
Max. fast mode speed (m/min) 20
Y-axis of the vertical slide
Maxi. stroke (mm) 210 (+120, -90)
Screw diameter (mm) 32
Max. fast mode speed (m/min) 12
C Axis Minimum programmable value 0,001°
B-axis unit Total rotation range 205°
Range of rotation beyond the tailstock axis 15°
Rotation range beyond the spindle axis 10°
Angular position with mechanical lock every 5°
Angular position through motor (without Resolution 0,001°
block)
Torque with mechanical lock (N*m) 3.600
Torque with lock through motor (N*m) 1.200
Tool Type of tool magazine chain
magazine
Magazine capacity 40 places
Max. tool diameter with adjoining tools 80
(mm)
Max. tool diameter without adjoining tools 140
(mm)
Max. tool length (mm) 295
Max. tool weight (kg) 7
Type of tool selection Fixed place
Time for tool changing (tool – tool) 5”
Hydraulic Max. unit capacity (l) 25
system
Motor power (kW) 2,2
Max pressure (MPa) 4,5 (45 bar)
Lubrification Reservoir capacity (l) 3
system
Cooling Tank capacity (l) 300
system Max. nominal displacement (l/min) 230
1,8 MPa (18 Bar) pump with 20 l/min 1
Electropump motor power (kW) 3
Max nominal displacement (l/min) 60
0,4 MPa (4 Bar) pump with 70 l/min 1
Electropump motor power (kW) 1,5

3.1 Technical Data 20


T140-00325_0

3.2 Power diagrams

Technical Specifications
3.2.1 Main Spindle

In the Smart Turn machine, we can find two spindle lines:


Ø The basic version, which is characterized by a line made up
of an electric motor, drive belt and spindle;
Ø The Smart S version, which is equipped with an electrospindle
ASA 8”.

Main Spindle mod. SMART (basic version)

kW Nm
100 1000
776 Nm S3
569 Nm S1
50 500
40 371 Nm S3 400
30 30.0kW S3 300
272 Nm S1
22.0kW S1
20 22 Kw 200

15 Kw

10 100
75 Nm S3

5 51 Nm S1 50
4 40
3 30

2 20
LOW VELOCITA'
SPEED

1 10
SPEED
ALTA VELOCITA'

0.5 5
BASSA

HIGH

0.4 4
0.3 3

0.2 2
1928
2570

2800
369

771

0.1 1
10000
1000

2000

3000
4000
5000
100

200

300
400
500
10

20

30
40
50

giri/min

21 3.2 Power diagrams


T140-00325_0

Main Spindle mod. SMART S


Technical Specifications

Kw Nm
100 1000
795 Nm S3
588 Nm S1
50 500
40 400
30 300
25.0 Kw S3
20 18.5Kw S1 200

10 100

5 50
4 40
3 30

2 20

1 10

0.5 5
0.4 4
0.3 3

0.2 2

3500
300

0.1 1

10000
1000

2000

3000
4000
5000
100

200

300
400
500
10

20

30
40
50

giri/min

3.2.2 Sub-spindle
The Smart Turn S version is equipped with a sub-spindle having a
liquid-cooled electrospindle.

3.2.2 Sub-spindle 22
T140-00325_0

3.2.3 Motor-driven headstock

Technical Specifications
On the B-axis and provided with a liquid-cooled electrospindle for tool
rotation.
kW Nm
100 1000

50 500
40 400
30 300

20 200

10 86 Nm S3 9 kW S2 100

68.7 Nm S1 7.2 kW S1
5 50
4 40
3 30

2 20

14 Nm
11 Nm
1 10

0.5 5
0.4 4
0.3 3

0.2 2
1000

6000

0.1 1
10000
1000

2000

3000
4000
5000
100

200

300
400
500
10

20

30
40
50

giri/min

3.3 Axes stroke scheme

23 3.2.3 Motor-driven headstock


T140-00325_0

3.4 Specifications of HSK 63 tool taper


Technical Specifications

In the following image, you can see what is the piece shape that can
be used on the lathe.

ROLLING TOOLS SOLUTIONS

WRENCH (MALE)

FIXED TOOL SOLUTIONS

3.4 Specifications of HSK 63 tool taper 24


T140-00325_0

Technical Specifications
43

18

ø 12
ø 120

ø 90

25

The standardized HSK-A63 tool holders have to be bought in conformity


to the following regulations:
ISO 12164-2 for all the revolving tool holders (milling cutter holder, tip
holder, tap holder, etc.);
standard ICTM for all turning tool holders (external turning, internal
turning, etc.). This version has closer tolerances on the small key and
allows a more precise repositioning.

25 3.4 Specifications of HSK 63 tool taper


T140-00325_0

3.5 Noise level and vibrations


Technical Specifications

The machine produces a continuous equivalent weighted level of


sound pressure (noise), just a little higher than 75 dB (A), in the
working area.

A = Volumes of the machine; B = Volume of acoustic survey

The containment of the machine intrinsic air noise level is documented


by a test carried out on a standard unit, representing the model of the
machine.
Because working speeds are quite low, mechanical vibrations
during machine working are of slight importance, therefore, it is not
necessary to use damping shims in the support points of the machine
on the floor.
Phonometric measurements have been performed by feigning the
typical operating milling and turning conditions, by using a sound
level meter calibrator (in conformity to the standards EN 60651 and
EN 60804).
The measured values are the following ones:
• idling: 76 dB (A)
• turning: 79 dB (A)
• milling: 77 dB (A).

3.5 Noise level and vibrations 26


T140-00325_0

Transportation

Transportation
4.1 General safety instructions
The information included in this chapter offer the best instructions,
according to Biglia, to be followed during the transportation of the
machine and its fittings to the place of destination.
• Observe the instructions contained in the safety manual.
• Check the integrity of the machine and its detached parts upon
receipt: if any damage, deformation or mark of impact due to
transport is found, immediately send a written communication to
Biglia (within the set time limit), before any further intervention
on the machine is performed.
• Upon customer’s request, the machine can be provided on a
wooden transport platform, wrapped up in a plastic cloth, or
either in a transportation box.
• Use equipments and tools having sufficient capacity to bear the
machine (for weights, consult paragraph 3.1 “Technical data”).
• Make sure the way is free from obstacles, in order to avoid the
danger of crushing.
• If possible, transport the machine and its accessories to their
place, in their package.
• If this is not possible, or if you would like to move the already
assembled machine to another place:
o Use, as transportation equipments, only those ones
prescribed by Biglia;
o Pay your greatest attention in preparing the machine for
the transportation.
_________________________________________
Warning
! During machine transportation, there’s the danger of
accident, caused by the breaking of lifting supports,
by the moving of the barycentre, etc: keep always a
safety distance from the lifted machine. Danger of
death!
_________________________________________

Depending on the type of machine, some special components, fittings


and documents are separately supplied in different packages.

27 4.1 General safety instructions


T140-00325_0

_________________________________________
Transportation

! Important
Observe and respect the marks and instructions that
are affixed on the package. Carefully evaluate the
transportation weight and overall dimensions.
_________________________________________

4.2 Transportation equipments

_________________________________________

! Important
Lifting and handling have to be performed only by
using the equipments prescribed by Biglia.
_________________________________________

For the transportation of the machine without package, it is necessary


to use the following transportation device, consisting of:
• N°1 lifting bar;

• N°4 Stabilized and sheathed polyester yarn woven belts in


accordance with the standards DIN61360: diameter 25 mm,
length 3,000 mm (development 6,000 mm);
• N°2 bars for machine lifting;
• Bolts M12x150 UNI 5727

4.2 Transportation equipments 28


T140-00325_0

Transportation
The conveyor-man or the user have to realize the bearing bar in
accordance with the Biglia specifications illustrated in the following
drawing.
N° 6 through holes

6 holes 13 loops
A = bedframe jetting out from the front side of the machine
P = bedframe jetting out from the rear side of the machine
________________________________________
Warning
! The lifting system capacity must not be lower than
10,000 kg.
________________________________________

4.3 Arranging the transport


If you have to move the machine, which is already placed in a room,
toward a new place, you have to dismantle it and prepare it for the
transportation.
While transporting the machine, follow the safety instructions
described in the safety manual.
________________________________________

i Note
The interventions of dismantling, handling and new
installation can be performed by Biglia after-sales
customer service.
________________________________________

29 4.3 Arranging the transport


T140-00325_0

__________________________________________
Transportation

Warning
! Danger of accident owing to breakings of material,
slipping, barycentre shifts, etc.
__________________________________________

For a safe execution of the activity, follow the instructions below:

PROCEDURE
1. Take the tools out of the tool magazine and the spindle.
2. Accurately clean the machine, by removing chippings and
coolant.
3. Remove the material contained in the swarf conveyor. Dispose
of the coolant as prescribed by the environmental legislation.
4. Remove the content of the swarf collection tank. Dispose of the
coolant as prescribed by the environmental legislation.
5. Bring the machine axes in the transport position.
6. Empty the coolant container. Dispose of the coolant as
prescribed by the environmental legislation.
7. Disconnect and countermark the pipelines/connection cables of
the accessories toward the machine and the swarf conveyor.
8. Separate the swarf conveyor from the machine.
9. Turn the machine main switch off.
10. Take the socket off from the power supply.
11. Take the compressed air off.
12. Discharge the residual pressure from the pneumatic and
hydraulic circuits.
13. Turn completely right the movable control board and place it
parallel to the protection guards. Block it to the guard through a
sticky tape.
14. Cover the monitor with package material, against involuntary
collisions and scratches.
__________________________________________
Warning
! If you handle the machine without the transportation
safety devices, there is the danger of accident
because of machine mass moving.
__________________________________________

4.3 Arranging the transport 30


T140-00325_0

4.4 Lifting

Transportation
Before lifting the machine, some preparation activities have to be
performed according to the following procedure:

PROCEDURE

1. Take the fastening screws out and open the protection


panels A placed on the rear side.
2. Open the front doors B and move the video group to the
right.
3. Insert, from the front side, the sling hooking bars in the
machine bed holes.

INSERT THE delle


Inserimento SLING
barre
di sollevamento
HOOKING BARS

4. Insert the bolts D M12x150, used for sling hooking, in the


holes made in the bars.

31 4.4 Lifting
T140-00325_0

5. Hook the slings (on the front and rear side of the machine)
Transportation

to the two bars.


6. Hook the slings to the (upper) bearing bar.

WARNING
BEFORE LIFTINH THE MACHINE, ACT AS FOLLOWS:
1. OPENING THE FRONT DOOR
2. MOVE VIDEO GROUP TO THE RIGHT
3. INSERT THE BARS (2 FOR EVERY MACHINE)

LIFTING ROPE
arou
nd

7. Check that the slings come down perpendicularly from the


hooking points of the (upper) bearing bar to the (lower) sling
hooking bars.

4.4 Lifting 32
T140-00325_0

8. Check that the slings are centred as to the hooking point

Transportation
of the (upper) bearing bar and that they are spaced 1,200
mm from each other.
9. Slightly tighten the belts and check that they are
homogeneously tightened.
10. Before lifting, close the two rear panels.
11. Start the lifting movement very slowly, verifying that the
machine is parallel to the floor (max slope of 5°): if it is not
parallel, modify the sling length.

4.4.1 Swarf conveyor lifting


The swarf conveyor weight is about 850 kg; the following devices are
necessary for it to be lifted:

• stabilized polyester slings, sheathed according to the


standard DIN61360, and long 2,600 mm and 1,400 mm
(not supplied by Biglia).
• S-shaped hook (not supplied by Biglia).

33 4.4.1 Swarf conveyor lifting


T140-00325_0
Transportation

• Three ring screws (eyebolts)


Act in accordance with the following procedure:

PROCEDURE
1. Screw the eyebolts on the swarf conveyor.
2. Hook the S-shaped hook between the slings and the ring
screws.
3. Lightly tighten the slings by checking the parallelism between
the conveyor and the floor. If it is not parallel, modify the
sling length.

4.5 Transportation with package


Insert the lift truck forks, only from the rear side of the machine and
only through the pallet slots for handling, as the barycentre is by the
rear part of the machine.
Lift the machine very slowly, without doing any swift movement and
being very careful to possible swinging.
During handling and transport, try not to excessively tilt the machine
with the lift truck forks, because the barycentre is placed in the rear
part of the machine.
Avoid going along ramps having a high slope (both uphill and
downhill).
Once reached the place of destination, remove the package and

4.5 Transportation with package 34


T140-00325_0

dispose of it according to the provisions on waste, in force in that

Transportation
specific place.
_________________________________________
Warning
! There is the risk that, despite the precautions taken,
the machine can fall from its platform or capsize.
Never stay under the hanging load. Danger of
death.
_________________________________________

35 4.5 Transportation with package


T140-00325_0

Machine installation
Machine installation

5.1 General instructions

The machine placing, assembling, connection and starting up (except


for the first time with a new machine), can be carried out, upon request,
by the Biglia Customer After-Sales Service.
• Static stability
It is absolutely necessary that the machine and all its fittings lay firmly
and safely on the supporting surface.
It is very important that the building regulations concerning floor and
foundation are observed (paragraph 5.3). Observe also the building
regulations which are important for the static safety of bearing
structures.
The floor must not elastically react, in order to always keep the machine
correctly leveled.

_________________________________________

! Important
Check that the floor has a sufficient capacity, by taking
into account, beside the machine maximum weight,
also the pieces to be machined, the equipments, the
people, the support equipments, etc.
_________________________________________

• Accessibility
Before placing the machine, make sure that you have a good
accessibility within its perimeter in order to ensure its appropriate usage,
a safe maintenance and a satisfactory mobility for the operator.
• Safety instructions
As for the placing of the machine and of the electric cabinet, the
regulations and laws in force in the user’s country must be followed.
The supporting surface must be protected from oils and fats in order
not to diminish the friction coefficient of the machine supporting
elements.
The supporting surface must not only be even, but also homogeneous;
in other words, there must not be junctions, pits or grooves for cable
passing.

5.1 General instructions 36


T140-00325_0

5.2 Installation environment

Machine installation
The place where to set the machine must be dry and free from
aggressive vapours.
The machine shall be installed in a clean and sufficiently light work
environment (at least 300 Lux), heated in an homogeneous way with
limited sudden changes of temperature.
We recommend you to shield the machine from the thermal radiations
coming from the sun, from radiators and/or adjoining machines.
The optimum conditions of installation are:
Ø environmental temperature: 15÷35 °C
Ø related humidity: lower than 75%
Ø Supply voltage: 400 V (+10%, -15%)

_________________________________________
Warning
! The machine SHALL NOT be installed in an
atmosphere where the risk of explosion exists.
_________________________________________

_________________________________________

! Important
For a logistical question, we invite you not to install
the machine:
• in a place where it could be reached by water or other
liquid jets;
• near brazing, welding, painting, pickling, galvanic or
similar systems.
_________________________________________

5.3 Foundations
In order to let the machine always work in optimum conditions, it
is necessary to place it on a supporting floor having the following
features:
• supporting foundation realized with crushed stone having a
thickness of 100 mm;
• upper band made of reinforced concrete having a thickness of
250 mm.

37 5.2 Installation environment


T140-00325_0

_________________________________________
Machine installation

! Important
The static and dynamic structural calculations related
to the supporting plan are to be paid by the user and
they shall be performed by a building engineer.
_________________________________________

5.4 Rests and machine positioning


The machine can be used for chuck-machining, when simply resting
on the floor, thanks to the supplied bases, only if it has been leveled.
In the case of bar or chuck machining with eccentric or out-of-balance
parts, the machine has to be secured to the floor as illustrated in the
last phase after leveling.

Slot execution special seat screw anchor

15? 15?
60

2.5
10
.5
35

R12

2
31

2.5
2
40

40
34
1.6

1.6

60

M12

= =
134

25
40
40
25

3.2 ÿ68
Ground level
25

Wrench 41
60
40

35

Hole center with screw anchor fitting up

In order to position the machine, the following procedure has to be


observed:

5.4 Rests and machine position 38


T140-00325_0

Machine installation
PROCEDURE
1. Lift up the 8 rests so that, when the machine is positioned, its
bedframe rests on the floor.
2. Lower the rests to the floor. If necessary, oil the rests in the
point E so as to make the machine leveling easier.
3. Work on the rests from P1 to P5, the other three have to be
uniformly pulled so that the machine can constantly lay on
eight rests, by taking it to about 15 mm from the floor.

4. Make sure that the backing surfaces of the level are clean.
5. Select the manual mode (MAN).
6. Position the axes read on the “machine” at:
7. ������������������������������������������������������������
Y = 0° B = - 90° Z = - 600 X = - 950 (spindle centre)
8. ���������������������������������������������������������������
For a correct leveling of the machine, it is necessary to make
a check in the two end points, both in the longitudinal direction
and in the transverse one, by using a level.
The two points are on the right and on the left side of the Z carriage
group, which is positioned at about the half of the length of the Z
carriage slides.
9. Perform a first leveling both in the lengthwise and crosswise
directions.
The tolerance allowed in the alignment is 0.06 mm/m (max).

39 5.4 Rests and machine position


T140-00325_0

__________________________________________
Machine installation

i Note
1 and 2 are the leveling checking points.
__________________________________________

Lato contropunta
tailstock side

1
Lato mandrino
spindle side

_________________________________________

! Important
Control that the distance between the floor and the
machine bed is included between 15 and 20 mm.
_________________________________________

10. Perform a precise leveling: by repeating the operations


described at point 7. The tolerance allowed in this
alignment is 0.02 mm/m (max).
11. The tolerance allowed in the lengthwise and crosswise
directions is 0.002 mm/m.
12. Tighten the D and B nuts (following this order) on all
the rests.
13. Remove the level.

5.4 Rests and machine position 40


T140-00325_0

5.5 Positioning the swarf conveyor

Machine installation
The swarf conveyor (including the coolant collection tank) should be
positioned in the machine recess with extreme precision and care in
order to prevent coolant leakage during machining.
To position the swarf conveyor, follow the instructions below:

PROCEDURE
1. Take off the eyebolt C, used for swarf conveyor lifting.

2. Lift the drip cover A (fixed to the machine bed) and keep it
lifted;

3. Place the swarf conveyor against the machine bed: first


transversely and then longitudinally.
4. Lower the drip cover A.

41 5.5 Position the swarf conveyor


T140-00325_0
Machine installation

5. Install the guard B by fixing it to the headstock separation


cover.

6. By using a spanner WR 18, adjust the swarf conveyor height,


acting on the five rest screws. Lift the swarf conveyor so as to
almost align its front profile F with the profile E of the cabin.

5.5 Position the swarf conveyor 42


T140-00325_0

_________________________________________

Machine installation
i Note
The protection of the swarf conveyor in the unloading
area is limited; in order to limit the source of risks, a
specific swarf container is available. This container
should be watertight, mounted on swivel wheels, of
a self-dumping type and pre-arranged to fit the lift
truck forks.
_________________________________________

_________________________________________
Warning
! During each maintenance intervention, turn the
swarf conveyor off and never put your hands in the
conveyor belt or in the ejection pit.
_________________________________________

_________________________________________

i Note
The swarf conveyor belt only rotates if the doors of
the work zone are closed.
_________________________________________

43 5.5 Position the swarf conveyor


T140-00325_0

Connections
Connections

6.1 General instructions


The instructions contained in this chapter are useful for assembling,
connecting and dismantling the machine.
Upon Customer request, machine assembling and starting up can be
carried out by Biglia After-Sales Service.
_________________________________________

! Important
Before starting any assembling and connecting
operation, check that:
• the necessary connections for electrical energy and
for compressed air are available;
• the transportation safety devices have been
removed;
• the rust preventive of the polished parts of the
machine has been removed (by cleaning oil or other
suitable solvent), then grease the clean parts.
_________________________________________
6.2 Electric cabinet
The electric cabinet is on the left side of the machine in the rear
zone.
The connections between the machine and the electric cabinet are
already pre-arranged by Biglia factory. Reference electrical plans are
enclosed to this manual.

6.1 Generals instructions 44


T140-00325_0

Connections
___________________________________________
Warning
! The connection of the machine to the electric system
should be carried out only by qualified and authorized
staff. Observe the regulations and directives which are
locally in force.

Danger of accident because of electrocution!


___________________________________________
_________________________________________

! Important
While working on electrical devices, there could be
some damages to electronic components due to
connection errors and to damages for short circuit:
always pay the greatest attention when reading the
information contained in the wiring diagram enclosed
to the machine and control that the electrical rating
of the machine correspond to those of the supply
electrical system at the user’s.
_________________________________________

6.2.1 Power supply and protection


Aplate is fixed on the door of the electric cabinet. It is the type-approval plate
of the electric cabinet and it relates the data of current, voltage and supply
frequency to which the machine is arranged.���������


A = Type-approval plate; B = Ports locked through screws and not guarded

45 6.2.1 Power supply and protection


T140-00325_0

The actual mains voltage should not differ from the nominal voltage
Connections

more than the allowed tolerance, not even in case of load (nominal
voltage 400 V, tolerance +10% - 15%).
_________________________________________
Warning
! The standards EN 60204 Part 1 (Protection through
the automatic cutting off of the supply) and IEC 364-
4-41 should be respected during installation.
_________________________________________
_________________________________________

! Important
If the factory where the machine is installed has
a protection with residual current operated circuit-
breakers, the latter should be of an adequate
value and of “Inverter Type”, that is they should be
suitable for the protection of devices equipped with
inverter drives.
For machines having dissipated electrical power
up to 25 kVA, their electrical cables (copper core)
should have a section of at least 10 mm2 (cable
conduit connection); for powers higher than 25 kVA,
the cables should have a section of 16 mm2 (pipe
connection).
For the management of EMC, the machine has got
leakage currents superior to 3,5 mA, and for this
reason it has to be fixedly connected.
_________________________________________

_________________________________________

i Note
Make sure that the electrical supply is the most
possible “cleaned” from electrical troubles caused,
for example, by welding machines which give rise to
considerable fluctuations in the system during their
working.
_________________________________________

6.2.2 Connection
The machine is connected to the mains power supply through four-
pole cables (three phases and earthing), or four unipolar wires.

6.2.2 Connection 46
T140-00325_0

_________________________________________

Connections
Warning
! Before starting any intervention for electrical
connection, make sure that the supply cable is not
live. Do not touch cables, switches, etc. with wet and/
or sweaty hands.
Danger of death for electrocution!
_________________________________________

The electrical connection can be carried out through the following


procedure:

PROCEDURE

1. Make sure that the main switch handle is in position 0


(voltage off).
2. Loosen the switch cover screws B and remove the lid to
access the opening for the passage of cables.

3. Fit the fairlead with characteristics IP44 (IEC 529 and EN


60529) or higher (dust and water proof). The fairlead is not
supplied by Biglia.
4. Connect the supply cables to the three terminals L1, L2,
L3 of the main switch and the earthing wire in its proper
housing. Pay attention to the cable chromatic countermarks.
Well tighten the cable locking screws.

47 6.2.2 Connection
T140-00325_0

_________________________________________
Connections

Warning
! In the line inlet terminals of the main switch, branching
off with other cables does not exist and it is not even
allowed.
_________________________________________

The machine must have an earthing which is independent from the


other machines.
5. Check the earth resistance and the phases.
6. Fit the switch cover back.

6.2.3 Connection control


Before starting up the machine, control that the connections have
been correctly executed.
To facilitate your checking activities, the Biglia technical office
has prepared the following check list to be used as a guideline or
memorandum.
yes no
• Is there the correct mains voltage?
yes no
• Are the mains frequency and voltage those expected?
yes no
• To the present reactive power, is the mains voltage sufficiently

stable and does it keep within the tolerances allowed by the

nominal voltage?
yes no
• Have the power supply wires and the safety devices been

chosen according to the power absorption rate and to the

regulations in force?
yes no
• Are the power supply wires protected from any danger of

damages?
yes no
• Has the fairlead been correctly mounted?
yes no
• Have the connection plugs and wires been correctly inserted

and locked in their right position?


yes no
• Are electric cables protected against damages?

6.2.2 Connection control 48


T140-00325_0

6.3 Compressed air

Connections
The compressed air is connected to the distribution unit placed on the
right side of the machine; it can be accessed through a door guarded
by a key.
All the machines are provided with a quick connect for the connection to
the compressed air distribution system. The machine air consumption
depends also on the number of tool changes that are performed.
_________________________________________

! Important
Only clean and dry compressed air should be used.
Wet air could damage the pneumatic components,
by reducing their useful life.
_________________________________________

The need to clean the filter quite often shows that the conditions of
the air distribution system are not adequate, because an excessive
quantity of water is carried. It will be necessary to optimize the plant.
The operating pressure is included between 0.4 and 0.5 MPa (4÷5
bar); it can be adjusted through the knob B placed at the top of the
filter.

The pneumatic system diagram is enclosed to the Spare Parts Manual


to be consulted for further explanations.

49 6.3 Compressed air


T140-00325_0

_________________________________________
Connections

! Important
Check that the air volume that you can supply to
the machine is at least 20% higher than the one
expected, which is about 100 l/min.
_________________________________________

6.4 Swarf conveyor


To connect the swarf conveyor, act according to the following
procedure.

PROCEDURE
1. Through the appropriate electric cable (see paragraph
6.2.1), connect the power supply box A to the plug B.

2. Connect the coolant pipe C to the pump D.


_________________________________________

i Note
On customer’s request, some machine models could
be equipped with more optional pumps. Even for
these ones, you should follow the pipe connection
procedure described above.
_________________________________________
_________________________________________

! Important
Do not turn the pump if the coolant system has not
been filled, as indicated on the following plate. See
procedure at paragraph 10.3.5
_________________________________________

6.4 Swarf conveyor 50


T140-00325_0

6.5 Control pedals

Connections
Pedals to control the opening/closing clamping tool on the spindle and
the forward/backward of the tailstock, are supplied separate from the
machine when delivered. The connection consists in the insertion of
the male connector terminals of the cables of the control pedals in the
female pins placed in the left lower front area of the machine.

6.6 Tank positioning


From the rear side of the machine, position the tank underneath the
tool chain.It is used to collect coolant and swarfs that are carried during
the tool changing.

51 6.5 Control pedals


T140-00325_0

6.7 Final controls


Connections

After having concluded the machine assembly, it would be useful to


carry out a series of conclusive controls.
Use as a guideline for controls, the following list:
• Have all the protection covers been installed and do all the
yes no
protection devices work?
• Have all the safety regulations (working distances, IPDs, etc.)
yes no
been respected as prescribed by the law provisions in force?
yes no
• Has the machine been installed steadily and leveled?
• Has the electrical connection been checked by qualified
yes no
personnel?
• Have all the tools, equipments and auxiliary devices been
yes no
used for the assembly?
• Have all protection devices, covers and doors been installed
yes no
and do they perfectly work?
• Have all the filling levels been checked and filled up when
yes no
necessary?
yes no
• Are the technical documents of the machine on board?
yes no
• Have the documents been read and understood?

6.7 Final controls 52


T140-00325_0

Controls

Controls
7.1 Safety and reliability of control systems
The control system is a set of electric, electronic, hydraulic and
mechanical components which control the machine operations.
The control device represents the exterior part of the control system
commanded by the operator and it can be of various shapes: knob,
button, lever, etc.
__________________________________________
Warning
! Control systems can suffer the consequences of an
intense use, of the internal or external temperature, of
vibrations, collisions, presence of dusts, water, vapours
of various nature and electro-magnetic disturbances.
Regularly check the perfect functioning of control
systems, according to environmental conditions and
working conditions.
__________________________________________
M

B
I
C

E
H

G
F

Nomenclature of control panel


A PCMCIA Slot G Key selector switch for safety devices
B 10.4” Monitor H Biglia control board
C Function keys I FANUC control board
D Emergency stop push-button L RS232 and 220V sockets (on the panel side)
E Key selector switch for operating modes M Luminous LEDs
F Button to open the tool clamping collet (when
the button is released, the tool camping collet
closes). (Tool clamping is operating only
when the tool holding spindle is oriented and
locked).

53 7.1 Safety and reliability of control systems


T140-00325_0

7.2 Machine switching on


Controls

PROCEDURE
1. Take the main switch handle in position 1 (voltage on).

2. Turn the EMERGENCY mushroom button clockwise (or pull it


out).

3. When the EMERGENCY button lifts, push the green luminous


ON
button ON. The key lights up with fixed light.
4. After about 10”, the following video page displays:

5. Push the green luminous button ON again to start the motors


of the hydraulic and lubrification units. HOLD

6. At this point, the message “1007 MACHINE OFF” disappears


and the HOLD push-button lights up.
__________________________________________

i Note
The alarm message “1048 CHECK DOOR MICRO
SWITCH” remains on.
__________________________________________

7. Open and close the front sliding door to check the safety micro-
switch. On the video page, the alarm message goes off, the
HOLD button extinguishes and the flashing warning “ALERT”
goes out.

7.2 Machine switching on 54


T140-00325_0

8. Carry out a resetting operation by pressing the RESET button.

Controls
__________________________________________
Warning
! Make sure that no organ is moving, that the spindle
has stopped, and that no tool is machining.
__________________________________________

7.3 Machine switching off


In order to switch the machine off safely and without damages,
accomplish the following procedure:

1. Press the mushroom button EMERGENCY and loosen it


again.

2. Push the red luminous button OFF to switch the numerical


OFF
control off . The key lights up with fixed light. The following
video page will display:

3. Cut voltage off from the machine by taking the main switch
handle in position 0 (voltage off).
4. Close the front doors.

55 7.3 Machine switching off


T140-00325_0

7.4 Emergency stop


Controls

To stop the machine in emergency conditions, carry out the following


procedure:

PROCEDURE

1. Press the mushroom button EMERGENCY.


2. The button stops in the reached position, the machine drives
are immediately switched off and all machine organs are
stopped in the least time possible.
3. On the monitor, the video page below displays with the alarm
message 1007. HOLD

4. The HOLD button lights up.

__________________________________________
Warning
! Switching drives off through the EMERGENCY button
can cause damages to the piece which is being
machined and produce tool breaking.
__________________________________________

7.4 Emergency stop 56


T140-00325_0

7.4.1 Restarting after EMERGENCY

Controls
• Eliminate the cause of the emergency stop.
• Loosen the mushroom button EMERGENCY.
• Cancel the error message NC. The following video page will
display:

• Push the green luminous button ON. The key lights up with
ON
fixed light.

57 7.4.1 Restart after emergency


T140-00325_0

7.5 Front sliding door


Controls

The clamping device of the front door allows the operator to work
safely by locking the drives for spindle rotation, axes movement,
turret rotation, etcetera.

In some particular situations, the tooling-up operator may need to SAFETY

work with the door open: this is possible by acting on the key selector ON OFF

SAFETY in position OFF (safety devices deactivated).

_________________________________________

! Important
For safety reasons, in this phase, it is compulsory to
have just one operator on board.
_________________________________________

• With the door open, spindle and axes are deactivated and,
to highlight this condition, the button CONTROL DOOR
OPENING - CLOSING flashes (red light) on the control board
• With closed doors, axes and spindle are activated and the
flashing light of the button is turned off.

7.5 Front sliding doors 58


T140-00325_0

_________________________________________

! Important
To prevent danger of accidents, the device for the
automatic opening of the sliding door is electrically
interlocked if the spindle is working or if the automatic
cycle is ongoing.
_________________________________________
_________________________________________

i Note
With the front sliding door locked, the machine can
work without any restriction; with the door open, only
limited interventions of setting up work.
_________________________________________

59 7.5 Front sliding doors


T140-00325_0

Tool magazine – ATC (Automatic Tool Change)


Tool magazine – ATC (Automatic Tool Change)

8.1 Machine description


This unit runs firmly with the “axis Z” slide so as to allow tool change in
any position the machining permits it, and it is formed by three units:
• Tool magazine: chain magazine, having a maximum capacity
of 40 tools at a fixed place, and searching for the shortest way.
The magazine is commanded by the CNC. During machining,
the following tool can be searched for.
• Tool changer is formed by a double change-over arm which
rotates thanks to an axis motor, and it runs in an axial direction,
commanded by an axis motor as well as the arm. The head
receiving the new tool arranges itself in a longitudinal position
(B-90) and on definite dimensions of X and Y.
• Change-over arm intervenes to deposit/pick up the tool
selected from the chain for the subsequent moving, in changing
position with the tool changer arm. Depositing and picking up
are performed during machining cycle.

D E
A

CLOCKWISE
ROTAZIONE
ROTATION
ORARIA

MAGAZZINO
TOOL MAGAZINE
PORTAUTENSILI
(40 POSITIONS)
(40 POSIZIONI)

COUNTERCLOCK-
ROTAZIONE
ANTIORARIA
WISE ROTATION

B
C
A = Movable bulkhead; B = Tool; C = Tool holder gripper;
D = Change-over arm E = Tool changing unit

8.1 Machine description 60


T140-00325_0

8.2 Magazine description and tool data on NC

Tool magazine – ATC (Automatic Tool Change)


The management of tools and arrangement in the chain has been
subdivided by Fanuc into two important menus that can be selected
through the function keys [TOOLS] and [MAG]; these keys can be
activated by pushing the function keys [OFF/SET], [4] and [MANAG_
TOOL] in succession.

TOOL DATA
Through the function key [TOOL], you can access a page where there
is a table having 200 lines numbered from 1 to 200 in progressive
order.
Every line number represents the number of Tool File to which the
following data are coupled:
• Tool number: corresponding to the “T” called back by the
program;
• Tool data: eight bits defining the tool characteristics;
• Tool adjustments: it specifies the adjustment coupled to that
tool;
• Tool lifetime: set of data for the management of the tool
lifetime
TOOL MAGAZINE MANAGEMENT
Through the function key [MAG], you can access a page where there
is a 40-line table, corresponding to the 40 positions of the chain where
the number of Tool File referring to the loaded tool is coupled.

61 8.2 Magazine description and tool data on NC


T140-00325_0

8.2.1 Tool data


Tool magazine – ATC (Automatic Tool Change)

You can access this part of the menu by pushing the following function
keys in sequence:
[OFF/SET], [+], [MNG.T.], and [TOOL].

The table consists of three video pages which can be displayed through
a scrolling by using the horizontal arrows.
In this table, it is possible to store a maximum number of 200 tools
(NUM from 1 to 200) that can be displayed by the keys Page Up,
Page Down, or by the vertical arrows
In the opening video page of the series, the following information can
be found:
• NUM: it is the number of “Tool File” or line of this table. It cannot
be modified by the user.
• TYPE N.: it is the number of the “T….” tool to be called back
(used) in the part program or to be called back in MDI.
• POT: it is a number, included between 1 and 40, which indicates
the tool position in the chain (similar to the 12 turret positions).
It cannot be modified by the user.
• MG: it is a number indicating the instant position of the tool:
o 0 = tool not in chain
o 1 = tool in chain
o 11 = tool in change-over arm
o 21 = tool in the spindle in working position
It cannot be modified by the user.

8.2.1 Tool data 62


T140-00325_0

• TOOL DATA: it is a bit that can be modified by the user and

Tool magazine – ATC (Automatic Tool Change)


which is made of eight bits:
o Bit 7 = not used
o Bit 6 = not used
o Bit 5 = not used
o Bit 4 = ON (1): tool lifetime not used (it is the normal
condition to be enabled); OFF (0): tool lifetime used.
o Bit 3 = not used
o Bit 2 = BIG (1): heavy tool with a slow rotation of the
ATC arm; NORMAL (0): light tool with a rapid
rotation of the ATC arm.
o Bit 1 = TIME (1): counting the tool lifetime in machining
seconds; NUMBER (0): counting the tool
lifetime in number of pieces.
o Bit 0 = GOOD (1): the tool can be used in the chain.
It is necessary to enable it before calling the
tool back in the chain. NOTGOOD (0): the tool
is not in the chain or it cannot be used in the
chain.
• L-STATE: the lifetime state of tools is set up in this square, by
using the following function (or soft) keys:
o [NONMANAG] = tool lifetime management is not
active;
o [ACTIV] = tool lifetime management is activated;
o [EXPIR] = tool lifetime management is expired;
o [BROKEN] = the tool is to be considered as broken

63 8.2.1 Tool data


T140-00325_0
Tool magazine – ATC (Automatic Tool Change)

• LIFET. COMPUTAT.: when lifetime computation is enabled,


the number of machined pieces, or the tool working time, is
displayed in this square.
• L-WARNING: not used
• MAX LIFETIME: in this square, the number of pieces that can
be machined by the tool, or the tool maximum working time are
to be stored.

Change video page by pushing the key


• TG: it is the number of the adjusting tool coupled to the Tool
File and enabled through D999.

• GEOM (X), GEOM (Z), GEOM (Y), GEOM (R), GEOM (TIP):
they are a couple of the “GEOMETRY” values stored in the video
page that can be called back through the key OFS/SETT.

Change video page by pushing the key


• USUR (X), USUR (Z), USUR (Y): they are a couple of the
“WEAR AND TEAR” values stored in the video page that can
be called back through the key OFS/SET .

8.2.1 Tool data 64


T140-00325_0

Tool magazine – ATC (Automatic Tool Change)


• CHAIN POSITION: each tool’s chain position is stored in
this table. It is constantly updated by the NC. Only in very
extraordinary situations, when manually loading the tools
from the front side directly to the spindle, a change could be
necessary. It is a parameter that can be modified by the user.
If the present value is zero (0), the machine goes into alarm.

65 8.2.1 Tool data


T140-00325_0

8.2.2 tool magazine


Tool magazine – ATC (Automatic Tool Change)

This video page includes the table named “Tool Magazine


Management” where we find information (POT, NUM, TYPE N.)
similar to those indicated in the starting table “TOOL DATA” and
previously described.

Video Page 1

Video Page 2

8.2.2 Tool magazine 66


T140-00325_0

By pushing the key , the second video page will display.

Tool magazine – ATC (Automatic Tool Change)


In order to change the data of the NUM column, follow the procedure
below:
1. push the function (or soft) key [(OPRT)] and [EDIT] in order.
2. the flashing notice EDIT will appear.
3. by using the direction keys , take the cursor in the NUM column
and insert the value of the Tool File loaded into the chain.
In addition to these information, on the right side of the video page,
there is a table indicating:
• MAND1: it indicates the tool assembled in the
machine;
• ATTE1: it indicates the tool waiting in the change-over
arm.

67 8.2.2 Tool magazine


T140-00325_0

8.3 Manually loading tools in the chain


Tool magazine – ATC (Automatic Tool Change)

In this chapter, we describe the operations to perform in order to load


the tools in the chain.
The machine is set by Biglia so as to use the tool magazine with the
SIMPLE management.
The kind of SIMPLE management is normally recommended when
HSK 63 tapers (tool holders) are re-equipped with different tools for
the creation of new parts.
The tool table proves set up, if we couple the same number for the tool
file, the number of “T” tool and for the adjusting tool to each number of
the position in the chain.
It is important to notice that in the positions POT 3 and 5, the zero
value appears in the columns NUM and TYPE N.

These tools can be respectively found:


• N°3 on the change-over arm
• N°5 in the spindle head, as indicated in the box on the right at
the top of the video page 1 (tools from 1 to 30).

Example: procedure to load the tool T20 on the chain position N°20 to
which the adjusting tool N°20 will be coupled.

1. Call back the tool that has to be loaded in MDI, through


the command T20 M6.
2. the machine loads the tool T20 on the spindle, even if it
is not physically present in the chain.
3. Insert the new tool on the spindle through the appropriate
button.
4. Reset the new tool on the adjusting tool N°20.
5. Repeat the sequence for all the tools.
This manoeuvring does not dephase the tool table, which
always keeps the correspondence between the numbers
of:
• Chain position;
• Number of T tool;
• Adjusting tool.

8.3 Manually loading tools in the chain 68


T140-00325_0

8.4 “ARCHIVE” and “LIFE” Management

Tool magazine – ATC (Automatic Tool Change)


This paragraph deals with the management of coded tools, always
assembled and reset, not necessarily always present in the
machine.
This kind of management allows us to identify the various tools
according to the Number of Tool File.
This number will have to be present in a ineffaceable way on the
tool, in such a way so as to be easily recognized, as well as the Tool
Number corresponding to the program recalling “T”.
__________________________________________

! Important
To simplify the management of those tools not using
the “LIFE”, we suggest to associate each Number of
Tool File to the same Tool Number and Adjusting
Tool.
__________________________________________

For every tool family using the “LIFE”, we will have different numbers
of Tool File and Adjusting Tool, with the same Tool Number.
As for the chain position, it will have to be updated every time.

8.4.1 Initialization of tool table


In order to use the tools in the above-described way, it is necessary
to:
> TOOL DATA
Register all tools available that can be mounted on the chain.
By setting to line 1 NUM of the Number of Tool File, the number
1 to the TIPE N. column referred to the Tool Number “T1” and
always on the same line, 1 to the TG column for the Adjusting
Tool.

69 8.4 “ARCHIVE” and “LIFE” Management


T140-00325_0

8.5 Tool loading (rear side)


Tool magazine – ATC (Automatic Tool Change)

Usually, interventions on the tools already present in the chain are


used to control the wear and tear condition of the inserts and of the
tools themselves.
__________________________________________

i Note
We recommend working on tools, separately. In other
words, we suggest you to perform all the necessary
interventions on one tool at a time and to insert it again
in its seat before taking another one out.
__________________________________________

PROCEDURE
1. Take the machine to the JOG mode.
2. Control that the front sliding doors are closed.
3. If the doors D and E are closed, the chain can be moved in the
two directions by using the two buttons placed by the side of the
door. SAFETY

ON OFF

If the doors were open, the key selector should be turned in


OFF position. to let the chain turn.
4. When the tool desired position is reached (tool at the height of
the release lever), move the same lever down and pick the tool
up.

8.5 Tool loading (rear side) 70


T140-00325_0

_________________________________________

Tool magazine – ATC (Automatic Tool Change)


i Note
1. By pushing one of the two buttons (B), used for chain
handling, for less than 1 second, the chain will move
of one tool position;
2. By pushing one of the two buttons (B) for longer, the
chain keeps on rotating.
3. To stop the movement, release the button.
_________________________________________

A
B
C

A = Emergency stop button; B = Buttons for manual rotation of the chain; C = Key
for safety devices; D = General door of the tool magazine; E = Sliding door.

8.6 Tool setting


8.6.1 General remarks
Ø When the tool-setter arm stoops, the geometry page appears
with the adjusting tool 1 selected;
Ø The head must be disposed at B -90°;
Ø Tools have to be set to zero according to their way of working
(closed or open);
Ø Tools working in rotation have to be set to zero only in Z and
the value X has to be zero;
Ø The boring bars and/or the tools to be turned can be set to zero
either with their tip directed up or down, independently from
their use, which will be managed by the working program.

71 8.6 Tool setting


T140-00325_0

Every tool mounted in the chain and called back in the machine by the
Tool magazine – ATC (Automatic Tool Change)

program has to be set to zero on the electronic tool-setter arm.


When their dimension or their shape do not allow their setting on
the electronic arm, set the tool to zero on the piece according to the
traditional way.
8.6.2 Tool setting by tool-setter arm
The tool-setter arm with probe is an independent part mounted in the
machine and it has to be lowered exclusively during tool setting and it
should be folded back before machining starts. The tool-setter arm is
positioned inside the machining room.

PROCEDURE
1. Place the Z-slide in a pulled back position in order to prevent
collisions when the arm lowers;
2. Open the front sliding doors and control that the tool setter is
cleaned from possible chippings and/or coolant waste, or clean
it if necessary;
3. Close the doors and push the button (Tool setter forward);
4. Open the sliding doors and carefully clean the tool setting probe,
then close the door back;

8.6.2 Tool setting by tool-setter arm 72


T140-00325_0

Tool magazine – ATC (Automatic Tool Change)


5. Move the cursor on the adjusting tool of the tool which is being
set to zero;
6. Set to zero all the tools present in the chain or, in any case,
those tools used during the working cycle.
7. Push the button (tool setter backward) to bring the tool setter
arm into its rest position.

73 8.6.2 Tool setting by tool-setter arm


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8.7 Usefulness concerning the ATC (Automatic Tool Change)


Tool magazine – ATC (Automatic Tool Change)

Through the key CUSTOM on the operator panel, you can access
a menu containing information and commands concerning the tool
changer.

Below, instructions on the functions of the various function (soft) keys


associated to the ATC are related.
Ø By pushing [INFO TOOL MAGAZ.]: you can access a page
where you can find information about the state of tools (see par.
8.7.1 pag. 75);
Ø By pushing [DIAGNS ATC PHASES]: You gain access to the
page which displays the phases of the tool change (see par.
8.7.2 pag. 76);
Ø By pushing [MANUAL INCLIN]: you gain access to that page
which allows to linearly move the axes X and Z, in HAND
WHEEL or JOG mode, according to the angle of the B-axis;
Ø By pushing [CODES M]: you can gain access to those pages
which relate all the M functions.

8.7 Usefulness concerning the ATC (Automatic Tool Change) 74


T140-00325_0

8.7.1 ����������
Tool table

Tool magazine – ATC (Automatic Tool Change)


There could be three conditions on the state of tools; these
conditions are illustrated by a different background (led) colour in the
video page, in the column STAT:
> green: it means that the tool is in its normal working
conditions.
> Yellow: it indicates that it has reached its warning threshold
of lifetime ending.
_________________________________________

i Note
In case you would like to make the machine go
on working without the control of an operator, we
suggest you to replace the tool.
> red: it means that tool life has ended or that the
tool cannot be used.
_________________________________________
Other characteristic information present in this page concern the
tool which is on the spindle gripper at that moment and to the tool
which is on the change-over arm.

75 8.7.1 Tool table


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8.7.2 Menu of ATC manual commands


Tool magazine – ATC (Automatic Tool Change)

It is the video page used to manually move the ATC units and axes
one by one, after a sudden and not scheduled stop of the machine.
The information on the state of limit switches is illustrated through
some coloured fields (leds) in the following video page:

(green) tool change cycle starting condition (component in


rest position)
(red) condition of phase ended during the tool change
(white) phase not ended
In order to send single commands to the units, the machine should
be in the condition of manual functioning.
Below, the sequences for the various entries of the menu are
illustrated.

1 – TRAVERSE OF CHANGE-OVER ARM: the cylinder movement


of horizontal traverse will be arranged. Once this selection has been
performed, two arrows will appear to choose the movement direction.
When the two direction keys are pushed, the movement is impulsive;
once started, the movement cannot be stopped. The end of the
operation is signaled by the lighting of a led, that can be green or red
according to the backward or forward position.

8.7.2 Menu of ATC manual commands 76


T140-00325_0

2 - ROTATION OF CHANGE-OVER ARM: The horizontal

Tool magazine – ATC (Automatic Tool Change)


movement, shifting the tool from the chain position to the picking up
position and vice versa, is prepared. In this case, in order to choose
the movement direction, two vertical arrows will appear. When the
direction keys are pushed, the movement is impulsive; once started,
it cannot be stopped. This movement can occur only if the arm has
carried out the traverse 1 toward left.

V - TRAVERSE AXIS V: The horizontal movement of the ATC


change-over arm, axis (V), is arranged. The movement will be
performed by pushing the direction keys.
By releasing the direction keys, the ongoing movement stops.

__________________________________________

i Note
If you choose the HAND WHEEL mode, the axis can
be moved with the hand wheel backward-forward
in increments of 1-10-100 thousandths of mm (see
paragraph 8.7.5).
__________________________________________

The stroke is 40 mm and it goes from 0 (arm forward on the right) to


-40 (completely on the left).

4 – ATC GUARD: the closing/opening movement of the ATC front


bulkhead is arranged; the direction keys will make the movement
follow. When the direction keys are pushed, the movement is
impulsive; once started, it cannot be stopped.

5 – GRIPPER FOR TOOL LOCKING: the closing/opening


movement of the tool-holder gripper is prepared. When the selection
keys are pushed, you will choose to open/close the gripper.

77 8.7.2 Menu of ATC manual commands


T140-00325_0

6 - STOPPAGE OF TOOL ROTATION: it indicates the display of


Tool magazine – ATC (Automatic Tool Change)

the state of the rotating tool:


Ø green field (led): tool locked on toothing;
Ø white/red: tool unlocked.

7- B-AXIS BLOCK: it indicates the display of the head of axis B.


Ø Green field (led): table locked on toothing;
Ø white/red: table unlocked.

E - ROTATION OF E-AXIS: The rotating movement of the ATC


change-over arm, axis (E), is arranged. The movement will be performed
by pushing the direction keys and by releasing the direction keys, the
ongoing movement will be stopped. If you choose the HAND WHEEL
mode, the axis can be moved through the hand wheel backward-
forward in increments of 1-10-100 thousandths of mm (see paragraph
8.7.5).

8.7.2 Menu of ATC manual commands 78


T140-00325_0

8.7.3 Operational notes

Tool magazine – ATC (Automatic Tool Change)


A)
If you try to command the axis E – ARM ROTATION and the axis
V – ARM TRAVERSE is not in the right position, i.e. towards the
chain, the movement will not be performed.
To be driven, the axes E and V have to be on their positions with
green leds lit up.
It is not possible, for example, to turn the arm “E” if axis “V” is not in
the right position of completely forward or completely backward.
B)
If it is necessary to manually move one of these two axes even
if the other one is not in the right position (condition of current
failure or adjustment), one should force the movement through
a two-hand simultaneous command: turn the selector “safety
devices off” and, with the other hand, operate on the control of
the axis “V” or “E”.

79 8.7.3 Operation notes


T140-00325_0
Tool magazine – ATC (Automatic Tool Change)

_________________________________________
Warning
! After each manual movement and before starting
again with an automatic cycle, control that:
Ø in the video page “ATC PHASE ADVANCING”,
all leds are green coloured;

Ø the tool in the machine and the one in the


change-over arm correspond to those saved in
the tool magazine table.

8.7.3 Operation notes 80


T140-00325_0

8.7.4 Diagnosis of ATC phases

Tool magazine – ATC (Automatic Tool Change)


This page is used to diagnose the tool change phases.
If a green field (led) lights up in the video page, correspondingly to
the DEPOSITING PHASE or to the PICKING-UP PHASE, it means
that the related phase has ended.

81 8.7.4 Diagnosis of ATC phases


T140-00325_0

8.7.5 Inclined manual movement


Tool magazine – ATC (Automatic Tool Change)

If for an unexpected reason, or for loss of voltage, the machine


cuts out while it is performing a drilling with an inclined axis B, it is
necessary to use the JOG or MPG mode in order to come out from
this situation.

PROCEDURE
JOG Mode
1. Push the key JOG
2. Cut the movement speed down to about 50% through the
potentiometer F

60 70 80 90
50 100
40 110
30 120
20 130
10 140
0 150

JOG JOG
3. By pushing the function (soft) keys [ + ] or [- ], the desired
movement is performed.

8.7.5 Inclined manual movement 82


T140-00325_0

Hand wheel mode

Tool magazine – ATC (Automatic Tool Change)


1. Push the key MPG .
2. Select the movement speed by using the keys [X1] [X10]
[X100]
3. Push the function (soft) key [MPG OFF] which becomes
[MPG ON]
4. Turn the hand wheel towards the direction (+) or (-) to take
the tool out of the piece.
5. At the end of the movement, push the function key [MPG
ON] which becomes [MPG OFF].

8.7.6 List of “M” functions

The video pages developing from the preceding one give the full list
of the auxiliary “M” functions to the operator.

83 8.7.6 List of “M” functions


T140-00325_0

8.8 Tool phase advancing


Tool magazine – ATC (Automatic Tool Change)

When the machine stops in an emergency situation during the cycle of


tool change, it is necessary to reset the tool change unit by following
the two procedures A and B described below, in order to let it start up
again.

PROCEDURE A
You will follow this procedure if the machine stops during arm rotation
and, anyway, before extracting the tool present in the spindle. Take
the arm back in the rest position (vertical). The value of E can be 0 or
180.

8.8 Tool phase advancing 84


T140-00325_0

Tool magazine – ATC (Automatic Tool Change)


PROCEDURE B
You will follow this procedure if the machine stops after taking the tool
out of the spindle.
First of all, before starting any operation, the arm position should be
controlled:
• If the arm has not performed the rotation yet, take the tool
back in the gripper, lock it and take the arm back in its rest
position (vertical).
• If the arm is already in its rotation phase, continue the
same rotation in a manual way, then introduce the new tool
in the gripper, lock it and take the arm back in rest position
(vertical).

85 8.8 Tool phase advancing


T140-00325_0
Tool magazine – ATC (Automatic Tool Change)

_________________________________________
Warning
! At the end of every movement performed in manual
mode, before starting back the automatic cycle, it is
necessary to check, in the video page “MANAGING
TOOL MAGAZINE”, that the tool in the machine
and the one in the change-over arm correspond to
those saved in the table at the entries MAND1 and
ATTE1.
_________________________________________

8.8 Tool phase advancing 86


T140-00325_0

Main Spindle, Tailstock and Subspindle

Main Spindle, Tailstock and Subspindle


9.1 Main Spindle (Smart version)
In the B1200 Smart Turn base version, the spindle is of a cartridge
type, having the hydraulic cylinder, the safety micro-switch and the
coolant collection tank built-in.
It is driven by a motor with two speed ranges, obtained through an
automatic electronic change.
9.1.1 Main spindle - hole Ø 95 mm ASA 8”
Technical specifications
Max. rotating speed: 2,800 rpm Thrusting power at 30 bar: 7,290 daN
Cylinder thrust area: 243 cm2 Pulling power at 30 bar: 6,750 daN
Cylinder pull area: 225 cm2 Pressure control: from 5 to 35 bar
Marking

N°12 holes at 30°

A = Cylinder stroke; D = Driving pin;


B = Rotating distributor; E = Sleeve;
C = Container for coolant and swarf collection; F = Sleeve stroke: 35 mm

87 9.1 Main spindle (Smart ersion)


T140-00325_0

9.1.2 Main spindle - hole Ø 102.5 mm ASA 8”


Main Spindle, Tailstock and Subspindle

Technical specifications
Max. rotating speed: 2,800 rpm Thrusting power: 9,720 daN
Cylinder thrust area: 325 cm2 Pulling power at 30 bar: 9,720 daN
Cylinder pull area: 325 cm2 Pressure control: from 5 to 35 bar

27
+0.3
-0
Marking

-0.10
-0.15
ÿ 102.5

ÿ 111

ÿ 139.719 ASA 8"

TRACC. ÿ 171.4
ÿ 110x2

ÿ 210

16

45 INDIETRO CORSA 40

AVANTI 85

N°12 holes at 30°


A = Cylinder stroke; D = Driving pin;
B = Rotating distributor; E = Sleeve;
C = Container for coolant and swarf collection; F = Sleeve stroke: 35 mm

9.1.2 Main spindle - hole Ø 102.5 mm ASA 8” 88


T140-00325_0

9.2 Main spindle with electrospindle (Smart S version)

Main Spindle, Tailstock and Subspindle


In the B1200 Smart Turn S version, the spindle is of an electrospindle
type, thermally stabilized through coolant, and having the hydraulic
cylinder, the safety micro-switch and the coolant collection tank built-
in.
Technical specifications
Max. rotating speed: 3,000 rpm Thrusting power at 30 bar: 7,290 daN
Cylinder thrust area: 243 cm2 Pulling power at 30 bar: 6,750 daN
Cylinder pull area: 225 cm2 Pressure control: from 5 to 35 bar

42
TUTTO AVANTI

CORSA 35

1051

+0.3

M105x2
-0
ÿ106
ÿ95.5

ÿ95

A = Cylinder stroke; D = Driving pin;


B = Rotating distributor; E = Sleeve;
C = Container for coolant and swarf collection; F = Sleeve stroke: 35 mm

89 9.2 Main spindle with electrospindle (Smart S version)


T140-00325_0

9.3 Overall dimensions for bar feeder assembly


Main Spindle, Tailstock and Subspindle

SMART series lathes can be connected to a bar feeder and so bar


machine.

A = Cylinder stroke; D = Driving pin;


B = Rotating distributor; E = Sleeve;
C = Container for coolant and swarf collection; F = Sleeve stroke: 35 mm

__________________________________________

i Note
Value to be fixed according to the diameter of the bar
feeder nozzle.
__________________________________________

9.3 Overall dimensions for bar feeder assembly 90


T140-00325_0

9.3.1 Bar guides for Smart lathe and Smart S electrospindle

Main Spindle, Tailstock and Subspindle


The values indicated in brackets refer to the version with
electrospindle.

91 9.3.1 Bar guides for Smart lathe and Smart S electrospindle


T140-00325_0

9.3.2 Bar guides for version with hole for bar passage 102.5
Main Spindle, Tailstock and Subspindle

__________________________________________

i Note
Value to be fixed according to the diameter of the bar
feeder nozzle.
__________________________________________

Round off the corners not valued: 0,5 x 45°.


Material: Fe 510 UNI 7729
Heat Treatment: passived galvanization

9.3.2 Bar guides for version with hole for bar passage 102.5 92
T140-00325_0

9.4 Spindle of sub-spindle (Smart S)

Main Spindle, Tailstock and Subspindle


Technical specifications
Max. rotating speed: 4,000 rpm Thrusting power at 30 bar: 4,965 daN
Cylinder thrust area: 165,5 cm2 Pulling power at 30 bar: 4,560 daN
Cylinder pull area: 152 cm2 Pressure control: from 5 to 35 bar

1010 57
25 935 50
A 30
Ø 67

C B

20

5
30˚

30˚
Ø 19 h8

D
7˚7'30"

30˚
Ø 106,38 ASA 6"
Ø 133,4 Tracciatura
Marking

+ 0,035
-+ 0
Ø 79 x 1,5
Ø 156

- 0,03
- 0,06
+ 0,3

Ø 86 H7
-0
Ø 67

Ø 76

24

M12 H = 22 12
N˚ 12holes
N°12 fori aat
30˚
30°
57

30 F

93 9.4 Spindle of sub-spindle (Smart S)


T140-00325_0

9.5 Chuck machining


Main Spindle, Tailstock and Subspindle

Using a chuck needs a particular attention to prevent the coolant or


swarfs from entering the spindle; for this reason, the hole has to be
always guarded by a cover.
Machining parts without shank
Cover must always be fitted in.

Machining parts with shank


Cover must be removed and replaced by an appropriate bush, having
an inner diameter increased by 1 mm compared to the shank.

9.5 Chuck machining 94


T140-00325_0

Machining without the protection of the hole

Main Spindle, Tailstock and Subspindle


______________________________________________
Warning
! If it is not possible to protect the chuck hole, then it is
necessary to daily check the rear part of the spindle, where
swarfs can accumulate and clog up the coolant exhaust
pipe, with the consequent leakage of the liquid from the
spindle hole and the possible entering of the coolant into
the distributor and therefore in the hydraulic system
(hydraulic unit).
______________________________________________

9.5.1 Assembling chucks and collets on the main spindle


Ø 315/95 Chuck on spindle – hole Ø 95 ASA 8”

A chuck Ø 315 hole 95 (if ordered)


is supplied by Biglia with the
additional components A – B,
ready for fitting.
For assembly and disassembly,
follow the procedures described
on the user’s manual supplied by
the manufacturer.
If the chuck is not supplied
by Biglia, it has to be fitted to
the spindle nose shown in the
paragraph 9.1 and 9.2.

95 9.5.1 Assembling chucks and collets on the main spindle


T140-00325_0

Cover C
Main Spindle, Tailstock and Subspindle

Cover must always be fitted in. Its function is to prevent coolant and
chippings from entering the spindle.
Should it be removed for special machining with shank, it has to
be replaced by a bush having an inner diameter increased by 1mm
compared to the shank.

66,5 145
F ( KN )

�s ( KN )
�S
57,0 120 F
47,5 100
38,0 80
28,5 60
19,0 40
9,5 20
0 0
0 10 20 30 35 40 0 1000 2000 3000 4000 5000
P ( bar ) (rev/min
g/min )

Collet-holder
On request, Biglia can supply the MTSCN 100 collet-holder suitable
for bars up to 100 mm.
It can be fit for double-cone collets (BD 100) or simple-cone collets (BA
100), the selection is made based on the type of bar and machining to
be performed.
Collets are supplied only on request.

9.5.1 Assembling chucks and collets on the main spindle 96


T140-00325_0

9.5.2 Assembling chucks and collets on counterspindle

Main Spindle, Tailstock and Subspindle


ø 250/77 Chuck on spindle – hole ø 67,5 ASA 6”
A chuck Ø 250 mm, hole 67.5 mm (if ordered), is supplied by Biglia
with the additional components A – B, ready for fitting.
For assembly and disassembly, follow the procedures described on
the user’s manual supplied by the chuck manufacturer.
If the chuck is not supplied by Biglia, it has to be fitted to the spindle
nose shown in this manual.
128

24

Ø 67,5
Ø 220

Ø 77

Ø 250
C

A B

A = adapter flange; B = threaded joint; C = cover

Cover C
Cover must always be fitted in. Its function is to prevent coolant and
chippings from entering the spindle. Should it be removed for special
machining with shank, it has to be replaced by a bush having an inner
diameter increased by 1mm compared to the shank.
46,5 145
S (kN)
F (kN)

S
38 120 F

30,4 100
80
22,8
60
15,2
40
7,6 20
0 0
0 10 20 30 0 1000 2000 3000 4000 5000
P (bar) rev/min
giri/min
∑S
�������������������������
= clamping force (kN)
P = pressure applied on cylinder (bar) F = cylinder tractive force (kN)

97 9.5.2 Assembling chucks and collets on counterspindle


T140-00325_0

Simple-cone collet-holder
Main Spindle, Tailstock and Subspindle

The standard collet-


holder for the assembly 150

of the simple-cone Dis.


10.38.18.01 is supplied
by Biglia, ready to be

Ø max 60
Ø 67,5

Ø 158

Ø 132
fitted.
The collet is supplied on
request.

9.6 Tailstock
Tailstock slides on an independent guideway and is automatically set
in its work area.
When machining is over, always take the tailstock in its “Backward”
position to avoid collisions with the turret.
Tailstock is hooked and moved forward and backward by machine
slide Z both in manual and automatic mode.
The procedure for manual and automatic positioning is described in
the Operating Manual, Section G, chapter 5.

9.6 Tailstock 98
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9.6.1 Adjusting thrust pressure

Main Spindle, Tailstock and Subspindle


PROCEDURE
1. Open door F (placed on the lateral panel of the spindle side).
2. Push knob G (which is in the machine recess) and rotate it
clockwise or counterclockwise till you obtain the desired
pressure, shown on the pressure gauge H.

[daN] F
2
1500 44 cm
75 mm
1200 F
900

600

300

0 10 20 30 40 50 [bar]

99 9.6.1 Adjusting thrust pressure


T140-00325_0

9.6.2 Setting sleeve feed speed


Main Spindle, Tailstock and Subspindle

Sleeve feed speed can be adjusted acting on knob I located inside


the machine.
To reach the knob I, open the right door of the machine.

I: Sleeve speed adjuster knob


__________________________________________

i Note
Sleeve return speed is fixed.
__________________________________________

9.6.3 Adjusting sleeve micro limit switches


Sleeve movement is controlled by 2 magnetic limit switches 1 and 2,
that can be reached through the door J.
Limit switch 1 controls the sleeve return in “Backward” position and
it has never to be adjusted.
If the limit switch is not energized, or it is defective, the machine stops
with the “Start” light on (no alarms are displayed).
Limit switch 2 controls the sleeve “Forward” position in its working
position and it has to be adjusted according to the sleeve projection.
To position the limit switch, the following procedure should be
performed:

9.6.2 Setting sleeve feed speed 100


T140-00325_0

Main Spindle, Tailstock and Subspindle


1. Move the rotating head forward till it touches the workpiece.
2. Open door J and loosen screw L.

J = Door; K = Block; L = Limit switch lock screw


1 = Limit switch position – backward - ; 2 = Limit switch position -forward-

3. Move limit switch 2 under block K (limit switch excited).


4. Lock screw L and close door J back.

If limit switch 2 is not excited because the workpiece is too long, or


because the rotating head has not reached the piece to support it, or
even it has been excited and then released (no workpiece or part too
short), the machine stops in HOLD position with 1016 alarm on.
__________________________________________

i Note
Min. sleeve stroke is ~40 mm.
__________________________________________

__________________________________________
Warning
! The way of functioning described above is conditioned
by diagnosis parameter K0 bit 6.
__________________________________________
-1- when limit switch operation is disabled, the machine
works without safety devices.
-0- when limit switch operation is enabled, the machine
works with safety devices.

101 9.6.3 Adjusting sleeve micro limit switches


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9.6.4 M.T. fixed bushing (Standard)


Main Spindle, Tailstock and Subspindle

An M.T. 5 bushing P is supplied with the machine to house a rotating


head O to be traded (not supplied by BIGLIA).

To take the rotating head O out, it is necessary to remove the six


screws N which hook the bushing P to the sleeve.
Then pull the bushing P out with the rotating head O still assembled.

While reassembling the bushing, clean and grease its seat.

N = Screws M6x30 UNI 5931; O = Rotating head; P = Bushing.

9.6.4 M.T. fixed bushing (Standard) 102


T140-00325_0

9.6.5 Bushing with concentricity adjusting and lock ring

Main Spindle, Tailstock and Subspindle


(Optional)
Dis. 10.27.44.00
M.T. 5 bushing P1, seat of the rotating head O, is eccentric compared
to the outer diameter of 0.05 mm; therefore, it is possible to adjust the
probable concentricity error between the spindle and the rotating tool
of the tailstock.

103 9.6.5 Bushing with concentricity adjusting and lock ring (Optional)
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Main Spindle, Tailstock and Subspindle

PROCEDURE
1. Position tailstock in its employment area.

2. Mount the gauge holder with magnetic base R on the chuck


and place the gauge probe S on the conical part of the rotating
head O.
3. Check concentricity between spindle and rotating head by
rotating the gauge (chuck). If a correction is required, loosen
the six screws N and rotate the head-bushing set, towards
just one direction, by a pin wrench Q.

4. After performing the adjustment, tighten the six screws N.


To pull out the rotating head O, it is necessary to unscrew the lock
ring by using a pin wrench Q.

N = Screws M6x30 UNI 5931; O = Rotating head; P = M. T. 5 eccentric bushing


Q = Pin wrench size 80-90; R = Gauge holder; S = Gauge

9.6.5 Bushing with concentricity adjusting and lock ring (Optional) 104
T140-00325_0

9.6.6 Tailstock with integral rotating head (Optional) Dis.

Main Spindle, Tailstock and Subspindle


10.27.50.00
On request, BIGLIA provides a rotating head to be housed directly in
the sleeve body. This kind of head is ideal in the machining of trees
since this working requires a strong axial thrust.
No concentricity adjustments are needed with this version.
The integral rotating head T, directly fitted in the tailstock body, has an
interchangeable live centre U (C.M. 4).

T = Integral rotating head; U = Live centre; V = Nut WR. 41


Pulling out of live centre U:

PROCEDURE
1. Tighten the nut V up to abutting end.
2. Unscrew the live centre U with strength, by using two wrenches
WR. 27 and WR. 41.

__________________________________________
Warning
! Loosen gradually and avoid jerks, in order to prevent
your hands from being bruised.
__________________________________________

105 9.6.6 Tailstock with integral rotating head (Optional)


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9.7 Steady-rest (Optional)


Main Spindle, Tailstock and Subspindle

The steady-rest slides on the same guideway of the tailstock and


it can be placed in the work area through the slide Z. Indeed, the
steady-rest can be hooked and moved forward and backward by
slide Z both in manual and automatic mode.
When machining is over, we suggest to disassemble the steady-rest
in order to avoid collisions with the turret; for this reason, some rapid
couplings for hydraulic commands are provided.

9.7.1 Shift in the working position

PROCEDURE
1. Accurately clean the sliding guides A.

A = Guideways; B = Hooking plate; C = Pin.

2. Set the function select switch to HAND WHEEL (position 100)


and enable Z-axis by the button.
3. Slowly move Z-axis until positioning the slot on plate B near
the pin C of the hooking unit.
4. With the function selector switch in MDI position:

• type in M57 to engage the pin C into the slot


of plate B.
• In this condition, the steady-rest can be positioned in any
point of the work area by pulling it through the slide Z.

5. To unhook steady-rest from slide Z, press the key ; pin C


of the hooking unit retracts and the steady-rest is hydraulically
locked on guideways.

9.7 Steady-rest (Optional) 106


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9.7.2 Adjusting the locking pressure by the pressure switch

Main Spindle, Tailstock and Subspindle


After positioning the steady-rest, the arm locking pressure needs to
be adjusted by the regulator D (read pressure on pressure gauge
E); then, adjust the pressure switch F according to the following
procedure:

D = Pressure regulator; E = Pressure gauge; F = Pressure switch

PROCEDURE
1. Take the pressure switch F to the maximum level by using an
Allen wrench 5 (“start” keeps on).
2. Lock the steady-rest by the M55 (“start“ is still lit up).
3. Slowly reduce the calibration of the pressure switch F until
“start” switches off.
If the pressure switch F does not intervene during the machining
cycle, the cycle does not continue and, after almost a minute, the
machine stops and the following alarm message is displayed: “1017
- Function M not ended”.

107 9.7.2 Adjusting the locking pressure by the pressure switch


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Maintenance
Maintenance

10.1 General instructions


The operations of maintenance and repair should be performed only
by qualified and trained staff.
Basic instructions about the abilities and skills of the different professional
figures are contained in chapter 11 “Operational Personnel”.

__________________________________________
Warning
! During every operation, take the main switch to 0 and
guard it with a padlock against any accidental turning
on. Discharge pressure from pipelines before their
disassembly.
__________________________________________

__________________________________________

! Important
The intervals of maintenance indicated in the present
manual and in the maintenance manual are merely
suggestions; they can be sensibly modified on the
basis of the characteristics of the materials you are
machining, the working parameters you use and the
operating cycles the machine is undergoing.
__________________________________________

__________________________________________

i Note
Use only oils authorized by Biglia as lubricant: a list can
be found at paragraph 10.2. We recommend to follow
the instructions contained in the Safety Manual.
__________________________________________

__________________________________________
Warning
! In the machine, there are parts moving and pipelines
under pressure: danger of accident.
__________________________________________

10.1 General instructions 108


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Before operating on electronic devices or inside the electric cabinet,

Maintenance
cut voltage off from mains power supply line by turning the safety
switch off and by applying a warning notice “Maintenance is on”.
_________________________________________
Warning
! While servicing, there is a danger of accident for
electrocution on the electric plant! If protection
devices have been disassembled for maintenance
operations, check that they have been installed again
before starting the machine up and control that they
perfectly work.
_________________________________________

_________________________________________
Warning
! Even after turning the main switch off, strong magnetic
fields still remains: danger of accident.
_________________________________________

_________________________________________

! Important
Never clean the machine with high pressure water
cleaner or with compressed air equipment, but suck
machining residues. Never use cleaning woolen cloth
or frayed cloths.
_________________________________________

If the machine is heavily stressed and machining is made on materials


producing a high quantity of dust (i.e. grey cast iron), schedule
maintenance operations anew on shorter intervals.
Daily check if dirt is present on guideways and on scrapers and
remove it. Regularly clean the tank bottom.
During cleaning and servicing, do not walk on bellows and telescopic
metal covers: they could be damaged and start leaking.
_________________________________________

! Important
Never mix different kinds of oils, even if indicated
as compatible.In case you decide to change oil, you
have to completely empty the plant and clean it.
_________________________________________

109 10.1 General instructions


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__________________________________________
Maintenance

Environment
Do not pour coolants and/or lubricants, oils, greases,
detergents or other liquid, used by the machine, into
watercourses, into the canalization or into the ground,
but legally and ecologically dispose of them by
conforming to national regulations on environmental
protection.
__________________________________________

10.2 Characteristics of consumables


The lubricant/coolant should meet the following requisites.
• It has to be suitable for the material which the workpiece to be
machined is made up of.
• Fully synthetic or low oil coolants can stick to the oil of bed
guideways or trigger corrosion.
• It has to be well and easily mixed with water.
• Lacking in aggressive additives, and in additives detrimental to
our health (i.e. PCB, chlorine, nitro-oxidable amines, etc.).
• High cutting capacity, thanks to special additives.
• Sufficient corrosion protection (DIN 51360/2), corrosion degree
0.
• No skin irritation.
• No aggressiveness towards gaskets, elastomers and machine
paint.

10.2.1 Oils
To preserve high machining performances in time, it is necessary to
keep the right ratio between coolant (mixture oil – water) and lathe
lubricating oil.
In this way, it will be prevented the forming of deposits, of solid waste and
the forming of adhesive films which may cause a tolerance reduction,
a hardening of slide and tailstock and the absence of corrosive
phenomena on metal parts (ballscrews, guideways, bearings, etc.).
We suggest to install components useful to remove floating oily waste
on the swarf conveyor tank.

10.2 Characteristics of consumables 110


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_________________________________________

Maintenance
! Important
Using oils not present in the following list and/or
with characteristics different from those specified by
Biglia excludes the company from any responsibility
for possible damages to people and/or things.
_________________________________________
10.2.2 Lubricating oils
Lubricating system requires an oil having the following specification:
ISO G 68 Viscosity to 50 °C: 15,9 ÷ 17 E
The oil supplied by Biglia in the system at machine delivery is:
AGIP Exidia 68 HG.
Other kinds of oils that could be used are:

Producer Commercial name


ARAL Deganit BW68
BP Maccurat 68 D
Castrol Maccurat 68 D
Elf Hygliss 68
Esso Febis K 68
Wintershall Violan TH 68
Texaco Way Lubrificant 68
Mobil Bettbahnöl 68
Roloil ARM/68-EP

10.2.3 Oils for coolant


For the preparation of coolant, use only semisynthetic emulsifiable
oils, in the quantity of 5% of the liquid.
The oil recommended is: AGIP ULEX 260 EP.
Other kinds of oils that could be used are:

Producer Commercial name


ARAL Emulsol EPT
Blaser Blasocut 2000
BP Cutora HX
Cincinnati Cimcool 400 MSL
Fuchs Ratak Durant 20
Houghton Holcut B 61
Mobil Mobilmet 220
Shell A 44
Texaco Soluble Oil BS EP
Wynn’s V-008

111 10.2.2 Lubricating oils


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10.2.4 Oils for hydraulic unit


Maintenance

The oil to be used in the hydraulic unit has the following


characteristics:
ISO HG 32 Viscosity: to 50 °C: 2,9 E
The oil supplied by Biglia in the system at machine delivery is:
AGIP Exidia 32 HG.
Other oils that can be used are:

Producer Commercial name


Castrol Magna GC 32
Chevron H W S 280
Elf Hygliss 32
Esso Febis K 32
Fina Hydran CIN 32
Fuchs Renolin MR 10
Gulf Gulfwain 32 E
Houghton Hydrodrive HM 32
Mobil Vacuoline oil
Roloil LI/32 EP
Total Drosera MS 32

10.2.5 Liquid for cooling assembly


The liquid to be used for topping-up is a solution consisting of:
• 80% of demineralized water;
• 20% of liquid ANTIFROGEN N.
Percentages are expressed in weight.
The liquid ANTIFROGEN N is produced by the firm CLARIANT.
By visiting the Internet site www.clariant.com, you could become
acquainted with the name of the closest retailer.

10.3 Checks to be done before starting the machine up


Before starting his workshift, the operator in charge with the
management of machine during production has the task to perform a
series of preoperational checks to control the perfect technical state
of the machine and so to guarantee the highest performances and
efficiency.
If he finds technical troubles while checking, he has to refer to the man
responsible for the machine and/or to the maintenance-man.

10.2.4 Oils for hydraulic unit 112


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10.3.1 Chuck jaws

Maintenance
To make jaws work optimally, daily inject grease in the three greasing
points, fitted on the outside of the chuck body, near the jaws.
Greasing needs to be repeated at least every eight hours, since
coolant takes grease away.
When machining is very heavy, swarf and liquid being very intense, a
more frequent greasing is necessary.

_________________________________________

! Important
Never use compressed air to clean the chuck and
the spindle front flange: the front bearings could be
damaged.
_________________________________________

10.3.2 Machine conditions


Before starting any shift, always check that all machine protection
guards are installed and fixed and that all doors and windows are
closed.
Check that in the machine operating area there are no oil and/or
coolant spots.

Check that the pressure gauge (H), indicating


general pressure, shows the value zero.

113 10.3.1 Chuck jaws


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Maintenance

Check the filling up level of the chipping container and empty it if


necessary .

Open the two front sliding doors one after the other so as to let the
chippings, probably accumulated in the preceding machining, fall
down.
Let the swarf conveyor idle for some seconds.

Before starting any activity, control that there are no chippings in the
slots of collets and that all cleaning operations, to be done after every
shift, have been carried out: disassemble the collet, clean the pusher
and oil the collet.

10.3.2 Machine conditions 114


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10.3.3 Lubrification system

Maintenance
The oil level in the system can be checked through a hole in the panel
barring the access to the tank; this tank has a capacity of 2.7 l. and is
placed in the room on the right side of the machine.

If the level is low and the oil quantity is insufficient, a topping-up is


necessary to take the oil level back to its maximum point. Check
the oil tank stopper is correctly closed and the seal components and
pumps are efficient.

F = Condensation collection tank; G = Pressure gauge of lubrification system;


H = Pressure switch for closed steady-rest; M = Stopper for oil loader
_________________________________________

! Important
While topping up oil, do not overpass the maximum
level; there could be leakages when oil temperature
rises because of its expansion.
_________________________________________

115 10.3.3 Lubrification system


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10.3.4 Cooling system


Maintenance

Coolant (refrigerant emulsion) level can be controlled thanks to the


level indicator placed on the swarf conveyor tank.
If the level is under the maximum level, perform a topping-up till you
restore the initial level, through the cover.
__________________________________________

i Note
The quantity needed to have a complete topping-
up can vary from around 250 to 300 l., based on the
layout of pumps and tanks and on the kind of swarf
conveyor installed on your machine.
__________________________________________

Level indicator

_________________________________________

! Important
Never let coolant level go down, in its container,
under the notch indicating the minimum level.
Check emulsion conditions: check that the container
is clean and that there are no obstructions due to
dirtiness. If it was not so, change the emulsion and
accurately clean the container. Control the pump
connection seal.
_________________________________________

10.3.4 Cooling system 116


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10.3.5 Procedure of electropump topping-up

Maintenance
_________________________________________
Warning
! Before starting the electropumps of the coolant
system, control that, in the tank, the coolant liquid
is at the minimum level visible on the indicator and
that the procedure of electropumps filling is correctly
performed. This clever device is necessary to
prevent pumps from burning ceramic packing, by dry
turning.
_________________________________________

PROCEDURE
The procedure to be followed, in order to fill up the plant in the shortest
time possible, without causing damages to pumps, is the following
one:
1. Loosen the pipe going from the electrpump to the lubrication
strip, from the top of the strip.
2. Slip the just loosened pipe in the swarf conveyor tank to
prevent liquid leakage.
3. Set the pump corresponding to the loosened pipe (low or
high pressure) in motion for short periods by using in MDI the
functions M7 for high pressure and M8 for low pressure.
4. As water starts coming out from the pipe inserted in the tank,
stop the delivery and insert the pipe on the strip from which it
has been taken out.
5. Repeat the procedure with the other pumps.

117 10.3.5 Procedure of electropump topping-up


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10.3.6 Hydraulic unit


Maintenance

At machine delivery, the oil tank of the hydraulic unit is completely


filled up and ready to be used.
If, during its ordinary use, you should notice that oil level has lowered,
that would mean that an abnormal situation is present in the circuit.
Signal and let the situation been immediately check by the maintenance-
man.
You can have access to the hydraulic unit through a panel placed in
the rear left area of the machine. The oil level can be deduced through
an examination of the indicator which is placed in the lower part of the
tank.

When you fill up, never go beyond the maximum level and correctly
close the tank plug.

10.3.6 Hydraulic unit 118


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10.3.7 Air treatment unit

Maintenance
It is necessary to daily check the condensate level in the pneumatic
system .
To discharge condensate, follow the procedure below.

PROCEDURE
1. Shut off air coming from pipe A, through the shutoff slide valve B.
2. The condensate present is collected in container D.
3. Condensate can be discharged by opening valve E, and by
collecting it in a container.

A = Air feeding pipe; B = Shutoff valve (up: closed; down: open); C = Knob;
D = Condensation collection container; E = Condensation drain valve

10.3.8 Cooling unit


Daily check the level of coolant (B) and, if necessary, fill it up, through
(A).

119 10.3.7 Air treatment unit


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10.4 Checks to be done after machine switching on


Maintenance

Once the machine is switched on, listen carefully to find out the possible
abnormal noises made by the machine and its fittings.

On their respective gauges, control the pressure of the hydraulic


system (35 bar), of chuck clamping and of the pneumatic system.

Check that no alarm messages are displayed on the monitor and that
ON
push-button ON is lit up.
The tower light placed on the left upper side of the machine shall be
lit up in the green sector in normal conditions. In paragraph 2.3.1, it is
described how the tower light works.

10.4 Checks to be done after machine switching on 120


T140-00325_0

10.5 Oil filter

Maintenance
In the hydraulic circuit, in the direction of the delivery, a cartridge
filter, with clogging indicator, is installed .

When the filter is full of dirt, the message “FILTER CLOGGED”


appears on the CNC monitor and the red sector of the tower light,
placed on the machine top, lights up.
From the moment the alarm message appears, you have, at most,
about 4 hours to wash or replace the filter.
If the maintenance operation is not performed within that period, the
machine stops in alarm condition.

The spare filter cartridge must be of the following models:


SOFIMA type: DM-102-FV-1
UFI type: UDM-102-FV-1
MP-FILTRI type: MP 037-2-A25-A-N

121 10.5 Oil filter


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10.5.1 Disassembling oil filter


Maintenance

PROCEDURE
1. Cut voltage off from the machine by taking the main switch
handle in position 0.
2. Wait about 2 minutes to discharge the system residual pressure
and check the oil temperature, which has to be lower than 30
°C.
3. Put a container, having a capacity of at least 1 l., under the filter
to collect the oil.
4. By using an hexagonal wrench WR 22, loosen the bolt placed
in the lower part of the body A of the oil filter. Then manually
loosen the body filter until you get to slip it off from its seat.

5. Keep body and filter in vertical position, to avoid oil leakage,


and lay it down in the container B.

6. Wash and replace the cartridge C.


7. Re-assemble the body A in the filter seat and screw the lock nut
by a wrench WR. 22.

10.5.1 Disassembling oil filter 122


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10.6 Cleaning the coolant unloading area (for machines with

Maintenance
unloader, only)
• Remove the part container A.
• Remove chippings and dusty residues which have deposited
on the inclined plane B.
• Clean the hole C, which allows coolant to be unloaded in the
swarf conveyor tank, from dirtiness.

10.7 Covering, axes and guideways


Some parts are protected by bellows and/or telescopic coverings in
the work area; despite this precaution, some dirtiness can settle on
guideways: remove it regularly.
• During each operation, put the main switch in position 0 and
protect it, against any accidental start, by a padlock.
• Remove chippings from bellows and telescopic coverings; oil
parts.
• Check correct seal and the positioning of telescopic coverings.
If necessary, replace them.
• Clean and grease guideways.
• Clean and grease ball screws.
• Clean front doors and their sliding rails.
• Clean the guideways of the protection panel towards the tool
magazine.
• Never use compressed air or similar devices to clean. Remove
chippings more than once during every workshift by using
industrial fans.
• Clean the scrapers of the swarf conveyor and of the
guideways.
_________________________________________

! Important
To clean interior parts, do not go up the machine
components, especially on protective coatings,
lateral guards, etc. which could be damaged under
the action of your weight.
_________________________________________

123 10.6 Cleaning the coolant unloading area (for machines with unloader, only)
T140-00325_0

10.8 Tool magazine


Maintenance

You can access the tool magazine through the door which has a
window and which is placed on the rear side of the machine, or by
opening the general door and using the safety key.

A = Safety lock; B = Drives for manual handling of the chain;


C = General door; D = Back door of tool magazine; E = Tank

• During each operation, put the main switch in position 0 and


protect it, against any accidental start, by a padlock.
• Accurately clean the tool-holder collets and visually check that
they have not been damaged. Operate on the collets by making
the magazine rotate by sectors of 5-6 positions at a time.

• Clean the door and the glass panel of the magazine.


• Clean the bulkhead that separates the magazine from the
machining room and the sliding guides.
• Clean the drain sheet.
• Clean the drain area of the machine bed.
• Clean and oil the chain.

10.8 Tool magazine 124


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10.9 Maintenance program

Maintenance
This manual content represents only a summary of the maintenance
program contained in the “Maintenance manual” that you should refer
to.
_________________________________________

! Important
The intervals of maintenance indicated in the
present manual and in the maintenance manual are
merely suggestions; they can be sensibly modified
on the basis of the characteristics of the materials
you are machining, the working parameters you
are using and the operating cycles the machine is
undergoing.
_________________________________________

125 10.9 Maintenance program


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Operational Personnel
Operational Personnel

11.1 Professional profiles of machine operators


The operators allowed to work on the machine shall have adequate
technical skills and be required to attentively read the manuals
delivered together with the machine.

The machine operators are: the unskilled operator, the tooling-up


operator and the maintenance-man.

11.1.1 Unskilled operator


The unskilled operator of machine tools, expert in CNC, is able to
run high precision and programmable machine tools and machining
centres, both of a traditional kind and those with Computerized
Numerical Control, included those controlled by CAD CAM systems.

He has the ability to read 2D and 3D CAD drawings, arrange the tools
to be used, provide for the loading, positioning and unloading of the
workpieces under machining.
Besides, he has the task to constantly control the machining phases
and to evaluate the adequacy of machining parameters through the
operational console, thus solving possible problems or abnormal
situations when signaled.

He is well acquainted with the parts and the way of working of the
machines he is in charge of and he is able to provide for ordinary
maintenance and to signal possible anomalies to the maintenance
service.

Since he knows the materials, he also knows how to change tools,


how to identify the most adequate cutting parameters, how to use
CNC machine tools and computerized machining centres, and how to
bring possible adjustments during machining, how to handle workshop
records concerning his own work, how to collaborate with the technical
office and the upstream and downstream sectors of his function.

11.1 Professional profiles of machine operators 126


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Operational Personnel
Activity based on his Skills Knowledge
abilities (Be able to) (Knowing)
• to determine and set machine tools q The machining cycle of
1. Setting and adjusting for machining mechanics
machine tools • to determine and set functioning
parameters for the machining of q Main machining
mechanical workpieces by carrying processes: hot
out a test machining, cold
• to check the tools preset by machining, welding,
presetting data, to perform etc.
machining
• to interpret technical drawings of q Main tools and their
2. Machining mechanical mechanical pieces to be machined usage
pieces
• to differentiate and to adapt the
different machining methods, on q Main measuring tools:
machine tools, according to the gauges, micrometers,
drawing and the material used comparators, etc.
• to apply the main techniques of
mechanical machining by loading q Traditional and NC
and unloading workpieces Machine Tools:
• to check that the machining process component parts
of the mechanical workpiece is and their function,
exact and efficient
the plane and space
• to check the quality of raw materials where they work
3. Checking quality of and to signal non-compliant
mechanical products materials q Basic computing
• to identify and use the measuring applied to NC Machine
instruments of machined parts Tools
• to check that machined pieces
comply with the requirements q Main rules of drawing:
prescribed by quality control cards sheet format, marks
• to check the working conditions and symbols,
4. Preventive and of machine tools through representation scales,
ordinary maintenance precautionary inspections representation
of machine tools • to apply the main techniques methods, conventions
of preventive and ordinary on sections and on
maintenance according to
what provided by the “User’s section types
and maintenance manual” and
“Maintenance”. q Main raw materials
• to detect the worn out tools and and material properties
define their way of restarting
q Main machining
methods on machine
tools: drilling, turning,
milling, boring, grinding

q Standards
ISO9001:2000
concerning mechanical
machining

q Accident prevention
regulations to be
observed during
mechanical machining

127 11.1 Professional profiles of machine operators


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11.1.2 Tooling-up operator


Operational Personnel

The tooling-up operator of machine tools, expert in CNC, is able to


run machine tools, multifunction turning-milling centres, and high
precision and programmable machining centres, both traditional and
of a Computerized Numerical Control kind (CNC), included those
controlled by CAD CAM systems.

He has the ability to give instructions to the machining centre, to read


2D and 3D CAD drawings, arrange the tools to be used, provide
for machine tooling-up, for loading, positioning and unloading of
workpieces under machining.

Besides, he has the task to constantly control the machining phases


and to carry out elementary acceptance tests on finished pieces
to evaluate the adequacy of machining parameters through the
operational console, thus solving possible troubles or abnormal
situations when signaled.

He knows in detail the parts and the way of functioning of the


machines he is in charge of and he has the skills to provide for their
ordinary maintenance and to signal possible abnormal situations
to the maintenance service; since he knows the materials, he also
knows how to choose and change tools, how to identify the most
adequate cutting parameters, how to use and program CNC machine
tools and computerized machining centres, and how to bring possible
adjustments during machining, how to handle workshop records
concerning his own work, how to collaborate with the technical office
and the upstream and downstream sectors of his function.

11.1.2 Tooling-up operator 128


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Operational Personnel
Activity based on his Skills Knowledge
abilities (Be able to) (Knowing)
• to determine and set machine tools q The machining cycle of
1. Setting and adjusting for machining mechanics
machine tools • to determine and set functioning
parameters for the machining of q Main machining
mechanical workpieces by carrying processes: hot
out a test machining, cold
• to check the tools preset by machining, welding,
presetting data, to perform etc.
machining
• to interpret technical drawings of q Main tools and their
2. Machining mechanical mechanical pieces to be machined usage
pieces
• to differentiate and to adapt the
different machining methods, on q Main measuring tools:
machine tools, according to the gauges, micrometers,
drawing and the material used comparators, etc.
• to apply the main techniques of
mechanical machining by loading q Traditional and NC
and unloading workpieces Machine Tools:
• to check that the machining process component parts
of the mechanical workpiece is and their function,
exact and efficient
the plane and space
• to check the quality of raw materials where they work
3. Checking quality of and to signal non-compliant
mechanical products materials q Basic computing
• to identify and use the measuring applied to NC Machine
instruments of machined parts Tools
• to check that machined pieces
comply with the requirements q Main rules of drawing:
prescribed by quality control cards sheet format, marks
• to check the working conditions and symbols,
4. Preventive and of machine tools through representation scales,
ordinary maintenance precautionary inspections representation
of machine tools • to apply the main techniques methods, conventions
of preventive and ordinary on sections and on
maintenance according to
what provided by the “User’s section types
and maintenance manual” and
“Maintenance”. q Main raw materials
• to detect the worn out tools and and material properties
define their way of restarting
q Main machining
methods on machine
tools: drilling, turning,
milling, boring, grinding

q Standards
ISO9001:2000
concerning mechanical
machining

q Accident prevention
regulations to be
observed during
mechanical machining

129 11.1.2 Tooling-up operator


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11.1.3 Maintenance man


Operational Personnel

This figure attends to the maintenance of production machines.


He intervenes in mechanical, pneumatic and electronic parts to prevent
or repair troubles in their functioning.

The main job of a mechanical maintenance man is to detect a failure, in


a direct way when it is visible, or through a numerical control machine,
when the abnormal situation cannot be easily found, or through the
machine scheme reproduced in a drawing.

The scheme is a kind of instruction book reproducing the electric-


electronic and hydraulic circuits. In this case, a failure “diagnosis” is
made and it consists in identifying the part which does not work and,
especially, the reason that has caused the breaking so as to prevent
its recurrence in the future.

Subsequently, the maintenance man proceeds with replacing or fixing


the piece by using mechanical tools (screwdrivers, monkey spanners,
etc.).

11.1.3 Maintenance man 130


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Operational Personnel
Activity based on his Skills Knowledge
abilities (Be able to) (Knowing)
• to determine and set machine tools q The machining cycle of
1. Setting and adjusting for machining mechanics
machine tools • to determine and set functioning
parameters for the machining of q Main machining
mechanical workpieces by carrying processes: hot
out a test machining, cold
• to check the tools preset by machining, welding,
presetting data, to perform etc.
machining
• to interpret technical drawings of q Main tools and their
2. Machining mechanical mechanical pieces to be machined usage
pieces
• to differentiate and to adapt the
different machining methods, on q Main measuring tools:
machine tools, according to the gauges, micrometers,
drawing and the material used comparators, etc.
• to apply the main techniques of
mechanical machining by loading q Traditional and NC
and unloading workpieces Machine Tools:
• to check that the machining process component parts
of the mechanical workpiece is and their function,
exact and efficient
the plane and space
• to check the quality of raw materials where they work
3. Checking quality of and to signal non-compliant
mechanical products materials q Basic computing
• to identify and use the measuring applied to NC Machine
instruments of machined parts Tools
• to check that machined pieces
comply with the requirements q Main rules of drawing:
prescribed by quality control cards sheet format, marks
• to check the working conditions and symbols,
4. Preventive and of machine tools through representation scales,
ordinary maintenance precautionary inspections representation
of machine tools • to apply the main techniques methods, conventions
of preventive and ordinary on sections and on
maintenance according to
what provided by the “User’s section types
and maintenance manual” and
“Maintenance”. q Main raw materials
• to detect the worn out tools and and material properties
define their way of restarting
q Main machining
methods on machine
tools: drilling, turning,
milling, boring, grinding

q Standards
ISO9001:2000
concerning mechanical
machining

q Accident prevention
regulations to be
observed during
mechanical machining

131 11.1.3 Maintenance man


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Appendix 1
Technical reference documentation

Technical reference documentation


12.1 List of normative documents

While editing this user’s and maintenance manual, we referred to


the following European directives, Italian national laws, harmonized
standards and national standards.

12.1.1 European Directives


• 98/37/CE: approximation of the laws of the Member States
relating to machinery.
• 92/58/CE: minimum requirements for safety and/or health signs
at work.
• 1999/34/CE: (ex 85/374/CE) product liability.
• 73/23/CE: electrical material destined to be used within voltage
limits.
• 89/336/CE: electromagnetic compatibility (EMC).
• 89/391: measure destined to foster safety and health
improvements of workers during their work.
• 8/181/CEE: International System unit of measurement.

12.1.2 General regulations and safety criteria


• EN ISO 12100: Safety of machinery. Basic concepts, general
principles for design.
• EN 60204-1 Safety of machinery - Electrical equipment of
machines
• EN 12417-2001: Machine tools – Safety - Machining centres
• UNI 10693: documentazione tecnica di prodotto. Qualità della
documentazione tecnica di prodotto.
• UNI 10893: documentazione tecnica di prodotto. Istruzioni per
l’uso. Articolazione ed ordine espositivo del contenuto.
• UNI EN 349: Safety of machinery. Minimum gaps to avoid
crushing of body parts.
• UNI EN 414: Safety of machinery. Regole
���������������������������
per la stesura e la
redazione delle di norme di sicurezza.
• EN 614-1: Safety of machinery. Ergonomic design principles.
Terminology and general principles.
• EN 614-2: Safety of machinery. Ergonomic design principles.

Appendix 1 132
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Interactions between the design of machinery and work

Technical reference documentation


tasks.
• EN 811: Safety of machinery. Safety distances to prevent
danger zones being reached by the lower limbs.
• EN 953: Safety of machinery. Guards. General requirements
for the design and construction of fixed and movable guards.
• EN 954-1: Safety of machinery. Safety related parts of control
systems. General principles for design.
• ISO/DIS 11021:����������������������������������������
���������������������������������������
measurement of emission sound pressure
levels at the work station and at other specified position.

12.1.3 Regulations of mechanical pertinence


• UNI EN 294: Safety of machinery. Safety distances to prevent
danger zones being reached by the upper limbs.
• UNI EN 349: Safety of machinery: Minimum gaps to avoid
crushing of body parts.
12.1.4 Regulations of electrical pertinence
• IEC 529: codifica dei criteri di protezione degli apparati
elettrici.
• EN 60529: meaning of IP codes
• CEI EN 60204-1 (IEC 204-1): Electrical Equipment for Industrial
Machines. Part 1. General rules.
12.1.5 Regulations of plant engineering pertinence
• UNI EN 418: dispositivi di arresto d’emergenza, aspetti
funzionali. Principi di progettazione.
• UNI EN 417: segnali acustici di pericolo. Requisiti generali,
progettazione e prove.
• EN 982: Safety of machinery. Safety requirements for fluid
power systems and their components. Hydraulics.
• EN 983: Safety of machinery. Safety requirements for fluid
power systems and their components. Pneumatics.
12.1.6 Italian national legislation
• Ministerial decree of 16th March 1998: sound source.
Measurement criteria.
• D.P.R. 459/1996: acknowledge of EEC directive 89/392/CE
about machines.
• D.Lgs. 626/94
��������������������������������������������������
e s.m.i.: improvement of worker safety and
health during their work.

133 Appendix 1