AMBOSS AMB-50MT-OPTI User manual

GB
Operating instructions
Milling machine
Version 1.1.1
AMB-50MT-OPTI


Version 1.1.1 dated February 25th, 2013 Page 2 Original operating instructions MT50 GB
Table of contents
1 Safety
1.1 Safety instructions (warning notes) ......................................................................................................... 6
1.1.1 Classification of hazards ............................................................................................................. 6
1.1.2 Other pictograms......................................................................................................................... 7
1.2 Intended use ........................................................................................................................................... 7
1.3 Reasonably foreseeable misuse ............................................................................................................. 8
1.3.1 Avoiding misuses ........................................................................................................................ 8
1.4 Possible dangers caused by the milling machine. ............................................................................... . 9
1.5 Qualification of the staff........................................................................................................................ 10
1.5.1 Target group.............................................................................................................................. 10
1.5.2 Authorized staff ......................................................................................................................... 11
1.5.3 Obligations of the operating company....................................................................................... 11
1.5.4 Obligations of the operator........................................................................................................ 11
1.5.5 Additional requirements regarding the qualification .................................................................. 11
1.6 Operator positions ................................................................................................................................ 11
1.7 Safety measures during operation........................................................................................................ 12
1.8 Safety devices ...................................................................................................................................... 12
1.8.1 Lockable main switch ................................................................................................................ 13
1.8.2 EMERGENCY-STOP push button ............................................................................................ 13
1.8.3 Milling table ............................................................................................................................... 13
1.9 Safety check......................................................................................................................................... 14
1.10 Personnel protective equipment ........................................................................................................... 14
1.11 Safety during operation ......................................................................................................................... 15
1.12 Safety during maintenance ................................................................................................................... 15
1.12.1 Disconnecting and securing the milling machine ...................................................................... 15
1.12.2 Using lifting equipment.............................................................................................................. 16
1.12.3 Mechanical maintenance work.................................................................................................. 16
1.13 Accident report ...................................................................................................................................... 16
1.14 Electrical system ................................................................................................................................... 16
2 Technical data
2.1 Type plate ............................................................................................................................................. 17
2.2 Electrical connection ............................................................................................................................. 17
2.3 Dimensions ........................................................................................................................................... 17
2.4 Adjustment travels/ Slewing ranges/ Distances .................................................................................... 17
2.5 Speeds / Infeeds ................................................................................................................................... 18
2.6 Drilling capacity ..................................................................................................................................... 18
2.7 Coolant lubricant system ...................................................................................................................... 18
2.8 Operating material ................................................................................................................................ 18
2.10 Emissions ............................................................................................................................................. 19
2.9 Environmental conditions ...................................................................................................................... 19
3 Assembly
3.1 Scope of delivery .................................................................................................................................. 20
3.2 Transport .............................................................................................................................................. 20
3.3 Storage ................................................................................................................................................. 20
3.4 Installation and assembly ..................................................................................................................... 21
3.4.1 Requirements to the installation site ......................................................................................... 21
3.4.2 Load suspension points............................................................................................................. 22
3.4.3 Installation................................................................................................................................. 23
3.4.4 Anchoring-free assembly........................................................................................................... 23
3.4.5 Anchored assembly................................................................................................................... 23
3.5 First commissioning .............................................................................................................................. 24

Version 1.1.1 dated February 25th, 2013 Page 3 Original operating instructions MT50 GB
3.5.1 Cleaning and lubricating............................................................................................................ 24
3.5.2 Assembly of the chip tray.......................................................................................................... 24
3.5.3 Electrical connection ................................................................................................................. 24
3.5.4 Functional test........................................................................................................................... 25
3.5.5 Check the filling level of the gear oil.......................................................................................... 25
3.5.6 Refill coolant.............................................................................................................................. 25
3.5.7 Warming up the machine.......................................................................................................... 25
4 Operation
4.1 Safety ................................................................................................................................................... 26
4.2 Control and indicating elements ........................................................................................................... 26
4.2.1 Operating panel......................................................................................................................... 27
4.2.2 Switching elements ................................................................................................................... 27
4.3 Switching on the Milling machine ......................................................................................................... 28
4.4 Switching off the Milling machine ......................................................................................................... 28
4.5 Insert tool .............................................................................................................................................. 28
4.6 Speed variation vertical-/ horizontal milling.......................................................................................... 29
4.6.1 Horizontal milling....................................................................................................................... 29
4.6.2 Speed table horizontal milling................................................................................................... 30
4.6.3 Vertical milling........................................................................................................................... 31
4.6.4 Speed table vertical milling ....................................................................................................... 31
4.7 Standard values for cutting speeds...................................................................................................... 32
4.8 Manual spindle sleeve feed .................................................................................................................. 33
4.8.1 Rough adjustment..................................................................................................................... 33
4.8.2 Fine adjustment......................................................................................................................... 34
4.9 Swivelling the milling head ................................................................................................................... 34
4.9.1 Set milling head to the zero position ......................................................................................... 35
4.10 Move cross table up and down ............................................................................................................. 35
4.11 Move spindle head carrier backwards and forwards ............................................................................ 35
4.12 Move cross table to the left / right (X axis) ........................................................................................... 36
4.12.1 Manual movement of the X axis................................................................................................ 36
4.12.2 Switch on / off the automatic table feed (X axis)....................................................................... 37
4.13 Move cross table forwards / backwards (Y axis) .................................................................................. 38
4.14 Turn spindle head carrier...................................................................................................................... 39
4.15 Conversion to horizontal milling............................................................................................................ 40
4.16 Cooling ................................................................................................................................................. 42
5 Digital position display
5.1 The position display at the front and a description of the keys ............................................................. 43
5.2 The position display at the rear ............................................................................................................ 43
5.3 Description of the keys ......................................................................................................................... 44
5.4 Reader connector pin signals ............................................................................................................... 46
5.5 Input / output connection ...................................................................................................................... 46
6 Basic operation of the position display
6.1 Activation .............................................................................................................................................. 48
6.2 Deleting ................................................................................................................................................ 48
6.3 Setting current coordinate values of the axis ........................................................................................ 49
6.4 Conversion of radius/diameter on the X axis........................................................................................ 50
6.5 Lathe/milling machine switching the function ....................................................................................... 50
6.6 Setting of the machining zero point ...................................................................................................... 50
6.7 Function of tool data ............................................................................................................................. 51
6.8 Display of the Z+Z0 value (3 axes)....................................................................................................... 52
6.9 Conversion metric/inch ......................................................................................................................... 52
6.10 Function of the reader - reference (zero position) ................................................................................ 52

Version 1.1.1 dated February 25th, 2013 Page 4 Original operating instructions MT50 GB
6.11 Calculator function................................................................................................................................ 54
6.12 Plunging hole along the inclined line function ....................................................................................... 54
6.13 Subdivided hole on the circle function .................................................................................................. 56
6.14 Machining along the inclined line function ............................................................................................ 59
6.15 Arc machining function ......................................................................................................................... 60
7 Position display, internal parameter settings
7.1 Programming function ........................................................................................................................... 64
7.2 The meaning of the parameters ............................................................................................................ 65
7.3 Setting of the linear machining speed and of the workpiece diameter ................................................. 67
8 Maintenance
8.1 Safety .................................................................................................................................................... 68
8.1.1 Preparation................................................................................................................................ 69
8.1.2 Restarting.................................................................................................................................. 69
8.2 Inspection and maintenance ................................................................................................................. 69
8.3 Repair ................................................................................................................................................... 74
9 Ersatzteile - Spare parts
9.1 Säule und Fuß - Column and Base ...................................................................................................... 75
9.2 Frästisch - Milling table......................................................................................................................... 76
9.3 Schaltgetriebe Vertikalfräsen - Transmission gear vertical milling ....................................................... 77
9.4 Riementrieb Horizontalfräsen - Belt drive horizontal milling ................................................................. 78
9.5 Universal Schwenkkopf - Universal swiveling head.............................................................................. 79
9.6 Übersicht Lager - Overview bearings ................................................................................................... 80
9.7 Ersatzteilbestellung - Spare parts ordering ........................................................................................... 80
10 Wiring diagram
11 Malfunctions
12 Troubleshooting position display
13 Annex
13.1 Copyright ..............................................................................................................................................
13.2 Terminology/Glossary ...........................................................................................................................
13.3 Change information manual ..................................................................................................................
13.4 Product follow-up..................................................................................................................................
13.5 Liability claims for defects / warranty.................................................................................................... 9
13.6 Advice for disposal / Options of reuse: ................................................................................................. 9
13.6.1 Decommissioning...................................................................................................................... 9
13.6.2 Disposal of the packaging of the new machine......................................................................... 9
13.6.3 Disposal of the used machine................................................................................................... 9
13.6.4 Disposal of electrical and electronic components ..................................................................... 9
13.6.5 Disposal of lubricants and cooling lubricants ............................................................................ 9
13.7 Disposal via municipal collecting points ................................................................................................
13.8 RoHS , 2002/95/EC ..............................................................................................................................
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Version 1.1.1 dated February 25th, 2013 Page 5 Original operating instructions MT50 GB
1 Safety
Representation Conventions
This part of the operating instructions
explains the meaning and use of the warning notices included in these operating
instructions,
defines the intended use of the milling machine,
points out the dangers that might arise for you or others if these instructions are not
observed,
informs you about how to avoid dangers.
In addition to these operation instructions, please observe
applicable laws and regulations,
legal regulations for accident prevention,
the prohibition, warning and mandatory signs as well as the warning labels on the milling
machine.
When installing, operating, maintaining and repairing the milling machine it is necessary to
observe the European standards.
The still applicable country-specific regulations need to be applied for the not yet for the
corresponding national country law implemented German standards.
If required it is necessary to take the corresponding measures to comply with the
country-specific regulations before commissioning the milling machine.
ALWAYS KEEP THIS DOCUMENTATION CLOSE TO THE MILLING MACHINE.
INFORMATION
If you are unable to solve a problem using these operating instructions, please contact us for
advice:

gives additional advices
calls on you to act
enumerations

Version 1.1.1 dated February 25th, 2013 Page 6 Original operating instructions MT50 GB
1.1 Safety instructions (warning notes)
1.1.1 Classification of hazards
We classify the safety instructions into different levels. The table below gives an overview of
the classification of symbols (pictograms) and signal words for the specific danger and its
(possible) consequences.
Pictogram Signal word Definition/Consequences
DANGER! Imminent danger that will cause severe injury of death to the
staff.
WARNING! Risk: A danger that might cause severe injury to the staff or can
lead to death.
CAUTION! Danger of unsafe procedure that might cause injury to the staff
or property damages.
ATTENTION!
Situation that could cause damage to the milling machine and
products and other types of damage.
No risk of injury to the staff.
INFORMATION
Application tips and other important or useful information and
notes.
No dangerous or harmful consequences for the staff or objects.
In case of specific dangers, we replace the pictogram by
or
general danger by a warning of injuries to
hands, hazardous electrical
voltage,
rotating parts.

Version 1.1.1 dated February 25th, 2013 Page 7 Original operating instructions MT50 GB
1.1.2 Other pictograms
1.2 Intended use
WARNING!
In the event of intended us e of the milling machine
the staff will be endangered,
the milling machine and other material property of the operating company will be
endangered,
the correct function of the milling machine may be affected.
The milling machine is designed and manufactured to be used in a non-explosive
environment. The milling machine is designed and manufactured to be used for milling and
drilling cold metals or other non-flammable materials or materials that do not constitute a
health hazard by using commercial milling and drilling tools.
The milling machine must only be installed and operated in a dry and well-ventilated place.
The table housing of the cross table included in the scope of delivery can be used as chip and
spray guard. The table housing does not possess any safety relevant function. If required it is
possible to disassemble the table housing.
If the milling machine is used in any way other than described above or modified without the
approval of the company Optimum Maschinen Germany GmbH then the milling machine is
being used improperly. We do not take any liability for damages caused by intended use.
We expressly point out that the guarantee will expire due to any constructive technical or
procedural changes which had not been performed by the company Optimum Maschinen
Germany GmbH.
It is also part of intended use that you
observe the limits of the milling machine,
observe the operating instructions,
observe the inspection and maintenance instructions.
Warning of
automatic start-up! Activation forbidden! Disconnect the mains plug! Use protective glasses!
Use safety
gloves Use protective protection Use protective suit! Use ear protection!
Read
the operating
instructions before
commissioning!
Protectthe
environment! Contact address

Version 1.1.1 dated February 25th, 2013 Page 8 Original operating instructions MT50 GB
 "Technical data“ on page 17
WARNING!
Very serious injury due to intended use.
It is forbidden to make any modifications or alternations to the operation values of the
milling machine. They could endanger the staff and cause damage to the milling
machine.
1.3 Reasonably foreseeable misuse
Any other use as the one determined under the "Proper use" or any use
beyond the described use shall be deemed as not in conformity and is forbidden.
Any other use has to be discussed with the manufacturer.
It is only allowed to process metal, cold and non-inflammable materials with the milling
machine.
In order to avoid misuses it is necessary to read and understand the operating instructions
before the first commissioning.
The operating staff has to be qualified.
1.3.1 Avoiding misuses
Use of suitable cutting tools.
Adapting the speed adjustment and feed to the material and workpiece.
Clamp workpieces firmly and vibration-free.
ATTENTION!
The workpiece must always be fixed in a machine vice, jaw chuck or another
appropriate clamping tool such as e.g. clamping jaws.
WARNING!
Risk of injury caused by workpieces flying off.
Clamp the workpiece in the machine vice. Make sure that the workpiece is firmly
clamped in the machine vice resp. that the machine vice is firmly clamped on the
machine table.
Use cooling and lubricating agents to increase the durability of the tool and to improve
the surface quality.
Clamp the cutting tools and workpieces on clean clamping surfaces.
Sufficiently lubricate the machine.
Correctly adjust the bearing clearance and the guidings.
It is recommended:
Insert the drill in a way that it is exactly positioned between the three clamping jaws of
the quick action chuck.
Clamp and mills by means of the collet chuck and the corresponding collets.
Clamp end face mills by means of shell end mill arbors.
When drilling make sure that
the suitable speed is set depending on the diameter of the drill,
the pressure must only be such that the drill can cut without load
in case of too strong pressure the drill will get worn early or even might break resp. get
jammed in the hole. If the drill gets jammed immediately stop the main motor by pressing
the emergency stop button
for hard materials, e.g. steel, use commercial cooling / lubricating agents,
generally always drive the turning spindle out of the workpiece.

Version 1.1.1 dated February 25th, 2013 Page 9 Original operating instructions MT50 GB
ATTENTION!
Do not use the quick action dr ill chuck for milling tools. Never clamp a mi lling cutter
into the quick action drill chuck. Use a collet chuck and the corresponding collets for
the end mill.
When milling make sure that
the corresponding cutting speed is selected,
for workpieces with normal strength values, e.g. steel 18-22 m/min,
for workpieces with high strength values 10-14 m/min,
the pressure is selected in a way that the cutting speed remains constant,
for hard materials commercial cooling / lubricating agents are used.
1.4 Possible dangers caused by the milling machine.
The milling machine is state-of-the-art.
Nevertheless, there is a residual risk as the milling machine operates
at high speeds,
with rotating parts and tools,
with electrical voltages and currents.
We have used construction resources and safety techniques to minimize the health risk for
the staff resulting from these hazards.
If the milling machine is used and maintained by the staff who are not duly qualified, there
may be a risk resulting from incorrect or unsuitable maintenance of the milling machine.
INFORMATION
All staff involved in assembly, commissioning, operation and maintenance, must
be duly qualified,
strictly follow these operating instructions.
Always disconnect the milling machine from the electrical power supply when performing
cleaning or maintenance works.
WARNING!
The milling machine may only be used with functional safety devices.
Disconnect the milling machine immediately, whenever you detect a failure in the
safety devices or when they are not fitted!
All additional devices installed by the operator have to be equipped with the
prescribed safety devices.
This is your responsibility being the operating company!
 "Safety devices“ on page 13

Version 1.1.1 dated February 25th, 2013 Page 10 Original operating instructions MT50 GB
1.5 Qualification of the staff
1.5.1 Target group
This manual is addressed to
•the operating companies,
•the operators,
•the staff for maintenance works.
Therefore, the warning notes refer to both, operation and maintenance staff of the milling
machine.


Determine clearly and explicitly who will be responsible for the different activities on the
machine (operation, maintenance and repair).
Unclear responsibilities constitute a safety risk!
Always lock the main switch after switching off the milling machine. This will prevent it from
being used by unauthorized staff.
INFORMATION
Unclear responsibilities constitute a safety risk!
The qualifications of the staff for the different tasks are mentioned below:
Operator
The operator is instructed by the operating company about the assigned tasks and possible
risks in case of improper behaviour. Any tasks which need to be performed beyond the
operation in the standard mode must only be performed by the operator if it is indicated in
these instructions and if the operating company expressively commissioned the operator.
Electrical specialist
Due to his professional training, knowledge and experience as well as his knowledge of
respective standards and regulations the electrical specialist is able to perform works on the
electrical system and to recognise and avoid any possible dangers himself.
The electrical specialist is specially trained for the working environment in which he is
working and knows the relevant standards and regulations.
Specialist staff
Due to its professional training, knowledge and experience as well as his knowledge of
relevant regulations the specialist staff is able to perform the assigned tasks and to
recognise and avoid any possible dangers himself.
Instructed persons
Instructed persons were instructed by the operating company about the assigned tasks and
any possible risks in case of improper behaviour.