Bridgeport GX 300 User manual

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Operating Manual
Fanuc 0i-MC
GX 300
GX 480
GX 480 APC
GX 710
Fanuc 0i-MC
Fanuc 18i-MB (Option)
GX 510
GX 600
GX 1000
GX 1300
GX 1600
Original instructions
Document Number 1902505
Issue D
February 2009

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CONTENTS Page
1.1INTENDEDUSE 3
1.2 IMPORTANT SAFETY NOTICE WARNING! 4
1.3 SAFETY LISTS ALL COUNTRIES 5
1.4 GUARD WINDOW SAFETY 7
1.5 BEFORE SWITCHING ON 8
1.6 WARRANTY INFORMATION 9
1.7 ROUTINE INSPECTION 9
1.8 MACHINE WARM UP 10
1.9 SPINDLE MAINTENANCE 10
1.10 INTERRUPTING MACHINING 11
1.11 COMPLETING A JOB 11
1.12 SAFETY DEVICES 12
2.1 OPEATOR PANEL 13
2.2 MACHINE FUNCTIONS 15
2.3 INDICATOR LIGHTS 20
2.4 MACHINE POWER ON/ZERO RETURN 21
2.5 MANUAL AXIS JOG 21
2.6 MPG OPERATION 22
2.7 SPINDLE OPERATION 23
2.8 M-FUNCTION CODES 24
2.9 LOADING A TOOL INTO THE SPINDLE 26
2.10 TOOL MAGAZINE DATA TABLES 27
2.11 MANUALLY CONTROLLING THE TOOL MAGAZINE 31
2.12 APC ALARM MESSAGE 32
2.13 TOOL CHANGER FAULT RECOVERY 33

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1.1 INTENDED USE
This machining centre is a numerically controlled machine tool designed to shape cold
metal by the application of rotating cutting tools capable of performing two or more
machining processes (e.g. boring, drilling, milling, thread tapping) at one set-up of a
workpiece and incorporating automatic facilities to:
Select and change tools from a magazine
Change the position of the workpiece relative to the spindle mounted cutter
Select and apply spindle speeds and axis feeds
Control ancillary services (e.g. coolant flow)

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1.2 IMPORTANT SAFETY NOTICE WARNING!
It is the user’s responsibility to be acquainted with the legal obligations and
requirements in the safe use and application of the machine, particularly under the
Health and Safety at Work Act 1974 and in the British Standard document
PD 5304:2005 Guidance on the Safe Use of Machinery, and other standards and safety
codes applicable in the country of use.
SAFE INSTALLATION
It is the customer’s responsibility to ensure the machine is installed in a safe operating
position, with all service pipes and cables clear of the operation area so as not to cause
a hazard. Access must be allowed for safe maintenance, swarf and oil disposal including
safe stacking of machined and un-machined components.
MACHINE GUARDING
The Bridgeport Machining Center is fitted with completely enclosed guards as standard.
In certain cases and tooling applications additional guarding may have to be provided
by the user.
The standard machine guarding has special safety interlocks on the guard doors that
comply with the Machinery Directive. Guards and interlocks must be kept fully
maintained and tested by the customer and shall not be removed.
The guards are made with clear observation windows having high impact resistance to
provide operator safety and a clear unobstructed view of the operations in process. The
opening of any guard door provides access to potential hazard areas. Opening of the
front working area guard doors is not allowed whilst the spindle is rotating but it is still
possible to manually initiate axis movements whilst these doors are open albeit at a
reduced traverse rate. Extreme care must therefore be used at all times.
SOFTWARE
Unauthorised changing of machines software or control parameters is hazardous and is
not permitted. Hardinge will not accept any liability whatsoever for unauthorized
changes in this area.
AUTHORISED PERSONNEL AND TRAINING
Operating, service and maintenance engineers shall be authorised by the ‘User
Company’ and properly trained in the use of the machine.
SAFE WORKING PRACTICE
Workholding devices, lifting equipment, tooling and their use shall be the responsibility
of the user. It is the user’s responsibility to protect against the hazards caused by swarf,
leaking oil or coolant and their use.
Use of proprietary oil or coolant is the responsibility of the user. Special instructions
from the suppliers concerning their use should be carefully read and understood before
use.
To prevent bodily injury, safe working practices should be employed when operating or
servicing the machine.

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1.3 SAFETY LISTS ALL COUNTRIES
• It is the user’s responsibility to ensure all local regulations and safety instructions are
followed.
• Users should consult with their own safety representative to ensure that all such
regulations are known and acted upon.
• Additional safety notices may exist for certain specific countries for which Hardinge
may be able to advise. Please ask.
• DON’T run the machine until you have made clear to your supervisor that you
understand the potential hazard of spindle rotation, the throwing of coolant and the
removal of swarf from the cutting process.
• DON’T run the machine until you have read and understood all manuals provided with
the machine.
• DON’T run the machine until you have read and understood all the machine and
control keys.
• DON’T run the machine for the first time without a qualified instructor. Ask your
supervisor for help when you need it.
• PROTECT your eyes. Wear safety glasses with side shields at all times.
• DON’T get caught in moving parts. Remove watches, rings, jewellery, neckties and
loose fitting clothes.
• PROTECT your head. Wear a safety helmet when working near overhead hazards.
• KEEP your hair away from moving parts.
• PROTECT your feet. Always wear safety shoes with steel toecaps and oil resistant
soles.
• Gloves are easily caught in moving parts. TAKE THEM OFF before you turn on the
machine.
• Loose objects can become flying projectiles. REMOVE all loose items (wrenches, chuck
keys, rags etc.) from the machine before starting.
• NEVER operate a machine tool after taking strong medication, using non-prescription
drugs, prescription drugs or consume alcohol which may impair concentration.
• ALWAYS make sure the working and cutting zone is safeguarded.
• PROTECT your hands. Make sure the spindle is stopped before manually changing a
tool or a workpiece.
• PROTECT your hands. Make sure the spindle is stopped before manually clearing away
swarf or oil. Use a brush or chip scraper. NEVER use your hands.
• PROTECT your hands. Make sure the spindle is stopped before manually adjusting the
work piece or fixture or coolant nozzle.
• PROTECT your hands. Make sure the spindle is stopped before you take
measurements.
• PROTECT your hands. Make sure the spindle is stopped before you move a safeguard.
Never reach round a safeguard.
• PROTECT your hands. Make sure the machine is switched off and electrically isolated
before making any mechanical adjustment.
• PROTECT your hands. Beware sharp edges of cutting tools when changing and
handling tools.
• PROTECT your hands. Beware of sharp edges on newly machined components. Wear
gloves when unloading.
• PROTECT your eyes and the machine. Never use a compressed air hose to remove
swarf or to clean out air vents.
• KEEP the work area well lighted. Ask for additional lighting if needed.
• DON’T slip. Keep your work area clean and dry. Remove swarf, oil and obstacles.
• NEVER lean on the machine. Stand away when machine is running.
• DON’T get trapped. Avoid pinch points caused between other machines and the
machine you are working.
• PREVENT objects from flying loose. Securely clamp and locate the workpiece.

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SAFETY LISTS ALL COUNTRIES (Cont.)
• PREVENT cutter breakage. Use correct cutter speed and axis feed rate for the job.
Make manual over ride adjustments of axis feed rate or spindle speed if you notice
unusual noise or vibration. Ask your supervisor for help if you need it.
• PREVENT cutter breakage. Rotate the spindle in a clockwise direction for right handed
tools, counter clockwise for left handed tools. Use the correct tool for the job.
• PREVENT work piece and cutter damage. Never start the machine when the cutter is
in contact with the work piece.
• Dull and damaged tools break easily. Inspect tools and tool holders. Keep tools sharp.
Keep overhang short.
• KEEP all lubrication reservoirs maintained at the correct level. Always keep to the
maintenance schedule.
• Certain materials such as magnesium are highly flammable in dust and chip form. See
your supervisor before working these materials.
• PREVENT fire. Keep flammable liquids and materials away from the work area and
from hot swarf.
• PREVENT the machine from moving unexpectedly. When leaving the machine
unattended, not producing, leave switched in the MANUAL mode, with the
EMERGENCY STOP button depressed.
• DON’T use the machine in a volatile atmosphere. Electrical devices fitted to the
machine are for normal factory use and are not explosion proof.
• ALWAYS keep the machine clean and do not let swarf collect.
• ALWAYS keep the area around the machine clean and tidy. Opening the guards
creates the potential for residual coolant and swarf to fall to the swarf tray and
possibly to the floor. Good housekeeping minimizes the potential for trips, slip or fall
of all personnel.
• DON’T reach into any control or power case, unless electrical power is OFF.
• DON’T touch electrical equipment when hands are wet or when standing on a wet
surface.
• ASCERTAIN AND CORRECT the cause of a shutdown caused by overload heaters
before restarting the machine.
• This machine tool is a machining center, and is intended for the use in machining
materials with the work piece fixed to the table, and the cutting tool rotating in the
spindle. The machine should not be used for any other purpose.
• INFORM all other personnel who approach the machine about the hazards described
in this safety list.
• When making adjustments with spanners, always ensure that the required leverage is
safely applied. Always avoid slippage. Always apply the leverage by pulling, never by
pushing. Always use the correct size spanner. Ensure the spanner is not damaged.
• Do not use organic chemical solvents to clean the machine guards or compressed air
services equipment.
• This machine is intended for use in an industrial environment and must not be used in
the residential, commercial and light industrial environment.
• The windows fitted to Bridgeport Machining Centers are manufactured from
bulletproof polycarbonate sheet. This material does deteriorate with age, and should
be exchanged within the time period described later in this manual.
• Any workholding device used in conjunction with this machining center must fit within
the working envelope available. Under no circumstances must any such workholding
device be used when it would require the need to override/defeat the safety
interlocks fitted as standard to this machine.

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1.4 GUARD WINDOW SAFETY
The majority of windows fitted to Bridgeport Machining Centers are manufactured from
the GE Plastics LEXAN® range of polycarbonate sheet, with a hardened surface coating
called Margard®. The hard coating gives protection against minor scratching. Testing
over the past few years has resulted in confirmation that the impact resistance of
polycarbonate degrades over time after exposure to the metalworking fluids and
lubricants used in the metalworking process. Although the Margard® coating provides
some protection against the cutting fluids, the polycarbonate still degrades. Guidance
on the replacement of windows is given in the Operators Safety Manual, section 1.7.

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1.5 BEFORE SWITCHING ON
Training on all aspects of this machine tool is available from Hardinge. Please contact
your Hardinge representative for further details.
Cables, cords or electric wires of which insulation is damaged can produce current leaks
and electric shocks. Check their condition before connecting.
A qualified electrician should only carry out connection of the power cable to the
machine.
Ensure the power cable to the machine main isolator has sufficient current carrying
capacity to handle the electric power used.
Cables which must be laid on the floor, must be protected against chips, oil and
coolants penetration, which might cause damage.
In the event of power failure, turn off the main circuit breaker immediately.
Fuses and circuit breakers should be replaced only with suitably rated alternatives.
Safety devices should be replaced only with the machine manufacturers recommended
parts.
Protect the CNC unit, operating panel, and electric cabinet etc from shocks which could
cause a failure of malfunction.
Check the condition of the warning labels. If they are missing or become illegible, order
replacements from Hardinge according to the part number on the label plate. Do not
remove warning labels.
After unpacking the machine clean all rust preventative from the machine with a non-
volatile cleaning fluid. Lightly lubricate each sliding part before trying to operate the
machine.
Use recommended oil brands and appropriate levels for all lubricating systems. See the
instruction plate at the rear of the machine.
The coolant system comprises a separate tank at the front of the machine and a coolant
pump located beneath the electrical cabinet.

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1.6 WARRANTY INFORMATION
Hardinge warrants to the original purchaser only that all products manufactured by it
will be free from defects in materials or workmanship, such warranty to remain in effect
if and only if such products are used in accordance with all instructions as to
maintenance and operations set forth in manuals and instruction sheets furnished by
Hardinge.
The machine manufacturer is not responsible for any danger or damage arising from
improper operation of the machine. Some examples of improper use are listed below.
1. Adding to or modifying the machine without consulting Hardinge.
2. Operating the machine outside the machining range.
3. Improper use of a workpiece holding or peripheral device.
4. Using the machine with interlocks or protection covers removed.
5. Carrying out machine operation, programming or maintenance and inspection work
without thoroughly understanding the caution information, i.e. without having read
the instruction manuals carefully.
1.7 ROUTINE INSPECTION
The schedules below are based on single shift operations using coolant at all times.
Daily
1. Check pressure gauge reading.
Air pressure 5.5bar (80psi)
2. Check that there is sufficient oil in the air lubricator.
3. Check motors and other parts for abnormal noises.
4. Check the lubrication of sliding parts for evidence of proper lubrication.
5. Check safety covers and safety devices for proper operation.
6. Check coolant level and fill as necessary.
7. Clean dirt and chips from the axes and empty the swarf trays.
Weekly (In addition to daily routine)
1. Clean chips and dirt from the entire machine and wipe down.
2. Check the air filter at the rear of the electrical cabinet. Replace the filter element
if it is contaminated.
3. Check all polycarbonate vision panels for signs of damage – crazing, cracking etc.
or reduced visibility and replace if necessary. Contact your Hardinge
representative for details.

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If the machine is used to produce components
immediately after being started, following a long
idle period, sliding parts may be worn due to lack
of oil and thermal expansion of the machine can
jeopardize machining accuracy. To prevent this
condition, always warm the machine up.
1.8 MACHINE WARM UP
We recommend that the machine is ‘Warmed up’ prior to first operation by running all
axes for 10 to 20 minutes at about half or one third the maximum speed in the
automatic operation mode before actual cutting.
This automatic operation program should cause each machine component to operate.
During this cycle check the correct function of these operations.
Be particularly careful to warm up the spindle.
SPINDLE WARM UP
It is essential that the spindle in the machine is correctly warmed up before use.
Short Term Spindle Warm up
If the machine has been idle for less than two weeks, run the spindle at 25% of the
maximum spindle speed for 15 minutes. Once this has been completed, the machine is
ready for operation
Long Term Spindle Warm up
If the machine has been idle for two weeks or more, run the spindle at 25% of the
maximum spindle speed for 20 minutes, then at 50% of the maximum speed for 30
minutes. Once this has been completed, the machine is ready for operation.
1.9 SPINDLE MAINTENANCE
Daily Maintenance.
Clean the front nose of the spindle but do not use compressed air.
Check the taper for dirt. If necessary, use a cleaning arbor.
Check coolant level in spindle cooler and top up if necessary.
Check air supply.
Monthly Maintenance.
Test tool change function.
Check the spindle knock out distance. Activate the tool un-clamp pushbutton to check
that the knock out distance is as specified in the maintenance manual.
Note: prior to inserting a tool holder, ensure that the spindle taper is clean.
Spindle Tooling
Tooling with a balance level of G2.5 or better should always be used. Failure to do so
will reduce spindle life and surface finish and may void the machine warranty.
For safe operation, refer to the informative tag and make sure the tool holder and pull
stud combination meet the standard.