Charmilles E110-D10 User manual

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Published by
ATELIERS DES CHARMILLES S.A.
GENEVA - SWITZERLAND
The handing over to a third party, the
publication or the reproduction even partial
of this document without any authorization
are forbidden.
All rights for modifications reserved.
Printed in
tzerl
MD10222370E

INDEX
1 - UNPACKING
2
- TRANSPORTATION
2.1 - The
machine
2.2 - The counterweight
2.3 - The
generator
3 -OPERATING
SITE
4 -INSTALLATION
5 -LEVELLING
OF THE MACHINE
6 - DEGREASING OF THE MACHINE
7 - MACHINE ERECTION
7.1 -Mechanical assembling
7.2 - Setting up of the hydraulic circuit
7.3 -Checking for correct erection
7.3.1
-
Checking
of the
hydraulic
7.3.2
- Checking of the
dielectric
7. 3. 3 -
Checking of
the
generator
circuit
circuit
7. 3. 4
--
Checking of
the
angular position
of the magnetic chuck
8
-
DESCRIPTION
8.1 - Generalities
8.2
-
Carriage
8.3
-
Column
8.4
- Frame
8.5
-
Dielectric tank
8.6
-
X and
y
table
8.7
-
Work tank
8.8 -
Servo-mechanism
8.9
-
Hydraulic circuit
1
3
3
3
3
5
5
7
9
ll
ll
15
17
17
17
19
19
21
21
23
25
25
27
29
31
33
35

- Dielectric circuit
- Electrical circuit
8.10
8.11
8.12
- Interconnecting tubing and electrical
connections
8.13
- Safety devices and depth stop
9 - LUBRICATION
10 - CLEANING
ll - TROUBLE SHOOTING
12 - OPERATION
12.1 - Carriage
12.2 -- X andY table
12.3 -Work tank
12.4 - Machine start
12.5 -Clamping of the workpiece
12.6 -- Up and down manual control of chuck
travel
12.7 - Edge finder
12.8 - Depth stop
12.9 - Indicator
12.10 - Flushing mode
12.11 - Swivel-seat installation
12.12 - Chuck installation
12.13 - Set up of the electrode holder to the
magnetic chuck
12.14 -Angular alignment of the magnetic
12.15 -Alignments
13 - -
13.1
13.2
13.3
- Generalities
- Description
-- Handling of the acces es
13.4 - Checking adjustment of the
accessories
37
39
41
43
45
45
47
49
49
49
49
51
51
51
51
53
55
57
59
59
59
61
61
67
67
69
71
73

- 1 -
l -- UNPACKING
It is recommended
that
the
following
procedure observed
for removal
of the machine
from the packing
crate:
l.
Remove the top cover of the crate (fig.
1) .
2 • Remove
the
two beams that hold the machine
(fig. 2) •
3. Remove
the
two long side-flats of
the
case
(fig. 3) •
4 • Remove the
two lateral head-pieces (fig.
4) •
5. Cut the hoop-iron strips.
This will expose, from left to right on the bottom of the
crate (fig. 5):
- 1 machine, type D 10,
- 1 case containing accessories,
- l generator (800),.
- 1 tank for the dielectric fluid (500)
2 pipes (G & H) ,
- several hose clamps.
6. Remove the above units from the bottom of crate in
the following order: (first loosen the hold-down beams)
the case of accesso~ies,
- the generator (800) (refer to paragraph
on uTRANSPORTATION"),
-the pipes (G & H),
- the tank (500) (refer to paragraph on
''TRANSPORTATION"),
7. Remove the two wood beams that clamp down the metal bars
used to secure machine (fig. 6).
8. Lift the machine and remove it from the base of the crate.

Fig 2
Fig 4
800
Fig 5
Fig 6

- 3 -
2 - TRANSPORTATION
The various units contained within the crate can be trans-
ported in the following manner:
2.1 The machine:
2.2 The dielectric tank:
2.3 The generator:
wei~ht: soo lb (230'Kg)
2 through-holes (307), diameter
1~" (30 mrn), have been provided to
permit of transportation by
different means:
a) by means of a crane (figs. 1 & 2)
b) by means of a fork-lift (fig. 3)
c) manually, by 4 persons (fig.4)
weight: 260 1b (120 Kg)
remove the tank-cover (502) by means
o~ the loop-handles (581), (fig. 5),
and transport the tank-cover separately
Irom the tank itself (501).
weight: Pl2
P25
180 lb (80 Kg)
270 lb (125 Kg)
the generator can be transported
quite easily by fastening a rope
through the holes of the two screws
(802) (fig. 6)'

Fig 4
581
Fig 5
301
fig 1
Fig 3
Fig 6
307
Fig 2
802

- 5 -
3 - OPERATING SI.TE
We recommend that the machine installed in a clo and
clean room, or at least, that it located in a site is
well protected against dirt, dust and grit usually encoun-
tered in workshops.
~he floor plan (fig. 1) takes care of not only the actual
space taken up by the machine, the generator and the dielectric
tank, but also the space required for their correct location
in relation to each other and the space necessary for normal
operating and maintenance of the complete installation. The
dotted line refers to cases in which the dielectric tank
is located in the rear of the machine (refer to paragraph
on
11
INSTALLATION
11
).
On the site chosen, provision must be made for :
- A
3-phase, 3 KVA electrical supply outlet, complete
with all necessary protective devices (fuses, over-
load relays), to power the installation.
- A suitable system for - supply and disposal of
coolant water at a pressure not to exceed 120 PSI
(10 Kg/cm2), pipe ~ 3/8" (10 mm).
-
Efficient ventilation or an installation for the
exhaust of fumes.
- An adequate lighting installation.
4 - INSTALLATION
It is necessary to comply with two very important considerations
a) The dielectric tank must always be located at
a lower level than the machine.
b) The generator must be located as close as
possible to, and on the right-hand side of the
machine.
1§~ possibility : on a single workbench. Minimum dimensions
2~~ possibility
of the bench area: 60" x 32" (1500 x 800 mm).
If the dielectric tank (500) is located
immediately underneath the machine, the
height available below the workbench must
be of at least 33" (830 mm) (fig. 2).
on two workbenches. Minimum dimensions
of the area of each workbench: 30" x 32"
(1500 x 800 mm). If the dielectric tank
(500) is located immediate underneath
the machine, the height available below
the workbench must be of at t 33
11
(830 mm) (fig. 3).
The tank for the dielectric fluid may be installed either
a) immediately underneath the machine (fig. 4)
b) in the rear or at the side of the machine (figs. 5 & 6).

60 em
\
-
3KVA
- .J
/
----
Fig 5
50 cm
150
em
Fig 1
Fig 3
E
co
60 em
E
rnm
Fig 2
Fig 4
Fig 6,
co
E

- 7 -
5 - LEVELLING OF THE MACHINE
The machine must never fastened to the workbench by bolts
or screws. It must stand free on the bench.
The frame of the machine must not touch the bench, it should
rest firmly on the three feet provided for this purpose
(fig. 1 a & b) .
If the surface of the bench is not of sufficient hardness,
bearing-plates should be placed under the feet to distribute
the weight of the machine over a larger area. It is not
advisable to place more than one bearing-plate under each
foot.
The three following arrangements are suggested
a) the use of a single metal sheet
(650 X 350 X 2 rom) (fig. 2)
26" X 14" X 3/32"
b) the use of 3 round discs ~ 2" x 1/8" (~ 50 x 3 mm)
(fig. 3)
c) the use of 3 square plates of
(fig. 4)
8" (3 mm) thickness
The top of the workbench should be as nearly horizontal as
possible. For more accurate levelling, make use of shim-
stock placed either under the bench feet or under the
bearing-plates or use bearing-plates of different thickness.
Levelling to an accuracy of 0.5% is sufficient, even 1% will
be satisfactory if the slope helps the evacuation of the
dielectric fluid.

E
E
Fig
fig 2
-
b
Fig 4

9 -
6 - DEGREASING
(fig. l a, b, & c)
In order to protect the machine against rusting, all the
machined or scraped surfaces, and othe~ delicate parts,
have been coated with grease prior to -delivery.
To remove this grease we recommend the use of
- kerosene
- fuel oil
- gasoline
The principal parts to be degreased are shown marked in
red in the three accompanying sketches
Important : the lead-screws must be thoroughly cleaned.
After degreasing, the above parts must be oiled, particular
attention being given to the lead-screws and the slide-
ways of the machine.
The following oils are recommended though others, of
similar characteristics, may be used :
for
the
slideways
and
lead-screws
BP
ENERGOL
HP
20 c
BP
BP
ENERGOL
HP
10 c
BP
WAY LUBRICANT MEDIUM
Chevron
FEB IS K - 43
Esso
FEB IS
K -
53 Esso
GULF
52 Gulf
GULF 59
Gulf
VACTRA 1 Mobiloil
TONNA OIL
27
Shell
for the other
degreased parts:
MOBILKOT
203
Mobiloil

F1g 1

- 11 -
7 - MACHINE ERECTION
7.1 MECHANICAL ASSEMBLING
It is recommended that assembling of the machine be
carried out in the order indicated below (f . 1 & 2)
1. Fit the handles on the hand-wheels (606-633) and
fit in their place the locking levers (308-604)
that controls the longitudinal and the cross travel
of the table.
2. Unclamp the locking levers (101) of the carriage (100)
and raise it by hand (needed power about 90 lb), till
it reaches the heigts to which the fastening of the
chain (207) is possible.
Tighten the looking levers (101) and attach the chain
to the carriage. Remove the string retaining the chain.
From undernath, the base of the column loosen the nut
MlO and remove the plate and the threated rod. So as
to unlock the counterweight (206).
Freethe carriage (100) by means of the locking levers
( 1:01) ... Lower it slightly by means of the rotating
:'handle (219). Lock it again and remove the wooden block
by·rotating it a quarter of a turn.

219
206
606

-- 13 -
*
.3. Set the indicator (145) and the micrometer stop (141)
(fig. 13).
4. Install the dielectric tank (500) in its final location.
5. Connect the pipes (H-G-I-J) and complete the connections
between the dielectric tank (500) and the machine (fig. 14),
(refer to paragraph 8.12 for details of connections).
6. Connect the dielectric tank (500) to the water supply
(fig. 15). These hoses are to be furnished the
customers.
7. Install the generator (800) in its final.location.
8. Set up the generator (800), (refer to chapter
11
SETTING
UP OF THE GENERATOR").
9. Connect the cable (D), from the input of the junction
box (851) on the generator (800) (fig. 16), to the
electrical power outlet •. The cable (D) and the plug are
to be furnished by the customers.
0. Connect the control cable (A) of the machina to its
socket (852) on the generator (800) (fig. 17).
1. Connect the control cable (B) of the dielectric tank to
its socket (853) on the generator (800) (fig. 18).
2. Connect the control cable (F) of the magnetic chuck
(fig. 19).
3. Connect the machining cable (E) to the machine, the
black lead to the magnetic chuck, the yellow lead to
the table (fig. 20).
4. Fill the dielectric tank (500) wi 20 American gallons*
(80 litres) of dielectric fluid (fig. 21). The following
dielectric fluids are recommended, though others having
the same characteristics may be used
EDM 71
LM
HONIL0-401
MENTOR-28
CHEVRON
BP
CASTROL
ESSO
5. Switch power on means of the main switch (821) and
start the pump (503) of the dielectric circuit (fig. 22 a & b
by means of its switch (824) which is located on the
control panel (820) of the generator (fig. 22 b). Check,
immediately, that the pump is rotating in the direction
indicated the arrow on the pump housing. If the
direction of rotation is that indicated, let pump
operate for a moments. If the pump i~ totating in
the reverse direction, immediately stop the pump and switch
two the 3-phase leads of the mains power line (fig. 22 c).
6. Proceed to set up the hydraulic system, as indicated
below.
American gallon = 1.2 British gallon.

145
Fig 15
Fig 13
Fig 14
800
: 852
: B
800
:
: 853
'
Fig 17
Fig 18
Fig Hi
F
Fig 19
Fig 20
821
Fig 22

- 15 -
7.2 - UP OF THE HYDRAULIC CIRCUIT
1. Remove the metal plug fro~ the free end the rubber
pipe but leave the diaphragm plug on rubber
pipe (K) (fig. 23).
2. Fill a very clean can wi l. 5 American: gallon* ( 5 li tres)
of hydraulic oil. We recommend the use of the following
oils though others having similar characteristics be
used:
ENERGOL-HYDRAULIC-40
CHEVRON 5 X
SPINESSO -
34
VELOCIT 6
PENNOL GC - 34
TELLUS OIL - 15
PURFINA-HYDRAU - 125/12
BP
Chevron
Esso
Mobiloil
Pennsylvania
Shell
Socal
3. Insert the ends of the rubber pipes (M & K) into the can,
without removing the diaphragm plug from pipe (K), then
pour a small quantity of oil into the filter (593) (fig. 24).
4. Start up the pump (590) (fig. 25 a) of the hydraulic
circuit by means of the switch (823) (fig. 25 b) located on
the control panel (820) of the generator, make sure that
the direction of rotation of the pump is correct and
then let the oil circulate for at least two hours in
order to filter out any impurities it may contain.
5. Having let the oil circulate for a period of two hours,
switch off the hydraulic pump (590) by means of the switch
(823).
6. Remove the adhesive tapes covering the openings (108-109-
125) and also the rubber guard placed as protection over
the nozzle (104) (fig. 26).
7. Remove the diaphragm plug from the end of pipe (K) and
fit this rubber pipe onto nozzle (104) (fig. 27). Start
up the pump (590) again by means of tch (823). The
piston (121) will then rise automatically to the highest
point of its stroke.
8. As soon as the oil within the indicator tube (107) reaches
a level intermediate between 5" (125 mm) (minimum) and
5~ ( 14 0 mm) (maximum) (fig. 28) , switch off pump ( 590)
of the hydraulic circuit by means of switch (823).
9. Remove the rubber guard from nozzle (106) and quickly
insert the free end of the pipe (M) into the nozzle in
order to prevent loss of oil (fig. 29).
10. Connect the cable ) of the servo-mechanism to the
socket (108) located at the upper end of the oil-level
indicator tube (107) (fig. 30).
* American gallon = 1.2 Bri sh gallon

Fig 24
Fig 26
Fig 25
Fig 27
.-
Fig 30
fig 28
Fig 29