DONAUMERIC 440 User manual

Machine-No./Construction Year:
Original Operating Instructions
CNC Rapid Radial Drilling Machine
DONAUMERIC 440

Operating Instructions DONAUMERIC 440 2
Inquiries and orders should be directed to:
Donau Werkzeugmaschinen GmbH
Harald-Friedrich-Straße 2 - 8
D-83352 Altenmarkt (Germany)
Phone: + 49 (0) 8621/ 88 0
Fax: + 49 (0) 8621/ 88 413
Homepage: www.donau-wzm.de
E-mail: [e-mail]

Operating Instructions DONAUMERIC 440 3
Altenmarkt, 2015-01-07
Conformity Declaration
in the sense of the EC-guidelines for machines 2006/42/EC, annex II, No. 1A
Design of the machine/system: Radial Drilling Machines
DONAUMERIC 440
Machine number:
The machines have been conceived and built in conformity with the regulations under the
following EC-guidelines:
•„Machines“ 2006/42/EC
•„Electromagnetic compatibility“ 2004/108/EC
The following harmonised standards were used:
EN 50370-1:2005 EMC-Product family standard - Emission
EN 50370-2:2005 EMC-Product family standard - Immunity
EN ISO 12100:2010 Safety of machinery – basic concepts, risk assessment
and risk reduction
EN 60204-1:2006 Safety of machinery
Electrical equipment of machines
EN ISO 13849-1:2006 Safety of machinery
Safety-related parts of control system
EN 12717:2001+A1:2009 Safety of machine tools – drilling machines
Roland Ilg Dipl. Ing. (Univ.) Matthias Hausmann
President Manager Development & Design
Responsibility fort he machine documentation
within the European Community

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Operating Instructions DONAUMERIC 440 5

Operating Instructions DONAUMERIC 440 6

Operating Instructions DONAUMERIC 440 7
Introduction
Dear Customer!
These operating instructions are designed to familiarize you with the machine and its
intended use.
-Description of the System
The Donau-Rapid Radial Drilling Machine of the type DONAUMERIC 440 is designed,
manufactured, tested and documented according to the state of the art and in compliance
with the relevant safety standards.
-Location of the System
The system is to be a stationary installation, connected to the terminal box of the existing
industrial network by competent, trained personnel.
With the present operating instructions useful instructions are presented to the operator.
Every person responsible for transporting, commissioning and/or installing must read and
understand these operating instructions.
This applies particularly to the chapter safety instructions, safety-related information, as
well as the safety guidelines and warnings in the individual chapters of these operating
instructions.
To ensure failure-free operation of the machine, the complete operating instructions must
always remain at the machine.
These operating instructions are intended for the transport, operation and installation per-
sonnel. It contains descriptions, rules and technical drawings, which may neither be com-
pletely nor partially duplicated, distributed or utilized for purposes of competition in an un-
authorized way or disclosed to others. Non-compliance results in damage liability. All
rights reserved, including rights in case of patent grant or other registrations.
Subject to technical changes.
Good luck in performing your production tasks
Your DONAU

Operating Instructions DONAUMERIC 440 8

Operating Instructions DONAUMERIC 440 9
Contents of the Operating Instructions
1 GENERAL INFORMATION ........................................................................................ 12
1.1 Technical Specifications of the Machine..............................................................................................12
2SAFETY ................................................................................................................................................ 14
2.1 Safety Instructions and their Explanations..........................................................................................14
2.2 Safety-Related Information ....................................................................................................................15
2.3 Possible Hazards Arising from the Machine........................................................................................16
2.4 Intended Use ...........................................................................................................................................17
2.5 Sources of Danger ..................................................................................................................................18
2.6 Dangers due to Accessories..................................................................................................................19
2.7 Emissions ................................................................................................................................................20
2.8 Work Areas and Safety Areas ................................................................................................................21
2.9 Personal Protective Equipment.............................................................................................................27
2.10 Safety Measures at the Installation Site of the Machine.....................................................................27
2.11 Emergency Procedure............................................................................................................................27
3PROTECTIVE DEVICES .................................................................................................................28
3.1 Protective Devices for the Operator .....................................................................................................28
3.2 Protective Devices for the Machines and their Components.............................................................29
3.3 Protective Device, Drill Protection ........................................................................................................29
4TRANSPORT OF THE MACHINE ................................................................................................30
5INSTALLATION AND COMMISSIONING OF THE MACHINE ................................... 34
5.1 Requirements to the Location of Use ...................................................................................................34
5.2 Supply Connections ...............................................................................................................................34
5.3 Space Requirements/Dimensions.........................................................................................................35
5.4 Foundation of the Machine....................................................................................................................38
5.5 Electrical Connection of the Machine...................................................................................................43
5.6 Removing the Boom Support ................................................................................................................44
5.7 Removing the Rust-Protective Agent ...................................................................................................44

Operating Instructions DONAUMERIC 440 10
5.8 Alignment of the Machine ......................................................................................................................45
6OPERATION AND HANDLING OF THE MACHINE IN RADIAL MODE .....................46
6.1 Functional Description of Control Elements........................................................................................46
6.2 Operation of the Machine in Radial Mode ............................................................................................51
6.2.1 Select Radial Mode ...................................................................................................................51
6.2.2 Manually Traversing the X and Y Axes ...................................................................................51
6.2.3 Raising and Lowering the Column..........................................................................................51
6.2.4 Insert tool/tool change..............................................................................................................52
6.2.4.1 Tool Tray for Radial Mode.................................................................................................55
6.2.5 Selecting the Speed ..................................................................................................................56
6.2.6 Selecting Direction of Rotation................................................................................................56
6.2.7 Selecting the Feed ....................................................................................................................57
6.2.8 Resetting the Z-Axis..................................................................................................................57
6.2.9 Drilling and Threading..............................................................................................................58
6.2.9.1 General……………..............................................................................................................58
6.2.9.2 Drilling………......................................................................................................................58
6.2.9.3 Threading….. ......................................................................................................................59
7MAINTENANCE AND REPAIR....................................................................................60
7.1 Machine Design.......................................................................................................................................60
7.2 Machine Image ........................................................................................................................................61
7.3 Safety Instructions for Maintenance and Repair .................................................................................62
7.4 Maintenance ............................................................................................................................................63
7.4.1 Preventive Maintenance ...........................................................................................................63
7.4.2 Adjusting the Guide Arm of the Column up and down Movement ......................................64
7.4.3 Re-Clamping of the Return Spring for the Drilling Spindle ..................................................65
7.4.4 Replacing Wear Parts ...............................................................................................................66
7.4.4.1 Toothed belt Replacement on Drilling Spindle Drive (see Drawing Next Page)..........66
7.4.4.2 Toothed Belt Replacement on Column Stroke Drive (see Drawing Next Page) ..........68
7.5 Lubrication Schedule..............................................................................................................................70
7.6 Hydraulic Schedule.................................................................................................................................72

Operating Instructions DONAUMERIC 440 11
7.7 Disposal ...................................................................................................................................................73
8APPENDIX .................................................................................................................. 73
8.1 Machine Accessories/Special Features/Options .................................................................................73
8.1.1 Angle Table................................................................................................................................73
8.1.2 Inclinable Swivel Table (option 2.40) ......................................................................................74
8.1.3 Clamping Cubes Swiveling from 0-90 Degrees .....................................................................75
8.1.4 Floor Plate .................................................................................................................................76
8.1.5 Coolant System Design B for Machines with Floor Plate.....................................................78
8.1.6 Separate Coolant Return..........................................................................................................79
8.1.7 Optical Operating Mode Display with Audible Warning Device...........................................80
8.1.8 Splash Guard at the Work Table for Chips and Coolant.......................................................81
Geometrical control

Operating Instructions DONAUMERIC 440 12
1 GENERAL INFORMATION
1.1 Technical Specifications of the Machine
Standard Version
- Tapping Device
- 2 T-slots 18 mm at the supporting structure of the machine rear
- 2 T-slots 18 mm at the supporting structure of the machine left
- Linear roller slideway for boom
- Central lubrication
- Machine lamp
- Axis drive via AC servo motors
Cutting Values
Drilling capacity St 60 mm Ø 40
GG 22 mm Ø 50
Tapping St 60 M 36
GG 22 M 45
Dimensions and Travelling Paths
Tool holder SK 40
Diameter of control pedestal mm 195
Distance spindle nose – table min. mm 95
max. mm 705
Distance spindle nose – ground min. mm 995
max. mm 1605
Table height mm 900
Quill stroke (Z-axis) mm 200
Column stroke (W-axis) mm 410
Rapid Traverse
X- and Y-axis m/min 7.5
Z-axis m/min 5
W-axis m/min 3
Accuracy
Positioning accuracy X-, Y-axis
over the entire table range mm ± 0.075
Repeat accuracy X-, Y-axis mm ± 0.03
Positioning accuracy Z-axis mm ± 0.05
Repeat accuracy Z-axis mm ± 0.03
Positioning accuracy W-axis mm ± 0 05
Repeat accuracy W-axis mm ± 0.03
Spindle Speeds and Feeds
Spindle speeds infinitely rev/min 15-2800
Feeds infinitely mm/min 5-2000

Operating Instructions DONAUMERIC 440 13
Machine-Specific Forces
Spindle torque max. Nm 250
Constant from rev/min 15-200
Clamping Radial Nm 5000
Axial N 5500
Quill force N 12000
Electrical Data
Operating voltage V ∼/Hz 400/50
Control voltage V = 24
AC spindle motor, frequency controlled kW 5.5 CT °= 65
max
X-axis Drive (AC servo motor) kW 0.25
Y-axis Drive (AC servo motor) kW 0.25
Z-axis Drive (AC servo motor) kW 4.5
W-axis Drive (AC servo motor) kW 2.5
Coolant pump COA 4-22 kW 0.12 CT °= 50
max
Spur gearing travel drive kW 0.25 CT °= 50
max
Hydraulic clamping unit kW 0.75
Total connected load KVA 10.00
Painting
Textured paint
Machine head light gray RAL 7035
Machine supporting structure distant blue RAL 5023
Machine Weight (without packaging)
with table 600 x 1200 mm kg 2610
with table 750 x 1200 mm kg 2700
with table 600 x 1800 mm kg 2900
Machinery Variants
Table dimensions 600 x 1200 mm with 4 T-slots
750 x 1200 mm with 5 T-slots Option
600 x 1800 mm with 4 T-slots Option
Boom travelling path 1050 mm (drilling radius max. 1590 mm)
750 mm (drilling radius max. 1290 mm) Option
Floor plate 1000 x 1400 x 100 mm
Angle table tensioning surface 600 x 800 mm
Heating: K
°
=
∆
105
ν
CT
A
°= 40
The losses resulting in the motor
are partially dissipated via flange
CT °= 65
max
(Flange)

Operating Instructions DONAUMERIC 440 14
2 Safety
2.1 Safety Instructions and their Explanations
The following safety instructions and warnings are intended to prevent hazards to life and
health of users and maintenance personnel as well as material damage.
The terms used for the purposes of these operating instructions have the following
meanings:
DANGER
for the purposes of these operating instructions refers to an imminent dan-
ger. If it is not avoided, death, serious injuries or substantial material dam-
ages are the consequence.
WARNING
for the purposes of these operating instructions refers to a possibly danger-
ous situation. If it is not avoided, death, serious injuries or substantial mate-
rial damages can be the consequence.
CAUTION
for the purposes of these operating instructions refers to a dangerous
situation. If it is not avoided, minor injuries or material damages can be the
consequence.
NOTE
for the purposes of these operating instructions refers to a possibly harmful
situation. If this note is not considered, the product or something in its
proximity can be damaged.
IMPORTANT
for the purposes of these operating instructions refers to operator and other
useful information.

Operating Instructions DONAUMERIC 440 15
2.2 Safety-Related Information
WARNING
When electrical or electronic equipment and devices are in operation, certain components
of these devices are under hazardous voltage. Unqualified intervention or non-compliance
with the warnings can lead to severe personal injuries or material damages. Only qualified
and trained personnel are allowed to perform necessary interventions.
WARNING
Operation, maintenance and repair of the machine may be performed only by qualified
personnel. These include persons who are trained as operators in the use of devices of
the machine and automation and know the operator-related content of the operating in-
structions. These also include persons who are trained as maintenance and repair per-
sonnel in the use of devices of the machine and automation and know the contents re-
lated to maintenance and repair of the operating instructions.
DANGER
The rotating drilling spindle as well as power-operated moving parts can draw in clothing
and jewelry. Serious personal injuries, death or material damages are the result. For safe
handling of the machine loose-hanging hair is to be protected. When working at the ma-
chine, scarves, ties and necklaces are to be taken off.
DANGER
Explosion and fire hazard. Serious personal injuries or material damages are the result.
Heat generated by welding or soldering in the area of pressure lines is to be avoided.
DANGER
Leakage of oil mist in the hydraulic system represents a fire hazard. The fire may cause
death or serious burn injuries. Destruction of the entire machine and building are the re-
sult. A leak must be corrected immediately with spray effect.
WARNING
In reviewing the safety circuits, no persons may remain in the danger zone of the machine.

Operating Instructions DONAUMERIC 440 16
WARNING
All safety instructions and warnings at the machine are to be complied with.
Missing, illegible or damaged safety signs are to be replaced immediately.
DANGER
Explosion and fire hazard. Serious personal injuries or material damages are the result.
Machining of magnesium and magnesium alloys is prohibited.
The use of non-soluble coolants (e.g. oil) is prohibited. Always work with water-soluble
coolants.
WARNING
Only safe coolant lubricant emulsions are to be used. The use of coolants which can form
an explosive aerosol is generally prohibited (observe safety data sheet of the coolant).
It should be noted that contact with coolants in any form may be hazardous to health.
WARNING
In case of safety-related changes in operational performance or malfunction of the ma-
chine, stop the machine immediately and report the malfunction to the competent author-
ity.
2.3 Possible Hazards Arising from the Machine
The DONAU-Rapid Radial Drilling Machine of the type DONAUMERIC 440 is designed,
manufactured, tested and documented according to the state of the art and in compliance
with the relevant safety standards.
WARNING
Consequences of improper use of the machine:
• Danger to life and limb of the operator or other persons
• Material damages to the machinery and other property
Observe danger notices in these operating instructions!

Operating Instructions DONAUMERIC 440 17
2.4 Intended Use
The Rapid Radial Drilling Machine of the type DONAUMERIC 440 is designed, manufac-
tured, tested and documented according to the state of the art and in compliance with the
relevant safety standards.
The machine is intended for use in an industrial environment and must not be operated
outdoors.
The machine is to be used exclusively for drilling, counterboring, reaming, centering and
tapping. Any other or additional use shall not be deemed as intended.
The machine may not be used for cutting, welding, turning, grinding, eroding, pressing and
other manufacturing processes not expressly recommended. The following materials may
not be machined: Magnesium and magnesium alloys, stone, concrete, glass and plastics
inappropriate for machining (see manufacturer's specifications).
Always work with water-soluble coolants.
WARNING
Improper handling of the machine can cause serious personal injuries or substantial mate-
rial damages.
If the machine is used for other than the above-mentioned manufacturing process, or if
changes are made to the machine that affect the safety of the machine and the intended
machining procedure, the manufacturer or vendor is not liable for incurred personal in-
juries, material or consequential damages.
The specifications of the operating instructions are to be observed for operation and main-
tenance of the machine. If handled improperly, the manufacturer or vendor is not liable
for resulting personal injuries, material or consequential damages.

Operating Instructions DONAUMERIC 440 18
2.5 Sources of Danger
DANGER
Danger due to rotating tool/spindle and drawing in or winding up.
Do not reach into the rotating tool. Plying in an unprotected work area is prohibited. Parts
of clothing can be drawn in by the rotating tool or the rotating spindle. Serious personal
injuries, death, or material damages are the result. For safe operation of the machine, long
hair is to be tied together and scarves, ties, necklaces, bracelets etc. are to be taken off or
secured before initiating the spindle rotation.
The operator must wear close-fitting work clothes. Too long sleeves must be turned in-
ward.
Gloves must not be worn during the drilling process.
CAUTION
Danger due to crushing fingers.
Do not reach between boom flange/spindle head and cross-head during boom procedure.
Do not reach between tool and workpiece when approaching a machining position in the
automatic mode.
CAUTION
Cuts from chips in the machine area.
Drilling spindle must be switched off to remove chips from the machine area. The chips
may only be removed with suitable tools (chip hook with hand shield).
CAUTION
Crushing through reaching into the drive systems.
Disassembled or damaged covers of the drive systems cause personal injuries and mate-
rial damages. Regular checks must be carried out. Defective or missing covers must be
mounted/replaced by the maintenance staff.
CAUTION
Injuries from tools.
When handling tools (e.g. tool change, production planning) they must not be touched at
the cutting edges. There is an acute risk of injury.

Operating Instructions DONAUMERIC 440 19
CAUTION
Danger due to blows to the upper body and head from traversing boom.
No other person may remain in the work area when working in manual mode. No one may
remain in the work area during automatic mode.
CAUTION
Danger due to burning after contact.
The motors and pumps of the machine can get very hot.
WARNING
Injuries caused by ejected parts.
Serious personal injuries result from ejected parts.
The following preventive measures are therefore to be observed:
• Protect workpiece against twisting and lifting with up-to-date and appropriate clamping
devices.
• Handle workpieces with suitable slings only.
• In case of tool breakage, tool fragments can be ejected from the machine. Protective
goggles must therefore be worn.
• Tools must be suitable and approved for the machine and machining and in a clean
and undamaged condition.
• Chucks must be equipped with a tensile lock to prevent loosening of the tool at high
speed.
• When using tools with a conical holder, the tools in the cone must be absolutely tight fit.
2.6 Dangers due to Accessories
Only parts, tools and auxiliary equipment may be used which are approved by the ma-
chine manufacturer or vendor. The manufacturer or vendor is not liable for third party
products or modifications to the accessories.
CAUTION
Improper handling of the accessories may result in personal injuries and material dam-
ages to the machine. Maximum values of the machine and handling instructions in the
operating instructions are to be observed.
IMPORTANT
Add-on parts such as angle tables, swivel table, T-slotted plate and other devices selected
by the customer that are intended for mounting in the vertical T-slots in the supporting
structure must be adjusted in height with suitable hoisting gear and secured against falling
down after loosening the terminal screws.

Operating Instructions DONAUMERIC 440 20
2.7 Emissions
Measurement setup (measurement according to DIN 45 635)
Measuring conditions
• The machine is ready for operation.
• The main drive will traverse in its complete speed range.
• The distance of the measuring device from the enveloping surface of the machine is
1 metre, the measurement height is 1.7 metres.
• Measurement is done at the points indicated in the drawing above.
Type of Measuring Device: Rohde & Schwarz; Precision Sound Level Meter ELT 2
Measured Value: maximum of 78 dB (A)