KaVo Everest engine Base Camp 4140 User manual

Assembly instructions
Everest® engine Base Camp 4140
Always be on the safe side.

Sales:
KaVo Dental GmbH
Bismarckring 39
D-88400 Biberach
Tel. [phone]
Fax [phone]
Manufacturer:
Kaltenbach & Voigt GmbH
Bismarckring 39
D-88400 Biberach
www.kavo.com

Assembly instructions Everest® engine Base Camp 4140
Contents
Contents
Contents ...........................................................................................................................................................1
1 User instructions ............................................................................................................................................3
1.1 User guide ................................................................................................................................................3
1.1.1 Abbreviations ...................................................................................................................................3
1.1.2 Symbols ...........................................................................................................................................3
1.1.3 Target group .....................................................................................................................................3
1.2 Service .....................................................................................................................................................4
2 Scope of delivery and packaging ..................................................................................................................5
2.1 Scope of supply for the Everest engine Base Camp ...............................................................................5
2.2 Packaging ................................................................................................................................................7
3 Safety ............................................................................................................................................................8
3.1 Description of safety instructions .............................................................................................................8
3.1.1 Warning symbol ...............................................................................................................................8
3.1.2 Structure ...........................................................................................................................................8
3.1.3 Description of hazardous steps ........................................................................................................8
4 Product description ........................................................................................................................................9
4.1 KaVo Everest engine Base Camp ...........................................................................................................9
5 First use .......................................................................................................................................................11
5.1 Important instructions for startup ...........................................................................................................11
5.2 Location .................................................................................................................................................12
5.3 Installation ..............................................................................................................................................13
5.3.1 Set up the Everest engine Base Camp .......................................................................................... 13
5.3.2 Connect the compressed air service unit ....................................................................................... 13
5.3.3 Adapt the voltage ...........................................................................................................................14
5.3.4 Connect the system .......................................................................................................................15
5.3.5 Connect the cooling lubricant .........................................................................................................17
5.3.6 Connect the computer network ......................................................................................................19
6 Settings for service ......................................................................................................................................21
6.1 Overview of control panel ......................................................................................................................21
6.2 Start the Everest engine Base Camp .....................................................................................................23
6.3 Do a reference run ................................................................................................................................. 24
6.4 Mount the housing .................................................................................................................................26
7 Calibrate the Everest engine Base Camp 4140 ..........................................................................................27
7.1 Required tools and materials for the calibration .....................................................................................27
7.2 Mill the calibration body .........................................................................................................................28
7.2.1 Start the KaVo Everest Base Camp control ................................................................................... 28
7.2.2 Change the milling tool ...................................................................................................................28
7.2.3 Changing the gripping yoke ........................................................................................................... 30
7.2.4 Insert the Everest Insert ................................................................................................................. 31
7.2.5 Start the warm-up program ............................................................................................................32
7.2.6 Start the CNC/MMI software ..........................................................................................................33
7.2.7 Start the calibration program P650042 .......................................................................................... 33
7.2.8 Grind the calibration body side 1 ....................................................................................................35
7.2.9 Grind the calibration body side 2 ....................................................................................................36
7.2.10 Remove the calibration body from the insert ................................................................................39
7.2.11 Deburr the calibration body .......................................................................................................... 40
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Assembly instructions Everest® engine Base Camp 4140
Contents
7.3 Evaluate the calibration body .................................................................................................................41
7.3.1 Measure the calibration body ......................................................................................................... 41
7.3.2 Check the active machine parameters ...........................................................................................41
7.3.3 Record the current machine and cycle parameters Y0,Alt and P51Alt ...............................................42
7.4 Calculate the correction values ..............................................................................................................45
7.4.1 Start the calibration program "Basecamp_calibration.exe" ............................................................ 45
7.4.2 Run the calculation with "Basecamp_calibration.exe" .................................................................... 45
7.4.3 Change cycle parameter P0051 .....................................................................................................46
7.4.4 Change the machine parameter Y0 ................................................................................................ 46
7.5 Back up and load the machine and cycle parameters ...........................................................................48
7.5.1 Back up the machine parameter file under a new version number ................................................ 48
7.5.2 Load the new machine parameters ................................................................................................48
7.5.3 Check the new active machine parameters ...................................................................................49
7.5.4 Backup cycle parameters ...............................................................................................................49
7.5.5 Back up the machine and cycle parameters on an external medium ............................................. 51
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Assembly instructions Everest® engine Base Camp 4140
1 User instructions | 1.1 User guide
1 User instructions
Note
The assembly instructions must be read by the technicians before start-up to pre‐
vent improper use and damage. The prior approval of KaVo is required before
copying and passing on instructions for use and assembly or technical instructions.
1.1 User guide
1.1.1 Abbreviations
Short
form
Explanation
GA Instructions for use
PA Care instructions
MA Assembly instructions
TA Technician's instructions
STK Safety check
IEC International Electrotechnical Commission
RA Repair instructions
EMC Electromagnetic compatibility
1.1.2 Symbols
See the section Safety/Warning Symbols
Important information for users and technicians
CE mark (Communauté Européenne). A product with this mark meets the
requirements of the corresponding European directive, i.e., the applicable
European standard.
Action required
1.1.3 Target group
This document is for service technicians who have been trained by KaVo for the
product.
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Assembly instructions Everest® engine Base Camp 4140
1 User instructions | 1.2 Service
1.2 Service
Service hotline:
[phone]
[email protected]
User hotline:
[phone]
Please indicate the product serial number or version number.
Additional information can be obtained at: www.kavo.com
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Assembly instructions Everest® engine Base Camp 4140
2 Scope of delivery and packaging | 2.1 Scope of supply for the Everest engine Base Camp
2 Scope of delivery and packaging
2.1 Scope of supply for the Everest engine Base Camp
C
P-H andbu ch
x8
x8
x4
x4 6
13
11
9
10
7
5
4
8
12
13
KaVo Everest engine Base Camp 4140
① Milling/grinding unit ⑧Gripping yokes and tension rings
② Software and operating instructions ⑨Maintenance unit incl. pressure regu‐
lator for compressed air and com‐
pressed air connection
③ Flat monitor with connecting cable,
keyboard and mouse
⑩Power cables (3)
④ Cooling lubricant drain hose ⑪Power supply
⑤ Cooling lubricant unit ⑫Control PC
⑥ Connecting lines X4, X8 ⑬ID reader
⑦ Network cable RJ 45 (cross-over), 10
m
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Assembly instructions Everest® engine Base Camp 4140
2 Scope of delivery and packaging | 2.1 Scope of supply for the Everest engine Base Camp
Consumables (no illustration):
Allen key
Wrench size Mat. no.
2.5 mm 1.005.0600
5 mm 1.004.1568
6 mm 1.001.7574
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Assembly instructions Everest® engine Base Camp 4140
2 Scope of delivery and packaging | 2.2 Packaging
2.2 Packaging
Packaged unit 1: Milling/grinding unit
▪ Length: 1,040 mm
▪ Width: 890 mm
▪ Height: 1,432 mm
▪ Weight: Approx. 305 kg gross and approx. 280 kg net
Packing piece 2 Industrial PC with keyboard, mouse, monitor and
power supply
▪ Length: 1,200 mm
▪ Width: 820 mm
▪ Height: 760 mm
▪ Weight: Approx. 92 kg gross
Packaged unit 3: Coolant/lubricant tank
▪ Length: 1,200 mm
▪ Width: 820 mm
▪ Height: 960 mm
▪ Weight: Approx. 45 kg gross
Packaged unit 4: Housing
▪ Length: 1,200 mm
▪ Width: 800 mm
▪ Height: 1300 mm
▪ Weight: Approx. 42 kg gross
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Assembly instructions Everest® engine Base Camp 4140
3 Safety | 3.1 Description of safety instructions
3 Safety
3.1 Description of safety instructions
3.1.1 Warning symbol
Warning symbol
3.1.2 Structure
DANGER
The introduction describes the type and source of the hazard.
This section describes the potential consequences of non-observance.
▶ The optional step contains necessary measures for avoiding hazards.
3.1.3 Description of hazardous steps
Safety instructions with three hazard levels are used in this document for avoiding
personal and property damage.
CAUTION
CAUTION
indicates a hazardous situation that can lead to property damage or minor to mo‐
derate injury.
WARNING
WARNING
indicates a hazardous situation that can lead to serious injury or death.
DANGER
DANGER
indicates a maximum hazardous situation that can directly cause serious injury or
death.
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Assembly instructions Everest® engine Base Camp 4140
4 Product description | 4.1 KaVo Everest engine Base Camp
4 Product description
4.1 KaVo Everest engine Base Camp
Milling/grinding unit
PC Monitor and Keyboard
Control PC
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Assembly instructions Everest® engine Base Camp 4140
4 Product description | 4.1 KaVo Everest engine Base Camp
ID reader and adapter
max
Everest
R
engine
min
Coolant/lubricant unit
Power pack with power switch ① to turn off the power supply.
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Assembly instructions Everest® engine Base Camp 4140
5 First use | 5.1 Important instructions for startup
5 First use
5.1 Important instructions for startup
Note
The KaVo Everest engine Base Camp may only be started up by engineers trained
by KaVo.
Note
No additional software may be installed on the control computer for the KaVo Eve‐
rest engine Base Camp!
Note
If the KaVo Everest engine has been transported and delivered at very low tem‐
peratures (below 0 C°), malfunctions can occur if it is operated immediately. Wait
at least two days before start-up.
When unpacking and setting up, proceed with extreme caution in order to prevent
accidental damage to the device.
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Assembly instructions Everest® engine Base Camp 4140
5 First use | 5.2 Location
5.2 Location
CAUTION
Damage or injury from improper setup or the wrong location.
When setting up the device and choosing a location, a series of factors must be
observed to prevent damage and injury:
▶ Only use the provided device to transport the milling/grinding unit due to its
weight.
▶ Only trained personnel may move the milling/grinding unit.
▶ Since the milling and grinding unit is so heavy, make sure that the table or row
of cabinets is sufficiently stable and large enough (weight bearing capacity over
300 kg).
▶ Make sure that the unit is set up on a perfectly level surface.
▶ The KaVo Everest engine Base Camp must be set up so that the mains dis‐
connection switch can be activated without difficulty at any time.
The above arrangement is recommended:
① Milling/grinding unit ④Cooling lubricant unit
② ID reader ⑤Power supply
③ PC monitor, keyboard and mouse ⑥Control PC
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Assembly instructions Everest® engine Base Camp 4140
5 First use | 5.3 Installation
5.3 Installation
5.3.1 Set up the Everest engine Base Camp
▶ Select a suitable location for the milling and grinding in it. Make sure that the
table or row of cabinets is sufficiently stable and large enough (weight bearing
capacity over 300 kg).
See also: 5.2 Location, Page 12
▶ Use the provided means of transportation (lifting straps, hoisting crane) to place
the KaVo Everest engine Base Camp on the table. Make sure that the lifting
straps do not damage the electronics or the Z motor.
▶ Align the Everest table with a spirit level while ensuring that all of the legs are
resting on the surface and fixed with a locknut.
▶ Remove the transport brace (Y guide).
▶ Ensure that the milling and grinding unit is level by using a spirit level. Make sure
that all four legs of the machine are on the table.
▶ Affix all four of the machine's legs to the table.
5.3.2 Connect the compressed air service unit
Technical data and requirements of the compressed air connection
Compressed air connection: DN10 rapid
action coupling
6 bar (+/- 0.5 bar)
Compressed air consumption: max. 60 NL/h
Note
Ensure that the cross-section of the supply lines is big enough.
Compressed air requirements (in accordance with ISO 8573-1:2001
(E))
Pressure dew point (class 3) max. -20°C
Overall oil content (class 1) max. 0.01 mg/m3
Contamination by solid particles (Class 1)
Particle size d maximum number
0.1 < d ≤ 0.5 µm 100/m3
0.5 < d ≤ 1.0 µm 1/m3
1.0 < d ≤ 5.0 µm 0
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Assembly instructions Everest® engine Base Camp 4140
5 First use | 5.3 Installation
Connect the compressed air service unit
CAUTION
Damage as a result of incorrect fitting
Damage may occur if it is not fitted correctly
▶ Fit the maintenance unit of the compressed air line vertically.
▶ Connect compressed air line ① to supply available in the building.
See also: "Technical data" in the instructions for use
▶ Set air pressure on the manometer of the maintenance unit ② to 5.5 bar.
5.3.3 Adapt the voltage
▶ Ensure that the nominal voltage and nominal frequency of the milling/grinding
unit corresponds to the nominal voltage and nominal frequency of the building
wiring.
BAZYX
x4 x1
x8 +130V
+24V
M
3~
120
230
100
T10H 250V
T6,3L 250V T3,15L 250V T6,3L 250V
▶ Disconnect the power entry module ① from the power supply and pull out the
fuse drawer ③ from the power entry module.
▶ Remove the fuse holder ② from the fuse drawer and turn it so that the required
voltage value appears in the inspection window.
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Assembly instructions Everest® engine Base Camp 4140
5 First use | 5.3 Installation
5.3.4 Connect the system
Note
When running mains current circuits and EDP circuits, the relevant regulations
must be complied with!
When connecting up appliances, proceed with the greatest care and attention so
as to avoid any damage to cables and plug-fit connections.
CAUTION
Electrical current
Electrical shock
▶ Make sure that the system voltage is disconnected while connecting the sys‐
tem.
▶ Connect the components of the KaVo Everest engine Base Camp according to
the connection plan.
x8
x4
37P
37P
50P
x
a
m
n
i
m
BAZYX
x8
NET
50P
x4
Connection diagram
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Assembly instructions Everest® engine Base Camp 4140
5 First use | 5.3 Installation
Power supply unit
(X) X-Axis Stepper Motor Power Supply (x4) Stepper motor control to PC (B axis)
(Y) Y-Axis Stepper Motor Power Supply (x8) Stepper motor control to PC (X, Y, Z,
A axis)
(Z) Z-Axis Stepper Motor Power Supply ①Mains input
(A) A-Axis Stepper Motor Power Supply ②Coolant/lubricant pump power supply
(B) B-Axis Stepper Motor Power Supply ③Spindle motor power supply
(x1) Control cable to milling-grinding unit
(37P)
X8
X6
X4
PC
① ID reader input (X6) PLC interface to the milling/grinding
unit (50P)
② Network (X4:)Stepping motor actuation (B-axis)
(X8) Stepping motor actuation (X, Y, Z, A-
axis)
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Assembly instructions Everest® engine Base Camp 4140
5 First use | 5.3 Installation
5.3.5 Connect the cooling lubricant
① Mains cable for the cooling lubricant
pump
④Connecting cable between power
supply and pump
② Aerosol exhaust power cable ⑤Aerosol exhaust hose
③ Cooling lubricant supply hose ⑥Cooling lubricant drain hose
▶ In the cooling lubricant container, mix ① part cooling lubricant concentrate
(Mat. no. 1.001.6002) with 24 parts clean tap water.
▶ Connect the cooling lubricant supply hose ③.
▶ Connect the cooling lubricant drain hose ⑥
▶ Connect the power cables for the cooling lubricant pump ① .
▶ Connect the power cable for the aerosol exhaust ② .
▶ Connect the aerosol exhaust hose ⑤. Make sure that the aerosol exhaust hose
is connected so that it can be run at a downward slope. It may not sag.
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Assembly instructions Everest® engine Base Camp 4140
5 First use | 5.3 Installation
Using a candle filter (optional accessory)
Candle filter (Mat. no. 1.005.2070)
① Candle filter outlet ③Sump
② Candle filter inlet
Installing the candle filter
▶ Connect the candle filter inlet ② to the cooling lubricant supply hose.
▶ Connect the candle filter outlet ① to the cooling lubricant unit.
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