Milltronics VM Series manual 

Instruction Handbook for VM Series Machining Centers
Milltronics Manufacturing Company
1400 Mill Lane
Waconia, MN 55387 USA
Phone [phone] Fax [phone]
www.milltronics.net
Rev 9-17-2013

I NSTRUCTION H ANDBOOK
S ERVING THE M ETAL C UTTING I NDUSTRY S INCE 1973
1400 M ILL L ANE • W ACONIA , MN 55387
T EL : 952.442.6455 • F AX : 952.442.6457
Table Of Contents
Chapter 1 - Safety...........................................................................................................1
Safety Checklist............................................................................................................2
Basic Points Of Safety..................................................................................................2
Clothing and Personal Safety.......................................................................................3
Safety Related to Workpiece Machining And Tooling...................................................5
Safety Related To Machine Maintenance.....................................................................5
Electrical Safety............................................................................................................6
Release of Trapped Persons........................................................................................6
Machine Safety Labels.................................................................................................7
Safety and Maintenance Label Locations and Descriptions.........................................8
Chapter 2 - Specification...............................................................................................13
Basic Machine Specifications.....................................................................................13
Coolant Recommendation..........................................................................................13
Control Instructions, Schematics, Complete Specification Sheets.............................13
VM22-30 Machine Layout ..........................................................................................14
VM15-20 Machine Layout ..........................................................................................15
Item Identification.......................................................................................................16
Retention Knob Chart.................................................................................................18
Torque specifications .................................................................................................19
Chapter 3 - Site Preparation..........................................................................................21
Machine Placement Considerations...........................................................................21
Power And Ground Requirements..............................................................................22
Connecting a Transformer..........................................................................................23
Autotransformer Connection Diagram........................................................................24
Air Supply System......................................................................................................25
Lifting By forklift..........................................................................................................26
Lifting By Crane or Hoist ............................................................................................27
Chapter 4 - Installation..................................................................................................28
Startup checklist.........................................................................................................28
Required Assembly....................................................................................................28
Finish Level and Tram the Machine ...........................................................................31
Initial Checks of the Machine, its Guards and Safety Systems ..................................32
General Checks..........................................................................................................32
Electrical Checks........................................................................................................32
Visually Check That Guards Are In Place ..................................................................33
Safety Checks............................................................................................................34
Test the Emergency Stop Circuit................................................................................34
Test the enclosure safety circuit (CE machines only).................................................35
Spindle Start up Procedure........................................................................................36

I NSTRUCTION H ANDBOOK
S ERVING THE M ETAL C UTTING I NDUSTRY S INCE 1973
1400 M ILL L ANE • W ACONIA , MN 55387
T EL : 952.442.6455 • F AX : 952.442.6457
Chapter 5 - Failure Modes, Detection and Prevention...................................................37
Minimizing Wear and Tear .........................................................................................37
Clearing Faults in Electrical Components...................................................................37
Diagnosing Mechanical Faults ...................................................................................38
Chapter 6 – Maintenance..............................................................................................39
Periodic Maintenance; Verification Of Safety Systems...............................................39
Maintenance Schedule...............................................................................................39
Always........................................................................................................................39
Daily...........................................................................................................................39
Weekly .......................................................................................................................40
Monthly.......................................................................................................................40
Annually .....................................................................................................................41
Safety Checks, to be carried out monthly and after maintenance operations.............41
Air System Maintenance ............................................................................................42
Way Lube Maintenance..............................................................................................43
Adjustment.................................................................................................................43
On / Off Timer Settings...............................................................................................43
Automatic Tool Changer (ATC) Maintenance.............................................................44
Drawbar cylinder Maintenance (Inline spindle models only).......................................45
Chapter 7 – 8200 CNC Operation.................................................................................47
Milltronics 8200 CNC Front Panel..............................................................................47
Power ON...................................................................................................................47
Power OFF.................................................................................................................47

1
Chapter 1 - Safety
The general principles for safe operation of Milltronics machines are outlined in this
manual. Every Milltronics machine is engineered for safety. You will note, for example,
that all rotating parts are protected by specially designed covers. On some models, the
entire machine will be enclosed to protect the operator from flying cutting chips and to
prevent an insecurely clamped work piece from being thrown out during cutting
operations. If a Milltronics machine is operated in accordance with the manufacturer’s
instructions, it will provide safe and reliable service. However, with machines of this
nature, serious injuries or death can occur from careless or improper operation. Do not
attempt to operate this equipment without reading and thoroughly understanding this
manual. Not every example of improper operation or unauthorized usage that may lead
to malfunction or accident can be anticipated. If a particular operation is not
documented in this or any other Milltronics manual as authorized usage for the
particular equipment, it should be assumed that this is an unauthorized or improper
usage with potential danger and should be avoided.
A. This machine is provided with various safety devices to protect the operator and the
machine. However, these cannot cover all aspects of safety, therefore the operator
must thoroughly read and understand all machine manuals before operating the
machine. The operator should also take into consideration other aspects of safety
related to the particular environment and conditions.
B. Three categories of safety guidelines have been used throughout this manual:
DANGER, WARNING, and CAUTION. The Ansi Z535.4 safety alert symbols and
their meanings are as follows:
1. DANGER: Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
2. WARNING Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
3. CAUTION: Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.

2
Safety Checklist
• Always observe the safety instructions inscribed on the safety labels fixed onto the
machine. Do not remove or alter these labels.
• Do not attempt to operate this machine until you have read the manuals supplied
with the machine and understand each of the functions and operation methods.
• Operators should be trained formally either by a technical school or some form of
apprenticeship program in machining and machining safety.
• Installation and maintenance should be performed only by qualified personnel.
• Qualified personnel shall be trained and knowledgeable of the construction and
operation of this equipment and work methods. Such persons shall be trained to
recognize and avoid hazards that might be present with respect to this equipment
and work methods. Such persons shall also be familiar with the proper use of any
special precautionary techniques, personal protective equipment, including arc-flash,
insulating and shielding materials, and insulated tools and test equipment.
Basic Points Of Safety
1. DANGER
• There are high voltage terminals on the electrical panel, transformer, motors,
junction boxes and other equipment.
• DO NOT touch the high voltage terminals or components under any
circumstances when the power supply is on. Make sure that all doors and
safety covers are fitted before switching the power supply on. If any door or
safety cover is to be removed, first switch off the main circuit breaker.
• DO NOT enter the machining envelope at any time that the machine is under
power. The machine should be entered only when powered off and properly
locked out to prevent accidental energizing of the machine while persons are
inside.
2. WARNING:
• Memorize the location of all emergency stop buttons, so that you can press
one immediately from any position.

C HAPTER 1 - S AFETY
3
• Take care not to touch any switches accidentally while the machine is in
operation.
• Under no circumstance touch any rotating work piece or tool in the spindle
with any object or hands.
• If in the slightest doubt about any procedure, consult appropriate persons or
manuals.
• Always press the emergency stop button when leaving the machine
unattended.
• If more than one person is operating the machine, do not proceed to next step
until notifying the other operator(s).
• Do not modify the machine in any way that will affect the safety of the
machine.
• Never machine flammable or explosive materials.
• Never use flammable cutting fluids.
3. CAUTION
• Do not subject the CNC control unit, the operator’s panel, or the electrical
control panel to strong voltage fluctuations.
• Do not change any machine parameter values without consulting Milltronics
service department. If it becomes necessary to change a value, first check if it
is safe to do so, then make a note of the original value so it can be reset if
necessary.
• Do not open any doors or remove any safety covers while the machine is
under operation.
• Stop all machine operations before cleaning the machine.
• Never leave the machine to run unattended.
Clothing and Personal Safety
1. DANGER
• Tie back long hair that could become entangled in machine mechanisms.
• Eye protection and hearing protection should be worn at all times when
operating the machine.

4
• Always use safety shoes with steel toecaps and oil resistant soles.
• Do not operate the machine while wearing loose or baggy clothes.
• Always completely fasten buttons and hooks on the arms of clothing to avoid
danger of entanglement in machine mechanisms.
• Do not operate the machine under the influence of drugs or alcohol.
• If wearing gloves to load or unload parts, be sure the machine is in
emergency stop mode.
2. WARNING
• Close all doors and covers of the CNC unit, operation panel and electrical
panel to prevent damage from water, chips, and oil.
• Emergency stop the machine and turn off the main power during electrical
storms.
• Check all safety covers regularly to make sure they are properly fitted and not
damaged.
• Always obtain assistance when handling loads beyond your ability.
• Do not adjust coolant nozzles while the machine is in operation.
• Do not remove or interfere with any machine safety devices.
• Do not wipe the work piece with a rag while the spindle is rotating or the
machine is in motion.
• Always stop the machine before removing or inspecting a tool.
• Tools and tooling can be very sharp. Take care when handling.
• Never place an object or your hand in the carousel or tool changer without
putting the machine in emergency stop.
• Never place anything between the machine spindle and tool changer.
• Never use additional clip-on or poorly secured lighting.
3. CAUTION
• Do not allow chips to accumulate during heavy cutting.
• Never use compressed air to clean the machine bed.
• Never wear gloves while operating panel switches.