Milltronics SL12 Series manual 

Instruction Handbook for SL12 Lathes
Milltronics Manufacturing Company
1400 Mill Lane
Waconia, MN 55387 USA
Phone [phone] Fax [phone]
www.milltronics.net
Rev 1 1-7-13

2

INSTRUCTION HANDBOOK
SERVING THE METAL CUTTING INDUSTRY SINCE 1973
1400 MILL LANE •WACONIA, MN 55387
TEL: [phone] •FAX: [phone]
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...............................................................................................11
Machine Weights........................................................................................................11
Current/Voltage requirements ....................................................................................11
Coolant Capacities.....................................................................................................11
Coolant Recommendation..........................................................................................11
Hydraulic Fluid Tank Capacity....................................................................................11
Control Instructions, Schematics, Complete Specification Sheets .............................11
Tooling Specifications ................................................................................................12
Tool shank size SL6-10..............................................................................................12
Tool shank size SL12.................................................................................................12
Boring bar size SL6-10...............................................................................................12
Boring bar size SL12..................................................................................................12
SL12 Series Machine Layout .....................................................................................13
Chapter 3 - Site Preparation..........................................................................................17
Machine Placement Considerations...........................................................................17
Power And Ground Requirements .............................................................................18
Connecting a Transformer..........................................................................................19
Autotransformer Connection Diagram........................................................................20
Air Supply System (if equipped).................................................................................21
Lifting..........................................................................................................................22
By Crane or Hoist.......................................................................................................22
Chapter 4 - Installation..................................................................................................23
Startup checklist.........................................................................................................23
Required Assembly....................................................................................................23
Level the Machine......................................................................................................25
SL Lathe Head Stock Taper Specification..................................................................25
Initial Checks of the Machine, its Guards and Safety Systems ..................................27
General Checks .........................................................................................................27
Electrical Checks........................................................................................................27
Visually Check That Guards Are In Place ..................................................................28
Safety Checks............................................................................................................29
Test the Emergency Stop Circuit................................................................................30
Test the enclosure safety circuit.................................................................................30

iv

INSTRUCTION HANDBOOK
SERVING THE METAL CUTTING INDUSTRY SINCE 1973
1400 MILL LANE •WACONIA, MN 55387
TEL: [phone] •FAX: [phone]
Chapter 5 - Failure Modes, Detection and Prevention...................................................31
Minimizing Wear and Tear .........................................................................................31
Clearing Faults in Electrical Components...................................................................31
Diagnosing Mechanical Faults ...................................................................................32
Chapter 6 – Maintenance..............................................................................................33
Periodic Maintenance; Verification Of Safety Systems...............................................33
Maintenance Schedule...............................................................................................33
Always........................................................................................................................33
Daily...........................................................................................................................33
Weekly .......................................................................................................................33
Monthly.......................................................................................................................34
Annually .....................................................................................................................34
Safety Checks, to be carried out monthly and after maintenance operations.............35
Air System Maintenance (if equipped)........................................................................36
Way Lube Maintenance..............................................................................................37
Tool Turret Maintenance – Pragati (if equipped)........................................................38
Hydraulic System Maintenance..................................................................................38
Hydraulic Tailstock and chuck pressure adjustments.................................................39
Hydraulic Chuck Pressure and Proximity Switches....................................................39
Chapter 7 – 7200 CNC Operation.................................................................................41
Milltronics 7200 CNC Front Panel..............................................................................41
Power ON...................................................................................................................41
Power OFF.................................................................................................................41
Diagram of Main Screen.............................................................................................44
C-Axis and Live Tooling Operation (option)................................................................47
Chapter 8 Parts Lists and Drawings..............................................................................49
Hydraulic Chuck.........................................................................................................50
Spindle Transmission System....................................................................................52
Spindle Speed Detector .............................................................................................54
Headstock (C-axis option).........................................................................................56
Parts Catcher (option)................................................................................................58
Cut off Detector (option).............................................................................................60
X-Axis.........................................................................................................................62
Z-Axis.........................................................................................................................64
Tailstock.....................................................................................................................66
Guarding ....................................................................................................................70
Guarding - Door..........................................................................................................72
Guarding (Electrical Box) ...........................................................................................74
Air FRL and Parts Catcher Solenoid ..........................................................................76
Startup Checklist For SL Series Lathes.........................................................................79

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.
1

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 the emergency stop button(s), so that you can press
emergency stop immediately from any position.
2

CHAPTER 1 - SAFETY
• 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.
3
• 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.
4

CHAPTER 1 - SAFETY
Safety Related to Workpiece Machining And Tooling
1. DANGER
• Never operate the spindle above the rated speed of accessories mounted on
it (chucks, tooling, etc).
• Do not extend stock out of a lathe headstock without an appropriate bar feed
or support.
2. WARNING
• Always use tools suitable for the work and that conform to machine
specifications.
• Replace badly worn tools.
• Be sure that all workpieces and fixtures are secured properly.
• Do not overhang any work piece on a mill table.
• Never operate the machine beyond its specified power limits.
• Never machine flammable or explosive materials.
• Never use flammable materials as cutting fluid.
3. CAUTION
• Be sure the tool length is such that the tool will not interfere with any fixtures
or other objects.
• Perform test operations after mounting tools.
Safety Related To Machine Maintenance
• Maintenance should be performed only by qualified personnel as defined in
the safety checklist on page 2.
• Beware that the machine cross slide can fall if unsupported while servicing
the X-axis motor or ballscrew. Brace the cross slide while servicing in this
area.
• Maintain a clean floor around the work area.
• Employ proper lighting in the area.
• Ensure any ladders used are safe, stable, and secure.
• Ensure all hardware is tight and properly tightened after performing
maintenance operations.
5

Electrical Safety
Read and understand the following list of cautions before attempting to perform service
on this equipment. Failure to observe these rules can result in death or serious
injury.
1. DANGER
• Only qualified personnel should attempt to take current and voltage readings
or perform service. See the safety checklist on page 2 for qualifications.
• Arc flash and shock hazard. Follow ALL requirements in NFPA 70E for
safe work practices and for Personal Protective Equipment before opening
electrical cabinet or performing adjustments or diagnostic measurements
while energized.
• Always keep hands and fingers away from live electrical terminals.
• Remove jewelry while servicing the machine to avoid shorting any electrical
circuits.
• Allow all components to discharge before servicing them. After removing
power, verify that the CHARGE LED indicator and 7-segment display on the
spindle drive have turned OFF before servicing.
FAILURE TO FOLLOW THESE RULES CAN RESULT IN SERIOUS INJURY OR DEATH
Neither the manufacturer nor the manufacturers representatives or dealers can
assume responsibility for any mishaps, damage, or personal injury that may
occur as a result of improper operation or from failure to observe safety
precautions.
Release of Trapped Persons
The purpose of covers and enclosures is to prevent persons from becoming trapped or
entangled in a machine. Be sure all machine covers are in place. Be sure the machine
enclosure is closed when the machine is operating in automatic mode.
6
Maintenance should be performed only by qualified personnel. They should follow the
guidelines in chapter one for safe maintenance practice. Maintenance should not be
performed on a machine under power. For even the most routine day-to-day

CHAPTER 1 - SAFETY
maintenance, such as cleaning the table or removing chips from the machining
enclosure, the machine should be put in an emergency stop condition, de-energizing
the axis servo motors and spindle motor.
Following these precautions prevents someone from becoming trapped or entangled in
the machine.
If a person should become trapped in the machine, the safest procedure is to put the
machine in emergency stop by pressing the red EMERGENCY STOP button, then
powering the machine down using the main disconnect switch on the door of the
electrical cabinet at the rear of the machine.
When the machine is put into emergency stop mode, the servo motors and the spindle
motor are de-energized. If the machine has a horizontal tool change platter and the
platter is under the spindle, emergency stop causes the platter to withdraw from
underneath the spindle.
When there is no power to the machine, the ballscrew for the Z axis may be moved by
hand. The X axis remains locked to prevent the cross slide from falling.
Machine Safety Labels
Please read and understand all of the safety and warning labels on the machine prior to
using the equipment. Failure to observe these labels can result in injury or death.
7

Safety and Maintenance Label Locations and Descriptions
Item Description Page
1 Danger and Safety Precaution 9
2 Extended Material/Stock Danger 9
3 Chip Auger/Conveyor Hazard 9
4 Main Power Hazard and Notice 10
5 Lathe Safety Operation Instructions 10
6 Warmup and daily checks 10
7 Hydraulic Oil Maintenance Notice 10
8 Waylube maintenance 10
8
7
9
5
1
3
6
2
3
4

CHAPTER 1 - SAFETY
1
2
3
Read and understand all Safety, Operation, and Maintenance labels affixed to
the machine to ensure safet
y
and reliabilit
y
.
Located at headstock end near spindle
through hole.
Located around hazard areas on models
equipped with chip conveyor.
9

4
5
6
7
8
Located near main power disconnect
switch on all models.
Located at front of lathe near operator
station where it is clearly visible.
Important safety guidelines that must be
observed.
A
ll models, located near operator station.
Perform all checks to prevent damage
and ensure reliable operation.
Perform maintenance to prevent damage
and ensure reliable operation.
Ensure waylube pump is operating and oil is
being dispensed regularly. Use only proper
lubrication type.
10

11
Chapter 2 - Specification
Machine Weights
SL6 SL10 SL12
Lbs. 7000 7000 13,250
Kg 2700 2700 6000
Current/Voltage requirements
SL6 SL10 SL12 STD SL12 OPT
Voltage 208-240 VAC 208-240 VAC 208-240 VAC 208-240 VAC
Current 50 Amps 60 Amps 60 Amps 100 Amps
Transformer 11 KVA 20 KVA 20 KVA 38 KVA
Coolant Capacities
SL6 SL10 SL12
Gallons 36 36 48
Liters 140 140 185
Coolant Recommendation
Consult with a reputable coolant supplier in your area. You should use non-toxic, non-
corrosive, and non-flammable coolant. Avoid chlorine and sulfur, which may harm the
paint finish.
Hydraulic Fluid Tank Capacity Use Mobil DTE24 or Equivalent
SL6 SL10 SL12
Gallons 10.5 10.5 18
Liters 40 40 68
Control Instructions, Schematics, Complete Specification Sheets
• Detailed instructions for programming the machine and operating it from the front
panel are given in the CNC operation manual provided separately.
• Electrical schematics, pneumatic diagrams (if applicable) and hydraulic diagrams
(if applicable) are located in the electrical and mechanical manual.
Machine specification sheets including travels, tool capacity, etc. are included at the back
of this manual.

Tooling Specifications
Milltronics SL series lathes come equipped for various tooling sizes depending on
machine model and turret size selected. Please refer to your machine order or dealer to
find out what tooling is required for your particular machine.
Tool shank size SL6-10
The standard 8-position turret uses 1” (25mm) tooling while the optional 12 position turret
uses ¾” (20mm) tooling.
Tool shank size SL12
1-1/4” x 6” (32mm x 150mm), 8 position
Boring bar size SL6-10
The standard 8-position turret uses 1.5” (38mm) boring bar holders while the optional 12
position turret uses 1.25” (32mm) boring bar holders.
Boring bar size SL12
2” (50mm) boring bar holders.
12

CHAPTER 2 - SPECIFICATION
13
SL12 Series Machine Layout
168”
4” 122”
23” 74”
81”

Item Identification (SL10 shown)
10
7
1 2 3 4 5
6
89
1 Worklight
2 Tool Turret and Tailstock
3 Operator panels
4 Setup/door switch
5 Waylube unit and hydraulic fluid
level indicator.
14