Okuma VTM-200 Manual

VERTICAL MULTITASKING MACHINE
VTM-200
OSP-P200
OPERATION & MAINTENANCE
(1st Edition)
Pub No. 5699-E (LE11-214-R1) Dec. 2009

5699-E P-(i)
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
The machine is equipped with safety devices which serve to protect personnel and the machine itself from
hazards arising from unforeseen accidents. However, operators must not rely exclusively on these safety
devices: they must also become fully familiar with the safety guidelines presented below to ensure accident-
free operation.
This instruction manual and the warning signs attached to the machine cover only those hazards which
Okuma can predict. Be aware that they do not cover all possible hazards.
1. Installing the Machine
•When selecting the machine installation site, ensure that the following conditions are met.
If not, it may be difficult to perform safe operation or maintain the guaranteed accuracy.
a. The machine ambient temperature is within the range from 5 to 40°C.
b. The machine ambient humidity is within the range from 40 to 75% at 20(C and no conden-
sation is allowed.
c. Avoid installation near the factory door because the machine is subject to rapid tempera-
ture change by warm or cool air blowing against the machine.
d. Also avoid installation in a place which is subject to direct sunlight.
e. For the installation ground conditions, refer to Section 2 “Transportation and Installation
(Relocation).”
f. To maintain the guaranteed accuracy, you are advised to care and control the factory tem-
perature.
•Prepare the primary power supply that satisfies the following conditions:
a. Primary power supply: 200 V
b. Voltage fluctuation: ±10% or less
c. Power source frequency: 50/60 Hz
d. Do not connect the machine power cable to the same power board as noise generating
equipment, such as an electric welder and electric discharge machine. Doing this will
cause the NC to malfunction.
e. The law stipulates that the machine tools must be grounded (by Class D grounding work).
When you ask an electrical worker for grounding work, request the worker to perform Class
D grounding based on the electrical facility technical standards.If the machine is not
grounded, it is possible that insulation failure will cause a leak current to flow through the
human body, resulting in serious injury or accidents involving death.
f. The machine should be grounded independently of other machines. If the machine must be
grounded with other machines, do not connect the ground cable to the same ground termi-
nal as noise generating equipment, such as an electric welder or an electric discharge
machine.
Recommended temperature change for 24 hours: : Within ±2°C
Temperature difference between the measurement near
the floor and the measurement at a position 3 m high
from the floor
:Within±1°C

5699-E P-(ii)
SAFETY PRECAUTIONS
2. Before Turning on the Power
•Make sure that the doors to the operation panel and the electric control cabinet are closed.
•Make sure that there are no obstacles around the machine.
•Turn on the main power disconnect switch before turning on the CONTROL on the operation
panel.
3. Chuck Precautions
•Always close the front shield before starting the spindle or cutting operations.
•Always observe the spindle speed maximums for the installed chuck.
Never run the spindle exceeding the maximum allowable chuck speed.
•If a chuck or fixture is unique to your application, check the maximum allowable spindle speed
and stay within the limit. Also, take note of the workpiece gripping force and balance.
•The maximum spindle speed can be limited by inputting a G50 command with the spindle
speed. The G50 command helps to ensure safety in operation.
•If the spindle must be rotated close to the maximum allowable chuck speed, observe the follow-
ing points:
The maximum allowable spindle speed and application pressure are indicated on the name
plate on the front shield and on the chuck body. The allowable maximum speed and the applica-
ble pressure ensure a chucking force that is more than one-third over the original chuck grip-
ping force with the standard soft-top jaw set in line with the periphery of the chuck body.
a. Make sure that the workpiece clamped in the chuck is balanced.
b. Apply the allowable maximum amount of pressure to grip the workpiece because centrifu-
gal force reduces the chuck gripping force.
•If special jaws (larger than standard soft-top jaws) are used, observe the following points:
a. Lower the spindle speed because centrifugal force and lower efficiency reduce the chuck
gripping force.
b. If the jaw tightening nut (jaw nut) is outside of the periphery of the chuck, only one tighten-
ing bolt is holding the jaws in place. This is a potentially dangerous condition. Jaw nuts
must always be within the periphery of the chuck.
c. Machine the jaws to the workpiece shape.
•Securely tighten the bolts on the chuck body, the jaws, and the block to the specified torque.
Use lubrication oil. Make sure that the torque is at least 392 to 490 N (88 to 110 lbf).

5699-E P-(iii)
SAFETY PRECAUTIONS
4. General Checks
•Check the amount of lubricating oil every day before starting operation.
•Always use the specified brand of lubricating oil.
•Use the recommended type of cutting fluid (coolant) when possible.
•It is recommended to use a water-soluble coolant to prevent fire. Do not attempt unmanned
operation if a non-soluble coolant is used.
•Change and replenish the lubricating oil and coolant in each reservoir according to the sched-
ules in the manual.
•Clean the filters according to the schedules in the manual.
•Make sure that each pressure gauge on the air and hydraulic lines display the correct value as
described in this manual.
•Always turn off the power before beginning any work inside the front shield. In addition, turn off
the power before beginning work at the back of the machine that requires an operator to enter
the machine operating zone.

5699-E P-(iv)
SAFETY PRECAUTIONS
5. Before Starting Operation
•Always follow the instructions in the operation manual.
•Always make sure that all of the protective covers including the front door and the chuck cover
are in place before operating the machine.
•Always close the front shield before starting operation.
•Never attempt to run a new program without checking its operation. Run the program without a
workpiece set in the chuck and make sure that there is no interference. After making sure that
the program has no bugs, cut a workpiece in the single block mode. If no problems are discov-
ered, automatic operation may be started.
•Before attempting the following operations, make sure that they can be accomplished safety.
a. Spindle rotation
b. Turret indexing
c. Axis movement
•Never touch chips or the workpiece while the spindle is rotating.
•Never attempt to stop a moving object by hand or with a tool.
•Check the jaw installation conditions, the hydraulic pressure, and the maximum allowable spin-
dle speed for the power chuck.
•Check the installation and arrangement of the tools.
•Check the tool offset settings.
•Check the zero offset settings.
•Make sure that the spindle speed and feedrate override settings are at 100%.
•Check the X- and Z-axis software limits before moving the turret to avoid interference with the
chuck.
•Check the turret index/rotation position.
•Make sure the cutting operation is within the allowable transmission power and torque ranges.
•Make sure that the workpiece securely fitted in the chuck or fixture.
•Check the cutting fluid nozzle positions. They must be set to properly supply cutting fluid to the
appropriate points.

5699-E P-(v)
SAFETY PRECAUTIONS
6. Precautions against Fire
•Selecting Coolant
Use nonflammable coolant.
a. Never use oil coolant because it could catch fire from heated chips, tool’s frictional heat, or
grinding spark.
When using oil coolant for unavoidable reason, observe the following:
a. Check the tool edge condition, tool life, and set the cutting conditions that never cause fire
before you start machining.
b. Clean the coolant filter at regular intervals to maintain sufficient coolant discharge, and
always check the coolant for normal discharge.
c. Take every measures so that you can extinguish the fire immediately by placing a fire extin-
guisher near the machine and have an operator always watch the machining condition, or
installing an auto extinguisher.
d. Do not place any flammable objects near the machine.
e. Dispose of chips not to allow them to stack.
f. Periodically clean the inside and surrounding of the machine while checking that all the
devices are normally operating.
g. Never attempt untended operation.
h. When using oil coolant for grinding, you are requested to install fire-fighting equipment
such as auto extinguisher. In this case, inform us of your intention in the stage of examining
your facility.
•When machining flammable material
a. Before machining any of the flammable solid materials such as resin, rubber, or wood,
carefully study and understand the material characteristics and observe the above precau-
tions to take all possible measures to prevent fire.
b. Use particular care when machining magnesium, because its chips react to the water-solu-
ble coolant and generate hydrogen. The hydrogen may catch fire from burnt chips, result-
ing in explosive fire.
•Performing Dry Machining
a. Dry machining is a fire hazard because workpiece, tool, or chips are not cooled. Therefore,
never place any flammable objects near the machine and dispose of chips not to allow
them to stack.
b. Take the same safety measures as in the case of using oil coolant described above, such
as checking the tool edge state and tool life, and setting cutting conditions that never cause
fire.
•Emergency Measures in Door-close and Power-OFF State
a. Should fire break out in the machine when the door is closed and the power is OFF, open
the door using the door lock switch release key and extinguish the fire.
(For details, refer to “Safety door switch” in Section 3. Interlock.)

5699-E P-(vi)
SAFETY PRECAUTIONS
7. Setup
•Make sure that setup is complete.
•If the setup is changed, operate the machine step-by-step to make sure that cutting can be per-
formed without any problems.
•Before changing the chuck and/or chuck jaws, make sure that the chuck fits the intended job.
•If two or more workers must work together, establish signals so that they can communicate (for
example, when lifting or setting heavy objects). Each worker should be aware when a new pro-
cess is about to begin.
•Use the crane or equivalent tool to handle heavy objects.
•When attempting an unfamiliar setup, recheck the setup before beginning operation.
•Remove unnecessary toolholders from the turret.
•Ensure that the bolts for fixing the toolholders to the turret are securely tightened.
•Remove the bolts which are not used for fixing the toolholders.
8. Workpiece Loading and Unloading
•Make sure that workpieces are loaded and unloaded securely.
•Before loading or unloading a workpiece, retract the turret so that the cutting tools in the turret
cannot injure the operator.
•Before loading and unloading a workpiece, make sure that the spindle has come to a complete
stop.
•Before running a new program, rotate the spindle to make sure that the workpiece is securely
clamped in the chuck.
•Before machining an irregularly-shaped workpiece, make sure that it is balanced properly.
•When handling heavy workpieces, use the a crane, hoist, or other similar tool.
•Before loading a workpiece, make sure that the workpiece has a portion that can be used for
proper chucking.
9. At the End of the Day
•Clean the machine.
•Move the turret to the predetermined retraction position.
•Make sure all power switches are turned off.
•Turn off the CONTROL, before turning off the main power disconnect switch.

5699-E P-(vii)
SAFETY PRECAUTIONS
10. When a Problem Occurs
•Stop the machine immediately by pressing the EMERGENCY STOP switch on the operation
panel.
•Consult with the person in charge of maintenance to determine what corrective measures need
to be taken.
•If two or more workers must work together, establish signals so that they can communicate (for
example, when lifting or setting heavy objects). Each worker should be aware when a new pro-
cess is about to begin.
•Only use specified replacement parts and fuses.
11. Powerful Magnet inside the Product
Some products contain powerful magnets, which could be dangerous if exposed by disassembling
the products. Those which contain powerful magnets are provided with a caution plate to indicate
where such magnets are used.
(1) Get assistance from Okuma for disassembling or repairing the powerful magnet housing unit.
•It is dangerous as strong magnetic attraction is exposed while/after disassembling the
strong magnetic housing unit.
•Disassembling work requires special knowledge and jigs.
(2) Danger of powerful magnet
Following are the examples of possible damage caused by being close to powerful magnet.
•Medical electronic instruments such as pacemaker produce malfunction, resulting in seri-
ous bodily injury or loss of life.
•Implanted magnetic metal devices such as artificial eye, clip used for artery of the brain,
etc. get attracted by powerful magnet, resulting in loss of life.
•Metal clothing accessories get attracted by powerful magnet, resulting in bodily injury.
•Tools or parts get attracted by powerful magnet, resulting in bodily injury.
•Precision instrument becomes out of order.
•Magnetic memory device causes data loss.
(3) Contact Okuma when disassembling a magnet housing unit is necessary to dispose of the
machine.
12. General Precautions
•Wear appropriate clothing.
•Keep the machine and the area around it clean and organized.
•Never touch controls or switches with wet hands.

5699-E P-(viii)
SAFETY PRECAUTIONS
13. Safety Devices and Functions
14. Symbols Used in This Manual
The following warning indications are used in this manual to draw attention to information of particu-
lar importance. Read the instructions marked with these symbols carefully and follow them.
Contents Location Remark
Front shield with safety glass and polycarbonate Machine optional
Shield open/close interlock Machine
Chuck interlock Electric control cabinet optional
Software limit Operation panel
Chuck barrier Operation panel
Turret barrier Operation panel
Emergency stop button Operation panel
Slide hold button Operation panel
Alarm display Operation panel
Short circuit breaker Electric control cabinet optional
Cycle start requiring simultaneous depression of both buttons Machine optional
Magazine door open/close interlock Machine
indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
indicates a potentially hazardous situation which, if not avoided, may result in minor or moder-
ate injury.
indicates a potentially hazardous situation which, if not avoided, may result in damage to your
property.
indicates general instructions for safe operation.
DANGER
WARNING
CAUTION
CAUTION
SAFETY INSTRUCTIONS

5699-E P-(ix)
SAFETY PRECAUTIONS
15. For Safe Chuck Work
•When using a chuck, refer to the instruction manual provided by the manufacture of the chuck.
And strictly observe the safety items stated in the manual.
•Set the chuck gripping force by ensuring sufficient margin of safety (2 to 3 or over). Run the
spindle within the allowable speed range set at this time.
LE11214R0100100160001
•In constant peripheral speed cutting, calculate the actual machining speed before designating
G50 (max. speed limit function).
LE11214R0100100160002
•Secure the jaw gripping depth as much as possible.
LE11214R0100100160003
•When gripping a workpiece, soft top jaws must be at the central area of the entire jaws stroke
(see the illustration) or the base line mark on the master jaws must be located within the appro-
priate chuck stroke range.
LE11214R0100100160004
Centrifugal force
µ× (F0-f)×R0>F1×R1
F1
F0
R0 R1
(Cutting force)
N = (1000 × V)/(π× D)
N:Spindle speed
V:Cutting speed
π:Circumference-to-diamete
r
ratio, 3.14
D:Machining diameter
Must be
deep
Appropriate stroke range Central one third of the entire stroke
Entire stroke

5699-E P-(x)
SAFETY PRECAUTIONS
•Before machining an unbalanced workpiece, carry out balancing of the workpiece weight by
gradually changing the spindle speed.
LE11214R0100100160005
•Never attempt to install jigs using T-nut.
Be sure to fix the jigs with bolts.
No chucks prepared by Okuma have T-groove.
LE11214R0100100160006
•Never use double chucking method.
LE11214R0100100160007
16. Caution Plate
•The machine and its components are fitted with various caution plates. Carefully read these
plates and follow the instructions described there.
•Do not tear or damage the caution plates. In case a plate has been lost or become illegible, ask
us for a new plate, quoting the Okuma part number written in this manual.
Clamping block Balance weight
T-slot Jig
Jaw
T-nut
Bolt
Chuck
Workpiece

5699-E P-(xi)
SAFETY PRECAUTIONS
16-1. Caution Plate Positions
LE11214R0100100180001

5699-E P-(xii)
SAFETY PRECAUTIONS
16-2. Caution Plates and Okuma Part Numbers
(1) Precautions on machine operation
Okuma Part No. H1090-1044-74-3
LE11214R0100100190001
No. Item Japan English
1 Precautions on machine operation H1090-1044-73-3 H1090-1044-74-3
2 Cautions on ATC magazine H1090-1039-34-3 H1090-1047-91-2
3 Cautions for removing the maintenance cover H1090-1020-35 H1090-1018-33
4 Cautions for steps H1090-1090-62 H1090-1091-84
5 Caution for MG H1090-1144-61 H1090-1144-65
6 Caution on open/close of operator door H1090-1018-80-1 H1090-1018-82-1
7 Caution plate for getting caught in spindle H1042-1187-54 H1044-1110-43
8 Caution plate for getting caught in chuck and jaw H1042-1187-55 H1044-1110-44
9 Cautions for chuck H1090-1142-73 H1090-1144-66
10 Cautions on chuck replacement H1090-1100-17 H1090-1100-21
11 Cooling oil maintenance H1090-1022-21-1 H1090-1022-32-1
12 Tool handling, locked-in, and fire prevention H1090-1042-42-1 H1090-1042-43-1
13 Control panel nameplates E5421-019-001 E5421-019-002
14 Cautions for setting air source pressure H1090-1022-22-2 H1090-1022-33-1
15 Cautions for operating spindle and ATC H1090-1042-93 H1090-1041-41
16 Cautions on manual tool change H1090-1042-94 H1090-1042-95
17 Caution on automatic door (optional) H1090-1090-76 H1090-1090-77
18 Air pressure for ABSOSCALE (optional) H1090-1024-64-1 H1090-1024-66-1
19 Filter maintenance for ABSOSCALE (optional) H1090-1064-03-1 H1090-1066-98-1

5699-E P-(xiii)
SAFETY PRECAUTIONS
(2) Cautions on ATC magazine
Okuma Part No. H1090-1047-91-2
LE11214R0100100190002
(3) Cautions for removing the maintenance cover
Okuma Part No. H1090-1018-33
LE11214R0100100190003
(4) Cautions for steps
Okuma Part No. H1090-1091-84
LE11214R0100100190004

5699-E P-(xiv)
SAFETY PRECAUTIONS
(5) Caution for MG
Okuma Part No. H1090-1144-65
LE11214R0100100190005
(6) Caution on open/close of operator door
Okuma Part No. H1090-1018-82-1
LE11214R0100100190006

5699-E P-(xv)
SAFETY PRECAUTIONS
(7) Caution plate for getting caught in spindle
Okuma Part No. H1044-1110-43
LE11214R0100100190007
(8) Caution plate for getting caught in chuck and jaw
Okuma Part No. H1044-1110-44
LE11214R0100100190008
(9) Cautions for chuck
Okuma Part No. H1090-1144-66
LE11214R0100100190009

5699-E P-(xvi)
SAFETY PRECAUTIONS
(10) Cautions on chuck replacement
Okuma Part No. H1090-1100-21
LE11214R0100100190010
(11) Cooling oil maintenance
Okuma Part No. H1090-1022-32-1
LE11214R0100100190011
(12) Tool handling, locked-in, and fire prevention
Okuma Part No. H1090-1042-43-1
LE11214R0100100190012
(13) Control panel nameplates
Okuma Part No. E5421-019-002
LE11214R0100100190013

5699-E P-(xvii)
SAFETY PRECAUTIONS
(14) Cautions for setting air source pressure
Okuma Part No. H1090-1022-33-1
LE11214R0100100190014
(15) Cautions for operating spindle and ATC
Okuma Part No. H1090-1041-41
LE11214R0100100190015
(16) Cautions on manual tool change
Okuma Part No. H1090-1042-95
LE11214R0100100190016

5699-E P-(xviii)
SAFETY PRECAUTIONS
(17) Caution on automatic door (optional)
Okuma Part No. H1090-1090-77
LE11214R0100100190017
(18) Air pressure for ABSOSCALE (optional)
Okuma Part No. H1090-1024-66-1
LE11214R0100100190018
(19) Filter maintenance for ABSOSCALE (optional)
Okuma Part No. H1090-1066-98-1
LE11214R0100100190019

5699-E P-(i)
INTRODUCTION
INTRODUCTION
This manual explains the proper handling of the machine to make the best use of its performance and the
maintenance inspection to maintain the machining accuracy for a long period of time. Carefully read this man-
ual and follow the instructions described there.