OPTIMUM Maschinen OPTImill Bf 46Vario User manual

GB
OPTIMUM
MASCHINEN - GERMANY
Operating manual
Version 1.1.3
Drilling-milling machine

OPTIMUM
MASCHINEN - GERMANY
Version 1.1.3 dated 2016-7-5Page 2 Original operating instructions
BF46 Vario | BF46TCGB
Table of contents
1 Safety
1.1 Safety instructions (warning notes)...........................................................................................................6
1.1.1 Classification of hazards...........................................................................................................................6
1.1.2 Other pictograms......................................................................................................................................7
1.2 Intended use.............................................................................................................................................8
1.3 Reasonably foreseeable misuses.............................................................................................................9
1.3.1 Avoiding misuses......................................................................................................................................9
1.4 Possible dangers caused by the drilling-milling machine .......................................................................10
1.5 Qualification of personnel.......................................................................................................................11
1.5.1 Target group...........................................................................................................................................11
1.6 Operator positions ..................................................................................................................................12
1.7 Safety measures during operation..........................................................................................................12
1.8 Safety devices ........................................................................................................................................12
1.8.1 EMERGENCY STOP impact switch.......................................................................................................13
1.8.2 Lockable main switch..............................................................................................................................13
1.8.3 Protective cover......................................................................................................................................14
1.8.4 Separating protective equipment............................................................................................................14
1.9 Safety check...........................................................................................................................................14
1.10 Personnel protective equipment .............................................................................................................15
1.11 For your own safety during operation.....................................................................................................15
1.12 Disconnecting and securing the drilling-milling machine ........................................................................16
1.13 Using lifting equipment ...........................................................................................................................16
1.14 Position of labels on the drilling-milling machine....................................................................................16
2 Technical data
2.1 Electrical connection...............................................................................................................................17
2.2 Drilling-milling capacity...........................................................................................................................17
2.3 Spindle seat............................................................................................................................................17
2.4 Drill-Mill head..........................................................................................................................................17
2.5 Cross table..............................................................................................................................................17
2.6 Working area ..........................................................................................................................................17
2.7 Speeds....................................................................................................................................................17
2.10 Emissions ...............................................................................................................................................18
2.8 Environmental conditions........................................................................................................................18
2.9 Operating material..................................................................................................................................18
3 Unpacking and connecting
3.1 Scope of delivery....................................................................................................................................19
3.2 Transport ................................................................................................................................................19
3.3 Storage...................................................................................................................................................20
3.4 Installation and assembly .......................................................................................................................20
3.4.1 Requirements regarding the installation site...........................................................................................20
3.4.2 Load suspension point............................................................................................................................21
3.4.3 Assembly................................................................................................................................................21
3.5 Dimensions, installation plan BF46V......................................................................................................22
3.6 Dimensions, installation plan BF46TC....................................................................................................23
3.7 Installation plan of optional substructure ................................................................................................24
3.8 First commissioning................................................................................................................................25
3.8.1 Power supply..........................................................................................................................................25
3.8.2 Cleaning and lubricating.........................................................................................................................25
3.8.3 Filling in gear oil......................................................................................................................................25
3.8.4 Warming up the machine........................................................................................................................25
3.8.5 Compressed air supply on BF46TC........................................................................................................26

OPTIMUM
MASCHINEN - GERMANY
Version 1.1.3 dated 2016-7-5 Page 3Original operating instructions
BF46 Vario | BF46TC GB
4Operation
4.1 Control and indicating elements BF46V.................................................................................................27
4.1.1 Control panel..........................................................................................................................................28
4.2 Switching on the drilling-milling machine................................................................................................29
4.3 Switching off the drilling-milling machine................................................................................................29
4.4 Inserting a tool on BF46V.......................................................................................................................30
4.4.1 Installation..............................................................................................................................................30
4.4.2 Unfitting..................................................................................................................................................30
4.5 Threading ...............................................................................................................................................31
4.6 Control and indicating elements BF46TC...............................................................................................32
4.6.1 Control panel BF46TC............................................................................................................................33
4.7 Switching on the drilling-milling machine................................................................................................34
4.8 Switching off the drilling-milling machine................................................................................................35
4.9 Traveling the drilling milling head (Z-axis) upward respectively downward............................................35
4.9.1 Traveling the drill-mill head upward respectively downward by actuating the crank handle ..................35
4.10 Threading ...............................................................................................................................................36
4.10.1 Traveling the drill-mill head upward respectively downward using the control panel.............................36
4.11 Inserting a tool on BF46TC ....................................................................................................................36
4.11.1 Installation..............................................................................................................................................36
4.11.2 Unfitting..................................................................................................................................................37
4.12 Safety.....................................................................................................................................................39
4.13 Use of collet chucks ...............................................................................................................................39
4.14 Clamping the workpieces .......................................................................................................................39
4.15 Changing the speed range.....................................................................................................................39
4.16 Manual spindle sleeve feed with the fine feed........................................................................................40
4.17 Digital display for spindle sleeve travel ..................................................................................................40
4.17.1 Malfunctions...........................................................................................................................................41
4.18 Manual spindle sleeve feed with the spindle sleeve lever......................................................................42
4.19 Swivelling the drill-mill head...................................................................................................................42
4.20 Selecting the speed................................................................................................................................42
4.20.1 Standard values for cutting speeds........................................................................................................43
4.20.2 Standard values for speeds with HSS – Eco – twist drilling...................................................................44
5 Maintenance
5.1 Safety.....................................................................................................................................................45
5.1.1 Preparation.............................................................................................................................................45
5.1.2 Restarting...............................................................................................................................................45
5.2 Inspection and maintenance ..................................................................................................................46
5.3 Repair.....................................................................................................................................................49
6 Ersatzteile - Spare parts
6.1 Fräskopf - Milling head 1 - 3...................................................................................................................50
6.2 Fräskopf- Milling head BF 46 TC Vario ..................................................................................................51
6.3 Fräskopf - Milling head 2 - 3..................................................................................................................52
6.4 Fräskopf - Milling head 3 - 3...................................................................................................................53
6.5 Fräskopf - Milling head BF46TC.............................................................................................................53
6.6 Säule - Column.......................................................................................................................................54
6.7 Säule - Column BF46TC ........................................................................................................................55
6.8 Kreuztisch - Cross table 1 - 2.................................................................................................................56
6.9 Kreuztisch - Cross table 2 - 2.................................................................................................................57
6.10 Schutzeinrichtung - Protection device....................................................................................................58
6.11 Maschinenunterbau (Optional) - Machine stand (option) .......................................................................59
6.12 Maschinenschilder - Machine labels ......................................................................................................60
6.12.1 Maschinenschilder - Machine labels ......................................................................................................60
6.12.2 Ersatzteileliste - Spare parts list.............................................................................................................61

OPTIMUM
MASCHINEN - GERMANY
Version 1.1.3 dated 2016-7-5Page 4 Original operating instructions
BF46 Vario | BF46TCGB
6.13 Schaltplan 1 von 2 - Wiring diagram 1 of 2/ BF46, BF46TC...................................................................66
6.14 Schaltplan 2 von 2 - Wiring diagram 2 of 2/ BF46TC .............................................................................67
6.14.1 Teileliste Elektrik - Parts list electrical components BF46 Vario, BF46TC Vario ....................................68
6.15 Schmierplan - Lubrication diagram.........................................................................................................69
6.15.1 Teileliste Schmiervorrichtung - Lubricating unit......................................................................................69
7 Malfunctions
7.1 Damage to the drilling-milling machine...................................................................................................70
8 Appendix
8.1 Copyright ................................................................................................................................................71
8.2 Terminology/Glossary.............................................................................................................................71
8.3 Change information manual....................................................................................................................71
8.4 Liability claims for defects / warranty......................................................................................................72
8.5 Note regarding disposal / options to reuse:............................................................................................72
8.5.1 Decommissioning ...................................................................................................................................73
8.5.2 Disposal of the packaging of new devices..............................................................................................73
8.5.3 Disposing of the old device.....................................................................................................................73
8.5.4 Disposal of electrical and electronic components...................................................................................73
8.5.5 Disposal of lubricants and coolants ........................................................................................................74
8.6 Disposal via municipal collection............................................................................................................74
8.7 RoHS , 2002/95/CE................................................................................................................................74
8.8 Product follow-up....................................................................................................................................74

OPTIMUM
MASCHINEN - GERMANY
Version 1.1.3 dated 2016-7-5 Page 5Original operating instructions
BF46 Vario | BF46TC GB
Preface
Dear customer,
Thank you very much for purchasing a product made by OPTIMUM.
OPTIMUM metal working machines offer a maximum of quality, technically optimum solutions and convince
by an outstanding price performance ratio. Continuous enhancements and product innovations guarantee
state-of-the-art products and safety at any time.
Before commissioning the machine please thoroughly read these operating instructions and get familiar with
the machine. Please also make sure that all persons operating the machine have read and understood the
operating instructions beforehand.
Keep these operating instructions in a safe place nearby the machine.
Information
The operating instructions include indications for safety-relevant and proper installation, operation and main-
tenance of the machine. The continuous observance of all notes included in this manual guarantee the safety
of persons and of the machine.
The manual determines the intended use of the machine and includes all necessary information for its eco-
nomic operation as well as its long service life.
In the paragraph "Maintenance" all maintenance works and functional tests are described which the operator
must perform in regular intervals.
The illustration and information included in the present manual can possibly deviate from the current state of
construction of your machine. Being the manufacturer we are continuously seeking for improvements and
renewal of the products. Therefore, changes might be performed without prior notice. The illustrations of the
machine may be different from the illustrations in these instructions with regard to a few details. However,
this does not have any influence on the operability of the machine.
Therefore, no claims may be derived from the indications and descriptions. Changes and errors are reserved!
Your suggestion with regard to these operating instructions are an important contribution to optimising our
work which we offer to our customers. For any questions or suggestions for improvement, please do not hesi-
tate to contact our service department.
If you have any further questions after reading these operating instructions and you are not able to
solve your problem with a help of these operating instructions, please contact your specialised
dealer or directly the company OPTIMUM.
Optimum Maschinen Germany GmbH
Dr.- Robert - Pfleger - Str. 26
D-96103 Hallstadt
Mail: [e-mail]
Internet: www.optimum-maschinen.com

OPTIMUM
MASCHINEN - GERMANY
Version 1.1.3 dated 2016-7-5Page 6 Original operating instructions
BF46 Vario | BF46TCGB
1 Safety
Glossary of symbols
This part of the operating instructions
explains the meaning and use of the warning notices included in these operating instruc-
tions,
defines the intended use of the milling-machine.
points out the dangers that might arise for you or others if these instructions are not
observed,
informs you about how to avoid dangers.
In addition to these operation instructions, please observe
the applicable laws and regulations,
the legal regulations for accident prevention,
the prohibition, warning and mandatory signs as well as the warning labels on the milling-
machine.
When installing, operating, maintaining and repairing the milling machine it is necessary to
observe the European standards.
With regard to relevant national legislation which has not yet been adjusted to the European
standards, the applicable national legislation needs to be observed.
If required it is necessary to take the corresponding measures to comply with the country-spe-
cific regulations before commissioning the milling-machine.
Always keep this documentation close to the milling-machine.
INFORMATION
If you are unable to solve a problem using these operating instructions, please contact us for
advice:
Optimum Maschinen Germany GmbH
Dr. Robert-Pfleger-Str. 26
D-96103 Hallstadt
Email: [e-mail]
1.1 Safety instructions (warning notes)
1.1.1 Classification of hazards
We classify the safety warnings into various levels. The table below gives an overview of the
classification of symbols (ideogram) and the warning signs for each specific danger and its
(possible) consequences.
gives further advice
calls on you to act
enumerations
Ideogram Warning alert Definition / consequence
DANGER! Threatening danger that will cause serious injury or death to people.
WARNING! A danger that might cause severe injury to the staff or can lead to death.
CAUTION! Danger or unsafe procedure that might cause injury to people or damage
to property.

OPTIMUM
MASCHINEN - GERMANY
Version 1.1.3 dated 2016-7-5 Page 7Original operating instructions
BF46 Vario | BF46TC GB
1.1.2 Other pictograms
ATTENTION!
Situation that could cause damage to the milling machine and products
and other types of damage.
No risk of injury to people.
INFORMATION
Application tips and other important or useful information and notes.
No dangerous or harmful consequences for people or objects.
Ideogram Warning alert Definition / consequence
In case of specific dangers, we replace the pictogram by
or
general danger by a warning of injury of hands, hazardous electri-
cal voltage, rotating parts.
Warning of danger of slip-
ping! Warning risk of stumbling! Warning hot surface! Warning biological hazard!
Warning of automatic start-
up! Warning tilting danger! Warning of suspended loads! Caution, danger of explo- sive substances!
Activation forbidden! Read the operating instruc-
tions before commission-
ing!
Disconnect the mains plug!

OPTIMUM
MASCHINEN - GERMANY
Version 1.1.3 dated 2016-7-5Page 8 Original operating instructions
BF46 Vario | BF46TCGB
1.2 Intended use
WARNING!
In the event of improper use, the drilling-milling machine
will endanger personnel,
the drilling-milling machine and other material property of the operating company
will be endangered,
the correct function of the drilling-milling machine may be affected.
The drilling-milling machine is designed and manufactured to be used for milling and drilling
cold metals or other non-flammable materials or materials that do not constitute a health hazard
by using commercial milling and drilling tools.
The drilling-milling machine must only be installed and operated in a dry and well-ventilated
place.
If the drilling-milling machine is used in any way other than described above, modified without
the approval of the company Optimum Maschinen Germany GmbH then the drilling-milling
machine is being used improperly.
We will not be held liable for any damages resulting from any operation which is not in accord-
ance with the intended use.
We expressly point out that the guarantee or CE conformity will expire due to any constructive
technical or procedural changes which had not been performed by the company Optimum
Maschinen Germany GmbH. It is also part of intended use that
the limits of the drilling-milling machine are observed ,
the operating manual is observed,
the inspection and maintenance instructions are observed.
 "Technical data“ on page 17
WARNING!
Heaviest injuries through improper use.
It is forbidden to make any modifications or alternations to the operation values of the
drilling-milling machine. They could endanger the staff and cause damage to the drilling-
milling machine.
INFORMATION
The drilling-milling machine BF46 Vario | BF46TC is built according to the standard DIN EN
55011 class A.
WARNING!
The class A (machine tools) is not intended to be used in residential facilities, where the
power is supplied via a public low voltage supply system. In these areas it may possibly
be difficult to guarantee electromagnetic compatibility due to lead bound as well as
emitted interferences.
Use protective glasses! Use protective gloves! Use protective boots! Use protective suit!
Use ear protection! Only switch in standstill! Protect the environment! Contact address

OPTIMUM
MASCHINEN - GERMANY
Version 1.1.3 dated 2016-7-5 Page 9Original operating instructions
BF46 Vario | BF46TC GB
ATTENTION!
If the drilling-milling machine is not used as intended or if the safety directives or the
operating instructions are ignored the liability of the manufacturer for any damages to
persons or objects resulting hereof is excluded and the claim under guarantee is
becoming null and void!
1.3 Reasonably foreseeable misuses
Any other use as the one determined under the "Intended use" or any use beyond the
described use shall be deemed as not in conformity and is forbidden.
Any other use has to be discussed with the manufacturer.
It is only allowed to process metal, cold and non-inflammable materials with the milling-
machine.
In order to avoid misuses it is necessary to read and understand the operating instructions
before the first commissioning.
The operators must be qualified.
1.3.1 Avoiding misuses
Use of suitable cutting tools.
Adapting the speed adjustment and feed to the material and workpiece.
Clamp workpieces firmly and vibration-free.
For the drilling-milling machine there are conversion kits.
The attachments are provided as a kit to computer-controlled milling (CNC Computerized
numerical control). However, the control of the step motors can also be done manually via a
special controller (control, potentiometer). A step motor control is required in each case.
The drilling-milling machine must only be installed and operated in a dry and well-ventilated
place.
The machine BF46 Vario | BF46TC covered by the standard DIN EN 13128 (milling machines,
including drilling machines). Therein, the manually controlled machines are divided into two
classes with different protection levels, depending on the travel speed of a single power-driven
axis. In addition, the requirements for automatically controlled machines listed (highest level of
protection).
The one who changed the manually controlled BF46 Vario | BF46TC on CNC control is legally
the manufacturer of a new machine due to the significant change in the machine and is there-
fore responsible for compliance with the requirements of the Machinery Directive and the DIN
EN 13128.
The tool follows a path of movement which is normally not predictable by the operator. Because
of the additional hazards caused by flying parts the standard defines protective devices. It does
not matter what speeds are available on the axes.
We expressly point out that the guarantee will expire due to any constructive technical or proce-
dural changes which had not been performed by the company Optimum Maschinen Germany
GmbH.
With the conversion of the machine BF46 Vario | BF46TC an cabinet is required.
A suitable cabinet for these machines you can order:
Cabinet SHC 3 for BF46 Vario | BF46TC, item no. 353 9093
ATTENTION!
The workpiece is always to be fixed by a machine vice, jaw chuck or by another
appropriate clamping tool such as for the clamping claws.

OPTIMUM
MASCHINEN - GERMANY
Version 1.1.3 dated 2016-7-5Page 10 Original operating instructions
BF46 Vario | BF46TCGB
WARNING!
Risk of injury caused by workpieces flying off.
Clamp the workpiece in the machine vice. Make sure that the workpiece is firmly clamped in the
machine vice resp. that the machine vice is firmly clamped on the machine table.
Use cooling and lubricating agents to increase the durability of the tool and to improve the
surface quality.
Clamp the cutting tools and workpieces on clean clamping surfaces.
Sufficiently lubricate the machine.
Correctly adjust the bearing clearance and the guidings.
It is recommended:
Insert the drill in a way that it is exactly positioned between the three clamping jaws of the
quick action chuck.
Clamp and mills by means of the collet chuck and the corresponding collets.
Clamp end face mills by means of shell end mill arbors.
When drilling make sure that
the suitable speed is set depending on the diameter of the drill,
the pressure must only be such that the drill can cut without load
in case of too strong pressure the drill will get worn early or even might break resp. get
jammed in the hole. If the drill gets jammed immediately stop the main motor by pressing
the emergency stop button,
for hard materials, e.g. steel, use commercial cooling / lubricating agents,
generally always drive the turning spindle out of the workpiece.
ATTENTION!
Do not use the quick action drill chuck for milling tools. Never clamp a milling cutter into
the quick action drill chuck. Use a collet chuck and the corresponding collets for the end
mill.
When milling make sure that
the corresponding cutting speed is selected,
for workpieces with normal strength values, e.g. steel 18-22 m/min,
for workpieces with high strength values 10-14 m/min,
the pressure is selected in a way that the cutting speed remains constant,
for hard materials commercial cooling / lubricating agents are used.
1.4 Possible dangers caused by the drilling-milling machine
The drilling-milling machine is state-of-the-art.
Nevertheless, there is a residual risk as the drilling-milling machine operates with
at high speeds,
with rotating parts and tools,
with electrical voltages and currents.
We have used construction resources and safety techniques to minimize the health risk to per-
sons resulting from these hazards.
If the drilling-milling machine is used and maintained by personnel who are not duly
qualified, there may be a risk resulting from incorrect or unsuitable maintenance of the drilling-
milling machine.
INFORMATION
Everyone involved in the assembly, commissioning, operation and maintenance must