Optimum BF16 Vario User manual

OPTIMUM
MASCHINEN - GERMANY
3 / 08 / 2006 Page 1Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006
GB
Modification instructions
Version 1.4.7
Adapter kit CNC milling machine
BF16 Vario / BF20 Vario / BF20L Vario
Keep for future reference!

OPTIMUM
MASCHINEN - GERMANY
3 / 08 / 2006Page 2 Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006 GB
Table of Contents
1 Packing list
2 Safety warnings (warning notes)
2.1 Classification of hazards......................................................................................................... 5
2.2 Proper use .............................................................................................................................. 6
2.3 Required auxiliary material...................................................................................................... 6
3 Assembly
3.1 Assembly X axis...................................................................................................................... 7
3.2 Assembly Y axis.................................................................................................................... 10
3.3 Assembly Z axis.................................................................................................................... 12
4 Installation of step motors
4.1 Wiring X / Y / Z axis............................................................................................................... 19
4.2 Assembley X / Y / Z -Axis...................................................................................................... 21
5 Assembly and maintenance instruction ball bearing spindle
5.1 Assembly............................................................................................................................... 24
5.2 Installation with spindle......................................................................................................... 25
5.3 Lubricating notes................................................................................................................... 25
5.4 Protective measures ............................................................................................................. 25
5.5 Packing list............................................................................................................................ 26
6 Modification BF20 to a ball bearing spindle
7 Appendix
7.1 Copyright............................................................................................................................... 56
7.2 Warranty................................................................................................................................ 56
7.3 Disposal ................................................................................................................................ 57
7.4 Product follow-up .................................................................................................................. 57
7.5 EC Declaration of Conformity................................................................................................58
8 Appendix
8.1 Copyright............................................................................................................................... 59
8.2 Terminology/Glossary........................................................................................................... 59
8.3 Warranty................................................................................................................................ 60
8.4 Disposal ................................................................................................................................ 60
8.5 Product follow-up .................................................................................................................. 61

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MASCHINEN - GERMANY
Packing list
3 / 08 / 2006 Page 3Packing list Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006
GB
1 Packing list
Bezeichnung
Designation CNC - Anbausatz MK F 20 PD
BF20 Vario; BF20L Vario
Artikelnummer Anbausatz
Item No. adapter kit 357 0020
Netto Gewicht
Net weight 5,6 kg
Brutto Gewicht
Gross weight 6,3 kg
Abmessung (Lx B x H)
Dimension (L x W x H) 320 x 285 x 80 mm
Nr.
No Bezeichnung Description Artikelnummer Item No. Teile Nr. Part N
o.
Grösse
Size Abbildung Illustration Stck. Qty.
1Gehäuse für Z - Achse
Driver housing for Z axis 359 0201 BF20CNC-01 1
2Gehäuse für X , Y - Achse
Driver housing for X , Y axis 359 0202 BF20CNC-02 2
3Montagering X - Achse
Assembly ring 359 0203 BF20CNC-03 1
4Stützhülse
Support sleeve 359 0204 BF20CNC-04 2
5Zahnriemenscheibe für Welle Z - Achse
Toothed belt disk for shaft Z axis 359 0205 BF20CNC-05 36 Zähne/teeth,
HTD-18-3M-9 ZL 103 1
6Zahnriemenscheibe für Welle X , Y - Achse
Toothed belt disk for shaft X , Y axis 359 0206 BF20CNC-06 30 Zähne/teeth,
HTD-18-3M-9 ZL 103 2
7Zahnriemenscheibe für Motor X , Y - Achse
Toothed belt disk for motor X , Y axis 359 0207 BF20CNC-07 24 Zähne/teeth,
HTD-18-3M-9 ZL 103 2

Packing list
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MASCHINEN - GERMANY
3 / 08 / 2006Page 4 Packing list Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006 GB
8Zahnriemenscheibe für Motor Z - Achse
Toothed belt disk for motor Z axis 359 0208 BF20CNC-08 18 Zähne/teeth,
HTD-18-3M-9 ZL 103 1
9Abdeckplatte Antriebsgehäuse
Housing cover gear case 359 0209 BF20CNC-09 3
10 Abdeckplatte Z-Achse
Housing cover Z-axis 0357002010 BF20CNC-10 1
11 Schraube
Screw - GB70 M6 x 45 2
12 Schraube
Screw - GB70 M6 x 25 1
13 Schraube
Screw - GB70 M6 x 12 4
14 Zahnriemen
Gear belt 359 0211 3M-9
255 Zähne/teeth 3
15 Schraube
Screw -GB70M4x8 12
16 Schraube
Screw - GB70 M5 x 12 12
17 Schraube
Screw -GB77M4x5 6
18 Schrittmotor Z-Achse, X-Achse, Y-Achse
Step motor Z axis, X axis, Y axis 357 3304
23H280-01EA
2,2 Nm
3A
40V
3
19 Kabel
Cable wire 359 0212 4 x 0,75mm29m
Nr.
No Bezeichnung Description Artikelnummer Item No. Teile Nr. Part N
o.
Grösse
Size Abbildung Illustration Stck. Qty.
Prüfer:
Verified by: Datum:
Date:

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MASCHINEN - GERMANY
Safety warnings (warning notes)
3 / 08 / 2006 Page 5Safety warnings (warning notes) Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006
GB
2 Safety warnings (warning notes)
2.1 Classification of hazards
We classify the safety warnings into various levels. The table below gives an overview of the
classification of symbols (pictograms) and warnings for the specific danger and its (possible)
consequences.
2.1.1 Glossary of symbols
Picto-
gram Alarm expres- sion Definition/Consequences
Danger! Imminent danger that will cause serious injury or death to
personal.
WARNING! Risk: A danger that might cause serious injury or death to
personal.
CAUTION! Danger of unsafe procedure that might cause injury to
personal or damage to property.
ATTENTION!
Situation that could cause damage to the machine and
product and other types of damage.
No risk of injury to personal.
INFORMATION
Application tips and other important or useful information
and notes.
No dangerous or harmful consequences for personal or
objects.
In the case of specific dangers, we replace the pictogram by
or
General dan-
ger with a warning of injuries to hands, hazardous electrical
voltage,
rotating parts.
gives additional advices
enumerations

Safety warnings (warning notes)
OPTIMUM
MASCHINEN - GERMANY
3 / 08 / 2006Page 6 Safety warnings (warning notes) Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006 GB
2.2 Proper use
WARNING!
In the event of improper use of the add-on pieces, it
• will endanger the user,
• will endanger the machine and other material property of the operator or user,
• may affect proper operation of the machine.
The add-on pieces as conversion kit are provided for the computer-aided - CNC, Computerised
Numerical Control - milling operations of your machine.
The drive of the step motors may also be performed manually with a control unit
(potentiometer).
Improper
use! The milling machine with the adapter kit must only be placed and operated in dry and ventilated rooms.
The hand wheels need to be disassembled.
If the adapter kit is used in any way other than described above or modified without approval of
the company Optimum Maschinen Germany GmbH the adapter kit is no longer properly used.
We do not take liability for any damage caused by improper use.
We would like to stress that any modifications to the construction, or technical or technological
modifications that have not been authorised by Optimum Maschinen GmbH will also render the
guarantee null and void.
2.3 Required auxiliary material
Means of shaft lock-down device "Loctite 648, join the shaft".
The designation of the parts in the assembly description corresponds to the numbering of the
packing list.
In order to degrease the shaft, a cleaner for brakes or a corresponding cleaning agent is
required.
A tenacious grease e.g. Mobilux 3 or a corresponding lubricating grease serves to grease the
bearings.
Required tools:
lubricating oil for thread cutting, twist drill 5mm,
counter sink; screw tap M6, manual drilling machine, calliper gauge,
a set of Allen keys, set of fork wrenches, blow-back proof plastic tip hammer,
box wrench 13mm, screw driver, tongs, chipping spanner,
soldering iron with accessories, abrasive cloth, small chisel (you may also use a small screw
driver).

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MASCHINEN - GERMANY
Assembly
3 / 08 / 2006 Page 7Assembly Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006
GB
3 Assembly
CNC conversion kit MK F 20 PD
3.1 Assembly X axis
3.1.1 Disassemble the self-locking nut and
the shim of the left handwheel of the X
axis.
3.1.2 Remove the handwheel with a blow-
back proof plastic tip hammer with
smooth knocks. Turn the handwheel at
the same time.
Fig.3-1: Handwheel on the left
3.1.3 Remove the rivet of the nonius with a
hammer and a small chisel (or use a
screw driver as chisel).
3.1.4 Grind off the relief with an abrasive
cloth in order to facilitate the mounting
of the assembly ring.
Fig.3-2: Grinding
INFORMATION
The axial deep groove ball bearing of the milling machine table has to be disassembled on the
right side and reassembled on the left side. The bushing of the milling machine table has to be
disassembled on the left side and reassembled on the right side.
unscrew the
handwheel of the X
axis
grinding of the relief

Assembly
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MASCHINEN - GERMANY
3 / 08 / 2006Page 8 Assembly Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006 GB
3.1.5 Modify the axial deep groove ball bea-
ring and the bushing.
3.1.6 Shift the assembly ring (No. 3) with the
slot downward on the relief - if required
- with slight beats of the hammer with a
blow-back proof plastic tip hammer.
3.1.7 Beat on the assembly ring until a small
collar is being formed (2 to 3mm). In
this place the housing will centre later
on.
Fig.3-3: Assembly ring
3.1.8 Do not clamp the assembly ring yet! (The ring should be positioned as parallel as possible).
3.1.9 Mount the pulley of the toothed belt
(No. 6) on the shaft.
3.1.10 Fasten the pulley of the toothed belt
with the nut and shim of the handwheel.
3.1.11 Do fasten the nut too much otherwise
the shaft might clamp.
3.1.12 Check if the shaft is running well by
turning the pulley of the toothed belt.
Fig.3-4: Pulley of the toothed wheel X axis
3.1.13 If the shaft is too tight, detach the nut a little.
3.1.14 Uniformly fasten the housing (No. 2)
with the screws (No.12) on the assem-
bly ring.
3.1.15 The housings differ in the diameter of
the through hole. The hole for the Z
axis is a little larger.
Fig.3-5: Assemble housing
assembly ring
relief (2 to 3mm)
pulley of the toothed
wheel
nut, shim
assembly ring
housing
screws

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MASCHINEN - GERMANY
Assembly
3 / 08 / 2006 Page 9Assembly Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006
GB
3.1.16 Horizontally aline the housing with a
blow-back proof plastic tip hammer.
Fig.3-6: Aline the housing
3.1.17 Fasten the assembly ring with a screw
(No. 11).
Fig.3-7: Assembly ring
CAUTION!
Danger by catching or winding up.
3.1.18 The right handwheel needs to be disas-
sembled. It is not sufficient to have the
handle disassembled.
Fig.3-8: Right handwheel
3.1.19 Assemble the step motor as described under  “Installation of step motors“ on page 19.
housing X axis
Allen screw
housing
assembly ring
screw
handle

Assembly
OPTIMUM
MASCHINEN - GERMANY
3 / 08 / 2006Page 10 Assembly Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006 GB
3.2 Assembly Y axis
3.2.1 Disassemble the self-locking nut and
shim of the handwheel.
Fig.3-9: Diemndwheel Y axis 1
3.2.2 Remove the handwheel with a blow-
back proof plastic tip hammer with
smooth knocks. Turn the handwheel at
the same time.
Fig.3-10: Disassembly handwheel Y axis 2
CAUTION!
Do not fasten the self-locking screw with force. Allow enough clearance for the spindle
(air, clearance).
3.2.3 Mount the pulley of the toothed belt
(No. 6) on the shaft and fasten it with
the self-locking nut and the shim of the
handwheel.
3.2.4 Control if it is running well by turning
the pulley of the toothed belt manually.
Fig.3-11: Assembly of the pulley of the toothed
belt Y axis
handwheel
self-locking nut
plastic tip hammer
handwheel
pulley of the toothed
belt
self-locking nut and
shim

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MASCHINEN - GERMANY
Assembly
3 / 08 / 2006 Page 11Assembly Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006
GB
CAUTION!
Do not turn the shaft after loosening the screws.
3.2.5 Remove the screws for the pillow block
of the handwheel.
Fig.3-12: Remove screws
CAUTION!
Always fasten the screws uniformly so that the housing will not jam.
3.2.6 Assemble housing (No. 2) with screws
(No. 10).
3.2.7 The two supporting bushings (No. 4)
need to be inserted between the hou-
sing and the pillow block. The smaller
diameter of the supporting bushing
needs to be oriented to the machine!
Fig.3-13: Assembly housing
3.2.8 Mount the step motor as described under  “Installation of step motors“ on page 19.
pillow block of the
handwheel
screws
pillow block
housing
support bushing

Assembly
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MASCHINEN - GERMANY
3 / 08 / 2006Page 12 Assembly Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006 GB
3.3 Assembly Z axis
CAUTION!
Imperatively clamp the Z axis, otherwise, the whole milling head will slide downward as
soon as you remove the nut of the Z axis.
INFORMATION
For machines from model 2006 the fastening holes of the housing are already provided in the lid
of your machine. Therefore, it is not required to disassemble the lid with the nut from the Z axis.
3.3.1 Wind the milling head in the Z axis
completely up.
3.3.2 Clamp the Z axis with the clamping
levers!
Fig.3-14: Clamp Z axis
3.3.3 Disassemble the covering of the groove
nuts.
Fig.3-15: Disassemble covering
clamping lever
Z axis
milling head
covering groove nuts

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MASCHINEN - GERMANY
Assembly
3 / 08 / 2006 Page 13Assembly Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006
GB
3.3.4 Remove the two nuts of the shaft with a
sickle spanner.
Fig.3-16: Disassemble nut
3.3.5 Unscrew the screws from the lid and
remove the lid.
Fig.3-17: Disassemble lid
3.3.6 Remove the bearings from the lid.
3.3.7 In order to avoid soiling put the bearing
on a clean cloth and protect it from
dust.
3.3.8 Before inserting the axial deep groove
ball bearing, grease it again.
Fig.3-18: Bearing
sickle spanner
nut
screws
lid
distance ring
bearing

Assembly
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MASCHINEN - GERMANY
3 / 08 / 2006Page 14 Assembly Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006 GB
3.3.9 Mark the holes on the covering plate in
a way that the assembled housing will
be at an angle of 45° degrees to the
right if you look at the machine from the
rear.
Fig.3-19: Mark the holes
3.3.10 In order to determine the distance bet-
ween the holes of the housing, simply
put the housing on the covering plate
and aligne the holes of the housing and
of the lid to one another (screw-hole
circle 50 mm).
3.3.11 Mark the holes with a felt pen.
Fig.3-20: Aligne holes
3.3.12 Mark the holes which you had pre-
viously marked with a felt pen with a
center punch now (see red framed mar-
king on the illustration).
Fig.3-21: Center the holes
covering plate
housing
angle 45°
hole housing
hole covering plate
housing
centered
holes
covering plate

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MASCHINEN - GERMANY
Assembly
3 / 08 / 2006 Page 15Assembly Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006
GB
3.3.13 Drill holes of 5 mm into the covering
plate with a core hole drill.
3.3.14 When both holes are drilled deburr the
holes with a counter sink.
Fig.3-22: Drill holes
3.3.15 Cut a thread M6 into the lid. Make sure
that the screw tap is placed at a right
angle.
3.3.16 Use cutting oil when threading.
Fig.3-23: Threading
3.3.17 Thoroughly clean the covering plate
after threading (seat of the bearing and
thread) in order to prevent from latter
damages.
Fig.3-24: Clean covering plate
diameter of the drill
5mm
covering plate
angle
screw tap
brush with
cleaning agent
covering plate

Assembly
OPTIMUM
MASCHINEN - GERMANY
3 / 08 / 2006Page 16 Assembly Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006 GB
3.3.18 Grease the seat of bearing of the shaft
with grease for bearings. Do not use
any spray grease as this grease tends
to resinify.
Fig.3-25: Greasing
3.3.19 Mount the covering plate and insert the
bearing into the seat of the bearing.
Grease the bearing.
Fig.3-26: Covering plate
3.3.20 Uniformly screw down the lid with four
screws. The milling head has to be at
the top position.
Fig.3-27: Tighten the covering plate
brush with
grease for bearings
seat of the bearing
covering plate
seat of bearing
covering plate
screws

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MASCHINEN - GERMANY
Assembly
3 / 08 / 2006 Page 17Assembly Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006
GB
3.3.21 Grease the thread of the shaft and pul-
ley part 5, apply means of securing
(join shaft) to the thread.
3.3.22 Screw the groove nut on the shaft
(hand-tight).
3.3.23 Detatch the clamping of the axis and
check the clearance by actuating the
handwheel and by moving the machine
on the axis.
3.3.24 If required detatch the nut a little more if
the shaft is too tight.
Fig.3-28: Clearance of the shaft
3.3.25 Screw the pulley item 5 on the shaft,
hold the nut with the sickle spanner and
tighten the pulley with a wrench.
3.3.26 Then control the clearance once again,
if required, losen the nut of the shaft a
little.
Fig.3-29: Assemble pulley
3.3.27 Mount housing item 1 and tighten it with
screws item 12.
3.3.28 The housings differ in the diameter of
the through hole. The hole of the Z axis
is a little larger.
Fig.3-30: Mount housing
covering plate
nut
wrench
pulley
sickle spanner
Allan-
key
housing

Assembly
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MASCHINEN - GERMANY
3 / 08 / 2006Page 18 Assembly Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006 GB
3.3.29 Remove screws and shims from the
handwheel.
Unscrew the four screws of the faste-
ning and remove the whole handwheel
fixture.
Fig.3-31: Disassemble handwheel
3.3.30 Fasten the lid item 10 with the 4 screws
of the handwheel.
Fig.3-32: Assemble covering
3.3.31 Mount the step motor as described under  “Installation of step motors“ on page 19.
position handwheel
column Z axis
covering
column Z axis

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Installation of step motors
3 / 08 / 2006 Page 19Installation of step motors Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006
GB
4 Installation of step motors
4.1 Wiring X / Y / Z axis
4.1.1 Open the lid of the step engine with a
cross slot screwdrive.
Fig.4-1: Open the lid of the step engine
4.1.2 Remove the outer isolation of the cable
and make sure that the lower isolation
of the single conductor will not be
damaged.
4.1.3 The bared part should be about 6 cm
long.
Fig.4-2: Remove outer isolation
4.1.4 Twist the fabric of the shielding.
Fig.4-3: Twist screening
screw of the step
engine
lid of the step engine
outer isolation
screening
cut outer isolation
screening
cable

Installation of step motors
OPTIMUM
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3 / 08 / 2006Page 20 Installation of step motors Adapter kit BF20 Vario; BF20L Vario ; Version 1.4.7
© 2006 GB
INFORMATION !
The shielding will be conntected to the terminal block of the engine on one side.
4.1.5 The cables will be peeled off at a length of about 5 mm with insulation stripping tongs.
4.1.6 Plug and press wire terminations on the ends of the cable.
4.1.7 Plug the strain relief over the cable.
4.1.8 Insert the cable through the opening of
the cover plate of the step engine.
4.1.9 Connect the cable to the engine and
tighten the strain relief.
4.1.10 The twisted screening goes with the
clamping "GND" .
Fig.4-4: Terminal block of the engine
4.1.11 Fasten the lid of the step engine with
the cross slot screwdriver.
4.1.12 Then cut the cable to the length which
is required to connect it to the CNC
controller.
Fig.4-5: Screw the lid
4.1.13 Connect the cable to the CNC controller as required.
Fig.4-6: Strip terminal CNC Controller VI
INFORMATION !
Do not connect a screening nor an earthing cable to the CNC Controller.
terminal block engine
screening
lid step engine
strip terminal
CNC Controller
Motor Controller
A- to A-
A+ to A+
B- to B-
B+ to B+
GND