Optimum Optimill F3 User manual

GB
OPTIMUM
MASCHINEN - GERMANY
Operating manual
Version 1.0
CNC milling machine

OPTIMUM
MASCHINEN - GERMANY
Version 1.0 dated 2015-05-27Page 2 Original operating instructions
F3GB
Table of contents
1 Safety
1.1 Type plate .................................................................................................................................................6
1.2 Glossary of symbols .................................................................................................................................6
1.3 Safety instructions (warning notes)...........................................................................................................7
1.3.1 Classification of hazards...........................................................................................................................7
1.3.2 Other pictograms ......................................................................................................................................7
1.4 Intended use .............................................................................................................................................8
1.5 Reasonably foreseeable misuse...............................................................................................................9
1.5.1 Avoiding misuse........................................................................................................................................9
1.6 Possible dangers caused by the CNC machine .......................................................................................9
1.7 Qualification of personnel .......................................................................................................................10
1.7.1 Target group ...........................................................................................................................................10
1.7.2 Authorized personnel..............................................................................................................................11
1.8 Operator positions ..................................................................................................................................12
1.9 Safety devices ........................................................................................................................................12
1.9.1 Lockable main switch..............................................................................................................................12
1.9.2 Emergency-stop button...........................................................................................................................13
1.9.3 Control technical protection ...................................................................................................................14
1.9.4 Polycarbonate windows .........................................................................................................................14
1.9.5 Prohibition, warning and mandatory labels.............................................................................................14
1.10 Safety check ...........................................................................................................................................14
1.11 Personal protective equipment ...............................................................................................................15
1.12 Safety during operation...........................................................................................................................15
1.13 Safety during maintenance.....................................................................................................................16
1.14 Disconnecting and securing the CNC machine ......................................................................................17
1.14.1 Using lifting equipment ...........................................................................................................................17
1.14.2 Mechanical maintenance work ...............................................................................................................17
1.15 Unattended Operation ............................................................................................................................17
1.16 Accident report........................................................................................................................................18
1.17 Electrical system.....................................................................................................................................18
1.18 Inspection deadlines ...............................................................................................................................18
1.19 Clamping devices for workpieces and tools............................................................................................18
1.20 Environmental protection and water conservation..................................................................................18
2 Technical data
2.1 Electrical connection...............................................................................................................................20
2.2 Milling spindle .........................................................................................................................................20
2.3 Lubricant/coolant system ........................................................................................................................20
2.4 Compressed air ......................................................................................................................................20
2.5 Dimensions .............................................................................................................................................21
2.6 Working area, traverse path ...................................................................................................................21
2.7 Accuracy .................................................................................................................................................21
2.8 Milling table.............................................................................................................................................21
2.9 Environmental conditions - operation .....................................................................................................22
2.10 Environmental conditions - storage ........................................................................................................22
2.11 Emissions ...............................................................................................................................................22
2.12 Tools and tool holding fixtures ................................................................................................................23
3 Assembly and commissioning
3.1 Scope of delivery ....................................................................................................................................25
3.2 Transport ................................................................................................................................................25
3.3 Installation and assembly .......................................................................................................................26
3.3.1 Requirements regarding the installation site...........................................................................................26

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3.3.2 Installation plan F3 ................................................................................................................................. 27
3.3.3 Machine mounting .................................................................................................................................. 28
3.3.4 Corrosion protection ............................................................................................................................... 28
3.3.5 Electrical connection .............................................................................................................................. 29
3.3.6 Current in the Protective Earth Ground Wire.......................................................................................... 30
3.3.7 Connection compressed air supply ........................................................................................................ 31
3.4 First commissioning................................................................................................................................ 31
3.4.1 Refilling the cooling lubricant.................................................................................................................. 31
3.4.2 Cooling lubricants ................................................................................................................................... 31
3.5 Refill central lubrication system .............................................................................................................. 33
3.6 Functional test and controls ................................................................................................................... 35
3.6.1 Warming up the machine ...................................................................................................................... 35
4 General information about CNC
4.1 Compensation of geometry .................................................................................................................... 36
4.2 Coordinate systems on CNC-machine tools .......................................................................................... 36
4.2.1 Cartesian coordinate system.................................................................................................................. 36
4.2.2 Polar coordinate system......................................................................................................................... 37
4.2.3 Machine coordinate system.................................................................................................................... 37
4.2.4 Workpiece coordinate system ................................................................................................................ 37
4.2.5 Rotary axes and secondary axes ........................................................................................................... 38
4.3 NC mathematics..................................................................................................................................... 38
4.3.1 Basics of the coordinate calculation ....................................................................................................... 38
4.3.2 Parameters of a triangle ......................................................................................................................... 38
4.3.3 Angle on a triangle ................................................................................................................................. 38
4.4 Trigonometric functions .......................................................................................................................... 39
5 User interface, machine control panel
5.1 Screen arrangement............................................................................................................................... 40
5.2 Elements on the PPU(Panel Processing Unit) front ............................................................................... 41
5.2.1 Key combination..................................................................................................................................... 45
5.3 Controls on the machine control panel................................................................................................... 46
5.4 Protection levels ..................................................................................................................................... 51
5.4.1 Passwords.............................................................................................................................................. 52
5.4.2 Change passwords................................................................................................................................. 52
6Operation
6.1 Safety ..................................................................................................................................................... 53
6.2 Control and indicating elements ............................................................................................................. 53
6.3 Operational modes ................................................................................................................................. 54
6.4 Programming.......................................................................................................................................... 54
6.5 Operation of the machine ....................................................................................................................... 55
6.5.1 Turning on the CNC- machine................................................................................................................ 55
6.5.2 Reference point approach after turning on............................................................................................. 56
6.5.3 Using the electronic handwheel ............................................................................................................. 58
6.5.4 Insert tool................................................................................................................................................ 58
6.5.5 Manual tool change ................................................................................................................................ 59
6.5.6 Clamping the workpiece ......................................................................................................................... 59
6.5.7 Turning off the CNC- machine................................................................................................................ 60
6.6 Operational modes ................................................................................................................................. 60
6.7 Programming.......................................................................................................................................... 60
6.8 Starting the program............................................................................................................................... 60
6.9 Central lubrication system ...................................................................................................................... 61
6.10 Data interfaces and current collection .................................................................................................... 61
6.11 Selecting the speed................................................................................................................................ 61
6.11.1 Standard values for cutting speeds ........................................................................................................ 61
6.11.2 Standard values for speeds with HSS – Eco – twist drilling ................................................................... 62

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7 M - Code list, M functions
7.1 M-function for milling machines according to PAL................................................................................153
7.2 G functions to PAL................................................................................................................................155
8 Notes, messages and error messages
9 SINUMERIK 808 D
10 Maintenance
10.1 Operating material ................................................................................................................................160
10.1.1 Machine lubricants................................................................................................................................160
10.1.2 Cooling lubricants .................................................................................................................................160
10.2 Safety....................................................................................................................................................161
10.2.1 Preparation ...........................................................................................................................................162
10.2.2 Restarting .............................................................................................................................................162
10.3 Inspection and maintenance.................................................................................................................163
10.3.1 Cleaning and replacing of the polycarbonate windows.........................................................................165
10.3.2 Cleaning the electrical cabinet..............................................................................................................166
10.4 Interlock switch sliding door..................................................................................................................166
10.4.1 Drain the compressed air service unit ..................................................................................................166
10.5 Cooling lubricants and tanks.................................................................................................................167
10.5.1 Inspection plan for water-mixed cooling lubricants ...............................................................................168
11 Ersatzteile - Spare parts - F3
11.1 Ersatzteilbestellung - Ordering spare parts ..........................................................................................169
11.2 Elektrische Ersatzteile - Electrical spare parts......................................................................................169
11.3 Schaltplan - Wiring diagram..................................................................................................................169
11.4 Gehäuse - Housing...............................................................................................................................170
11.5 Unterbau - Substructure .......................................................................................................................171
11.6 Fräskopf - Milling head .........................................................................................................................172
11.7 Frästisch - Milling table .........................................................................................................................173
11.8 Frästisch - Milling table .........................................................................................................................174
11.9 Säule - Column .....................................................................................................................................175
11.10 Zentralschmierung ................................................................................................................................178
11.11 Schaltplan .............................................................................................................................................179
12 Appendix
12.1 Copyright ..............................................................................................................................................186
12.2 Changes ...............................................................................................................................................186
12.3 Storage .................................................................................................................................................186
12.4 Terminology/Glossary...........................................................................................................................187
12.5 Product follow-up ..................................................................................................................................187
12.6 Re-export ..............................................................................................................................................188
12.7 Liability Claims for Defects / Warranty..................................................................................................189
12.8 Note regarding disposal / options to reuse: ..........................................................................................189
12.8.1 Decommissioning .................................................................................................................................190
12.8.2 Disposal of new device packaging........................................................................................................190
12.8.3 Disposing of the old device...................................................................................................................190
12.8.4 Disposal of electrical and electronic components.................................................................................190
12.8.5 Disposal of lubricants and coolants ......................................................................................................191
12.9 Disposal via municipal collection ..........................................................................................................191
12.10 RoHS, 2002/95/EC ...............................................................................................................................191

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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

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1 Safety
This part of the operating instructions
explains the meaning and use of the warning notes included in these operating instructions,
defines the intended use of the CNC 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 statutory provisions for accident prevention,
the prohibition, warning and mandatory signs as well as the warning labels on the CNC
machine.
Always keep this documentation close to the CNC machine.
If you would like to order another documentation for your CNC machine, please indicate the
serial number of your CNC machine. The serial number is printed on the type plate.
1.1 Type plate
1.2 Glossary of symbols
provides further instructions
calls on you to act
enumerations

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1.3 Safety instructions (warning notes)
1.3.1 Classification of hazards
We classify the safety warnings into different categories. The table below gives an overview of
the classification of symbols (ideogram) and the warning signs for each specific danger and its
(possible) consequences.
1.3.2 Other pictograms
Symbol Warning alert Definition / consequence
DANGER! Impending danger that will cause serious injury or death to people.
WARNING! A danger that can cause serious injury or death.
CAUTION! A danger or unsafe procedure that can cause personal injury or damage to
property.
ATTENTION!
Situation that could cause damage to the CNC-machine and products and
other types of damage.
No risk of injury to people.
INFORMATION
Practical tips and other important or useful information and notes.
No dangerous or harmful consequences for people or objects.
In case of specific dangers, we replace the pictogram with
general danger by a
warning of
injury to hands, hazardous electrical
voltage,
rotating
parts.
Activation forbidden! Do not step into the
machine!
Do not extinguish with
water!
Access forbidden!
Wear protective boots! Use ear protection! Wear protective glasses! Read the operating instruc-
tion before commissioning!

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1.4 Intended use
WARNING!
In the event of improper use of the CNC machine
will endanger personnel,
the CNC machine and other material property of the operating company will be
endangered,
the correct function of the CNC machine may be affected.
The CNC 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.
Using this machine it is possible to perform dry processing as well as processing by using cool-
ing lubricants.  "Cooling lubricants“ on page 160
The limit values of the balances of the tools need to be observed.  "Tools and tool holding
fixtures“ on page 23
The CNC machine must only be installed and operated in a dry and well-ventilated place.
The CNC machine is designed and manufactured to be used in a non-explosive environment.
Intended useIf the CNC machine is used in any way other than described above, modified without the
approval of the company Optimum Maschinen Germany GmbH then the CNC 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, if any constructive, tech-
nicalor procedural changes are not performed by the company Optimum Maschinen Germany
GmbH.
It is also part of intended use that you
the limits of performance of the CNC machine are observed,
the operating manual is observed,
the inspection and maintenance instructions are observed.
WARNING!
Severe injuries due to non-intended use.
It is forbidden to make any modifications or alternations to the operation values of the
CNC machine. They could endanger the personnel and cause damage to the CNC
machine.
Warning: suspended loads! Warning of oxidizing sub-
stances!
Caution, danger of explo-
sive substances!
Warning: danger of slip-
ping!
Protect the environment! Contact address

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1.5 Reasonably foreseeable misuse
Any other use other than that specified under "Intended use" or any use beyond the described
use shall be deemed as non-intended use and is not permissible.
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 misuse, it is necessary to read and understand the operating instructions
before first commissioning.
Operators must be qualified.
1.5.1 Avoiding misuse
Use of suitable cutting tools.
Adapting the speed adjustment and feed to the material and workpiece.
Clamp workpieces firmly and vibration-free.
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.
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.
ATTENTION!
Do not use the drill chuck for milling tools. Never clamp a milling cutter into a drill
chuck. Use a collet chuck with collets for the end mill.
1.6 Possible dangers caused by the CNC machine
The CNC machine was tested for operational safety. The construction and type are state of the
art.
Nevertheless, there is a residual risk as the CNC machine operates with
rotating parts,
electrical voltage and currents,
compressed air,
rapid moves.
We have used construction resources and safety techniques to minimize the health risk to per-
sonnel resulting from these hazards.
If the CNC 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 lathe.
INFORMATION
Everyone involved in the assembly, commissioning, operation and maintenance must
be duly qualified,

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strictly follow these operating instructions.
In the event of improper use
there may be a risk to personnel,
there may be a risk of damage to the CNC machine and other material values,
the correct function of the CNC machine may be affected.
Always switch off the CNC machine and disconnect it from the mains if you perform cleaning or
maintenance works.
WARNING!
The CNC machine may only be used with functional safety devices. Disconnect the CNC
machine immediately, whenever you detect a failure in the safety devices or when they
are not fitted!
All additional parts of the machine which had been added by the customer need to be
equipped with the prescribed safety devices.
This is your responsibility being the operating company!
1.7 Qualification of personnel
1.7.1 Target group
This manual is addressed to
the operating companies,
operators having sufficient specialist knowledge,
the maintenance personnel.
Therefore, the warning notes refer to both, operation and maintenance personnel of the CNC
machine.
Determine clearly and explicitly who will be responsible for the different activities on the CNC
machine (operation, setting up, maintenance and repair). Please note the name of the responsi-
ble person into an operators´s log.
INFORMATION
Unclear responsibilities constitute a safety risk!
Always lock the main switch after switching off the CNC machine. This will prevent it from being
used by unauthorized persons.
The qualifications of the personnel for the different tasks are mentioned below:
Operator
The operator has been instructed by the operating company regarding the assigned tasks and
possible risks in case of improper behaviour. Any tasks which need to be performed beyond the
operation in standard mode must only be performed by the operator, if so indicated in these
instructions and if the operator has been expressively commissioned by the operating com-
pany.
Qualified electrician
With professional training, knowledge and experience as well as knowledge of respective
standards and regulations, qualified electricians are able to perform work on the electrical sys-
tem and recognise and avoid any possible dangers.
Qualified electricians have been specially trained for the working environment, in which they are
working and know the relevant standards and regulations.

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Qualified personnel
Thanks to professional training, knowledge and experience as well as knowledge of relevant
regulations the qualified personnel is able to perform the assigned tasks and to independently
recognise and avoid any possible dangers themselves.
Instructed person
Instructed persons were instructed by the operating company regarding the assigned tasks and
any possible risks of improper behaviour.
1.7.2 Authorized personnel
INFORMATION
Sufficient expertise is required for working on the CNC machine. No one must work on
the machine without having the necessary training, not even for a short while.
We recommend the use of the CNC software SinuTrain as an aid for training and
operation.
SinuTrain made by Siemens is the perfect software supplement for the CNC machine F3 of
OPTIMUM.
This training software supports the rapid training for the operation of the control Sinumerik Sie-
mens SINUMERIK 808D. Employees having little CNC-experience can learn the basics of the
DIN-programming by using SinuTrain and are finally able to write and test programs using
SINUMERIK 808D.
Please find SinuTrain and further information on the website of Siemens.
http://www.cnc4you.siemens.com
WARNING!
Inappropriate operation and maintenance of the CNC machine constitutes a danger for
the personnel, objects and the environment.
Only authorized personnel may operate the CNC machine !
Persons authorized to operate and maintain should be trained technical personnel and
instructed by the ones who are working for the operating company and for the manufacturer.
The operating company must
Obligations of
the operating
company
train the personnel,
instruct the personnel in regular intervals (at least once a year) on
- all safety standards that apply to the CNC machine,
- operation of the CNC machine,
- generally accepted engineering standards.
- possible emergency situations,
check the personnel‘s knowledge level,
document training/instruction in a operation book,
require personnel to confirm participation in training/instructions by means of a signature,
check whether the personnel is working safety and risk-conscious and observes the operat-
ing instructions.
define and document the inspection deadlines for the machine in accordance with the Fac-
tory Safety Act and perform an operational risk analysis in accordance with the Work Safety
Act.
The operator must
Obligations of
the operator
be specially trained in handling and programming the CNC machine,
know and understand the program sequence and which effects the individual process
parameters will have,
keep an operator‘s log,

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before taking the machine in operation
- have read and understood the operating manual,
- be familiar with all safety devices and instructions.
Additional
requirements
regarding the
qualification
For work on the following CNC- machine parts there are additional requirements:
Electric components or operating materials: Must only be worked on by a qualified electri-
cian or person working under the instructions and supervision of a qualified electrician.
1.8 Operator positions
The operator position is in front of the CNC machine at the sight window or on the machine con-
trol panel.
1.9 Safety devices
Use the CNC machine only with properly functioning safety devices.
Stop the CNC machine immediately if safety device fails or is not functioning for any reason.
It is your responsibility!
If a safety device has been activated or has failed, the drilling machine must only be used if you
the cause of the fault has been eliminated,
you have verified that there is no danger to personnel or objects.
WARNING!
If you bypass, remove or deactivate a safety device in any other way, you are
endangering yourself and other personnel working with the CNC machine. The possible
consequences are:
injuries due to tools, workpieces or fragments hereof which are flying off at high
speed,
contact with rotating or moving parts,
fatal electrocution,
pulling-in of clothes.
The CNC machine includes the following safety devices:
a lockable main switch,
One EMERGENCY STOP push-button on the machine control panel and on the electronic
handwheel,
A locked, separating protective equipment around the CNC milling machine with sight win-
dows made of break-proof Makrolon.
Locking switch on the separating safety devices.
1.9.1 Lockable main switch
In the "0" position, the lockable main switch can be secured against accidental or non-author-
ised switching on by means of a padlock.
The power supply is interrupted by switchingoff the main plug.
Except for the areas marked by the pictogram in the margin. In these areas there might be volt-
age, even if the main switch is switched-off.

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Img.1-1: Main switch
WARNING!
Dangerous voltage even if the main switch is switched off.
The areas marked by the pictogram might contain live parts, even if the main switch is switched
off.
1.9.2 Emergency-stop button
ATTENTION!
The EMERGENCY STOP push button immediately stops the operation of the CNC
machine.
Press the EMERGENCY STOP button only if there is a risk! If this push button is
actuated in order to switch off the CNC machine in the standard operation the tool or
workpiece might get damaged.
After having actuated the EMERGENCY-STOP mushroom switch, turn the knob of the particu-
lar push button to the right in order to restart the machine.
Img.1-2: Emergency-stop push button

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1.9.3 Control technical protection
WARNING!
If you bypass a controller you endanger yourself and other persons working on the CNC
machine.
injuries due to tools, workpieces or fragments hereof which are flying off at high
speed,
contact with rotating parts,
fatal electrocution,
pulling-in of clothes.
If you bypass a controller in exceptional cases (e.g. during electrical repairs) short term you
must continuously monitor the CNC machine during this time.
1.9.4 Polycarbonate windows
Polycarbonate viewing window in chip protection, must be visual inspected by the customer
responsible personnel at regular intervals to guarantee the operational safety of the CNC
machine.
Polycarbonate viewing panes are subject to an ageing process and are classified as wear
parts.
The aging of polycarbonate windows can not be detected by visual inspection. It is therefore
necessary to replace the polycarbonate windows after a certain time.
Prolonged exposure from polycarbonate windows to cutting fluids can lead to accelerated age-
ing, i.e. deterioration of the mechanical properties (brittleness). Coolant vapours, detergents,
greases and oils or other corrosive substances from the operator side can also lead to a deteri-
oration of the polycarbonate windows. The result in reduced impact resistance of the polycar-
bonate windows.
 "Cleaning and replacing of the polycarbonate windows“ on page 165
1.9.5 Prohibition, warning and mandatory labels
INFORMATION
All warning and mandatory signs must be legible. They must be checked regularly.
1.10 Safety check
Check the CNC machine at least once per shift. Inform the person responsible immediately of
any damage, defects or changes in the operating function.
Check all safety devices
at the beginning of each shift (when the machine is operated continuously),
once per day (during one-shift operation),
once per week (when operated occasionally),
after all maintenance and repair work.
Check that prohibition, warning and information signs and the labels on the CNC machine
are legible (clean them, if necessary),
and complete (replace them, if necessary).
INFORMATION
Organise the checks according to the following table;

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1.11 Personal protective equipment
For certain work personal protective equipment is required.
Protect your face and your eyes: Wear a safety helmet with facial protection when performing
work where your face and eyes are exposed to hazards.
Wear protective gloves when handling pieces or tools with sharp edges.
Wear safety shoes when you assemble, disassemble or transport heavy components.
Use ear protection if the noise level (emission) in the workplace exceeds 80 dB (A).
Before starting work make sure that the required personnel protective equipment is available at
the work place.
CAUTION!
Dirty or contaminated personnel protective equipment can cause illness. It must be
cleaned after each use and at least once a week.
1.12 Safety during operation
WARNING!
Before activating the CNC machine, ensure that this will not endanger other persons or
cause damage to equipment.
Avoid any unsafe work methods:
The instructions mentioned in these operating instructions have to be strictly observed dur-
ing assembly, operation, maintenance and repair.
General check
Equipment Check OK
Protective housing Switching function, firmly bolted and not damaged
Signs,
Markers
Installed and legible
Sight window Check for mechanical damage (scratches, cracks).
cracks,,  "Polycarbonate windows“ on page 14
Date: checked by (signature):
Functional check
Equipment Check OK
EMERGENCY STOP
push button
After actuating an EMERGENCY STOP push button the CNC
machine must be switched off.
Switch cabinet cooling The cabinet cooling must be running.
Separating protective
equipment around the
CNC machine
If the protective equipment is open it must not be possible to
start program.
Date: checked by (signature):

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MASCHINEN - GERMANY
Safety
Version 1.0 dated 2015-05-27Page 16 Original operating instructions
F3GB
Do not work on the CNC machine, if your concentration is reduced, for example, because
you are taking medication.
Stay on the CNC machine until the program is termi-
nated.
The running program can be identified by means of
the signal lamp.
- Green light: Program run active
- Yellow light: Malfunction
- Red light: Actuated emergency stop push button
Img.1-3: Signal lamp
Safely and firmly clamp the workpiece before switching on the CNC machine.
Never change the dosing of the coolant supply during operation.
Never open the sliding door of the separating protective unit when the CNC-program is run-
ning.
WARNING!
When chipping magnesia materials (aluminium-/magnesium alloys), spontaneously
inflammable or explosive particles (powder, dust, chips) might be generated, which
might cause a fire and/or explosion (deflagration).
Magnesium is designated a dangerous material in the list of dangerous materials and
preparations according to para. 4a of the Ordinance of Hazardous Substances.
In case of a fire with magnesium, only use appropriate and admitted extinguishing
agents. Never extinguish using water. If burning magnesium is extinguished with water,
this might lead to dangerous reactions (hydrogen gas). Water would be decomposed in
its components hydrogen (H) and oxygen (O).
Only the following extinguishing agents are permissible:
solid extinguishing agent of fire class D (fires involving metals)
dry covering salts for magnesium
a mixture of sand and cast chips
argon (Ar) or nitrogen (N2)
If fine mist and smoke is generated at the workplace, suction units must be provided in
order to avoid the accumulation of ignitable mixtures and emissions.
We provide information about the specific dangers when working with and on the CNC machine
in the descriptions for these types of work.
1.13 Safety during maintenance
Inform the operators in good time of any maintenance and repair works.
Report all safety-relevant changes and performance characteristics of the CNC machine. Any
changes must be documented, the operating instructions updated and machine operators
instructed accordingly.

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MASCHINEN - GERMANY
Safety
Version 1.0 dated 2015-05-27 Page 17Original operating instructions
F3 GB
1.14 Disconnecting and securing the CNC machine
Turn off the main switch of the CNC machine before starting any maintenance or repair work.
Use a padlock to prevent the switch from being turned on without authorization and keep the
key in a safe place.
All machine parts as well as all dangerous voltages are switched off.
Excepted are only the positions which are marked with the adjoining pictogram. These positions
may be live, even if the main switch is switched off.
Place a warning sign on the CNC machine.
WARNING!
Live parts and moves of machine parts can injure you or others dangerously!
Proceed with extreme care if you cannot switch off
switch due to required works (e.g. functional control).
1.14.1 Using lifting equipment
WARNING!
The use of unstable lifting and load suspension equipment that might break under load
can cause severe injuries or even death. Observe the accident prevention regulations
issued by your Employers Liability Insurance Association or other supervisory
authorities responsible for your company.
Check that the lifting and load-suspension equipment are of sufficient load-bearing
capability and are in perfect condition.
Fasten the loads carefully.
Never walk under suspended loads!
1.14.2 Mechanical maintenance work
Remove or install protection safety devices before starting or after completing any mainte-
nance work; this include:
covers,
safety instructions and warning signs,
grounding cables.
If you remove protective or safety devices, re-fit them immediately after the completing the
work.
Check if they are working properly!
1.15 Unattended Operation
CNC machines are designed for unattended operation. However, it may not be safe to let your
machining process run unmonitored. As it is the shop owner’s responsibility to set up the
machine safely and use best practice machining techniques, it is also their responsibility to
manage the progress of these methods. The machining process must be monitored to prevent
damage in case of a hazardous situation.
For example, if there is a risk of fire due to the machined material, an appropriate fire suppres-
sion system must be installed to reduce the risk of harm to personnel, equipment and the build-
ing. Have a specialist supplier install monitoring tools, before allowing machines to run
unattended.
It is especially important to select monitoring equipment that can immediately perform an appro-
priate action without human intervention to prevent an accident, should a problem be detected.

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MASCHINEN - GERMANY
Safety
Version 1.0 dated 2015-05-27Page 18 Original operating instructions
F3GB
1.16 Accident report
Inform your supervisors and Optimum Maschinen Germany GmbH immediately in the event of
accidents, possible sources of danger and any actions which almost led to an accident (near
misses).
There are many possible causes for "near misses".
The sooner they are notified, the quicker the causes can be eliminated.
INFORMATION
We specifically point out the dangers when describing the work with and on the lathe.
1.17 Electrical system
Have the machine and/or the electric equipment checked regularly. Immediately eliminate all
defects such as loose connections, defective wires, etc.
A second person must be present during work on live components to disconnect the power in
the event of an emergency. Disconnect the CNC machine immediately if there is a malfunction
in the power supply!
Comply with the required inspection intervals in accordance with the factory safety directive,
operating equipment inspection DGUV, formerly BVG.
The operator of the machine must ensure that the electrical systems and operating equipment
are inspected with regards to their proper condition, namely,
by a qualified electrician or under the supervision and direction of a qualified electrician,
prior to initial commissioning and after modifications or repairs, prior to recommissioning
and at certain intervals.
The deadlines must be set so that arising, foreseeable defects can be detected in time.
The relevant electro-technical rules must be followed during the inspection.
The inspection prior to initial commissioning is not required if the operator receives confirma-
tion from the manufacturer or installer that the electrical systems and operating equipment com-
ply with the accident prevention regulations, see conformity declaration.
Permanently installed electrical systems and operating equipment are considered constantly
monitored if they are continually serviced by qualified electricians and inspected by means of
measurements in the scope of operation (e.g. monitoring the insulation resistance).
1.18 Inspection deadlines
Define and document the inspection deadlines for the machine in accordance with § 3 of the
Factory Safety Act and perform an operational risk analysis in accordance with § 6 of the Work
Safety Act. Also use the inspection intervals in the maintenance section as reference values.
1.19 Clamping devices for workpieces and tools
ATTENTION!
Attention when taking over existing clamping devices. Pleased thoroughly check that
the clamping device is appropriate for your CNC machine.
Only use clamping devices with a complete inherent rigidity.
Contact the manufacturer of the clamping device regarding the reuse of clamping
devices after damage to the clamping device due to collisions.
Correctly insert the workpiece and make sure that the machine is proper working
condition.
1.20 Environmental protection and water conservation
The CNC machine is a device to produce, handle and use materials which are hazardous to
water according to para. 19g of the Water Resources Law.

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Safety
Version 1.0 dated 2015-05-27 Page 19Original operating instructions
F3 GB
Please follow the requirements of the Water Resources Law when operating, decommissioning
or disassembling the CNC machine or parts hereof. Detailed information regarding this can be
found in the Ordinance on Installations for the Handling of Substances Hazardous to Water
(VAwS).

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MASCHINEN - GERMANY
Technical data
Version 1.0 dated 2015-05-27Page 20 Original operating instructions
F3GB
2 Technical data
The following information represents the dimensions and indications of weight and the manu-
facturer‘s approved machine data.
2.1 Electrical connection
2.2 Milling spindle
2.3 Lubricant/coolant system
2.4 Compressed air
Total connection 3 x 400V ~ 50Hz 2.5 KW
performance spindle drive 1.5 KW
Torque 10 Nm
Speed 200 - 4000 min-1
Spindle seat ISO 30 / BT 30 x 45°
Power of the coolant/lubricant pumps [W] 95
Tank capacity [l] 50
Connection [MPa] 0.8 (8 bar)
Air consumption 0.01 - 0.015 m3/ h at 0.8 MPa
Recommended compressed air quality ISO 8573.1 class 2
Compressed air consumer • Tool clamp / unclamp
Compressed air service unit Drainage filters 40 µm
max. pressure 1.5 MPa
Housing Polycarbonate
Recommended oil lubrica-
tor for compressed air
ISO VG32
Quantity of oil Lubricator for
compressed air
90ml
Drainage manually
Compressed air connec-
tion thread
3/8"