OptiPro Systems eSX 300 CTS User manual

User Manual –eSX
OptiPro Systems, LLC. Page 1 of 111 Last Modified: 8/27/2014
OptiPro Systems, LLC
User Manual –eSX

User Manual –eSX
OptiPro Systems, LLC. Page 2 of 111 Last Modified: 8/27/2014
1Contents
2Contacting OptiPro................................................................................................................................ 6
3Document Revisions.............................................................................................................................. 7
4Safety .................................................................................................................................................... 8
4.1 Employer’s Responsibilities........................................................................................................... 8
4.2 General Safety Concerns............................................................................................................... 8
4.2.1 Personal Safety...................................................................................................................... 8
4.2.2 Electrical Safety..................................................................................................................... 9
4.2.3 Pneumatic Safety .................................................................................................................. 9
4.2.4 Chemical Safety..................................................................................................................... 9
4.3 Safe Operation of the Machine..................................................................................................... 9
4.4 In An Emergency .........................................................................................................................10
5Machine Overview and User Controls ................................................................................................ 11
5.1 Work Area and Machine Axes..................................................................................................... 13
5.2 Operator Panel Interface ............................................................................................................ 14
5.2.1 Jog Panel ............................................................................................................................. 14
5.2.2 Jog Pendant......................................................................................................................... 16
5.2.3 Door Interlock .....................................................................................................................17
5.2.4 Emergency Stop ..................................................................................................................17
5.2.5 Coolant Recirculation Control............................................................................................. 18
5.2.6 USB ports............................................................................................................................. 18
5.3 Utility Control Panel.................................................................................................................... 19
5.4 Vacuum Work Holding ................................................................................................................20
5.5 Coolant System ...........................................................................................................................21
5.5.1 Coolant Tank ....................................................................................................................... 21
5.5.2 Centrifuge............................................................................................................................22
5.5.3 Spindle Chiller ..................................................................................................................... 23
5.6 Electrical Cabinet A/C unit .......................................................................................................... 23
5.7 Pneumatic Automatic Greaser.................................................................................................... 24
5.8 Tool Spindle & Tool Holder Precautions ..................................................................................... 25

User Manual –eSX
OptiPro Systems, LLC. Page 3 of 111 Last Modified: 8/27/2014
5.9 Work Holding Chucks..................................................................................................................27
5.10 Work and Tool Probing ............................................................................................................... 28
5.11 Integrated Spherometer .............................................................................................................29
6Start Up, Shut Down, and Emergency Recovery Procedure ............................................................... 30
6.1 Startup ........................................................................................................................................ 30
6.1.1 Initial Power Up................................................................................................................... 30
6.1.2 Resuming From E-Stop or Auto Off..................................................................................... 30
6.2 Shutdown....................................................................................................................................31
6.2.1 Retaining Main Power......................................................................................................... 31
6.2.2 Full Power Down .................................................................................................................31
6.3 Emergency Stop .......................................................................................................................... 31
6.3.1 When to press E-STOP ........................................................................................................31
6.3.2 Returning machine to normal operation ............................................................................31
7Software Interface .............................................................................................................................. 32
7.1 Screen Layout.............................................................................................................................. 32
7.2 G-Series Submenu....................................................................................................................... 33
7.3 Manual Jog Mode........................................................................................................................ 34
7.4 Automatic Mode, for Jobs and External Programs .....................................................................35
7.4.1 Motion Stop (for non-emergencies) ................................................................................... 35
7.4.2 G-Code Viewer ....................................................................................................................36
7.4.3 Loading External Programs .................................................................................................36
7.5 Tools and the Tool Library...........................................................................................................37
7.5.1 Tool Library ......................................................................................................................... 37
7.5.2 Add, Delete, and Update Library Tools ............................................................................... 38
7.5.3 Ring Tools............................................................................................................................38
7.5.4 Ball Tools ............................................................................................................................. 39
7.5.5 Edge Tools ........................................................................................................................... 40
7.5.6 End Mill Tools......................................................................................................................41
7.5.7 Toroid Tools ........................................................................................................................ 42
7.5.8 RFID Tools............................................................................................................................43

User Manual –eSX
OptiPro Systems, LLC. Page 4 of 111 Last Modified: 8/27/2014
7.5.9 Scoop Tools ......................................................................................................................... 44
7.6 Creating and Running Jobs.......................................................................................................... 45
7.6.1 Loading an Existing Job ....................................................................................................... 45
7.6.2 Deleting an Existing Job ......................................................................................................46
7.6.3 Creating a New Job ............................................................................................................. 46
7.6.4 Executing a Process in a Job................................................................................................ 82
7.7 Settings........................................................................................................................................ 83
7.7.1 Settings –Page 1 ................................................................................................................. 83
7.7.2 Settings –Page 2 ................................................................................................................. 84
8Error Recovery and Troubleshooting ..................................................................................................85
8.1 Coolant Flow Fault ......................................................................................................................85
8.1.1 Reading the Flow Monitor ..................................................................................................85
8.1.2 Changing the Required Flow Rate....................................................................................... 85
8.1.3 Cleaning if Necessary .......................................................................................................... 86
8.2 Recovering from Error Messages................................................................................................ 86
9Machine Maintenance ........................................................................................................................89
9.1 Daily Maintenance ......................................................................................................................89
9.1.1 Start of Shift ........................................................................................................................89
9.1.2 End of Shift.......................................................................................................................... 89
9.2 Weekly Maintenance ..................................................................................................................89
9.3 Monthly Maintenance ................................................................................................................ 90
9.4 Semi-Annual Maintenance.......................................................................................................... 90
9.5 Yearly Maintenance ....................................................................................................................90
9.6 3-Year Maintenance.................................................................................................................... 90
9.7 Cleaning the Centrifuge ..............................................................................................................91
9.8 Replacing Existing Safety Windows.............................................................................................92
9.9 Cleaning the Tool-holder and Spindle......................................................................................... 97
9.10 Lubrication of Tool Spindle Locking Mechanism ........................................................................ 98
10 Appendices.......................................................................................................................................... 99
10.1 Tram Procedure .......................................................................................................................... 99

User Manual –eSX
OptiPro Systems, LLC. Page 5 of 111 Last Modified: 8/27/2014
10.1.1 Check Hydraulic Chuck Run Out........................................................................................ 100
10.1.2 Accessing the Tram Screens.............................................................................................. 101
10.1.3 Tram –B Zero Screen ........................................................................................................ 101
10.1.4 Tram –Spindles Aligned.................................................................................................... 101
10.1.5 Tram –Center of B ............................................................................................................ 103
10.1.6 Tram –Pinch Test.............................................................................................................. 104
10.1.7 Tram –Tool Probe............................................................................................................. 105
10.1.8 Tram –Lens Probe ............................................................................................................ 106
10.1.9 Validation ..........................................................................................................................106
10.1.10 Tramming Tips............................................................................................................... 107
10.2 Manual Commands................................................................................................................... 108
10.2.1 M Code List........................................................................................................................108
10.2.2 Manual Axis positioning.................................................................................................... 110
10.2.3 Spindle Command............................................................................................................. 110
10.3 Spare Parts and Consumables...................................................................................................111

User Manual –eSX
OptiPro Systems, LLC. Page 6 of 111 Last Modified: 8/27/2014
2Contacting OptiPro
Main Office
OptiPro Systems
6368 Dean Parkway
Ontario, NY 14519
Phone: [phone]
Fax: [phone]
Website: www.optipro.com
For Service and Parts
Contact: Service Coordinator
Email: [email protected]m
For Sales
Contact: Sales Coordinator
Email: [email protected]
For Process and Technical Support
Contact: Advanced Processes Development (APD) Lab
Email: [e-mail]

User Manual –eSX
OptiPro Systems, LLC. Page 7 of 111 Last Modified: 8/27/2014
3Document Revisions
The following is a summary of changes to this document.
Table 3-1: Document Revision Summary
Release Dated
Changes
2014, August
Initial Release

User Manual –eSX
OptiPro Systems, LLC. Page 8 of 111 Last Modified: 8/27/2014
4Safety
Safe usage of the machine requires careful adherence to all safety protocols as specified in this manual.
In order to ensure that all protocols are followed, the machine operator must be trained in all
operational aspects of the equipment. Operator safety is the number one priority at all times. Standard
shop safety protocols should always be observed to minimize mechanical, electrical, and chemical
hazards.
4.1 Employer’s Responsibilities
It is the employer’s responsibility to provide a safe working environment for all employees working with
and around the machine. This includes:
Keeping the working area well illuminated.
Training operators in all aspects of the operation of the machine.
Keeping this manual clean, near the machine, and accessible to the operator.
Following all relevant codes and regulations required by local or national regulatory bodies.
4.2 General Safety Concerns
4.2.1 Personal Safety
The following precautions should be taken when working in or around the machine to avoid severe
injury or death:
When working inside the machine make sure that all motion is disabled by powering down
the machine and turning off the main air valve (See Section 6), and follow proper lock-
out/tag-out procedures.
Never leave a loose part or tool in the work area.
Avoid using any tools in pinch points when possible.
Safety glasses must be worn at all times.
Loose fitting clothing, long sleeves, neckties, jewelry and other objects or clothing that could
become caught by moving parts must not be worn.
Rings, watches, and other jewelry can scratch or otherwise damage delicate machine
components and should not be worn.
Long hair must be tied back.
Always wear closed-toe footwear with a good quality tread.
Avoid walking through or standing in water, coolant, or other spills. Clean up any spills
immediately following precautions outlined in the relevant MSDS.

User Manual –eSX
OptiPro Systems, LLC. Page 9 of 111 Last Modified: 8/27/2014
4.2.2 Electrical Safety
All inspection and repair of any electrical components should be done by a qualified electrician. During
electrical repair, the power should be turned off and locked out. It must always be assumed that a
component is powered up when working with complex electronic systems.
4.2.3 Pneumatic Safety
Only a qualified technician should attempt to fix or adjust any component of the pneumatic system.
During the repair; the air system should be turned off and locked out.
4.2.4 Chemical Safety
All chemicals must be handled as specified by their Material Safety Data Sheets (MSDS). The MSDS can
be found in the Appendix of this manual if applicable.
4.3 Safe Operation of the Machine
This machine includes many safety features, however, the following guidelines must also be observed:
Never operate the machine with any doors open or safety guards removed, disabled or
bypassed.
Remove or properly secure all loose tools and work pieces before operating the machine.
Keep hands and all other body parts outside of the machine when moving any axis or
spindle.
Use reduced feed rates and extreme caution if a manual axis jog is necessary.
Never aim or adjust coolant nozzles while spindles are moving.
Clean all coolant leaks or spills immediately following precautions outlined in the relevant
MSDS.
Do not tamper with, override, remove, or otherwise hinder the functionality of safety
equipment installed on the machine.
Personal injury or equipment damage can be avoided when operating the machine as
designed.
Always turn the chiller off before service or maintenance.

User Manual –eSX
OptiPro Systems, LLC. Page 10 of 111 Last Modified: 8/27/2014
4.4 In An Emergency
The emergency stop button is located on the operator control panel. When the emergency stop button
is pressed all machine motion and spindle motion is shut down. The controller, however, remains active
and the software functions may be used. Once the reason for the Emergency Stop has been determined
and corrected, normal operations may resume by turning the EMERGENCY STOP button clockwise until
it releases from its locked position. The RESET button must then be pressed to clear the error bar (found
in the top right corner of the display).
IN AN EMERGENCY SITUATION:
Press the EMERGENCY STOP button.
In the case of serious injury, fire, or other hazardous conditions, IMMEDIATELY CONTACT
YOUR LOCAL EMERGENCY RESPONSE PROFESSIONALS.
If necessary, switch off the main power disconnect on the rear of the machine and the main
air supply at the utility control panel. It is preferred to follow the instructions in Section 6 to
properly shut down the machine.
Follow your company’s procedures and policies for emergency reporting, response,
resolution, and documentation.
Once the cause of the emergency has been resolved the procedure for restarting the
machine can be found in Section 6 of this manual.