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

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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

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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

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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

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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]

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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

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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.

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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.

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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.

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5Machine Overview and User Controls
This section provides a brief description of the components, controls, and features this machine is
available with. Some of the features shown in this manual are options and may not be included in your
machine.
Work
Area
Operator
Panel
Main
Door
Coolant
Tank

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Figure 5-1: Machine Front View
Figure 5-2: Left-Rear Machine View
Figure 5-3: Right-Rear Machine View
Main Air
Entry
Electrical
Cabinet A/C
Main Power
Disconnect
Vacuum
Pump
Left Side
Right Side
Side Access
Door
Side Access
Door
Centrifuge
Coolant Through
Spindle Filters
Pinch Valve
Assembly
Grease
Pump
Pneumatics
Panel
Chiller

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5.1 Work Area and Machine Axes
The eSX has 5 different axes of movement. Figure 5-4 shows the direction for each axis and labels to
spindles.
Figure 5-4: Machine Spindles and Axes
NOTE: If the machine is a twin spindle grinding machine, then the left spindle is referred to as S1 and the
right spindle is referred to as S3. A single spindle grinding machine refers to the spindle as the left spindle
or S1.
Tool Spindle
Work Spindle

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5.2 Operator Panel Interface
The machine is equipped with a touch screen interface.
Figure 5-5: Operator Panel
5.2.1 Jog Panel
Figure 5-6: Jog Panel
16
17
Not used on
OptiPro
equipment
15
21
22
18
19
20
Touch Screen
Jog Panel
1
3
4
5
6
7
8
9
13
14
10
11
12
2

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Table 5-1: Jog Panel Button Descriptions
Button Label
Description
1
Tool Changer Bypass (On/Off)
Disables all tool changer functions and ignores tool changer errors.
2
Air Blast (On/Off)
Activates foot switch to trigger air blast through the lower work
spindle to assist in part removal. Part fixture must have a thru hole;
else damage to machine could occur.
3
Vacuum (On/Off)
Activates vacuum for work spindle part holding. Vacuum level can
be monitored and adjusted from the control panel, see Section 5.3.
4
Left Tool (Instantaneous)
Release Left Spindle Tool (Release Enable must be active). WHEN
ALL MOTION HAS STOPPED, HOLD THE TOOL FIRMLY BEFORE
PRESSING BUTTON SO TOOL DOES NOT DROP AND CAUSE DAMAGE.
5
Release Enable (On/Off)
Enables ability to release Left and Right tools from spindles.
6
Right Tool (Instantaneous)
Release Right Spindle Tool (Release Enable must be active). WHEN
ALL MOTION HAS STOPPED, HOLD THE TOOL FIRMLY BEFORE
PRESSING BUTTON SO TOOL DOES NOT DROP AND CAUSE DAMAGE.
7
Coolant Auto (On/Off)
Automatic coolant feed during cycle.
8
Coolant Manual (On/Off)
Manually operates the coolant solenoid, turning coolant on and off.
9
Auto Mode
Activates CNC Auto Mode for running programs (Section 7.4).
10
Manual Mode
Activates CNC Manual Mode (Section 7.3).
11
MDI Command
This button is not needed in the G-Series software.
12
Auto Off
Used to power off servos and coolant at cycle end +5 minutes. To
activate, select “Auto Off” during a program in AUTO Mode. Air and
Vacuum will remain active. Press again to deactivate if needed.
13
Lights (On/Off)
Workspace lighting.
14
Servos
Turns Servos on if they are off.
15
Axis Jog Buttons
Manually move machine axes.
16
Jog Mode Select
Select between continuous and incremental jog modes.
17
Feed Rate Select
Feed rate can be overridden during any manual or automatic
motion in any software mode, except during the referencing
routine. Feed Rate Override does not affect spindle speed.
18
Zero
Axis Reference (see Section 6).
19
Single
Single Block Processing (Used for machine diagnostics).
20
Reset
Resets a part program or error condition.
21
Cycle Start
Starts the currently loaded program.
22
Motion Stop
Stops motion on all axes. DOES NOT STOP SPINDLE ROTATION.
CYCLE START can be pressed to continue program.

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5.2.2 Jog Pendant
Figure 5-7: Hand Wheel
Button
Description
Axis Selection
Selects which axis on the machine to move.
Feed Rate Control
Controls the feed rate of the selected axis.
Jog Wheel
The JOG WHEEL can be used to move all axes (X, Y, Z, 4, or 5). When Axis
Selection is on 4, the B-axis can be rotated. When Axis Selection is on 5,
the work spindle (S2) can be rotated.
Emergency Stop
The EMERGENCY STOP (E-STOP) button should be used to stop the
machine if there is any danger to the operator, machine, or process. See
Section 6.3 for more information.
+ / - Movement
Press to move the selected axis in the + or –direction.
See Fagor manual for additional information
Jog Wheel
Axis Selection
Feed Rate
Control
Emergency
Stop
+/- Movement

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5.2.3 Door Interlock
The DOOR INTERLOCK simply locks or unlocks the main door of the machine. While in the Active
position the door is locked and all controller functions are available for use. Override unlocks the door
and only allows the most basic functions such as jogging, mainly for cleaning or service.
Figure 5-8: Door Interlock Selector Switch
5.2.4 Emergency Stop
The EMERGENCY STOP (E-STOP) button should be used to stop the machine if there is any danger to the
operator, machine, or process. Once the button is pressed all motion will stop and servos will be turned
off. Function of the operator panel cannot be restored until the E-STOP button is released.
Figure 5-9: Emergency Stop Button
Twist in the direction of the arrows to release the E-STOP button. Pressing RESET then SERVOS on the
jog panel is also required to return the machine to a fully operational state. See Section 6.3 for more
information.

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5.2.5 Coolant Recirculation Control
The coolant recirculation system can be turned on and off by the buttons on the side of the operator
panel.
Figure 5-10: Coolant Recirc On/Off, USB ports
5.2.6 USB ports
On the side of the Control Panel are standard USB ports (Figure 5-10) that connect to the CPU. These
ports can be used, just like on a personal computer, to connect peripheral hardware or memory sticks
for data transfer.
Caution: Never run processing programs directly from a USB drive; always copy programs to the internal
storage before running.
Coolant Recirc
On
Coolant Recirc
Off
USB Ports

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5.3 Utility Control Panel
The components and controls shown here are described in various sections throughout this manual.
Figure 5-11: Utility Control Panel
The pneumatic panel houses all of the air regulators and switches machine. They are set when your
machine is first installed by OptiPro in your facility, and should not require further adjustment.
Main Air
Regulator
Air Prep Mist
Separator Filter
Air Prep
Regulator Filter
Main Air
Valve
Vacuum
Drain Tube

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5.4 Vacuum Work Holding
The Vacuum Drain Tube (in Figure 5-11) collects the small amount of coolant that commonly leaks into
the vacuum system. The purpose of the vacuum drain tube is to collect this coolant before it can get to
and harm the vacuum pump. When the vacuum drain tube gets close to being filled with coolant, it must
be emptied using the drain valve at the base, in order to protect the vacuum pump.
Caution: When draining the vacuum drain tube, vacuum suction will be lost at the work piece. Be sure
the machine is not running and that the work piece is adequately supported or removed from the
machine before draining the vacuum drain tube. Remember to close the drain tube when finished.
The work holding vacuum level can be controlled by a lever valve on the front of the machine. The lever
valve will turn the vacuum on or off. The Vacuum Gage display below will show the instantaneous
vacuum level in inHg. The vacuum circuit contains the Vacuum Safety Cup which will fill up in a situation
where the vacuum drain tube overfills, and will shut off any vacuum going to the pump so the pump will
not be damaged.
Figure 5-12: Vacuum Work Holding Controls
Vacuum
Lever Valve
Vacuum Gage
Vacuum Safety
Cup