OptiPro Systems ePx 200 User manual

User Manual –ePX 200
OptiPro Systems, LLC. Page 1 of 60 Last Modified: 7/30/2014
OptiPro Systems, LLC.
User Manual –ePX 200

User Manual –ePX 200
OptiPro Systems, LLC. Page 2 of 60 Last Modified: 7/30/2014
1Contents
2Contacting OptiPro................................................................................................................................ 5
3Document Revisions.............................................................................................................................. 6
4Safety .................................................................................................................................................... 7
4.1 Employer’s Responsibilities........................................................................................................... 7
4.2 General Safety Concerns............................................................................................................... 7
4.2.1 Personal Safety...................................................................................................................... 7
4.2.2 Electrical Safety..................................................................................................................... 8
4.2.3 Pneumatic Safety .................................................................................................................. 8
4.2.4 Chemical Safety..................................................................................................................... 8
4.3 Safe Operation of the Machine..................................................................................................... 8
4.4 In An Emergency ........................................................................................................................... 8
5Machine Overview and User Controls ................................................................................................ 10
5.1 Work Area and Machine Axes..................................................................................................... 10
5.2 Operator Panel Interface ............................................................................................................ 11
5.2.1 Jog Panel ............................................................................................................................. 11
5.2.2 Jog Pendant......................................................................................................................... 13
5.2.3 Door Interlock .....................................................................................................................14
5.2.4 Emergency Stop ..................................................................................................................14
5.3 Utility Control Panel.................................................................................................................... 15
5.4 Vacuum Workholding .................................................................................................................16
5.5 Containment ...............................................................................................................................17
5.5.1 Upper Containment ............................................................................................................ 17
5.5.2 Lower Containment ............................................................................................................17
5.5.3 Containment Safety Reminders ..........................................................................................18
5.6Slurry System and Chiller ............................................................................................................18
5.6.1 Chiller Basics ....................................................................................................................... 18
5.6.2 Slurry System Basics............................................................................................................19
5.6.3 Changing Between Slurry Types.......................................................................................... 20
5.6.4 Cleaning the Containment .................................................................................................. 20

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5.7 Electrical Cabinet A/C Unit..........................................................................................................23
5.8 Pneumatic Automatic Axis Greaser ............................................................................................ 23
5.9 Work and Tool Holding Chucks ...................................................................................................24
6Start Up, Shut Down, and Emergency Recovery Procedure ...............................................................25
6.1 Startup ........................................................................................................................................ 25
6.1.1 Initial Power Up................................................................................................................... 25
6.1.2 Resuming From E-Stop or Auto Off..................................................................................... 25
6.2 Shutdown....................................................................................................................................26
6.2.1 Retaining Main Power......................................................................................................... 26
6.2.2 Full Power Down ................................................................................................................. 26
6.3 Emergency Stop .......................................................................................................................... 26
6.3.1 When to press E-STOP ........................................................................................................ 26
6.3.2 Returning machine to normal operation ............................................................................26
7Creating and Running Programs ......................................................................................................... 27
7.1 Screen Layout.............................................................................................................................. 27
7.2 Jump To… ....................................................................................................................................28
7.3 P-Series Submenu .......................................................................................................................28
7.4 Manual Jog Mode........................................................................................................................ 29
7.5 Automatic Mode ......................................................................................................................... 30
7.6 Settings Screen............................................................................................................................ 31
7.7 Creating a New Job ..................................................................................................................... 33
7.8 Loading a Job from File ............................................................................................................... 37
7.9 Creating the Tram Check Program.............................................................................................. 40
8Error Recovery and Troubleshooting ..................................................................................................42
8.1 Slurry Flow Fault ......................................................................................................................... 42
8.1.1 Reading the Flow Monitor ..................................................................................................42
8.1.2 Changing the Required Flow Rate....................................................................................... 42
8.1.3 Cleaning if Necessary .......................................................................................................... 42
8.2 Z-Axis Over Travel at Cycle End................................................................................................... 43
8.3 Recovering from Error Messages................................................................................................ 43

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9Machine Maintenance ........................................................................................................................45
9.1 Daily Maintenance ......................................................................................................................45
9.1.1 Start of Shift ........................................................................................................................45
9.1.2 End of Shift.......................................................................................................................... 45
9.2 Weekly Maintenance ..................................................................................................................45
9.3 Monthly Maintenance ................................................................................................................ 46
9.4 Semi-Annual Maintenance.......................................................................................................... 46
9.5 Yearly Maintenance ....................................................................................................................46
9.6 Replacing the Lower Rotary Union ............................................................................................. 46
10 Appendices.......................................................................................................................................... 48
10.1 Tramming....................................................................................................................................51
10.1.1 Tramming Tips..................................................................................................................... 51
10.1.2 Checking Hydraulic Chuck Runouts..................................................................................... 51
10.1.3 Starting the Tram Sequence and Checking B-Zero (Vertical Alignment) ............................ 52
10.1.4 Spindles align (X- and Y-Axis Alignments) ........................................................................... 54
10.1.5 Checking Tram Ball Runout ................................................................................................. 55
10.1.6 Finding Center of the B-Axis................................................................................................ 55
10.1.7 Finding Z-axis Tool Length................................................................................................... 57
10.1.8 Finding the Z-axis Chuck-to-Chuck Distance .......................................................................58
10.2 Manual Commands..................................................................................................................... 59
10.2.1 Manual Axis positioning...................................................................................................... 59
10.2.2 Spindle Command...............................................................................................................59
10.3 Spare Parts and Consumables.....................................................................................................60

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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: [email protected]m

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OptiPro Systems, LLC. Page 6 of 60 Last Modified: 7/30/2014
3Document Revisions
The following is a summary of changes to this document.
Table 3-1: Document Revision Summary
Release Dated
Changes
2014, July
Initial Release

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4Safety
Safe usage of the machine requires careful adherence to all safety protocols 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, but 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 slurry nozzles while spindles are moving.
Clean all coolant leaks or spills immediately following precautions outlined in the relevant
MSDS (See Appendix).
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, slurry, and coolant systems off before service or maintenance, if
applicable.
4.4 In An Emergency
The emergency stop button is located on the operator control panel. When emergency stop 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).

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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.
Figure 5-1: Machine Front View
5.1 Work Area and Machine Axes
The ePX200 has 5 different axes of movement. Figure 5-2 is an illustration that shows the direction for
each axis.
Figure 5-2: Machine Axes
C-Axis
Z-Axis
B-Axis
Y-Axis
X-Axis
Tool
Spindle
Upper
Containment
Lower
Containment
Work Spindle
Z-axis
Screen
Bellows
Holder

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5.2 Operator Panel Interface
The ePX200 is equipped with a touch screen interface and may come with an external keyboard.
Figure 5-3: Operator Panel
5.2.1 Jog Panel
Figure 5-4: Jog Panel
1
2
3
5
6
7
8
9
10
11
12
13
14
15
16
17
Not used on
OptiPro
equipment
21
18
19
20
4

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OptiPro Systems, LLC. Page 12 of 60 Last Modified: 7/30/2014
Table 5-1: Jog Panel Button Descriptions
Button Label
Description
1
Left Door (Open/Close)
Operates the left-hand containment door
2
Right Door (Open/Close)
Operates the right-hand containment door
3
Air Blast (On/Off)
Air blast through the polisher spindle at cycle end. Tool must have
a thru hole or damage to machine could occur.
4
Vacuum (On/Off)
Vacuum for work spindle or bladder
5
Slurry Auto (On/Off)
Automatic slurry feed during cycle
6
Slurry Recirculation (On/Off)
Agitates slurry, pump runs continuously
7
Slurry Manual (On/Off)
Manually operates the slurry solenoid
8
Auto Mode
Activates CNC Auto Mode
9
Manual Mode
Activates CNC Manual Mode
10
MDI Command
Activates MDI command Mode
11
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.
12
Lights (On/Off)
Workspace lighting
13
Servos
Turns Servos on if they are off
14
Cycle Start
Starts the current loaded program
15
Motion Stop
Motions stop on all axes. DOES NOT STOP SPINDLES.
16
Jog Mode Select
Select between continuous and incremental jog modes
17
Feed Rate Select
Feed rate can be over ridden during any continuous motion in any
software mode. DOES NOT AFFECT SPINDLES.
18
Zero
Axis Reference (see Section 6)
19
Single
Single Block Processing
20
Reset
Resets a part program or error condition
21
Axis Jog Buttons
Manually move machine axes

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5.2.2 Jog Pendant
Figure 5-5: 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 5-6: Door Interlock Selector Switch
5.2.4 Emergency Stop
The EMERGENCY 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 5-7: Emergency Stop Button
Twist in the direction of the arrows to release the button. Pressing RESET then SERVOS on the jog panel
is also required to return the machine to a fully operational state.

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5.3 Utility Control Panel
Figure 5-8: Pneumatics Control Panel
The pneumatic panel is home to all of the air regulators and switches for the ePX machine. They are set
when your machine is first installed by OptiPro in your facility, and should not require further
adjustment.
Main Air
Regulator
Main Air
Valve
Air Prep
Regulator filter
Air Prep Mist
Separator Filter
Vacuum
Trap Tube
Vacuum
Tube Valve

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5.4 Vacuum Workholding
The Vacuum Drain Tube (in Figure 5-8) collects the small amount of slurry that commonly leaks into the
vacuum system. The purpose of the vacuum drain tube is to collect this fluid before it can get to and
harm the vacuum pump. When the vacuum drain tube gets close to being filled, it must be emptied
using the drain valve at the base, in order to protect the vacuum pump. The vacuum trap tube will be
filled with unfiltered slurry. It must be drained into a container and disposed of according to its MSDS.
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, off or partially on. The Vacuum Gage display will show the instantaneous
vacuum level in inHg. The vacuum circuit contains the Vacuum Safety Cup which will fill up only if the
vacuum trap tube overfills, and will shut off any vacuum going to the pump so the pump will not be
damaged.
Figure 5-9: Vacuum Work Holding Controls
Vacuum
Lever Valve
Vacuum Gage
Vacuum Safety
Cup

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5.5 Containment
5.5.1 Upper Containment
The upper containment of the machine is stationary. Maintenance items for the upper containment can
be found in Section 9: Machine Maintenance.
5.5.2 Lower Containment
The lower containment tray moves with the x- and y-axes of the machine. The lower tray is fitted with
quick-disconnect hose fittings for easy removal and cleaning. The hose fittings automatically lock when
the handles are in the “closed” position (See Figure 5-14). Depress the red button to release them.
Figure 5-10: Lower Containment Tray Stabilizers
The containment is set up to drain properly before each install. This may change with regular machine
use. If drainage problems occur, the following methods should be used to correct the issue:
Check that no blockages exist along in the drain hoses.
Make sure that the containment drain hose coming out of the machine going to the input on
the slurry pump does not sag lower than the lid of the containment.

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If it is necessary to adjust the tilt of the tray, loosen the jam nuts on each support and
unscrew or screw the four threaded rods into the linkages to adjust the tilt until the
containment drains properly. Reduce the length of a rod if that corner is too high, and
lengthen the rod if the corner is too low. Tighten the jam nuts once the tilt creates a
sufficient slope to make the containment drain. Make sure that the upper containment
does not interfere with the lower tray after it has been adjusted.
5.5.3 Containment Safety Reminders
Never operate the machine with any doors open or safety guards removed, disabled or
bypassed.
Keep hands and all other body parts outside of the machine when moving any axis or
spindle.
The safety guidelines in section 4.3 should always be observed to prevent injury.
5.6 Slurry System and Chiller
5.6.1 Chiller Basics
The Chiller On/Off switch should always be in the “On”position. The CNC will control the power state of
the chiller automatically when Servos are on. Temperature is factory set and is not to be adjusted.
TURN OFF POWER TO THE CHILLER BEFORE ANY CHILLER SERVICE OR CLEANING AND BEFORE
DISCONNECTING ANY CHILLER LINES THROUGHOUT THE MACHINE.
Figure 5-11: Chiller Unit
Temperature
Control
Chiller
On/Off
Fill Port
Fluid Level
Gage
Air Filter

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5.6.2 Slurry System Basics
Figure 5-12: Slurry Cart with Chiller Option
Figure 5-13: Slurry Valve Assembly
Make sure that the drain hose out of the containment and the slurry tank hoses are all connected
properly before running the machine.
Output Hose to
Valve Assembly
Chiller Coil
Input/Output
Fittings
Containment
drain hose
Slurry thru
Spindle Valve
Containment
Drain Fitting
Input from
slurry cart
On/Off Valve for
Pump Output
Flow Meter
Lift lid to access
bag filter and
chiller coil

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5.6.3 Changing Between Slurry Types
When a different type of slurry is required for a process, the slurry system must be thoroughly flushed
to prevent cross-contamination of slurry types. If, for example, you are switching from a larger diamond
size to a smaller size, the larger particles could result in an uneven, rougher polish than intended. The
slurry cart pump motor can be plugged into any 120V wall outlet. Follow these steps to change slurries:
Disconnect the 1.5in quick disconnect fitting from the containment drain (Figure 5-14).
Disconnect the 0.75in quick disconnect hose from the slurry cart input on the slurry valve
assembly (Figure 5-12).
Disconnect the chiller fittings (See Figure 5-12). ALWAYS TURN OFF THE CHILLER BEFORE
DISCONNECTING.
Empty the existing slurry into a container for storage, or dispose of it safely as described by
its MSDS.
Clean the slurry filter bag by rinsing it with clean water.
Chiller coil can be removed from the tank and cleaned separately.
Fill up the slurry cart with very warm water and reattach the input and output hoses to the
machine. Let the slurry system run for a few minutes, remembering to flush the spindle line
by using the spindle-through slurry valve .
Empty the slurry cart and refill it with clean hot water. Reattach the slurry cart to the
machine, and flush the containment system several times to clean out the hose system.
Change out the flushing water as needed.
After the water has run through a few times, clean the containment with warm water and a
sponge. For some tips on cleaning the containment, see below, section 5.6.4.
When the containment and slurry lines are sufficiently clean, empty the slurry cart and clean
the filter bag.
Add new slurry. Run the slurry pump briefly to flush any remaining water in the slurry
system out. Flush the water directly into a small bucket for disposal so it doesn’t mix into
the new slurry. Remaining water will change the intended slurry concentration and could
negatively affect the polishing process.
5.6.4 Cleaning the Containment
The drain hose out of the containment is fitted with quick-disconnect hose fittings for easy
removal and cleaning. Make sure that the hoses are all drained before removing them from
the machine. Make sure that the hoses are fully reconnected before adding more slurry to
the machine. See Figure 5-12 and Figure 5-14.
The side windows removable so they can be cleaned outside of the machine if needed. Lift
the windows up and then out of the machine to remove. (Figure 5-16)