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

User Manual –ePX 200
OptiPro Systems, LLC. Page 3 of 60 Last Modified: 7/30/2014
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

User Manual –ePX 200
OptiPro Systems, LLC. Page 4 of 60 Last Modified: 7/30/2014
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

User Manual –ePX 200
OptiPro Systems, LLC. Page 5 of 60 Last Modified: 7/30/2014
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: [email protected]m

User Manual –ePX 200
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

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

User Manual –ePX 200
OptiPro Systems, LLC. Page 8 of 60 Last Modified: 7/30/2014
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, 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).

User Manual –ePX 200
OptiPro Systems, LLC. Page 9 of 60 Last Modified: 7/30/2014
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.

User Manual –ePX 200
OptiPro Systems, LLC. Page 10 of 60 Last Modified: 7/30/2014
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