Proxxon PD 400 Quick start guide

Commissioning Manual
PD 400 CNC-ready
NO 24 504

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Commissioning Manual PD 400 CNC-ready
1. Something general in advance: ..............................................................................3
2. The technology of your PD 400 CNC-ready at a glance .........................................4
3. Scope of supply......................................................................................................4
4. View of the machine with its elements....................................................................5
5. Technical data........................................................................................................6
5.1. Lathe:.....................................................................................................................6
5.2. Drives of the tool axes............................................................................................7
5.2.1. Spindle drive Z-axis................................................................................................7
5.2.2. Spindle drive X-axis................................................................................................7
5.2.1. Pin assignment of the Sub D-9 connector...............................................................7
6. Unpacking and setting up the machine...................................................................8
7. Basic tips on setting up and assembling the machine.............................................9
7.1. Room EMERGENCY Off........................................................................................9
8. Basics of working with the machine........................................................................9
8.1. Fundamentals on turning and the PD 400 CNC-ready lathe.................................10
8.1.1. Straight turning.....................................................................................................10
8.1.2. Grooving and parting............................................................................................10
8.2. Various cutting tools and their properties..............................................................11
8.2.1. Roughing tools (1)................................................................................................11
8.2.2. Finishing or pointed tools (2) ................................................................................11
8.2.3. Right (3) or left cutters..........................................................................................11
8.2.4. Parting tools (4)....................................................................................................11
8.2.5. Threading tools (5) ...............................................................................................11
8.2.6. Inside turning tools (6)..........................................................................................11
8.3. Inserting the cutting tool in the tool holder ............................................................12
8.4. Clamping in the lathe chuck..................................................................................13
8.5. Machining longer work pieces with tailstock and lathe centre...............................13
8.6. Determining the correct spindle speed..................................................................14
8.7. Determining the spindle speeds ...........................................................................14
8.8. Shifting the drive belt............................................................................................15
8.1. Direction of rotation switch....................................................................................15
9. Service and Maintenance.....................................................................................15
9.1. General ................................................................................................................16
9.2. Cleaning...............................................................................................................16
9.3. Lubrication............................................................................................................16
9.4. Adjusting the play of the guides............................................................................17
9.4.1. Adjusting the play of the guide of the cross slide..................................................17
9.4.2. Adjusting the play of the guide of the support.......................................................17
9.5. Main spindle.........................................................................................................17
9.6. Care and maintenance checklist...........................................................................18
10. Disposal: ..............................................................................................................18
11. Compilation of safety notes ..................................................................................18
12. EC Declaration of Conformity...............................................................................20
13. List of components and exploded views ...............................................................21
13.1. Assembly group 01 Headstock.............................................................................22
13.2. Assembly group 02: Bed with drive for Z axis.......................................................26
13.3. Assembly group 03: Support with drive for X axis.................................................28
13.4. Assembly group 04: Tailstock...............................................................................30

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WARNING
Read all safety warnings, instructions, illustrations and specifications
provided with this power tool.
Failure to follow all instructions listed below may result in electric shock, fire and l or
serious injury.
Save all warnings and instructions for future reference.
The term "power tool" used inthe safety instructions refers to mains-operated power tools
(with mains lead) or battery-operated power tools (without mains lead).
1. Something general in advance:
Please note:
The information given and knowledge imparted in this manual are indispensable for the
safe commissioning and operation of the machine and the control system!
Therefore, read the manual carefully and make sure that you have understood the
contents!
WARNING
Familiarise yourself with the potential dangers of the machine before commissioning the
selected software control machine tool configuration! Observe all safety instructions from
this machine tool and from the manufacturer of the selected control. Note that the user
alone is responsible for safety when operating the application.
DANGER
In case of damage, do not touch any parts of the installation, disconnect the power supply
and send the parts concerned to a qualified service workshop, ideally to our central
service.
WARNING
Observe the electrical values specified in the technical data for controlling the stepper
motors of the machine tool. Make sure that the electrical configuration of the control is
compatible with the electrical data of the motors!

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2. The technology of your PD 400 CNC-ready at a glance
Dear User,
With the PD 400 CNC-ready lathe, you have acquired a powerful, precise processing
machine that meets high demands on operability, precision and reliability:
The mechanical basis is the proven PD 400 lathe from PROXXON.
However, the electronic control of the feeds of the two tool axes with a computer
comprehensively extends the possibilities of a conventionally, i.e. manually controlled
lathe:
The handwheels of the PD 400 are replaced by electric stepper motors, whose force is
converted into feed of the tool slides by means of high-precision recirculating ball screws.
The stepper motors are controlled by the selected CNC control, which is "operated" and
monitored by the control computer.
3. Scope of supply
1 pc. Lathe with attached stepper motors
1 pc. Three-jaw chuck (Ø 100 mm)
1 pc. Travelling centre punch
1 pc. Gear rim drill chuck (up to 10 mm clamping)
1 pc. Operating tool
1 pc. Multiple steel holder with 2 steel holder elements
1 pc. Rotary chuck guard

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4. View of the machine with its elements
1
Main spindle
2
Lathe chuck
3
Motor
4
Gearbox
5
Machine base
6
Tailstock
7
Drive for Z axis
8
Spindle for Z axis
9
Position switch Z axis
10
Drive for X axis
11
Spindle for X axis
12
Position switch X axis
13
Support
14
Cross slide
15
Multiple tool holder
16
Tool holder element
17
Sleeve
18
Sleeve adjusting wheel
19
Clamping screw for sleeve
20
Clamping screw for tailstock
21
Direction of rotation switch
22
Indicator light
023
Speed step switch
24
Speed table
25
Flange surface for milling unit PF 230/250/BL
26
Travelling lathe centre
27
Chuck guard
28
Cutting tool
29
Gear rim drill chuck
30
Key for drill chuck
31
Key for lathe chuck
32
Allen keys
33
Drill holes for fastening to table

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5. Technical data
5.1. Lathe:
Length between centres:
400 mm
Height of centres:
85 mm
Maximum work piece diameter:
116 mm
Machine base:
Cross-ribbed surface, high-quality cast iron with
ground prismatic guide
Spindle:
Main spindle, supported with 2 adjustable taper
roller bearings
Spindle receiver:
MK3
Spindle drill hole:
20.5 mm
Spindle concentricity:
5/1000 mm
Chuck (series):
Precise 3 jaw chuck, centrically clamped, 100 mm
diameter
Sleeve receiver:
MK2, retractable sleeve with scale
Spindle speeds:
Adjustable with switch (two-stage) and by shifting
the drive belt (three-stage)
Switch setting 1:
80 / 330 / 1400 rev/min
Switch setting 2:
160 / 660 / 2800 rev/min
Motor rating:
550 W
Motor type:
Induction motor
Size (L x D x H):
900 x 400 x 300 mm
Weight (complete):
approx. 45 kg

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5.2. Drives of the tool axes
5.2.1. Spindle drive Z-axis
Recirculating ball screw with 4mm pitch
Effective diameter 12 mm
Traverse path: 300mm
Limit switch position: left
Motor:
Current: 1,8 A
Holding torque: 50 Ncm
5.2.2. Spindle drive X-axis
Recirculating ball screw with 2 mm pitch
Effective diameter 8 mm
Traverse path: 70mm
Limit switch position: in front
Motor:
Current: 1,8 A
Holding torque: 50 Ncm
5.2.1. Pin assignment of the Sub D-9 connector
Coil 1a
Coil 1b
Coil 2a
Coil 2b
Limit Switch

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6. Unpacking and setting up the machine
6.
Please note:
The information given in this manual and the knowledge it conveys is indispensable for
the safe commissioning and the safe operation of the machine and the controls!
Please read the manual attentively and make sure you have understood the contents!
Carefully unpack the individual components from the Styrofoam packaging. Please
check for completeness of the delivery by using the list in the chapter "Scope of
Supply".
Caution!
Do not grasp the gear case, the motors, or the cover of the motor to lift the machine
out of the Styrofoam packaging. The plastic caps could break.
Please enlist the aid of a helper to lift your PD 400 CNC-ready out of the package as
illustrated in the figure on the right.

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7. Basic tips on setting up and assembling the machine
•The machine may only be set up and operated in dry and well ventilated rooms.
•The installation surface must be level and sufficiently stable to absorb the
vibrations that occur during operation. For this purpose, the machine must be fixed
to a firm, level surface using the holes provided.
•Please ensure that the mains cable is outside the danger zone and is not crushed
or otherwise damaged!
•Mount the lathe chuck on the main spindle with the 3 corresponding screws,
making sure that the seat of the chuck is free of dirt and that the chuck is perfectly
centred.
•Please note:
All bare metal parts of the machine are preserved with a corrosion protection when
delivered. This protection does not serve as lubrication, but only as preservation,
and must therefore be washed off before first use, e.g. with a petroleum-soaked
and non-fluffy cloth.
•All guides must be checked from time to time and, if necessary, adjusted in rare
cases due to wear. (See chapter " Adjusting the play of the guides ").
•Afterwards, the bare guides and spindles must be well oiled with a suitable
machine oil.
7.1. Room EMERGENCY Off
An EMERGENCY Off switch that disconnects the power supply in the entire room must
be installed in the room where the machines are operated. This red/yellow coloured
mushroom-shaped pushbutton must be easily accessible and arranged far enough
away from the possible hazardous area.
8. Basics of working with the machine
Caution!
Before switching on for the first time, check that the screws of the lathe chuck are
correctly tightened, that the lathe chuck key is not inserted and that the support has
sufficient distance to the lathe chuck.
Caution!
Please note that due to the construction type, the motor can become very hot if left in
idle operation for a longer period. This is not an indication for a motor defect; still, it is
recommended to avoidthis operating stateand not to leave the machine unnecessarily
in idle operation.

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8.1. Fundamentals on turning and the PD 400 CNC-ready lathe
8.1.1. Straight turning
Straight turning is the type of turning whereby the cutter moves on a path parallel to
the work piece axis, the "longitudinal feed".
The cutting depth, also called "infeed" is the amount by which the cutter dips deeper
into the material for every turning cycle.
"Feed" is the distance per revolution of the work piece which the tool travels on its path.
The cutting cross-section is therefore the product of feed and cutting depth. Straight
turning is the most common machining type.
8.1.2. Grooving and parting
Grooving is the manufacture of fine grooves through radial infeeding of the cutting tool
without longitudinal feed.
If the tool is infeed so much that the work piece is thus "cut through" (meaning up to
the rotary axis or the centre of the work piece), then this is called "parted".
In principle:
The height of the cutting edge of the parting tool must be adjusted precisely to the
height of the centre of the work piece! Also, the tool must be clamped as short as
possible:
Too much free length always means deformation and susceptibility to vibrations! This
naturally applies to straight turning as well.
Use a low speed and lubricate the tool if possible with a bit of machine oil.