Proxxon PD 400 CNC Quick start guide

Commissioning Manual
PD 400 CNC

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Ver. 3.0
03.04.07

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Commissioning Manual PD 400 CNC
1. Some generalities in advance….....................................................................................5
2. The technology of your PD 400 CNC at a glance .......................................................6
3. View of the machine with its elements ..........................................................................8
4. CNC control MCS with operating elements..................................................................9
5. Technical data .................................................................................................................10
5.1. Lathe:........................................................................................................................10
5.2. Drives of the tool axes............................................................................................11
5.3. Software and stepping motor controllers............................................................11
5.4. Generaldata............................................................................................................12
6. Scope of delivery............................................................................................................13
7. Unpacking and setting up the machine .......................................................................13
8. Basic tips on setting up and assembling the machine..............................................14
8.3. Connecting the cabling ..........................................................................................15
8.4. Additional connection options ...............................................................................16
9. Installing the software ....................................................................................................17
9.3. Minimum hardware requirements.........................................................................17
9.4. Installation procedure.............................................................................................17
9.5. Starting the software nccad7.5 .............................................................................18
9.6. Parameter settings..................................................................................................18
9.7. The status display at the CNC control MCS.......................................................18
9.8. EMERGENCY stop / lock......................................................................................19
10.The program nccad 7.5..................................................................................................20
10.3. The integrated manual with the help system......................................................20
10.4. The structure of the "Help Topics"window.........................................................21
10.5. Search methods......................................................................................................21
10.5.1. Contents ...............................................................................................................21
10.5.2. Index.....................................................................................................................21
10.5.3. Search..................................................................................................................21
10.5.4. Explanation of the icons.....................................................................................22
10.6. Online support.........................................................................................................22
11.Important note for working in practice .........................................................................23
11.3. Simple stopping of the machine and the Emergency-Off switch.....................23
11.4. Safety stop, lock......................................................................................................23
11.5. Direction of rotation switch....................................................................................23
11.6. Room EMERGENCY Off.......................................................................................23
12.First steps.........................................................................................................................24
12.3. Simple test of the machine....................................................................................24
13.Fundamentals on working with the machine ..............................................................26
13.3. Fundamentals on turning and the PD 400 CNC lathe ......................................27
13.3.1. Straight turning....................................................................................................27
13.3.2. Grooving and parting..........................................................................................27
13.4. Various cutting tools and their properties...........................................................28
13.4.1. Roughing tools (1)..............................................................................................28
13.4.2. Finishing or pointed tools (2).............................................................................28
13.4.3. Right (3) or left cutters........................................................................................28

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13.4.4. Parting tools (4)...................................................................................................28
13.4.5. Threading tools (5)..............................................................................................28
13.4.6. Inside turning tools (6)........................................................................................28
13.5. Inserting the cutting tool in the tool holder..........................................................29
13.6. Clamping in the lathe chuck..................................................................................30
13.7. Determining the correct spindle speed................................................................30
13.8. Setting the spindle speeds by shifting the drive belt .........................................31
13.9. Machining longer work pieces with tailstock and lathe centre .........................32
14.Service and Maintenance..............................................................................................33
In general...............................................................................................................................33
14.3. Cleaning ...................................................................................................................33
14.4. Lubrication................................................................................................................33
14.5. Adjusting the play of the guides............................................................................34
14.6. Main spindle.............................................................................................................34
15.Disposal:...........................................................................................................................36
16.Errors and their removal................................................................................................37
17.Compilation of safety notes...........................................................................................39
18.EC Declaration of Conformity.......................................................................................41
19.List of components and exploded views .....................................................................42
19.1. Assembly group 01 Headstock.............................................................................43
19.2. Assembly group 02: Bed with drive for Z axis....................................................46
19.3. Assembly group 03: Support with drive for X axis.............................................48
19.4. Assembly group 04: Tailstock...............................................................................50

1Some generalitiesin advance…
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1. Some generalities in advance…
Dear Customer!
Before you set up and commission your machine, please read through the manual and
make sure you have understood everything. This is a very complicated device which
poses the danger of injury or can cause damage to property if handled improperly.
Help to prevent this and familiarise yourself thoroughly with the machine and its
associated electronics without rushing matters.
The use of these instructions
-makes it easier to become acquainted with the device,
-prevents malfunctions due to improper handling, and
-increases the service life of your device.
Always keep these instructions close to hand.
Only operate this device with exact knowledge of it and comply with the instructions.
PROXXON will not be liable for the safe function of the device for:
-handling that does not comply with the usual intended use,
-other application uses that are not stated in the instructions,
-disregard of the safety regulations.
You will not have any warranty claims for:
-operating errors,
-lack of maintenance.
For your safety, please comply with the safety regulations at all costs.
Only use original PROXXON spare parts.
All rights reserved for further developments within the meaning of technical progress.
We wish you much success with the device.

2The technologyofyourPD 400 CNC at a glance
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2. The technology of your PD 400 CNC at a glance
Dear User,
With this PD 400 CNC lathe, you have acquired a powerful, precise processing machine
that fulfils the highest demands on ease of use, precision and reliability:
The mechanical basis is the successful PD 400 lathe from the company PROXXON.
The electrical control of the feeds of both tool axes by computer, however,
comprehensively expands the options of a conventional, i.e. manually controlled lathe:
The geometrical data of the desired work piece shape is constructed or programmed by
the NCCAD 7.5 software especially developed for this machine and can then be
reproduced automatically and any number of times on the PD 400 CNC.
The hand wheels of the PD 400 are replaced with electrical stepping motors whose force
is converted in the feed of the carriages with highly precise recirculating ball screws.
The stepping motors are actuated by the CNC control that is "operated" and monitored
bythe control computer.
All components are meticulously interfaced and thus offer optimum performance and the
basis for trouble-free operation.
For this state to remain, certain knowledge of how the machine and the software is set
up is required on the one hand and the interaction of these components on the other.
That is precisely what this manual is to convey at first: Not primarily the instruction into
the many "secrets" of the CNC program, but rather a solid knowledge base on the
commissioning of the machine.
Naturally it is also necessary to generally concern oneself with the possibilities of the
program and its structure, just to be able to use the many possibilities, to be more
efficient and to prevent dangerous situations from occurring.
We have integrated an "electronic manual" within the program just for that purpose. It
contains all the necessary information in a clearly structured and comprehensively
illustrated form and goes into exhaustive detail of the possibilities offered by the
program.
This is called up by clicking the "Help" menu and then clicking "Help Topics" in the next
window.
Finally, this manual can be used as a "Help" function to solve rather concrete and
current problems with an application with the help of a sophisticated navigation window.
This omits the annoying paging back and forth in a voluminous printed work: the
answers to specific problems are found quickly and precisely.
You will find notes on how to use the "Help" function further along in this manual.
Furthermore, we offer specific notes on what you can to do to not only use the excellent
features of the machine, but to maintain it for a long time.

2The technologyofyourPD 400 CNC at a glance
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If a malfunction occurs despite all these things, the error table at the end of the manual
will provide some help. We will also offer direct assistance in case of particularly
stubborn cases.

3View of the machine with its elements
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3. View of the machine with its elements
1Main spindle
2Lathe chuck
3Multiple tool holder
4Gearbox
5Machine base
6Tailstock
7Drive for Z axis
8Spindle for z axis
9Position switch z axis
10
Drive for X axis
11
Spindle for x axis
12
Position switch x axis
13
Support
14
Cross slide
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
Operational display
23
Multiple-contact switch for speed adjustment
24
Speed table
25
Flange surface for milling unit PF 400 (optional)
26
Travelling lathe centre
26
Ring gear drill chuck
27
Chuck guard
28
Cutting tool
30
Key for chucks
31
Key for lathe chuck
32
Allen key
33
Drill holes for fastening to table

4
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4. CNC control MCS with operating elements
Frontside:
Rear:
Plug Handwheel Connectors Status indicator "Emergency Stop" locking switch“
Connection for
communications cable to PC
25
-
pin plug to control
additional functions
(coolant pump, or similar)
Mainsconnection
Connection for
lathe mains
connection
Master
switch
Connection sockets for the plugs
of the stepping motors
Connection for rotary
pulse generator fo cut
threads(accessories)
USBconnection

5Technical data
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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
Machinebase: Cross-ribbed surface, high-quality cast iron with ground
prismatic guide
Spindle: Oversized 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 RÖHM-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

5Technical data
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5.2. Drives of the tool axes
Spindle drive Z axis
(Leading spindle, longitudinal drive,
support):
Recirculating ball screw with 4mm pitch, effective
diameter 12mm. Stepping motor 1.8A, holding torque
50Ncm
Traverse path: 300mm
Spindle drive X axis
(Transverse drive, support):
Recirculating ball screw with 2mm pitch, effective diameter 8mm. Stepping motor 1.8 A, holding torque 50
Ncm
Traverse path: 70mm
Activation of stepping motors:
Through CNC control unit (included)
Power supply:
Mains unit, output 35V (included)
5.3. Software and stepping motor controllers
Power supply
230V +-5%
Power consumption
min 150W
Gate
Serial interface -Connection cable to PC included
Stepping motor controller
Current control, pulse width modulation Current reduction during standstill, clocking independent
ofPC,microstepping

5Technical data
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5.4. General data
Ambientconditions:
5 -40°C (Class 3K3), max.60% relative humidity
User group
Persons as of 14 years of age

6Scope of delivery
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6. Scope of delivery
1Qty. Lathe with attached stepping motors
1Qty. CNC control unit MCS
1Qty. CD with program software (including electronic manual)
1Qty. Mains cable for CNC control unit MCS
1Qty. Connecting cable for computer / CNC control unit MCS
1Qty. Three-jaw chuck (Ø 100mm)
1Qty. Travelling lathe centre
1Qty. Ring gear drill chuck (clamped up to 10mm)
1Qty. Operating tool
1Qty. Multiple tool holder with 2 tool holder elements
1Qty. Three-jaw chuck (Ø 100mm)
1Qty. Lathe chuck guard
7. Unpacking and setting up the machine
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
Delivery".
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
CN out of the package as illustrated in the figure on
the right.

8Basic tips on setting up and assembling the machine
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8. 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
configuration of the
components is
illustrated in the
schematic figure on the
right.
The setup site must be
level and sufficiently
stable to absorb the
vibrations that occur
during work. The
machine must be
fastened to a fixed,
level underlay using
the drill holes intended
for this purpose.
Please make sure the mains cable is outside the hazard area and cannot be crimped or
otherwise damaged.
Mount the lathe chuck with its 3 screws on to the main spindle. Make sure that the seat
of the chuck is free from dirt and that the chuck is properly centred.
Please also read the separate, enclosed clamping chuck instructions!
Please note:
All blank metal parts of the machine are delivered conserved with corrosion protection.
This protection is not intended as lubrication but only as conservation and must be
removed before first use, such as with a lint-free cloth saturated with petroleum.
All guides must be checked, and in rare cases adjusted as necessary. (See chapter
"Maintenance").
The blank guides and spindles must then be oiled with suitable machine oil.

8Basic tips on setting up and assembling the machine
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8.3. Connecting the cabling
Caution!
Connect the mains cable to the CNC control MCS at the very last and make sure the
mains switch at the rear of the CNC control is set to "O", meaning switched off! Do not in
any case switch on any electrical device, be it the computer, the CNC control, or the
machine itself before the connection of the cables is completed!
The connection sockets on the CNC control are all located at the rear of the housing:
The connection cable of the two stepping motors is inserted in the provided sockets of
the CNC control. They are identified accordingly as "X" and "Z" of the respective CNC
axes. For your information: The X axis is the axis diagonal to the machining direction,
and the Z axis is the axis that is longitudinal to the machining direction.
The mains cable of the lathe is inserted in the provided socket at the rear of the CNC
control. The main spindle motor is switched on and off by the CNC programs.
Please leave the insertion of the mains plug of the computer and the CNC control in the
mains socket outlet for the very last.
The communications cable included in the delivery is used to connect the CNC control to
the control computer. It is inserted in the appropriate socket at the control and connected
to a serial interface at the computer.
These are often called "serial" or "COM" and usually have 9 pins. If the connector at
your computer has 25 pins instead of 9, you will need a corresponding adapter.

8Basic tips on setting up and assembling the machine
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8.4. Additional connection options
Several additional functions can be electronically
driven upon request, such as a coolant pump,
working light, or similar.
The inside of the control has centre-zero relays
whose connections can be executed through the
25-pin socket at the rear of the control. Each
relay has three pins that are identified by the
letters A, R and G. These letters stand for:
A: Make contact
R: Break contact
G: Common contact
The circuit design mode of operation is illustrated
in the picture on the right; both Relays 3 and 4 are
available.
Ground
+ 24 Volt
Makecontact
Common
Brake contact

9Installing thesoftware
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9. Installing the software
9.3. Minimum hardware requirements
The NCCAD software is very comprehensive and powerful, therefore there are certain
minimum requirements to the utilised control computer:
Simple operation and controller PC:
•Windows 98/2000/XP
•RAM: at least 16MB
•Free hard disk capacity: at least 60MB
•Graphics resolution 1024 x 768 pixel
Extended functionality (OpenGL simulation, manual control):
• Graphics resolution 1024 x 768 pixel
• Fast graphics card with chipset, at least Gforce4 or similar
9.4. Installation procedure
The software is included on the
enclosed CD. After being
inserted in the drive, the
Explorer will display the
following image:
Double-click the "Installation"
directory, then "English", and
finally "Setup Standard". This
starts the installation procedure.
Simply follow the entry
instructions.
The program is now written to a
directory called "Kosy 75" that
contains the necessary files.
The program icon will be
installed automatically to your
desktop.

9Installing thesoftware
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9.5. Starting the software nccad7.5
After the program was successfully installed, it can be started just as you are used to
from other applications on your computer. Simply select the "Start" button on the screen
with your cursor and select the desired file in the program title bar. It's even easier if you
simply click the program icon.
9.6. Parameter settings
The specific machine data (travel paths, limit values, working conditions, equipment,
etc.) are stored in the parameter files. These can be recognised by the ending "*.ini" in
the Windows Explorer.
Caution!
The values stored there are especially adapted to operation with the PD 400 CNC and
should not be changed without experience and knowledge of the program.
No changes may be made here especially before commissioning! False entries can lead
to system errors and dangerous operating states!
9.7. The status display at the CNC control MCS
There are three different coloured lights on the panel of the
CNC control; see picture. They indicate the operating status of
the CNC lathe.
•Yellow: Caution (in action) –command execution
running,even if the axis or spindle are not currently moving. Do not reach into the
CNC machine; it is possible that the command "pause" is running down and
machining can continue at any time.
•Green: Free (to receive commands) –Communications with the PC is
possible, commands can be received.
•Red: Locked (or error) –The movement and command receipt of the CNC
machine are locked. This could be the case if the EMERGENCY stop was
activated or if an error occurred in the system (e.g.: communications error, PC no
longer completely functional).
•All: After the CNC machine is switched on as a lamp test for a period of
approx. 1 second.

9Installing thesoftware
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9.8. EMERGENCY stop / lock
The EMERGENCY stop is used to lock the CNC machine for
command receipt and for command execution. Only the red status
lamp will light up in the "Lock" position. The lock can be useful, for
example, to prevent the execution of an unintentionally entered
movementcommand.
The lock is removed when the switch is set to "On" and the CNC
machine is ready for operation again. This is signalled by the
glowing green light.

10Theprogram nccad 7.5
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10. The program nccad 7.5
The program nccad 7.5
generates the control
program from the work
piece geometry data, co-
ordinates
communications with the
interface control
computer/CNC control,
the CNC axes, the
generation of the step
pulses, etc. etc.
The control "translates"
the signals into
commands for the
stepping motors.
The options the program
offers are manifold; the
scope is rather large.
Therefore, one should
consider that it takes some time until one has a complete overview of all the possibilities
of the program and can confidently move between the many functions.
Much practice, and naturally some patience is helpful to be able to use the software
thoroughly.
For the beginning it is helpful to know what the program can even do and that it owes its
capability in principle to several "Individual" functions.
On the one hand, it is utilised to create a part in electronically drawn form (CAD), and on
the other hand it then generates the control commands from that geometry for the
control (CAM) which it then processes as electric signals for the motors of the spindle
drives.
10.3. The integrated manual with
the help system
We deliberately refrained from using a
printed form of the manual and, as
already mentioned above, have
consolidated the necessary contents in a
help function within the program itself. A
much more practical and neat possibility
than having to handle a mountain of
paper: The structure of the topics has