Rittal BC 1007 HS User manual

Perforex Service Procedures
BC 1007/1008/2007/2014 HS
January 2020
Note: Some images may differ due to machine model and equipment revisions.
Important: The maintenance procedures discussed in this manual should only be performed by
trained individuals. Extreme caution should be used when changing any machine parameter or
setting. Consult Rittal Automation Systems Technical Support prior to any change. The user takes full
responsibility for any unintended results.

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1.0 Table of Contents
1.0 Table of Contents.............................................................................................................2
2.0 Lubrication Schedule .......................................................................................................6
Cutting Fluid –Tool Lubricant .............................................................................................6
2.1.1 Recommended Lubricant.............................................................................................6
2.1.2 Checking and Filling......................................................................................................6
Rack and Pinion Lubrication system....................................................................................7
2.2.1 Recommended Lubricant.............................................................................................7
2.2.2 Checking and Filling......................................................................................................7
Pressure Plate......................................................................................................................8
Rotating Clamp system........................................................................................................9
Linear Bearings ....................................................................................................................9
2.5.1 Recommended Lubricant.............................................................................................9
2.5.2 Recommended Grease Gun .......................................................................................10
2.5.3 Grease Points .............................................................................................................10
3.0 Preventative Maintenance ............................................................................................12
Pressure Plate....................................................................................................................13
3.1.1 Pressure Roller Cleaning ............................................................................................13
3.1.2 Pressure Roller Replacement.....................................................................................14
Pressure Plate Guides........................................................................................................15
3.2.1 Cleaning......................................................................................................................15
3.2.2 Pressure Plate Removal..............................................................................................15
3.2.3 Pressure Plate Replacement ......................................................................................16
Vacuum Seal Replacement................................................................................................17
Tool Lubrication –Cutting Fluid System............................................................................18
3.4.1 Cleaning......................................................................................................................18

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3.4.2 Testing for Oil Delivery...............................................................................................18
3.4.3 Air Pressure Adjustment ............................................................................................18
3.4.4 Adjustment of the Mist Volume.................................................................................19
3.4.5 Oil Conversion from MK 150 to MK 200 ....................................................................19
3.4.6 Adjusting the Oil Mist Angle ......................................................................................20
Vacuum System .................................................................................................................21
3.5.1 Nilfisk Vacuum Canister .............................................................................................21
3.5.2 Vacuum Hose .............................................................................................................21
3.5.3 Pressure Plate Manifold.............................................................................................21
3.5.4 Chip Trap/Dropout.....................................................................................................22
3.5.5 Vacuum Seal...............................................................................................................22
3.5.6 Testing the Vacuum System –F-Test Manual Operation ..........................................23
Spindle ...............................................................................................................................23
3.6.1 Spindle Chuck.............................................................................................................23
3.6.2 Cooling Fan.................................................................................................................24
Tools ..................................................................................................................................24
Tool Breakage Sensor ........................................................................................................25
Clamping System ...............................................................................................................25
3.9.1 Panel Clamp Cleaning and Lubrication ......................................................................25
3.9.2 Enclosure Clamp Cleaning..........................................................................................25
Electrical Enclosure........................................................................................................26
3.10.1 Fan Intake and Exhaust Filters ...................................................................................26
3.10.2 Electrical Power –Incoming Voltage..........................................................................26
3.10.3 Air Pressure Cutout Switch ........................................................................................26
Resetting PM Notifications ............................................................................................27
3.11.1 Machine Parameters - Maintenance .........................................................................27

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Servo System Types –DARC 2 or E DARC C ...................................................................28
Diode check –DARC 2 Servo drives only!......................................................................29
3.13.1 Servo Power Control Module.....................................................................................29
3.13.2 Servo Drives................................................................................................................30
3.13.3 Reverse Polarity .........................................................................................................31
3.13.4 Resistance Check........................................................................................................32
Servo Power Control Module ........................................................................................33
3.14.1 Removal......................................................................................................................33
3.14.2 Replacement ..............................................................................................................35
3.14.3 Replacing V05-20-05 with V05-20-15 Module...........................................................36
Spindle Servo Drive Module ..........................................................................................38
3.15.1 Removal......................................................................................................................38
3.15.2 Replacement ..............................................................................................................41
X/Y/Z Servo Drive Modules............................................................................................42
3.16.1 Removal......................................................................................................................42
3.16.2 Replacement ..............................................................................................................45
Spindle Replacement Procedure –HSD 939..................................................................46
3.17.1 Removal......................................................................................................................46
3.17.2 Replacement ..............................................................................................................52
3.17.3 Spindle Proximity Sensors –Location and Troubleshooting......................................53
3.17.4 Spindle Sensor Adjustments ......................................................................................58
3.17.5 HSD Spindle Parts.......................................................................................................61
X-Axis Motor Replacement............................................................................................62
3.18.1 Removal......................................................................................................................62
3.18.2 Replacement ..............................................................................................................63
Y-Axis Motor Replacement ............................................................................................64

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3.19.1 Removal......................................................................................................................64
3.19.2 Removing Y-Axis Motor and Gearbox........................................................................67
3.19.3 Pinion Gear Replacement ..........................................................................................70
3.19.4 Y-Axis Motor Replacement ........................................................................................71
Preforming an Axis Master Reference...........................................................................71
3.20.1 Saving Parameters to Device and Hard Disk ..............................................................74
Calibrating the Axis Base Offset.....................................................................................75
3.21.1 Axis Alignment –Test Program..................................................................................75
3.21.2 Axis Alignment –IB Start Drilling ...............................................................................75
3.21.3 Axis Alignment –Step Operation...............................................................................76
3.21.4 Correcting the Axis Base Offset Value .......................................................................77
Air Pressure Cutout Switch ............................................................................................80
3.22.1 Pressure Switch Troubleshooting ..............................................................................80
3.22.2 Pressure Switch Electrical Checks ..............................................................................80
Pneumatic Valve Locations............................................................................................82
3.23.1 Clamping Valve Blocks................................................................................................82
3.23.2 Spindle Valve Blocks...................................................................................................83
3.23.3 Lubrication Valve Blocks ............................................................................................84
Clamping System............................................................................................................85
3.24.1 Rotating Clamps .........................................................................................................85
4.0 Perforex Error Codes......................................................................................................86
DARC2 Error Codes............................................................................................................86

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2.0 Lubrication Schedule
Cutting Fluid –Tool Lubricant
2.1.1 Recommended Lubricant
The recommended lubricant used in the Minimal Tool lubrication system is;
MK 200 Metalworking Lubricant Rittal Part Number: 4050.894
2.1.2 Checking and Filling
The cutting fluid lubrication system is located on the spindle carriage, to the right of the
spindle. Loosen the thumb screws, located under the spindle carriage, to open the cover.
Check the oil reservoir sight tube shown below to check the oil level. If oil is needed, unscrew
the metal cap on the top of the reservoir body, fill and then re-install the cap.
Note: Always keep the fluid level above 50% for best operation. Do not fill past the top of the
translucent sight tube.

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Rack and Pinion Lubrication system
2.2.1 Recommended Lubricant
The recommended lubricant used for the Rack and Pinion lubrication system is;
ISO VG 32, DIN 51524 Rittal Part Number: 4050.862
2.2.2 Checking and Filling
The rack and pinion lubrication system is located on the spindle carriage, to the right of the
spindle. Loosen the thumb screws, located under the spindle carriage, to open the cover.
Check the oil reservoir cup shown below. If oil is needed, unscrew the cup from the reservoir
body, fill to the upper Max line and then re-install the oil cup.

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Pressure Plate
The pressure plate guide shafts require a light coat of multi-purpose oil such as 3-in-1, Super
Lube or air tool oil. Clean the guide shafts before lubricating.
Note: When the compressed air to the machine is turned off, the pressure plate should move freely. If
movement is not smooth and without binds, refer to Section 2.2 for proper pressure plate
maintenance procedures.

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Rotating Clamp system
The rotating clamping system requires a light coat of multi-purpose oil such as 3-in-1, Super
Lube or air tool oil. Clean the clamp shafts before lubricating, dirt and debris can accumulate
on the clamping shafts and cause slow, hesitant movement or improper clamping.
Linear Bearings
Each axis (X, Y, Z & Enclosure table) has four linear bearings with grease inserts (16 total).
Note: It is important that only a recommended grease gun be used to grease the bearings. The
standard North American grease gun will lock on the grease fitting, removing it could tear the grease
insert out of the bearing housing.
2.5.1 Recommended Lubricant
The recommended lubricant used for the linear bearing system is;
KP2K-NLGI2, DIN 51818 Rittal Part Number: 4050.863

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2.5.2 Recommended Grease Gun
Standard North American grease guns will damage the linear bearing. If the grease gun locks
or snaps onto the grease fitting, the fitting may get torn out of the bearing housing when
attempting to remove the grease
gun. The recommended grease gun
will not “lock” onto the grease fitting,
it will seal against it when filling the
bearing. Another disadvantage with
the standard grease gun is that the
tip will not fit between the spindle
mounting plate and the Y-Axis linear
ways.
To order, contact Rittal Automation Systems technical support.
2.5.3 Grease Points
X-Axis Locations;
oTwo on the upper linear guide rail (right & left), upper end of the gantry.
oTwo on the lower linear guide rail (right & left), lower end of the gantry.

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Y-Axis Locations;
Note: These locations are difficult to access and only the
recommended grease gun will fit between the spindle
mounting plate and the linear way.
oTwo above the spindle mount plate and two
below the spindle mount plate. The lower
grease fittings are not shown in the photo.
oMoving the Y-Axis may be required to gain
access to these grease locations.
Z-Axis Locations;
Note: Removal of the spindle covers will be required to
grease the two fittings furthest from the spindle chuck.
oTwo bearings will be located on the
linear guide rail near the spindle
chuck and two on the opposite end of
the spindle, near the spindle fan.
Motorized Table for enclosure clamping;
oTwo bearings will be located forward
of the motorized table and two behind the motorized table.

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3.0 Preventative Maintenance
Preventative Maintenance Schedule
Procedure
Period
Inspect and clean the pressure plate rollers and foam suction
ring.
Daily
Check the tool lubrication system for correct operation and oil
delivery.
Daily
Insure that the incoming air pressure is at 6 bar (87psi).
Daily
Test all safety barriers & switches (light curtains, E-Stop, Rear
door switch).
Daily
Check and fill the minimal tool lubrication (MK150).
Weekly
Check and clean the tool holders and apply a light coating of oil.
Weekly
Clean spindle chuck and apply a light coating of oil.
Weekly
Check and clean the broken bit detection.
Weekly
Check and clean the light curtain sensors.
Weekly
Drain compressed air water trap.
Weekly
Check and clean the vacuum & empty the shaving bin.
Monthly
Check and clean the electrical cabinet filters.
Monthly
Check and clean all linear bearing rails.
Monthly
Check and clean all pinion racks.
Monthly
Check and clean pinion rack for enclosure clamping system.
Monthly
Remove all support pegs and inspect for excessive damage.
Monthly
Clean the machine with all purpose cleaner.
Monthly
Clean the pneumatic rotating clamps and lubricate with light oil.
Monthly
Check and fill the rack/pinion lubrication system (ISO VG32).
Quarterly
Grease the linear bearings with all synthetic grease (NLGI-2).
Quarterly
Remove all spindle covers and clean the spindle carrier.
Semi-Annual
Check the operation of the compressed air alarm switch. See
Section 6.0 - Air Pressure Cutout Switch.
Semi-Annual

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Pressure Plate
On the Perforex machine, the pressure plate requires regular attention to insure proper
operation. If the maintenance and cleaning is preformed frequently, it will operate as
designed and not damage paint or stainless. The following steps will help explain the
necessary steps that will need to be completed.
3.1.1 Pressure Roller Cleaning
Cleaning of the pressure rollers should occur multiple times per day (depending on the
amount of machine usage). Metal shavings will become lodged in the recesses of the
pressure roller and possibly stop the movement.
Use a face shield and gloves when cleaning the pressure rollers.
Focus compressed air on the center of the pressure roller hub (between the upper
and lower rollers), this will make the roller spin and force the metal shavings out of
the recesses.
Do not blow air down into the rollers, this will force the metal shavings deeper into
the roller and cause them to get lodged.
Make sure that all of the rollers move freely.
Remove any chips that are imbedded into the rollers.

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3.1.2 Pressure Roller Replacement
Replacement of the pressure rollers can be accomplished quickly.
Note: The pressure plate does not need to be removed to accomplish this task.
Remove the pressure roller shafts. (Older pressure plates have C-clips at each end of
the roller shaft and the newer have a bolt with a nut located at the bottom.)
oFor the machines with
C-clips, remove the
lower C-clip and lift the
shaft up to remove the
pressure roller.
oFor the machines with
a bolt and nut, remove
the bottom nut and lift
the bolt up to remove
the pressure roller.
Install new rollers as the shaft
is lowered back into its normal
position.
Re-install the nut or C-clip that was previously removed.

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Pressure Plate Guides
3.2.1 Cleaning
Daily cleaning of the pressure plate will remove debris before it can solidify on the plate.
Wipe the pressure plate with all purpose cleaner and a soft rag.
Remove all build-ups of composite material and metal shavings.
3.2.2 Pressure Plate Removal
The pressure plate can be removed for maintenance/cleaning. To remove;
Turn off air pressure to the
machine.
Disconnect the vacuum hose.
Remove the tool lubricant
nozzle and hose.
Remove the cylinder nut
from the face of the pressure
plate.
Remove the lower guide
bolt.
Remove the upper guide
bolt.
The pressure plate should be
free of the machine and can
be moved to a workbench
for service.
Note: Use of BraKleen and Scotchbite
pads will ease the cleaning process.

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3.2.3 Pressure Plate Replacement
Replace the pressure plate by following the reverse procedure noted in section 3.2.2. Make
note of the tips below.
Note: Do not loosen or adjust the Guide Shaft End Stop Bolts, this will change the Zero reference for
the pressure plate.
Insure the pressure plate, guide shafts
and guide shaft bushings are
completely free of buildup, dirt and
metal shavings.
Apply a light coat of oil to the guide
shaft bushings.
Apply a light coat of oil to the upper
and lower guide shafts.
The guide shafts should move freely
before connecting to the pressure
plate.
When installing the guide shafts, be
sure that the Guide Shaft end stops line
up with the end stop bolts and they do
not contact the spindle mounting plate.
When the pressure plate is fully installed, the plate should slide in and out freely
(When compressed air is turned off).
If a bind is felt, adjust the alignment of the upper and lower guide bolts and
recheck the movement. The pressure plate must be evenly spaced between the
two guide shafts or binds will be felt when moving in or out.
oTry loosening the guide shaft bolts and check for binds, if no binds were
detected, adjust the guide bolt location (by lifting or lowering the pressure
plate) and slowly tighten.
oIf a bind is still detected after loosening the guide shaft bolts, there is likely
debris in the bushings or on the guide shaft. Remove and clean.

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Vacuum Seal Replacement
Replacement of the vacuum seal or pressure plate donut should be done when the oils start
to break down the material or the seal starts to deteriorate. Replacement can be done while
the pressure plate is on the machine.
Remove the six retention screws
and metal wedge rings
Pull out the old vacuum seal
Clean the vacuum seal seat with
solvent or cleaner
Install the new seal and align the
cutout for the tool lube nozzle
Replace all six retention screws
and wedge rings

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Tool Lubrication –Cutting Fluid System
The minimal tool lubrication system is designed to deliver a mist of compressed air and MK
200 cutting lubricant to the tool before, during and after the cut (depending on the tool
lubrication settings). This system consists of an oil pump, capillary tubes and an adjustable
spray nozzle.
3.4.1 Cleaning
The tool lubrication system requires little cleaning. Wiping off the spray nozzle each time the
pressure plate is cleaned should be sufficient.
3.4.2 Testing for Oil Delivery
Test for proper oil delivery each day, before the machine is put into operation.
Manually turn on the tool lubrication override valve (See Section 3.23.3 for valve
location).
Place a piece of paper or cardboard in front of the spray nozzle for about 2-3 seconds.
A light film of oil should appear but should not be
enough to run or drip down the paper or cardboard.
If you see an oil fog or cloud when milling, the
adjustment is set too high. Refer to Section 3.4.4 for
oil adjustment.
Turn off the pneumatic valve manual override when
the correct amount of oil mist is seen.
3.4.3 Air Pressure Adjustment
The air pressure for the minimum tool lubrication system
should always remain at 2.0 bar pressure. Adjustment
higher or lower is not recommended. See the image, on the
right, for the air pressure adjustment valve.
Note: Air pressure indication will not occur until the minimal oil
lubrication system turns on (either manually or automatically).

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3.4.4 Adjustment of the Mist Volume
The density of the oil or the amount of oil delivered to the tool can be increased or decreased
with the oil adjustment valve located on the top of the lubrication pump. This adjustment
valve is numbered 1-10 (1 = Minimum, 10 = Maximum). The correct oil mist volume will leave
a light residue on the panel, wipe your finger on the edge of the cut and it should remove a
light amount of oil. If oil is not visible, turn up the volume, if it is running down the panel or
creating a fog, turn the volume down.
If the oil mist continues to be too high (When it is at minimum) or too low (When it is at
maximum), do the following;
1. Using a 2.5mm Allen wrench, carefully remove the adjustment knob stop post.
2. Turn the adjustment knob past the stop + or –depending on the direction you are
trying to adjust.
3. Replace the adjustment knob stop post.
This will allow one more revolution, for more or less oil flow.
Note: The amount of oil delivered to the tool should not create a fog or cloud of mist.
3.4.5 Oil Conversion from MK 150 to MK 200
Due to the higher viscosity of the MK 200 (20 mm²) from the older MK 150 (13 mm²), the mist
volume adjustment, on the top of the reservoir, will need to be increased. Follow the
procedure described in Section 3.4.4 to increase the mist volume as needed.
The proper adjustment for the mist oil is about 25 ml/hr., however in a normal environment,
this is difficult to measure, follow the procedure in section 3.4.2 for an easier adjustment
method.
Air pressure to the lubrication system should remain at 2.0 bar pressure for both the MK 150
and the MK 200 lubricants.

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3.4.6 Adjusting the Oil Mist Angle
An optional adjustable spray nozzle mount is available. If equipped, this adjustable mount
allows the operator the flexibility to adjust the angle of the oil mist. This feature is especially
necessary when using the milling tool extension (Milling surfaces that require a negative
offset, the mist may be adjusted to match the negative offset).
To adjust the mist angle;
Drill, tap or mill a machined surface.
Visually check the machined surface and look for oil residue.
oIf oil residue could not be
seen, turn up the mist
volume, see Section 3.4.3.
When the angle of the mist is
correct;
o¼ of the residue should be
above the cut when not
using the pressure plate.
o⅓ of the residue should be
above the cut when using
the pressure plate.
Adjust the spray angle if needed
and repeat the cut. Be sure that
the oil mist is delivered properly
for both pressure plate positions
(On/Off).
Once the angle is correct, tighten
all the thumb screws on the
adjustable spray mount.