WABECO F1200 high speed User manual

Operating instructions
Universal drilling and milling machines
Version of February 2009
F1200 – F1200 high speed
CC-F1200 – CC-F1200 high speed
F1210 – F1210 high speed
CC-F1210 – CC-F1210 high speed
F1410 LF – F1410 LF high speed
CC-F1410 LF – CC-F1410 LF high speed
Walter Blombach GmbH
Tool and Machine Factory
D-42899 Remscheid Am Blaffertsberg 13 phone: [phone] fax: [phone] E-Mail: [email protected]
D-54673 Neuerburg WABECO Str. 1-10 phone: [phone] fax: [phone] E-Mail: [email protected]
www.wabeco-remscheid.de

2
Index
EC-Conformity Declaration 5
1. Dimensions 6
1.1 F1200 – F1210 6
1.2 F1200 – F1210 high speed 7
1.3 F1410 with trapezoid thread spindle 8
1.4 F1410 with ball screw 9
1.5 F1410 high speed with ball screw 10
2. Delivery and installation 11
3. Transport lock 12
4. Start-up and maintenance 13
5. Safety devices and recommendations 16
6. Clamping and ejecting tools 18
7. Assembly and disassembly of collets 20
8. Speed regulation 21
8.1 Speed regulation for machining aluminium and steel 21
8.2 Speed regulation for 1.4 kW motor 21
8.3 Speed regulation for 2.0 kW motor (high speed) 22
9. Feed motion X,Y und Z-axis 23
10. Recommendations for application and operation 24
10.1 Swivelling of the milling head 25
10.2 Drill stroke – depth stop 26
11. Coolant unit 27
12. Declaration of noise levels 28
13. Drawing and list of parts 29
F1200 – F1200 high speed - F1210 – F1210 high speed
13.1 Electronics - protective cover with 1.4 kW motor 29
13.3 Protective cover 31
13.4 Milling head for 1.4 kW motor 32
13.5 Milling head high speed with 2.0 kW motor 34
13.7 Z-column with vertical slide and trapezoid thread spindle 38
13.8 Z-column with vertical slide and ball screw 40
13.11 Z-clumn with vertical slide with automatic feed 46
13.18 Z-spindle complete 60
13.19 Lateral drive for Z-spindle complete 61
13.21 Lateral drive for Z-spindle with automatic feed 64
13.22 Cross support with trapezoid thread spindle 66
13.23 Cross support with ball screw 68
13.30 X-spindle 77
13.31 Y-spindle 78
13.34 X-spindle with automatic feed 84
13.35 Y-spindel with automatic feed 86

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Index
CC-F1200 – CC-F1200 high speed – CC-F1210 – CC-F1210 high speed
13.2 Electronics – Protective cover with 1.4 kW motor 30
13.3 Protective cover 31
13.4 Milling head with 1.4 kW motor 32
13.6 Milling head high speed with 2.0 kW motor 36
13.9 Z-column with vertical slide and trapezoid thread spindle 42
13.10 Z-column with vertical slide and ball screw 44
13.19 Lateral drive for Z-spindle complete 61
13.20 Z-spindle with CNC drive complete 62
13.24 Cross support with trapezoid thread spindle 70
13.32 X-spindle 80
13.33 Y-spindle 82
13.36 Control console nccad with 1.4 kW motor 88
13.37 Control console nccad with 2.0 kW motor 90
13.38 Support arm for control console 92
F1410 LF– F1410 high speed
13.1 Electronics – protective cover with 1.4 kW motor 29
13.3 Protective cover 31
13.4 Milling head with 1.4 kW motor 32
13.5 Milling head high speed with 2.0 kW motor 34
13.12 Z-column with trapezoid thread spindle 48
13.13 Vertical slide with trapezoid thread spindle 50
13.14 Z-column with ball screw 52
13.15 Vertical slide with ball screw 54
13.18 Z-spindle complete 60
13.19 Lateral drive for Z-spindle complete 61
13.25 Top slide 72
13.26 Cross slide with trapezoid thread spindle 73
13.27 Cross slide with ball screw 74
13.30 X-spindle 77
13.31 Y-spindle 78
13.34 X-spindle with automatic feed 84
13.35 Y-spindle with automatic feed 86
CC-F1410 LF– CC-F1410 high speed
13.2 Electronics – protective cover with 1.4 kW motor 30
13.3 Protective cover 31
13.4 Milling head with 1.4 kW motor 32
13.6 Milling head high speed with 2.0 kW motor 36
13.16 Z-column with ball screw 56
13.17 Vertical slide with ball ball screw 58
13.19 Lateral drive for Z-spindle complete 61
13.20 Z-spindle complete 62
13.28 Top slide 75
13.29 Cross slide 76

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Index
13.32 X-spindle 80
13.33 Y-spindle 82
13.36 Control console nccad with 1.4 kW motor 88
13.37 Control console nccad with 2.0 kW motor 90
13.38 Support arm for control console 92
14. Circuit diagram 93
14.1 Motor 1.4 kW 93
14.2 Motor high speed 2,0 kW 94
14.3 nccad with 1.4 kW motor 95
14.4 nccad with 2.0 kW motor 96
14.5 Stepper motor basic version 97
14.6 Stepper motor professional version 98
Dear customer!
Congratulations on choosing the WABECO Universal Drilling and Milling Machine. We have
taken great care in its manufacture and we have given it a thorough quality control test. These
operating instructions are to help you to work with it safely and properly. Therefore we request that
you read the respective instructions carefully and follow them exactly.
After unpacking the machine please check to see if any kind of damage has occurred during
transportation. Any complaints must be made immediately. Complaints made at a later date
cannot be accepted.
If you have any questions or need any spare parts, please quote the machine number
located on the front of the motor (see rating plate).
Disposal of the drilling and milling machine
The transport and protective packaging is made by means of the following materials:
corrugated cardboard
polystyrene free of freon
polyethelene foil
non-returnable wooded pallet (untreated)
Euro pallet (deposit)
If you have no further need of these articles or do not wish to use them again, please dispose of
them at the public recycling facilities.
The drilling and milling machine consists up to 98% of recyclable materials, i.e. steel, cast iron,
aluminium and 2% of chemical materials, e.g. the coating of electrical leads, printed circuits.
If you have trouble in disposing of these parts in a proper manner, we would be pleased to help
you: upon mutual agreement we will take the complete machine back and dispose of it.
However, the costs for transporting the machine to our plant must be at your expense.

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EC – Conformity Declaration
In the name of the manufacturer
Walter Blombach GmbH
Tool and Machine Factory
based in Remscheid and Neuerburg
D-42871 Remscheid Postfach 12 01 61 Phone: [phone] Fax: [phone]
D-54673 Neuerburg WABECO Str. 1-10 Phone: [phone] Fax: [phone]
We hereby declare that the universal milling and drilling machines specified below
Universal milling and drilling machine Typ:
F1210 E
F1210E high speed
CC-F1210 E
CC-F1210 E high speed
meet the following regulation requirements for standard series production
- directive for machines 98/37 EG
- low voltage directive 73/23/EWG
- EMV directive 89/336/EWG
In order to meet / implement the requirements of the above mentioned directives, the following
applicable and previously published standards have been adhered to:
EN ISO 12100-1
EN ISO 12100-2
EN 12840
EN 60204-1
D-54673 Neuerburg
________________________________
City
Signature

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1. Dimensions
1.1 F1200, F 1210 with trapezoid thread spindle or ball screw

7
1. Dimensions
1.2 F1200, F 1210 high speed with trapezoid thread spindle or ball screw

8
1. Dimensions
1.3 F1410 with trapezoid thread spindle

9
1. Dimensions
1.4 F1410 with ball screw

10
1. Dimensions
1.5 F1410 high speed with ball screw

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2. Delivery and installation
The drilling and milling machines are carefully packed in our factory.
Please check the following upon receipt of delivery:
1. Whether the packaging has been damaged and/or:
2. Whether the drilling and milling machine shows signs of transport damage or if there
are reasons for complaints. In this case we request your immediate notification. Claims
made at a later date cannot be considered.
The drilling and milling machine must be installed on an appropriate, level and firm base.
This would be, for example:
a base cabinet such as in our accessories’ programme
an own work bench as long as it is strong enough to carry the weight of the machine without
warping (see technical data and check with spirit level) and has an even surface
a steel plate
The drilling and milling machine must be firmly screwed down onto the base. To facilitate this, there
are 10 mm holes in the machine base. Good results and a minimum of vibration during
operation can only be guaranteed if the above mentioned requirements for secure mounting
have been adhered to.
The installation of the machine should take place where there is sufficient lighting, electrical cables
with earthed sockets and 0-conductors are installed adequately near to the machine so that the
mains connection lead is not subject to any tension whatsoever. The mains lead should be such
that, by means of a multiple socket, a coolant or lubrication unit can also be connected.

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3. Transport lock
F1410 high speed with ball screw
Attention!
The transport lock must be removed prior to the initial start-up of the machine.
Please proceed as follows:
1. Remove the wooden block below the milling spindle by slightly moving the milling head upward via
the handwheel of the z axis.
2. Remove the snap ring on both sides of the transport lock. Now the lock can be moved easily.
Otherwise, the milling head has to be moved until the wire ropes are tensioned and carry the
weight. Now the transport lock can be pulled out.
Transport lock

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4. Start-up and maintenance
After the machine has been professionally installed and securely mounted, it must be connected to
the mains supply.
1. A qualified electrician must connect the supply lead of the drilling and milling machine to the
local power supply.
2. Provide sufficient lubrication coolant for running the coolant unit
(optional).
3. All functions must be checked.
In order to clamp workpieces a machine vice or clamping screws (suitable for the T grooves) may
be used.
Greasing the milling machine
Every 6-8 weeks the Quill and the feed pinion should be greased (see sketch).
Therefore move the quill up and down while applying some lubricant to the lateral metal-on-metal
contact area of the quill and the feed spindle.
It is not necessary to lubricate the drilling spindle, as the ball bearings are fully enclosed and had
been lubricated during production for the entire service life of the machine.
The milling machines with linear guides are maintenance-free and do not need greasing.
Lubrication means: - reducing the wear and the frictional resistance
- extending the lifetime
- preventing the metal surfaces from corroding
We recommend: for lubrication: multi-purpose grease grade 2NLGI
for oiling: lubrication oil of 100 mm 2/s viscosity
Spindle nuts with trapezoid thread spindle:
The spindle nuts of the milling machines are adjustable.
Should a spindle nut of one of the three axes have some play, proceed as follows:

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4. Start-up and maintenance
X-axis:
To adjust the spindle nut, move the cross table to the centre. After loosening the set screw, the
adjusting nut is to be turned a bit in the clockwise direction. Turning the adjusting nut like this
achieves a mutual tightening of the two nuts and as a result play-free running of the threaded
spindle. After the adjustment, the set screw must be re-tightened firmly.
Y-axis:
The readjustment of the Y-axis requires unscrewing the concertina cover of the top slide.
The following procedure is as per instruction for the X-axis.

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4. Start-up and maintenance
Z-axis:
To adjust the spindle nut of the Z-axis, you have to unscrew the cover plate.
The further procedure is as for the X-axis.
In the case of spindle nuts with ball screw an adjustment is not necessary and also not
possible.

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5. Safety devices and recommendations
In order to make working with our drilling and milling machines safe, we have equipped them with
the following safety devices and thus they are in accordance with the relevant European safety
regulations.
1. Protective cover
The separating safety device attached to the machine housing, prevents reaching in and
coming into contact with the tool spindle. This safety device is constructed in such a way that it
can be adjusted to the necessary working height (depending on the dimensions of the
workpiece and tool).
2. Main switch with low voltage release
In order to disconnect the electrical parts of the drilling and milling machine safely from the
mains, we have provided a main switch with low voltage release besides the mains lead with
plug. This undervoltage release prevents the drive motor from coming on after a power cut and
so excludes the danger of the work spindle moving unexpectedly.
3. Emergency OFF switch
This enables a quick interruption of dangerous movements, in particular of the CNC
equipment.
4. Overload protection
This device has been developed to protect the drive motor and it must be noted that after the
motor has been turned off (by hand or automatically), because of overloading, a short pause of
1-3 seconds must be observed before turning the machine on again so that the relay of the
electronical parts can re-establish the closed circuit condition.
5. Safety machine cabin
During the CNC operation the door of the safety machine cabin must be closed. On the right upper
side there is a limit switch that is operated by closing the door. This is the only way to move the
feed motors at the axes independently via the controller.
Only with the door closed it is possible that the feed motors at the axes are moved
independently via the CNC-controller. When the door is open, the motors are being switched off
the power supply which enables manual operation. The main spindle can be swichted on either
when the door is closed or opened.
Working in manual mode with the door opened.
When switching from manual operation to CNC mode please proceed as follows:
1. close the door of the safety machine cabin
2. turn the flip switch from manual operation to CNC operation
3. select main spindle rotating direction left or right
4. set the spindle speed by means of the potentiometer
5. release the flip switch to move the axes
6. start the CNC programme
It is forbidden to remove the door limit switch or to put it out of action as this could lead to serious
danger to the machine operator and cause severe accidents.

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5. Safety devices and recommendations
We would like to draw your attention to the following safety recommendations which are a
result of a combination of the European standards and our own experience:
1. Workpieces must be secured in such a way that they cannot be propelled out of position by the
torque of the drill or mill.
2. Round workpieces such as corrugated pieces, round turning part or similar things must be fixed
into position by suitable means such as prisms in conjunction with a machine vice when drilling.
3. Machine drills and mills are sharp-edged tools. In order to protect hands, these tools should
only be held by the shaft and not by the cutting edge when being transported or changed.
The cutting edges of the tools are sharp and can cause serious
injury when touched.
4. Throughout the drilling and milling processes, sharp and often hot swarf is produced which is
then thrown off by the momentum of the tool in operation. In order to prevent accidents it is
necessary to wear goggles or a face shield.
5. It is furthermore recommended to wear well-fitting clothes, especially on the arms (nothing
loose) and in the case of long hair, a hair net should be worn to prevent anything being caught
or drawn in by the rotating work spindle or when changing the workpieces.
6. By pulling the mains plug, the drilling and milling machine is disconnected from the electrical
current. This should be observed when
- a drill or mill is changed
- the machine has to be serviced.
7. In order to avoid wear and tear on the tools and the drive motor, it is recommended that the
tools are to be selected with care, worn tools should be exchanged for sharp ones and the feed
should be calculated such that the r.p.m. of the work spindle is only slightly reduced. The depth
of the feed must be selected with precision so that it is not possible to drill into the support
table.
8. We recommend the installation of light which provides a level of at least 500 lux at the point of
tool cutting operations.
9. Appropriate means must be used to dispose of drilling and milling swarf.
10 We strongly recommend that the drill chuck key is be fixed to the machine by means of a clamp
or similar attachments only. This is in order to avoid the drill chuck key being caught by the tool
spindle and being thrown around if it is fixed to the machine with anything flexible like chains or
string.
11. When drilling and milling machines are not in use, we recommend installing a safety device to
prevent children or non authorized people from switching on the machine.
12. The drilling and milling machine should be set up where no humidity, apart from the lubrication
coolant, can affect it.
13. It is necessary to carry out regular checks for damages to parts and/or for the functions, on
drilling and milling machines. Please do not hesitate to call us if you require original spare parts
or advice!

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6. Clamping and ejecting tools
Allen key
Tool retaining/forcing
screw
Main spindle
Retaining bolt
Clamping chuck

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6. Clamping and ejecting tools
This is the core of the WABECO clamping and ejection system,
the tool retaining/forcing screw. It operates on the principle
of the screw having a fine thread located at its head and a
coarse thread on the shank. Due to this construction, a special
procedure has to be observed when clamping tools with an
internal thread.
It is not possible to insert a tool or tool holder with internal threads into the work spindle
first and to screw the tool retaining/forcing screw into the internal thread afterwards! The
tool or tool holder must be screwed onto the tool retaining/forcing screw.
As you can see on the picture (page 18), for clarification we have cut open the protective cover and
the spindle housing so that the tool retaining screw with the Allen key can be seen.
Please proceed as follows:
With the aid of the Allen key, screw the tool retaining/forcing screw into the work spindle right up to
the end of its thread. Once the screw blocks, turn it back 2-3 revolutions.
Now the tool is inserted by hand from underneath into the taper of the work spindle and screwed
onto the tool retaining/forcing screw. While this is being done, the tool retaining screw is held tight
by means of the Allen key.
Once the tool has been clamped hand-tight, the work spindle is held by means of the holding pin
and the tool retaining screw can be tightened with the Allen key without any effort.
To eject tools with an internal thread, hold the tool spindle tight with the holding pin and loosen
the tool retaining screw with the Allen key.
Now the tool can be screwed off the tool retaining/forcing screw by hand and taken out of the work
spindle taper from underneath.
Tools with flat tang (without internal threads) can be clamped by first of all screwing the tool
retaining screw as far back with the Allen key as is necessary to insert the tool into the work
spindle. After doing this, the tool retaining/forcing screw is screwed lightly onto the tool.
To eject the tool, the holding pin is inserted into the tool spindle and held tight with one hand. By
turning the Allen key to the left, the tool is released and can be easily removed from the work
spindle.

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7. Assembly and disassembly of collets
Disassembly
Take the clamping nut in one hand and press it against the collet as you can see it on the
illustration.
The lateral pressure exerted on the collet causes the clamping nut to leap so that can
easily be taken out of the nut.
Assembly
Put the collet on a flat underlay and place the clamping nut on the collet.
Now press the clamping nut down against the collet until it snaps. The collet can move freely in the
centrical chamfer. It will not fall out even if you turn it around.