WABECO CC-D6200 hs User manual

Operating Instructions
CNC lathe
With slant bed
CC-D6200 hs

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Please read before putting into operation for the first time!
Every person that operates the machine, maintains or repairs it, must have read the operating
instructions, and in particular, the safety notes prior to putting the machine into operation.
Please store these documents for subsequent use
Original version in German/translation in English
Status at 04/2015
Dear Customer!
With the purchase of the WABECO machine you have decided in favour of a quality tool. This
machine has been manufactured with the greatest of care and subject to precise quality controls.
These operating instructions are designed to help you to use your new machine safely and correctly.
For this reason, we ask you to read the appropriate notes through attentively and to take care to
observe them.
After unpacking the tool, check whether any transportation damages have occurred. Complaints,
whatever their nature, should be communicated immediately. Subsequent claims cannot be
recognised.
For all queries and replacement part orders, please always specify the machine number (see type
plate).
Reprinting and reproductions of any kind, even extracts, require the written permission of
WABECO
Disposing of the machine
The transportation and protective packaging is made of the following materials:
■Corrugated card
■Polystyrene without Freon
■Polyethylene foil
■Timber as single-use pallet (untreated)
■Euro pallet (multiple use packaging)
If you no longer need the items, or you do not want to reuse them, dispose of these items at the
officially recognised recycling points.
The machine is manufactured in such a way that 98% of the used materials that can be recycled, for
example, steel, cast iron, aluminium and only 2% are chemical materials, e.g. cable sleeves of
electrical cables, PCBs.
If you have any difficulties in disposing of these parts properly, we would be happy to help: with prior
agreement we will take back the machine in full and dispose of it. You must, however, cover the costs
of sending it to us.
wabeco-rs.de
Walter Blombach GmbH
42899 Remscheid
Am Blaffertsberg 13
Germany
Tel. [phone]
Fax [phone]
E-Mail [e-mail]

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Contents
Declaration of conformity CC-D6200 hs 5
1. Important safety notes 6
1.1 Intended use 6
1.2 Improper and incorrect use 6
1.3 Modifications to the machine 6
1.4 Safety regulations for proper use 6
1.5 Safety features 9
1.6 Explanations of the symbols 10
2. Delivery and set up 10
2.1 Transporting the machine 11
2.2 Setting up 12
3. Putting into operation 13
3.1 Setting up and connecting the control computer 13
4. Specifications regarding the machine 14
4.1 Identification of the model 14
4.2 Noise emission declaration 14
4.3 Technical data 15
4.4 Dimensions 17
4.5 Revolution selection 18
4.6 Electrical equipment 19
5. Set up tools 20
5.1 Set work piece zero point 20
6. Coolant system 21
6.1 Safety regulations for the handling of cooling lubricant 21
6.2 Filling the coolant system 21
6.3 Operating the coolant system 22
6.4 Positioning the segmented coolant hose 22
6.5 Controlling the flow of coolant using the coolant shut-off valve 23
7. Maintenance 24
8. Lubrication of the machine 24
9. Readjusting the main spindle 26
10. Overload coupling 27
11. Tool skid 27
12. Tailstock 29
13. 3 and 4 jaw lathe chuck 30
14. Operational faults and the elimination of such 31
15. Operating elements 33

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Contents
16. Drawings and legends 34
16.1 Headstock with motor 34
16.2 Bed with lead screw 36
16.3 Transverse skid with lock plate 38
16.4 Tailstock 40
16.5 CNC drive X-axis 42
16.6 Speed sensor 43
16.7 CNC 8-fold tool changer 44
16.8 Safety cabin hood 46
16.9 Safety cabin interior 47
16.10 Operating console 48
16.11 Bracket arm for operating console 50
16.12 Axis motor and rotary encoder 51
17. Circuit diagram 52
17.1 Overall connection diagram 52
17.2 Axis motor and rotary encoder 53
18. Camlock main spindle (optional) 54
18.1 Undoing a chuck or holding flange from the camlock 54
Main spindle lug
18.2 Blocking a chuck or holding flange on the camlock 54
Main spindle lug

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Declaration of conformity
We hereby declare, in the name of the manufacturer
Walter Blombach GmbH
Tool and machine factory
with registered office in Remscheid and Neuerburg
D-42871 Remscheid P O Box 12 01 61 Phone: [phone] Fax: [phone]
D-54673 Neuerburg WABECO Str. 1-10 Phone: [phone] Fax: [phone]
that the following named
CNC lathe
Type:
CC-D6200 hs
in the serial version, meets the following relevant regulations
- EU Machine Directive 2006/42/EC
- EMC Directive 2004/108/EC
- EU Low Voltage Directive 2006/95/EC
In order to fulfil/implement the requirements of the directives named above, the already
published and applicable standards were drawn upon:
EN ISO 12100:2010
DIN EN 60204-1:2006
EN ISO 23125:2010
Proxy for the compilation of the technical documentation is the operational head of the
above named manufacturer, Mr Christoph Schneider.
D-54673 Neuerburg 2015
________________________________
Place and date of issue
Betriebsleiter Christoph Schneider

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1. Important safety notes
1.1 Intended use
The lathes described in these operating instructions are designed for the processing of metal, plastic
and timber only.
To ensure safe operation of the lathes, the regulations set out in the chapter: "Safety regulations" must
be observed.
1.2 Improper and incorrect use
The lathes described in these operating instructions have been developed and manufactured for the
purpose named above. Walter Blombach GmbH accepts no responsibility for property damage and
personal injury caused as a result of not intended and incorrect use of the lathes.
1.3 Modifications to the machine
For reasons of safety, it is forbidden for the user to make modifications of any type to the lathe.
Walter Blombach GmbH accepts no responsibility for property damage and personal injury caused as
a result of any modifications to the lathe by the user that have not expressly been authorised by the
company.
1.4 Safety regulations for proper use
The machine may represent a source of danger if it is not used correctly. For this reason, it is
important that the following safety regulations are read attentively and observed carefully.
Every person that operates the machine, maintains or repairs it, must have read the operating
instructions, and in particular, the safety notes prior to putting the machine into operation.
In order to fulfil these requirements, these operating instructions must accompany the machine
throughout its entire lifetime and be available for research.
In the event that the machine changes owners, the operating instructions must thus be passed on to
the new owner along with the machine.

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1. Important safety notes
1.4 Safety regulations for proper use
Only spcedially trained persons may operate the machine. The guarantee and
warranty are voided if damages are caused by improper operation.
1. We remind you that no liability will be accepted for damages caused by not observing these
operating instructions.
2. The operator of the machine is to ensure that at least one copy of the operating
instructions is stored in the immediate vicinity of the machine and available to the people
who work with the machine.
3. The operator is to ensure that the safety and danger notifications on the machine are
observed and that the signs are kept in a legible state.
4. Do not work without goggles.
5. Wear close fitting clothing and, if you have long hair, wear a hair net. Do not wear loose
fitting or loose items (ties, shirt sleeves, jewellery etc.).
6. Gloves may not be worn.
7. In the event of an emission noise level as of 80 dB (A) at the workplace, ear defenders must
be worn.
8. The machine may not operate without supervision.
9. Secure your machine in such a way that it cannot be switched on by children. Persons who
have not been trained may not operate the machine.
10. Before using the machine, make sure it is in good working condition. Pay special attention
to any damage to the grounded plug or the electrical connections. Never operate the
machine with a defective, crushed or exposed cable.
11. Plug the grounded plug into a suitable socket for the machine. The cable for the machine
may only be connected to a safety socket or a connection box. Have the safety socket or
connection box checked by an electrical specialist before hand.
12. The safety socket or connection box must be close enough to the machine that the power
cable is not under strain.
13. When carrying out maintenance and cleaning work, the machine must be switched off and
the grounded plug pulled out.
14. Set-up work is only to be carried out with the machine switched off.
15. Do not reach into the operating machine.
16. Always switch the machine off when you are not using it.
17. Remain with the machine until it has come to a standstill.

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1. Important safety notes
1.4 Safety regulations for proper use
18. Only have repairs carried out by a qualified specialist! Repair work may only be carried out
by persons who are qualified for the relevant repairs and who are familiar with the
appropriate health and safety requirements.
19. Protect the machine from damp.
20. Constantly check the machine for damages. Replace damaged parts only with original parts
and have these replaced by a specialist. The guarantee and warranty is voided if
accessories and replacement parts are use that are not designed for the machine.
21. Do not remove the generated shavings with your hand. Use the appropriate tools (hand-
held sweeper, hook, brush).
22. Tools and work pieces may never be changed when the machine is running.
23. Do not brake work pieces and bush using your hand or another object.
24. Never leave the chuck key fitted (even when not in operation).
25. Pay attention to the spread of the lathe chuck.
26. The maximum revolution range specified on the lathe chuck may not be exceeded.
27. Always keep safety door to motor closed
28. The safety door to motor may only be opened by trained personnel with a special key by
unplugged safety contact pug
29. Turning steels must be firmly tensioned, at the correct height and as short as possible.
30. Do not measure at the rotating work piece (risk of accident, measuring tools will be
damaged).
31. When working between the tips, check the locking lever of the tailstock for firm seating.
32. When working with the automatic feed, always pay attention to ensure that the tool skid
does not come up against the lathe chuck or the tailstock.

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1. Important safety notes
1.5 Safety features
In order to enable you to work safely with our machines, we have incorporated the following safety
mechanisms. These meet the relevant European safety requirements.
■Safety cabin
In order fort he machine to operate in CNC mode, the door to the safety cabin must be closed.
■ON/OFF switch with under-voltage trigger
The ON/OFF switch is fitted with an under-voltage trigger, thus, in the event of a power failure, the
machine does not switch itself back on automatically. This prevents risks caused by the
unexpected motion of the spindle.
■Emergency off switch
The emergency off switch acts to quickly stop the machine
■Overload protection
The machine is fitted with an overload protection feature. This overload protection feature
switches the main drive motor off automatically when the machine is overloaded. The machine
can only then be switched on after a waiting period.
■Switch for operating modes (only for CNC machines)
The mode switch has 3 settings (CNC mode –Idle position –Manual mode) that can only be
selected with a key. After selecting the mode, the key can be removed in order to prevent a
switching of the mode type by unauthorised persons.
Working in CNC mode is only possible when door is closed. The door is locked as soon as the
main spindle starts. If the door is open, the main spindle cannot be started.
Working in set-up mode can be executed while the door is open. The switch for operating modes
has to be set to set-up mode.
The main spindle can be activated by closed as well as open door.

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1. Important safety notes
1.6 Explanations of the symbols
With an emission noise level as of 80 dB (A) at the workplace
ear defenders must be worn
Caution:
Always pull the power plug prior to any maintenance work!
Read the operating instructions prior to initial operation or
maintenance work!
Caution:
Dangerous electric voltage!
2. Delivery and set up
The machine is packed with care at the factory.
The following should be checked after delivery:
1. Whether the packaging shows damages to be reported or
2. Whether the machine shows transportation damages to be reported If this is the case, we ask you
to communicate this information immediately. Subsequent claims cannot be recognised.
The machine must be set up on a suitable, even and firm surface.
Suitable surfaces are, for example:
■A tool cabinet (available optionally)
■A separate workbench with a level surface (spirit level) that is strong enough to carry the weight of
the lathe without bending.
■A steel plate with a level surface (spirit level)
The machine must be screwed securely to the surface it is set up on. There are holes in the base of
the machine that are designed for this purpose. Good working results and low-vibration operation
can only be ensured when the prerequisites for fixture as set out above are maintained.

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2. Delivery and set up
The place of set-up should be selected in such a way that
■there is sufficient lighting
■the electrical supply cable with socket outlet with earthing contact and 0-conductor is installed
close enough to the machine that the supply line is not subjected to any tensile load.
The machine has to be screwed to the installation surface and/or provided with a safe stand by using
level elements. For this purpose, the base cabinet of the machine has four fixation thread bores (M10)
as well as four fixation bores (Ø 12.5 mm).
The doors of the safety cabin can only be opened if the machine is switched to operation modes CNC
or set-up if the main spindle is not moving.
2.1 Transport of machine
To transport the machine it is advisable to lift it at the lower cabinet with a forklift or platform trolley at
the base cupboard of the safety cabin and carefully move it to the desired location. For this purpose,
use wide forks (max. 1260 mm). We recommend using an intermediate plate for optimal load
distribution and the protection of the machine. For example, a Euro-pallet of 1200 x 800 mm is
suitable.
.

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2. Delivery and installation
2.2 Installation
The appropriate bores for the installation of the safety cabinet onto a WABECO machining tool cabinet
are already provided. The machining tool cabinet ensures secure positioning of the lathe and/or safety
cabin.
If the safety cabin is installed on another suitable installation surface, the 8 through-bores have to be
drilled in the customers installation surface. The positions of the 8 fixation threads (thread M8) of the
safety cabin are illustrated below. The diameter of the through-bores in the installation surface has to
be at least 9 mm.
The hexagon bolts (M10) included in the scope of delivery of the base cabinet can be used for
adjustments. For this purpose, first screw the hex nut (M10), which are also included in the scope of
delivery, to the hex bolts. Subsequently, insert the screws equipped with nuts into the four provided
threads from below in the base cabinet. The base cabinet can now be adjusted by tightening or
loosening the screw. Once the base cabinet is adjusted, you can counter the hexagon bolts with the
nuts on the screws to secure their position.
Good work results and low vibration running are only possible if the above-mentioned
prerequisites for mounting are complied with.

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3. Putting into operation
■Use a dry cloth to remove the corrosion protection that was applied to all exposed parts for
transport
■In the event of marine impregnation of exposed parts, it is recommended you spray them with oil,
allow it to work, and then remove the impregnation with a dry cloth
■Once set up properly (see the section on delivery and set up) connect the grounded plug directly
to a safety socket and the 230 V 50/60 Hz (optional 110 V 60 Hz) mains power supply
■Provision of sufficient coolant for the operation of a coolant system.
■Check all electronic operating elements, for example, ON/OFF switch, emergency off switch,
potentiometer, bush protection hood, etc. for functionality
■When putting CNC machines into operation for the first time, always read the start-up manual
3.1 Setting up and connecting the control computer
When selecting a suitable control computer, pay attention to the system prerequisites of the
control software. These are listed on the rear of the CD case sent with the machine.
Follow the instructions in the start manual of the software to install the control software on the
computer. The start manual can be found in the CD case of the control software included with the
machine.
In the next step, the software must be adapted to your machine. To do this, follow the instructions sent
with the machine which detail the editing of the parameters.
When the software has been successfully installed on the control computer and all parameters have
been adapted successfully, the control computer must be connected with the machine controller.
The machine controller communicates with the computer via the serial interface (COM port). In order
to establish a connection between the machine controller and the computer, connect the end of the
interface cable that is on the machine console to the COM port of the computer.
CAUTION:
The axis cable of the multiphase motors and the serial interface cable may only be plugged or
unplugged with the control switched off. Otherwise damages to the control, the machine or the
control computer may occur!

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4. Information regarding the machine
4.1 Identification of the model
The precise model designation of your machine can be found on the type plate attached to the
machine.
4.2 Noise emission declaration
Noise emission declaration in accordance with DIN EN ISO 3744
Emission values in idle
Emission noise level at the workplace
at 50 %
= 68.0 dB (A
at 100 %
= 73.6 dB (A)
Sound power level
at 50 %
= 77.8 dB (A)
at 100 %
= 82.3 dB (A)
With an emission noise level as of 80 dB (A) at the workplace
ear defenders must be worn

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4. Specifications regarding the machine
4.3 Technical data
Working areas
Distance between centres
600 mm
Centre height
135 mm
turning-Ø above cross slide
170 mm
Swing diameter via guide
270 mm
Bed width
185 mm
Main drive motor
Nominal voltage
230 V
Nominal frequency
50/60 Hz
frequency controlled main drive motor 230 V, 50/60 Hz
2.0 kW
Spindle revolutions, infinite
50 - 5000 rpm
Machine accuracy
Concentricity of the spindle lug
0,005 mm
Cylindrical rotation on 100 mm overhung
0,01 mm
Cylindrical rotation with simple turning on
300 mm between the centres
0,015 mm
Headstock
Main spindle aperture
Ø 20 mm
Taper in main spindle
MK3
Main spindle lug
According to DIN 6350
Tool skid
Adjustability of the transverse skid
140 mm
Adjustability of the longitudinal skid
60 mm
Longitudinal skid can be swivelled by
360°
Max. turning steel height
20 mm
Tailstock with quick adjustment
Lateral adjustability of the tailstock upper
± 10 mm
Tailstock sleeve
With inner Morse taper MK2
Sleeve adjustability
65 mm
Scale ring read accuracy
0.1 mm
Thread cutting
Tumbler gear drive
For left-right thread
2 automatic longitudinal feeds
0.085 and 0.16 mm/revolution
Change gear set for thread cutting
Metric 0.25 - 7.0 mm - imperial 10 - 40 G/"

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4. Specifications regarding the machine
4.3 Technical data
Positioning accuracy
± 0.015 mm
Travel speed (fast mode)
x and y axes
30 –1,000 mm/min
Toolchanger
cross section for 4 external machining tool
10 x 10 mm
location bore for 4 internal machining tools
Ø 16 mm
Safety cabin
volume coolant
27 litre
feed pump
230 Volt, 50/60 Hz

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4. Specifications regarding the machine
4.4 Dimensions

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4. Specifications regarding the machine
4.5 Revolution changer
The potentiometer ((8) of the control panel) allows the infinite setting of the revolutions of the tool
spindle from 50 to 4800 rpm (2. level = default setting). In order for the revolutions to be activated
correctly via software, the potentiometer must be set to 100%. During the operation, it can be used to
minimally adjust the revolution according to the processing conditions.
If the lower revolutions of 50-2500 rpm (1st setting) are required, the drive belt must be applied. To do
this, proceed as follows:
1. Open the gear cover hood by undoing the safety screw with the supplied special key.
2. Release the four hexagon nuts (5); this allows the sliding of the clamping sled (4) of the motor.
3. Slide the clamping sled incl. motor toward the machine; this loosens the belt tension and the belt
can be relocated.
4. Place the drive belt (2) onto the otertransmission oft he belt disks (1+3). (Small diameter at motor,
large diameter at main spindle.)
5. Pull the clamping sled (4) of the motor away from machine to tension the drive belt (2) and
refasten the four hexagon nuts (5).
6. Close the protective drive door and secure with both safety screws.

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4. Specifications regarding the machine
4.5 Revolution changer
The following table illustrates the torque of the work spindle depending on the selected gear level and
setting of the potentiometer.
Setting on the potentiometer
1st setting rpm
2nd setting rpm
0%
50
100
10%
200
370
20%
470
900
30%
725
1400
40%
970
1900
50%
1225
2400
60%
1470
2900
70%
1725
3400
80%
2000
4000
90%
2280
4500
100%
2500
4800
4. Specifications regarding the machine
4.6 Electrical equipment
The frequency-regulated main drive motor is delivered already installed
■the under-voltage trigger is integrated in the electronics of the motor
■The ON/OFF switch has to be switched on again also after an interruption of power
■In the event of the main drive motor being overloaded, it will switch itself off automatically.
■The main drive motor can only be switched back on again after a short waiting period
■For this purpose, first switch the machine off via the ON/OFF switch; wait 5 seconds and
reactivate.

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5. Set up tools
First, the correction values for all 8 tools have to be set to 0.00 in the tool memory in X and Z.
(Parameter CAM tool memory)
Tool 1 is the 0-tool,
The adjusted amounts are here generally maintained at X 0 and Z 0.
■Run machine reference
■Select tool T1
to random diameter in X and run to beginning of workpiece in Z.
(if required, clamp turned part and turn splint)
Leave X-axis at turned diameter in Xand set Z-axis
to beginning of workpiece.
Here, work piece zero point sets keyboard combination (Ctrl X) (Ctrl Z)
(Position display = X0.00 Z0.00)
■Select tool T3
Move to same position in X and Z with tool T3
where zero was set previously with T1
(in Xto turned diameter and in Zto workpiece starting point)
■The new position value of X-axis is not
X 0.00 at the turned diameter, but e.g. X 10.80
■Enter in tool memory at T3:
New position value in X= 10.80
Radius is / 2 = 5.40
Adjusted amount in X = 5.40
■The new position value of display Z-axis at start of work piece is e.g. Z–8.00
Enter at T3 in tool memory:
New position value in Z= = - 8.00
Adjusted amount in Z= - 8.00
5.1 Set workpiece zero point
Select T1
Drive with workpiece T1 to turned diameter in X-axis.
(Position display in X-axis = 0.00)
Measured turned diameter = e.g. 15.20
Now enter the required zero floating for X- axis in direct entry field.
G54 X- 15.20 (Enter)
New value in position display = X 15.20