WABECO CC-F1220 hs User manual

Operating instructions
CNC milling machine
with tool changer
CC-F1220 hs

2
Please read before putting into operation for the rst 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
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 your 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, wha-
tever 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
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 ofcially
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, aluminum and only 2% are chemical materials, e.g. cable sleeves of electrical
cables, PCBs.
If you have any difculties 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.
Disposing of the machine
wabeco-rs.de
Walter Blombach GmbH
42899 Remscheid
Am Blaffertsberg 13
Germany
Phone [phone]
Fax [phone]
E-Mail [email protected]
Status at 06/2018

3
Index
Declaration of conformity 5
1. Important safety notes 6
1.1 Intended use 6
1.2 Improper and incorrect use 6
1.3 Modications 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 11
2.1 Transporting the machine 11
2.2 Installation of the machine 12
3. Putting into operation 13
3.1 Connecting compressed air supply 13
3.2 Setting up and connecting the control computer 13
4. Specications regarding the machine 14
4.1 Identication of the model 14
4.2 Declaration of noise levels 14
4.3 Technical data 15
4.4 Dimensions 17
4.5 Revolution setting 18
4.6 Electrical equipment 19
5. Achieving optimum results and avoiding incorrect usage 19
6. Inserting tools into the main spindle 21
6.1 Loading an empty tool magazine 22
6.2 Tool exchange 23
7. Installation and removal of collets 24
7.1 Installation 24
7.2 Removal 24
8. Adjustment of the dovetail guides 25
9. Coolant unit 26
9.1 Safety regulations for the handling of cooling lubricant 26
9.2 Filling the coolant unit 26
9.3 Operating the coolant unit 27
9.4 Positioning the segmented coolant hose 27
9.5 Controlling the ow of coolant using the coolant shut-off valve 28
10. Maintenance 29
11. Lubrication of the machine 30
12. Maintenance of pressure intensier 32
13. Operational faults and the elimination of such 33

4
Index
14. Control elements 34
15. Drawings and legends 36
15.1 Milling head with pneumatic tension 36
15.2 Tensioning mechanism 38
15.3 Z-column with vertical slide 40
15.4 Spindle Z-axis 42
15.5 Cross slide support 44
15.6 Spindle X-axis 46
15.7 Spindle Y-axis 48
15.8 Limit switch X-axis 50
15.9 Limit switch Y-axis 50
15.10 Limit switch Z-axis 51
15.11 Tool changer 52
15.12 Tool support disk 53
15.13 Support arm tool support disk 54
15.14 Gripper 56
15.15 Support arm gripper 58
15.16 Machine safety cabin 60
15.17 Coolant unit 61
15.18 Control panel 62
15.19 Support arm control panel 64
15.20 Machine base cabinet 65
16. Circuit diagram 66
16.1 Overall connection diagram 66
16.2 Axis motor and limit switch connection X-, Y-, Z-axis 67
16.3 NC-rotary table 67
16.4 Axis motor and limit switch connection V-, W-axis 68
16.5 Sensors / relay 69
16.6 Legend for circuit diagrams 70
16.7 Pneumatic diagram tool changer 72
17. NC-rotary table (optional) 73
17.1 Clamping of workpieces on the NC-rotary table 73
17.2 Swiveling the worm shaft in and out 73
17.3 Setting the axial play of the NC-rotary table 74
17.4 Removing the NC drive unit 75
17.5 Setting the axial play of the worm shaft 76
17.6 Setting the axial play of the eccentric tappet 76
17.7 Drawing and legend 77

5
Declaration of conformity
We hereby declare, in the name of the manufacturer
Walter Blombach GmbH
Werkzeug- und Maschinenfabrik
mit Sitz in Remscheid und Neuerburg
D-42871 Remscheid Postfach 12 01 61 Telefon: [phone] Fax: [phone]
D-54673 Neuerburg WABECO Str. 1-10 Telefon: [phone] Fax: [phone]
that the following named
CNC milling machine
Type:
CC-F1220 hs
in the serial version, meets the following relevant regulations
- EU Machine Directive 2006/42 EG
- EMC Directive 2014/30/EU
- EU Low Voltage Directive 2014/35/EU
In order to full/implement the requirements of the directives named above, the already published and
applicable standards were drawn upon:
EN ISO 12100:2010
DIN EN 60204-1:2007
DIN EN 13128:2009
Proxy for the compilation of the technical documentation is the operational head of the above named
manufacturer, Mr Christoph Schneider.
D-54673 Neuerburg 2018
________________________________
Place and date of issue
________________________________
Operating head Christoph Schneider

6
1. Important safety notes
1.1 Intended use
The milling machines described in these operating instructions are designed for the processing of metal,
plastic and timber only.
To ensure safe operation of the milling machines, the regulations set out in the chapter: „Safety regula-
tions“ must be observed.
The milling machines 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 milling machines
1.2 Improper and incorrect use
1.3 Modications to the machine
For reasons of safety, it is forbidden for the user to make modications of any type to the milling machine.
Walter Blombach GmbH accepts no responsibility for property damage and personal injury caused as
a result of any modications to the milling machine 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 instruc-
tions, and in particular, the safety notes prior to putting the machine into operation.
In order to full these requirements, these operating instructions must accompany the machine throug-
hout 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

7
1. Important safety notes
1.4 Safety regulations for proper use
1. Only specially trained persons may operate the machine. The guarantee and warranty are voided
if damages are caused by improper operation.
2. We remind you that no liability will be accepted for damages caused by not observing these ope-
rating instructions.
3. 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.
4. The operator is to ensure that the safety and danger notications on the machine are observed
and that the signs are kept in a legible state.
5. Do not work without goggles.
6. Wear close tting clothing and, if you have long hair, wear a hair net. Do not wear loose tting or
loose items (ties, shirt sleeves, jewellery etc.).
7. Gloves may not be worn.
8. In the event of an emission noise level as of 80 dB (A) at the workplace, ear defenders must be
worn.
9. The machine may not operate without supervision.
10. 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.
11. 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.
12. 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.
13. The safety socket or connection box must be close enough to the machine that the power cable
is not under strain.
14. When carrying out maintenance and cleaning work, the machine must be switched off and the
grounded plug pulled out.
15. Set-up work is only to be carried out with the machine switched off.
16. Do not reach into the operating machine.

8
1. Important safety notes
1.4 Safety regulations for proper use
17. Remain with the machine until it has come to a standstill.
18. Only have repairs carried out by a qualied specialist! Repair work may only be carried out by
persons who are qualied 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. To avoid insufcient lighting, we recommend setting up a light source that provides a value of at
least 500 Lux at the tool‘s cutting edge.
22. Do not remove the generated shavings with your hand. Use the appropriate tools (hand-held
sweeper, hook, brush).
23. Never change tools and workpieces while machine is running.
24. Tools and workpieces may never be changed when the machine is running.
25. Workpieces must be secured by suitable xtures e.g. prisms, machine vice etc..
26. Chuck keys or similar tools may not be attached to the machine to ensure that they cannot be
caught by the spindle and thrown about.
27. Never reach into the spindle opening of the main spindle with ngers (risk of crushing).
28. The set-up mode may only be executed by qualied specialists.
29. Return the operation selection switch to CNC operation after completion of set-up mode and
remove key.
30. The magazine of the tool changer may only be loaded and unloaded via the spindle of the
machine.

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1.5 Safety features
1. Important safety notes
In order to allow for safe working with our machines, we have provided the following safety installations
and thus comply with the relevant European safety requirements
■Machine safety cabin
In CNC mode, the door to the machine safety cabin must be closed in order for the milling
machine to work in CNC operation.
■ON/OFF switch with under-voltage trigger
The ON/OFF switch is tted 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 tool spindle.
■Emergency off switch
The emergency off switchacts to quickly stop the machine.
■Overload protection
The machine is tted 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 operational modes
The switch for operational modes has 3 settings (CNC operation - zero setting - set-up mode)
which can only be selected via a key. Once the operational mode has been selected, the key
can be removed which prevents unauthorised changing of the operational mode.
Working in CNC mode is only possible with a closed door. 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 thus be activated by closed as well as open door.
■Pressure monitor
The compressed air supply for the machine and/or the required systems pressure is checked
by the pressure monitor. If the systems pressure drops below the critical value for any
reason (e.g. burst hose), the machine automatically switches to failure. The machine can
only be restarted once the error has been removed.

10
1. Important safety notes
1.6 Explanations of the symbols
With a measured noise level of 80 dB (A) at the workpla-
ce the operator should wear Ear Protection.
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
If the gripper of the tool changer is not swiveled in, the
positioning of the main spindle
(Z-axis) is admissible.
If the gripper of the tool changer is swiveled in, the posi-
tioning of the main spindle, (Z-axis) is not admissible. If
applicable, the gripper has to be swiveled out manually.
The operating pressure for the tool changer has to be set
to 5 bar at the pressure regulator of the machine.