You are on page 1of 154

Machine User's Manual

NC processing centre
Rover 20

5801A0225 ENGLISH
Issue.Revision: 7.0
Serial number

481/96
Information on this publication

Information on this publication

Code: Issue: Revision: Approval number: ctg


5801A0225 7 0 (12, 2003) 03/0196M A

List of changes
Revision: Additions: Deletions: Changes:
0 general revision

This manual has been prepared by BIESSE for use by clients only and it contains information
protected by copyright. It must not be photocopied or reproduced in any form, either fully or in part,
without the prior written consent of BIESSE.

The document is supplied together with the machine, and must be kept in a safe easily accessible
place known to those responsible for running or maintaining the machine. It must be used with
care throughout the machine's working life, and must be handed over with the machine if the latter
is passed on to third parties.

BIESSE S.p.A.
(5801a0225.fm-161203)
3
Information on this publication

4 BIESSE S.p.A.
(5801a0225.fm-161203)
Table of Contents

Table of Contents

Introduction
Field of application and purpose of this manual. . . . . . . -11
Documents Supplied with the Machine . . . . . . . . . . . . . -11
Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -12
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -12

Part 1 - Description

Chapter 1. Main parts


1.1 General description of the machine . . . . . . . . . . . . . . . . . . 1-1
1.2 General view and main parts . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Work table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Operating section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Collet spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.5 Safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6 Identification of the manufacturer and the machine . . . . . . 1-8

Chapter 2. Optionals
2.1 Electronic display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Additional mobile piece supports . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Additional rear stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Additional suction cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.5 Double movement stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.6 Bar or ball supports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.7 Collet spindles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.8 Electrospindle aggregates . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.9 Rack type tool magazine. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.10 Central lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Chapter 3. Basic operations


3.1 Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Manual movement of axes . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Variation of the axis movement speed . . . . . . . . . . . . . . . . 3-2
3.4 Working area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.5 Row of stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.6 Origin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Machine origin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Work table origin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.7 Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.8 Information on the spindle direction of rotation . . . . . . . . . . 3-6
Definition of a right or left spindle. . . . . . . . . . . . . . . . . . 3-6

BIESSE S.p.A.
(5801a0225TOC.fm-161203)
5
Table of Contents

Determining the spindle direction of rotation . . . . . . . . . 3-6

Chapter 4. Uses foreseen


4.1 How to use the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Characteristics and dimensions of workable materials . . . . 4-1
4.3 Machining operations foreseen . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Work area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.5 Danger area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Chapter 5. Controls and signalling devices


5.1 Layout of controls and signalling devices . . . . . . . . . . . . . . 5-1
5.2 Main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Numerical control functions keyboard . . . . . . . . . . . . . . . . . 5-3
5.4 Operator control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.5 PLC keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.6 Work table button pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.7 Axis speed control button pad . . . . . . . . . . . . . . . . . . . . . . . 5-6

Part 2 - Uses

Chapter 6. Starting, stopping and restoring functions


6.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Emergency stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Deactivating the emergency devices. . . . . . . . . . . . . . . . . . 6-3
6.5 Restoring the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.6 Machine axes reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Global reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Single reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Chapter 7. Carrying out a machining operation


7.1 Warnings regarding machining operations . . . . . . . . . . . . . 7-1
7.2 Procedure to be used to carry out the machining operation 7-2
7.3 Suspending the program . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 Program simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.5 Selecting a work table origin . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.6 Locking the piece. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Standard locking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Locking with clamp stops . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Locking with the aid of a jig . . . . . . . . . . . . . . . . . . . . . . 7-5
7.7 Starting the machining operation. . . . . . . . . . . . . . . . . . . . . 7-6
7.8 Unlocking and unloading the panel . . . . . . . . . . . . . . . . . . . 7-6

Part 3 - Tooling

Chapter 8. Fitting tools


8.1 Information on tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Boring tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Milling tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

6 BIESSE S.p.A.
(5801a0225TOC.fm-161203)
Table of Contents

Circular blade milling tool. . . . . . . . . . . . . . . . . . . . . . . . 8-4


8.2 Fitting the tool on the boring and milling unit . . . . . . . . . . . 8-5
Fitting the boring tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Fitting the circular blade milling tool. . . . . . . . . . . . . . . . 8-6
8.3 Fitting the tool on a collet spindle . . . . . . . . . . . . . . . . . . . . 8-7
8.4 Fitting the tool on the aggregate . . . . . . . . . . . . . . . . . . . . . 8-9
Locking an aggregate . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Fitting the tool on a boring aggregate . . . . . . . . . . . . . . 8-9
Fitting the tool on a straight milling and cutting aggregate8-10

Chapter 9. Preparing the operating section


9.1 Installing the collet spindle on the electrospindle . . . . . . . . 9-1
9.2 Installing the aggregate on the electrospindle . . . . . . . . . . 9-3
Adjusting the lockpin . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.3 Warming up the electrospindle . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Warming-up the boring and milling unit . . . . . . . . . . . . . . . 9-5

Chapter 10. Preparing the tool magazine


10.1 Preparing the tool magazine . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Housing collet spindles . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Housing procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.2 Preparing the rack type tool magazine . . . . . . . . . . . . . . . . 10-2
Housing collet spindles . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Housing aggregates. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Housing procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Chapter 11. Preparing the work table


11.1 Positioning the mobile elements on the work table. . . . . . . 11-1
Positioning the mobile piece support . . . . . . . . . . . . . . . 11-1
Positioning the side and centre stops . . . . . . . . . . . . . . 11-2
Positioning the shapeable suction cup . . . . . . . . . . . . . 11-2
11.2 Positioning the moving elements on the work table using the
electronic display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Transferring the work table configuration. . . . . . . . . . . . 11-3
Positioning the elements . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Reading and use of the electronic display . . . . . . . . . . . 11-3
11.3 Fitting the gasket on the shapeable suction cup. . . . . . . . . 11-5
11.4 Fitting the clamp stop plates function . . . . . . . . . . . . . . . . . 11-5

Part 4 - Operations

Chapter 12. Maintenance


12.1 Summary and frequency of operations . . . . . . . . . . . . . . . . 12-1
12.2 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
12.3 General cleaning of the machine . . . . . . . . . . . . . . . . . . . . 12-7
12.4 Draining condensation from the FRL unit . . . . . . . . . . . . . . 12-8
12.5 Checking tool lock on the electrospindle. . . . . . . . . . . . . . . 12-8
12.6 Cleaning the vacuum pump (Becker Picchio 2200) . . . . . . 12-9
12.7 Cleaning the vacuum pump (Becker VT 4.40) . . . . . . . . . . 12-10
12.8 Cleaning the guides and racks . . . . . . . . . . . . . . . . . . . . . . 12-10
12.9 Checking pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11

BIESSE S.p.A.
(5801a0225TOC.fm-161203)
7
Table of Contents

12.10 Lubrication of the slide blocks and ball screws . . . . . . . . . . 12-12


12.11 Cleaning the electrospindle . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
12.12 Cleaning the ISO 30 collet spindle . . . . . . . . . . . . . . . . . . . 12-14
12.13 Lubrication and cleaning of the aggregate . . . . . . . . . . . . . 12-14
12.14 Lubrication of the circular blade tool unit . . . . . . . . . . . . . . . 12-15
12.15 Lubrication and cleaning of the boring and milling unit . . . . 12-15
12.16 Lubrication (Becker Picchio 2200). . . . . . . . . . . . . . . . . . . . 12-16
12.17 Checking wear on the blades (Becker VT 4.40) . . . . . . . . . 12-17
12.18 Replacing the batteries in the NC 500 numerical control . . 12-18
12.19 Checking wear on the blades (Becker Picchio 2200) . . . . . 12-19
12.20 Topping-up lubricant in the FRL unit . . . . . . . . . . . . . . . . . . 12-20
12.21 Topping-up lubricant in the central greasing system . . . . . . 12-21

Chapter 13. Troubleshooting


13.1 Problems, causes and solutions . . . . . . . . . . . . . . . . . . . . . 13-1

Appendices

Appendix A. Safety information


A.1 Transport and moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A.4 Preparation and machining . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
A.6 Demolition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
A.7 Danger signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Appendix B. Technical characteristics


B.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
B.2 Position of the operating section units along the X-Y axes . B-2
B.3 Working field along the X - Y axes . . . . . . . . . . . . . . . . . . . B-3
B.4 Working field along the Z axis . . . . . . . . . . . . . . . . . . . . . . . B-4
B.5 Collet spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
B.6 Aggregate AGGRE4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
B.7 Aggregate AGGRE6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
B.8 Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

Appendix C. Transport
C.1 Parts to be transported . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
C.2 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Main structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Mesh guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Contact mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Vacuum pump and box of accessories . . . . . . . . . . . . . C-4
C.3 Moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Main structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
C.4 Repositioning the machine support feet . . . . . . . . . . . . . . . C-6

8 BIESSE S.p.A.
(5801a0225TOC.fm-161203)
Table of Contents

Appendix D. Installation
D.1 Layout of the machine, connection points and working
dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
D.2 Installation area requirements. . . . . . . . . . . . . . . . . . . . . . . D-5
Electrical system requirements . . . . . . . . . . . . . . . . . . . D-5
Pneumatic system requirements . . . . . . . . . . . . . . . . . . D-6
Suction system requirements. . . . . . . . . . . . . . . . . . . . . D-6
Flooring requirements . . . . . . . . . . . . . . . . . . . . . . . . . . D-7
Environmental requirements . . . . . . . . . . . . . . . . . . . . . D-7

Appendix E. Decommissioning - Demolition

Appendix F. Guarantee and client servicing


F.1 Conditions of the guarantee . . . . . . . . . . . . . . . . . . . . . . . . F-1
F.2 Client servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2

Analytical index

BIESSE S.p.A.
(5801a0225TOC.fm-161203)
9
Table of Contents

10 BIESSE S.p.A.
(5801a0225TOC.fm-161203)
Introduction

Introduction

Field of application and purpose of this manual

This manual provides information that is essential for correct use of the machine.

Because the subject matter is complicated, the procedures indicated in the manual should only be
carried out by those with adequate training in the operation of the machine.

The configuration of certain parts or devices described or illustrated in this manual may differ from
the ones actually fitted on your machine, but this will in no way compromise your understanding of
the manual itself. Some devices indicated and described in this manual may be optional features
and therefore not present on the machine.

To avoid any incorrect manoeuvres that could endanger people it is important to read and fully
understand all the documents that come with the machine, including those regarding special
devices. BIESSE may not be held responsible or liable in law for any damage resulting from
incorrect use of the manual and other accompanying documentation.

Documents Supplied with the Machine

The following is a list of the main documents provided with the machine:

n Machine user's manual; contains information on the use of the machine.

n Software users manual; contains information on the operations and procedures required to
create programs that can be run using the software connected to the machine.

n Spare parts catalogue; can be used to find and/or order components to be replaced.
If the machine is provided with the InDocs (Interactive Reference Documentation for User)
cd-rom, this document will only be supplied if specifically requested.

n Cd-rom InDocs (Interactive Reference Documentation for User); enables the operator to
carry out searches for and order replacement parts and to consult the following documents:
- Machine users manual;
- Software users manual;
- ISO 30 - HSK F63 aggregate users manual;
- Installation technicians manual;
- Pneumatic system diagrams.

n Wiring diagrams; describe the machine's electric system, and are to be used for problem
solving.

BIESSE S.p.A.
(a701h0005.fm-161203)
11
Introduction

n Pneumatic system diagrams; describe the machine's pneumatic system and are to be used
by the technician responsible for problem solving.

n CE Declaration of conformity; certifies that the machine conforms with the directives
indicated.
It is only issued for machines sold in EEC countries and in countries where Directive 98/37 is
applied.

n Documentation for special devices; contains information on any special parts of the
machine.

Warning Signs

Paragraphs that should not be overlooked are highlighted and preceded by the symbols described
and illustrated below.

DANGER
Paragraphs marked with this symbol indicate an imminent danger, and the contents must
therefore be taken into careful account in order to prevent a serious accident.

CAUTION
Paragraphs marked with this symbol indicate procedures to be used to avoid any damage
to goods and property.

INFORMATION
This symbol is used to indicate points of particular importance that must not be overlooked.

Warnings

The safety information provided in the appendix to this manual must be read before using the
machine.

12 BIESSE S.p.A.
(a701h0005.fm-161203)
Part 1 - Description

BIESSE S.p.A.
(a302h002.fm-161203)
BIESSE S.p.A.
(a302h002.fm-161203)
1-

Chapter 1. Main parts

This chapter contains a description of the main parts of the machine and the uses foreseen for
them. The descriptions refer to the standard version of the machine. For information on optional
devices, please see the relevant chapter.

1.1 General description of the machine

This machine is a numerical control processing centre, designed to carry out a wide range of
boring and milling operations. For further information on the machining operations that are
possible, on the loading methods and on the piece characteristics, please see chapter 4 Uses
foreseen.

The machine comprises a base, a group of devices that allow the piece/pieces being machined to
be positioned and locked (work table), and series of units used to machine the piece (operating
section). The operating section can be configured so as to satisfy the various machining needs of
customers. For more detailed information, please consult paragraph 1.2 General view and main
parts on page 1 - 2, in which the main parts of the machine are illustrated and described.

The machine is manufactured with safety systems that meet the regulations in force in the various
countries. Machines destined for use in Europe and those made in accordance with Directive
98/37 also bear the CE mark. Paragraph 1.5 Safety devices, page 1 - 6, describes the
machine's principal safety devices.

BIESSE S.p.A.
(a702h0014.fm-161203)
1-1
Chapter 1.
Main parts

1.2 General view and main parts

E
G

A - Base; this is the machines bearing structure.

B - Work table; this is equipped with the devices used to position and fix the piece to be
machined. For further details, please go to the paragraph 1.3 Work table.

C - Operating section; this is equipped with the groups used to machine the piece. For further
details, please go to the paragraph 1.4 Operating section.

D - Tool magazine; used to house collet spindles, fitted with tools, to allow automatic tool change
operations on the electrospindle. This type of tool magazine is equipped with 3 locations for
collet spindles with ISO 30 coupling.

E - Electrical cabinet; contains the principal electronic controls and devices used to manage
machine operations. For further information, please consult the Software users manual and
Chapter 5. Controls and signalling devices.

F - Vacuum pump; supplies the level of vacuum required to lock the piece to be machined on
the work table. The number of vacuum pumps on the machine depends on piece locking
needs.

G- FRL Unit: this filters, adjusts the pressure of and lubricates the compressed air.

1-2 BIESSE S.p.A.


(a702h0014.fm-161203)
Chapter 1.
Main parts

1.3 Work table

The main parts of the work table are illustrated and described below, and indications of their
position on the machine are also given (seen from above).

G
A

F
B C
D

E
front of the machine

A - Mobile piece support; supports the piece and its positioning and locking devices. It can be
positioned manually along the X axis.

B - Fixed piece support; supports the piece and its positioning and locking devices.

C - Shapeable suction cup; used to support and lock the piece. It can be positioned manually
along the Y axis. The channels formed on the surface of the cup allow the vacuum area to be
modified using a special rubber gasket. There are 2 types of shapeable suction cup: a
standard one and a small one.

D - Rear stop; used as a reference when positioning the rear side of the piece.

E - Centre stop; used as a reference when positioning the right or left hand side of the piece
(according to the working area being used).

F - Side stop; used as a reference when positioning the right or left hand side of the piece
(according to the working area being used).

G - Clamp stop plate; used on the stop when the characteristics of the piece do not allow it to be
locked safely using the suction cups alone. It is fitted on the top of the stops.

BIESSE S.p.A.
(a702h0014.fm-161203)
1-3
Chapter 1.
Main parts

1.4 Operating section

The following illustrates and describes the main parts of the operating section, and shows its
layout (view from above).

front of the machine

A - Boring and milling unit: this is equipped with 10 vertical boring spindles and 3 chucks, each
with 2 opposite spindles, for horizontal boring operations. The vertical boring spindles serve
to machine the top side of the piece. Of the 3 horizontal boring chucks, 2 are used to
machine the sides of the piece parallel to surface Y - Z, and 1 is used to machine the sides
parallel to surface X - Z. The spindles and chucks can be used individually or as a unit. A
circular blade tool unit is also provided for straight milling along the X axis.

B - Electrospindle; this is mainly used for milling operations. The electrospindle has a power of
7 kW (9.5 HP) and the ISO 30 type coupling allows rapid changing of the tool. The
electrospindle can also carry out automatic tool change operations using the tool magazine.
The electrospindle is fastened on a slide that allows it to drop down when in use and to rise up
again when machining operations have been completed.

1-4 BIESSE S.p.A.


(a702h0014.fm-161203)
Chapter 1.
Main parts

Collet spindle

The collet spindle is used to fit the tool on the electrospindle.

A - Coupling; this is the part that connects with


the electrospindle. It is an ISO 30 type C
coupling and is set up for use with ERC 32
type collets. Rotation can be to the right or B
to the left. A coupling that rotates to the left
can be recognised by the groove on its
outside.

B - Collet; used to house and lock the tool A


shank. The collets are type ERC 32, which
allow tools with a shank diameter of
between 6 and 20 mm to be used. Each
collet is set up for a specific shank
diameter.

C - Ring nut; used to tighten the collet and lock the tool. The grooves on the outside of the ring
nut give grip to the wrench.

BIESSE S.p.A.
(a702h0014.fm-161203)
1-5
Chapter 1.
Main parts

1.5 Safety devices

CE version

D
B

Non-CE version

H G
C
B

1-6 BIESSE S.p.A.


(a702h0014.fm-161203)
Chapter 1.
Main parts

A - Emergency button; used to shut down the machine immediately. It is located on the control
panel and in other points on the machine. For further information, please see Chapter 5.
Controls and signalling devices.

B - Emergency cord; this is foot-operated and is used to stop the machine immediately.

C - Curtain guards; these are made of PVC and serve to protect the operator from the risk of
airborne chips or tool fragments.

D- Cut-out valve; this is used to carry out maintenance operations or repairs on the machine in
complete safety, and it can be locked to prevent unauthorised tampering. When enabled,
which is done by turning the orange knob in an anticlockwise direction, it drains the pneumatic
system and blocks the flow of compressed air from the supply network. To restore the
machine after this device has been enabled, press the same knob and turn it in a clockwise
direction.

E - Mesh guard; protects the operator from the risk of interference with moving parts. It is fitted
with sliding doors that allow access to the internal area in order to carry out tooling and/or
maintenance operations. The doors are fitted with safety microswitches that can be locked.
Opening of the doors causes the machine to stop immediately

F - Contact mats: detect the presence of the operator and stop the machine immediately in the
event of danger. The mats detect any pressure over 13 kg/m2 (about that exerted by a person
weighing over 35 kg).

G - Chain guard; defines the area in which the operating section moves. When requested by the
client this device can be replaced by the mesh guard.

H - Photocell barrier; protects the operator from any risk of interference with moving machine
parts.

BIESSE S.p.A.
(a702h0014.fm-161203)
1-7
Chapter 1.
Main parts

1.6 Identification of the manufacturer and the machine

The manufacturer and the machine can be identified from the special identification plates located
at the points indicated in the figure. The identification plates contain various data and, for
machines sold within the European market and in markets where Directive 98/37 is applied, they
also carry the CE mark.

A - device

B - CE mark A B
BIESSE S.p.A - Via della Meccanica, 16 - 61100 Pesaro,PU ITALIA -Tel.0721/439100
C
Modello
Model D
C - address
Matricola
Serial number E
Anno di costruzione
Year of construction F
Alimentazione pneumatica
Bar G
D - model
Air supply
Velocita' aria di aspirazione
Suction flow rate m/sec H
Massa
Weight kg J
E - serial number

F - year of construction

G - pneumatic supply

H - suction air speed

J - machine mass

K - wiring diagram number

L - electrical cabinet mass

M - supply voltage

N - rated current

O - number of supply phases

P - power

Q - frequency A
BIESSE S.p.A. - Via della Meccanica, 16 - 61100 Pesaro,PU ITALIA -Tel.0721/439100
C
Modello
Model D
R - supply voltage short-circuit cut-out Matricola
Serial number E
power. N Schema elettrico
Wiring diagram number K
Massa
Weight kg L
Tensione di alimentazione
Power supply voltage VAC M
Corrente nominale
Rated current A N
Numero fasi alimentazione
Number of power supply phases O
Potenza
Power kW P
Frequenza
Frequency Hz Q
Potere di interruzione del corto circuito
alla tensione di alimentazione
Suitable for use on a circuit capable of
kA RMS Sym
at power supply voltage R
delivering not more than

electric system rating plate

1-8 BIESSE S.p.A.


(a702h0014.fm-161203)
2-

Chapter 2. Optionals

This chapter gives a brief description of all the optionals foreseen for the machine.

2.1 Electronic display

This is installed on the front of each mobile


support. It is used to display the positions at
which the supports themselves, the suction cups
and the stops must be positioned.

2.2 Additional mobile piece supports

It is possible to add 2 mobile piece supports complete with shapeable suction cups and rear stops.
The 2 supports are arranged as shown in the figure below.

BIESSE S.p.A.
(a702h0015.fm-161203)
2-1
Chapter 2.
Optionals

2.3 Additional rear stops

It is possible to add a series of rear stops to form an additional row of stops. For further
information on the rows of stops, please see paragraph 3.5 Row of stops page 3 - 3. The stops
are arranged as shown in the figure below.

2.4 Additional suction cups

It is possible to add a shapeable suction cup to each mobile piece support. The suction cups are
arranged as shown in the figure below, and can be of 2 types:

n standard shapeable suction cup (dimensions in mm = 160 x 160 x H 30);

n small shapeable suction cup (dimensions in mm = 160 x 80 x H 30).

2.5 Double movement stop

This can be used in place of the normal stop, or


fitted as an additional row of stops. It is used to
position special pieces with protruding edges.

2-2 BIESSE S.p.A.


(a702h0015.fm-161203)
Chapter 2.
Optionals

2.6 Bar or ball supports

These are fitted on the side of each mobile piece


support. They rise up automatically during
loading and unloading operations to support the
piece and facilitate its movement.

2.7 Collet spindles

It is possible to request collet spindles for ERC 40 collets. The ERC 40 collets make it possible to
use tools with a shank diameter of between 6 and 25 mm.

2.8 Electrospindle aggregates

The aggregates are used on electrospindles with ISO 30 or HSK F63 couplings, and they allow
particular machining operations to be carried out.

The following paragraphs describe all the available aggregates. The abbreviation AGGRE
followed by a number, indicated in the description, allows rapid identification of the aggregate in
question both in the manual and in the numerical control software.

The aggregate is fitted with plates providing the information necessary for use.

This plate serves to remind the operator to adjust the lockpin each time the
aggregate is fitted on another electrospindle (see paragraph Adjusting the
lockpin on page 9 - 4).

DANGER
Failure to adjust the lockpin may cause rapid deterioration of the
aggregate coupling, with the consequent risk of it disconnecting from the
electrospindle.

COD.67-14-A0560
This plate indicates, from top to bottom:
2=8050rpm MAX - the aggregate code;
1
2
= 0,7
- the maximum aggregate spindle rotation speed/s (rpm);
2 1
- the transmission ratio between the aggregate spindle rotation speed/s and the
electrospindle rotation speed.

BIESSE S.p.A.
(a702h0015.fm-161203)
2-3
Chapter 2.
Optionals

ISO 30 AGGRE4
Aggregate fitted with 1 horizontal spindle, for milling operations with circular
blade tools 120 mm.

ISO 30 AGGRE6
Aggregate fitted with 3 vertical spindles, for boring operations with cylindrical
shank tools. Used above all to machine the bores required to fix hinges.

2.9 Rack type tool magazine

It is possible to request the rack type tool magazine. It can be used to house collet spindles and/or
aggregates, fitted with tools, to allow automatic tool change operations on the electrospindle. It is
installed in the left hand portion of the base under a special cover. The tool magazine comprises 1
rack equipped with 4 tool holders.

2-4 BIESSE S.p.A.


(a702h0015.fm-161203)
Chapter 2.
Optionals

2.10 Central lubrication system

This device provides for automatic greasing of the ball screws and slide blocks used for movement
of the axes. The system comprises a grease pump located at the rear of the machine, connected
by pipes to the various elements requiring lubrication. Lubrication takes place at intervals specified
in the numerical control.

BIESSE S.p.A.
(a702h0015.fm-161203)
2-5
Chapter 2.
Optionals

2-6 BIESSE S.p.A.


(a702h0015.fm-161203)
3-

Chapter 3. Basic operations

This chapter deals with a variety of subjects that are of use when getting to know how the machine
operates.

3.1 Axes

The machine is fitted with a number of elements that move in various directions, and the position
of which must be kept under constant control. Each of these controlled mobile elements is known
as an axis. Movement of an axis is controlled by an encoder located on the drive motor. The turns
of the motor are detected by the encoder and sent to the numerical control, where they are
processed and displayed in the form of millimetres. To calculate the position of an axis it is
necessary to refer to a set point. The machine has various reference points, described in the
paragraph 3.6 Origin. Each axis can have a positive or negative direction of movement. The
following gives a description of all the axes and indicates with which mobile element in the
machine they are associated. Their positive or negative direction is also indicated.

X, Y and Z; these axes are associated with the movements of the operating section.

Z-
X- Y-

Y+ X+
Z+

BIESSE S.p.A.
(a705h0003.fm-161203)
3-1
Chapter 3.
Basic operations

3.2 Manual movement of axes

During tooling operations it may be necessary, or in certain cases essential, to move one of the
machine axes. To carry out this operation, use the JOG soft-keys located on the numerical control
functions keyboard and also the numerical control software. For the procedure to be used for
manual movement of the axes, please consult the Software users manual.

3.3 Variation of the axis movement speed

Variation of the axis movement speed is usually carried out during testing of a program, in order to
establish the most suitable speed for the material being machined, or to allow closer observation of
the movement of axes in particularly critical points of the program. The variation of speed is
carried out by turning the override manually. The percentage variation is displayed in a special
field on the numerical control software.

3.4 Working area

The working area is the surface of the work table on which the piece is positioned and locked. The
work table has 2 working areas. Each working area is equipped with one or more references for
positioning of the piece (see Work table origin page 3 - 3) and allows one piece at a time to be
locked. The working areas are identified as follows:

X+

Y+

SX1 DX1

3-2 BIESSE S.p.A.


(a705h0003.fm-161203)
Chapter 3.
Basic operations

3.5 Row of stops

A row of stops is a group of rear stops aligned along the X axis. The machine is fitted with 2 rows
of stops. Each row of stops allows a specific work table origin to be selected (see page 3 - 3). The
row of stops is selected using the soft-key on the PLC keyboard. The rows of stops can be
identified as follows:

X+
first row
Y+
second row

3.6 Origin

The origin is the reference point used to calculate axis coordinates. The machine has 2 types of
origin:

n machine origin;

n work table origin.

Machine origin

The absolute origin (or machine origin) is the 0 (zero) point for the cartesian axes and co-ordinates
system and for the main machine axes.
It is set by the manufacturer when the machine is first tested, using cams and limit switches
arranged in a suitable manner, and it is an imaginary point on the axis of the first electrospindle at
the height of the bottom end (nose) of the spindle itself.
All the other origins will be calculated with reference to this point.

Work table origin

The work table origins are reference points for the program positions. They are, in the direction of
cartesian axes X and Y, the point at which two imaginary lines tangent to the front and side stops
intersect, or, in the direction of cartesian axis Z, the surface of the piece resting on the work table.

BIESSE S.p.A.
(a705h0003.fm-161203)
3-3
Chapter 3.
Basic operations

There may be straight and mirror or symmetrical origins along the cartesian X and Y axes.:

X+
standard version of work table work table with additional rear stops
Y+

1 2 3 4 1 2 3 4

5 6 7 8

Straight origins; these use the top left


hand corner of the piece as a reference +X 0
point when the rear side of the piece is
pushed up against the front stops.
+Y

Mirror (or symmetrical) origins; these


use the top right hand corner of the piece +X 0
as a reference point when the rear side of
the piece is pushed up against the front +Y
stops.

The work table may have additional origins for supplementary piece positioning devices.

To carry out a machining operation it is necessary to select at least one work table origin, as
described on page 7 - 3.

The straight and mirror origins are normally used to create the left and right hand parts of a
furniture unit (sides, doors, etc.) with a single program.

3-4 BIESSE S.p.A.


(a705h0003.fm-161203)
Chapter 3.
Basic operations

The following example illustrates a program containing the instructions required to carry out a
vertical bore at X = +100 and Y = +70 and the result obtained on the various origins.

+X
with straight origin with mirror origin

+Y

70
70

100 100

3.7 Slot

The term slot is used to define certain areas, located on the operating section, set up for
installation of electrospindles. The term slot is also used to define the area on the boring and
milling unit in which the circular blade tool unit is fitted. The slots are identified as follows:

X+
slot B
(2)
Y+

slot A
(1)

BIESSE S.p.A.
(a705h0003.fm-161203)
3-5
Chapter 3.
Basic operations

3.8 Information on the spindle direction of rotation

The machine is equipped with various spindles, and it is extremely important, in order to avoid the
risks connected with fitting of an unsuitable tool, to understand the definition of right or left spindle
and be able to determine the direction of rotation of each spindle with certainty.

Definition of a right or left spindle

The definition of right spindle (DX) is given to a spindle that rotates in a clockwise direction, while
left (SX) is used for a spindle that rotates in an anticlockwise direction.

To define the direction of rotation of a spindle, you must look at it from direction A, as indicated in
the figure below.

boring and milling units spindle collet spindle aggregate spindle

DX
A A A

SX A

DX SX DX
SX

DX

SX

Determining the spindle direction of rotation

Information on the direction of rotation of the various spindles is given in appendix Appendix B.
Technical characteristics.
There are however conventions that enable quick determination of spindle rotation direction:

n A groove in the outside of the spindle (see


examples in figure A) indicates that it is a SX
left spindle.
A
n The direction in which the ring nut or flange
locking the tool screws on, which is always
the opposite to the direction of rotation of
the spindle. SX A

3-6 BIESSE S.p.A.


(a705h0003.fm-161203)
4-

Chapter 4. Uses foreseen

This chapter contains information defining the safe and proper uses for which the machine has
been built.

The machine has been designed, built and protected so as to offer maximum security, provided it
is only used in accordance with the specifications indicated below or supplied in another form by
BIESSE.

4.1 How to use the machine

The machine is not designed to be used in line with other machines. The material to be worked
must be loaded and unloaded manually by the operator on the machine work table.
If its dimensions along cartesian axis X allow it (see paragraph 4.2 Characteristics and
dimensions of workable materials on page 4 - 1), the piece may be loaded and unloaded in one
part of the work table while the operating section is machining in the opposite part, so as to reduce
production times (use in pendular machining mode).

4.2 Characteristics and dimensions of workable materials

The following materials can be worked:

n Wood (solid wood, plywood, fibre panels, stripboard, chipboard, veneered sheets).

n Wood derivatives (chipboard, MDF, OSB).

n Materials defined as plastics and composite materials, i.e. polymers (for example PVC, ABS,
cast methacrylate, lexan), resins (for example plastic reinforced with fibreglass),
thermoplastics (resulting from treatment of polymers) and rubber.

n Aluminium and alucobond (the machine is not fitted with liquid cooling systems).

CAUTION
Under no circumstances must the machine be used to work plasterboard, ferrous materials
or materials not mentioned above.

BIESSE S.p.A.
(a703h0010.fm-161203)
4-1
Chapter 4.
Uses foreseen

The maximum dimensions of the above mentioned materials must not exceed the ones indicated
in the table:

Y
Xb
Z X

Xb

front side
of the machine

Machine model X (mm) Xb (mm) Y (mm) Z (mm)


CE version 2884 900 900 65
non CE version 2884 1317 900 65

Values X and Y correspond to the surface of the piece that rests on the work table, along the
respective cartesian axes X and Y; Xb corresponds to the surface available along cartesian axis X
when two pieces are loaded simultaneously.
Value Z corresponds to the maximum thickness allowable for the piece to prevent it from
interfering with the operating section during movement.
Data relating to machining of the piece must be obtained each time, bearing in mind the maximum
movements that can be performed by the operating section unit involved in the machining
operation, the position of the piece on the work table, the tool dimensions and the working
dimensions of the other units present in the operating section.
It is also possible to position pieces with dimensions exceeding the ones indicated along cartesian
axes X and Y. In this case, always check before starting the machining operation, to ensure that
the piece is safely supported and locked.

Minimum dimensions are not easy to define, as the intensity with which the vacuum fastening
system works will depend on the porosity, thickness and dimensions of the piece. Furthermore, the
minimum locking intensity differs for each type of tool used. In the case of doubts regarding the
efficiency of the standard fastening system, it is recommended that auxiliary locking systems
(clamp stops, front pushers, etc.) be used. In any event, BIESSE is available for any clarification
that may be required.

4-2 BIESSE S.p.A.


(a703h0010.fm-161203)
Chapter 4.
Uses foreseen

4.3 Machining operations foreseen

All the machining operations that can be carried out by the machine are described and illustrated
below. Some of them can only be carried out using optional units.

n Vertical and horizontal boring operations.

n Vertical and horizontal milling operations.

n Cutting operations.

BIESSE S.p.A.
(a703h0010.fm-161203)
4-3
Chapter 4.
Uses foreseen

4.4 Work area

The areas in which the operator stands while the machine is operating, in order to activate and
oversee the control devices, are as follows:

Area A; in front of the control panel to use the NC, to activate controls and to oversee proper
operation of the machine.

Area B; in front of the work table, for loading and unloading of the material to be machined.

The areas to be used while setting up the machine will be specified in the following chapters.

4.5 Danger area

The danger area is the whole of the area occupied by moving parts during the machining
operation. This area is suitably marked by the mesh guard and the contact mats or photocell
barrier 1.5 Safety devices on page 1 - 6).

4-4 BIESSE S.p.A.


(a703h0010.fm-161203)
5-

Chapter 5. Controls and signalling devices

This chapter contains a description of the controls and signalling devices present on the machine.
These are arranged in various areas (see the figure below) and it is important that you note their
position carefully so that you can locate them more easily when working.

5.1 Layout of controls and signalling devices

D B A
C

E H

G G
L

G
J

G
J G

A - Main switch; this is located at the rear of the electrical cabinet (see page 5 - 3).

B- NC 500 or NC 1000 numerical control command unit; consists of a Personal Computer


(PC), equipped with monitor and keyboard, which allows management of machining
operations and of machine axis movements using the integrated software provided. For

BIESSE S.p.A.
(a704h0009.fm-161203)
5-1
Chapter 5.
Controls and signalling devices

further information please consult the documentation supplied with the PC and the Software
users manual.

C - Numerical control functions keyboard; (see page 5 - 3).

D- Operator control panel (see page 5 - 4 ).

E - PLC keyboard; (see page 5 - 5).

F - Override; used to vary the speed, expressed as a percentage, at which the programmed
axes are moved (see page 5 - 4).

G - Work table button pad; (see page 5 - 6).

H - Axis speed control button pad; (see page 5 - 6).

J - Piece locking pedal; controls locking of the piece to the work table. Each working area has
one pedal.

L - Emergency indicator light; when this is on it indicates that the machine is in emergency
mode, which has been triggered by the cord.

M - Tool unlock soft-key; used during preparation of the electrospindle, to install or remove a
collet spindle or an aggregate. When the soft-key is pressed the coupling is unlocked, and
when the soft-key is released the coupling is locked again. If more than one electrospindle is
present the relative slot will be specified on each soft-key.

5-2 BIESSE S.p.A.


(a704h0009.fm-161203)
Chapter 5.
Controls and signalling devices

5.2 Main switch

on The main switch is used to turn the power supply to the machine on and
off. It can be locked, to prevent tampering by third parties.
0-off = power off.
off 1-on = power on.
tripped = the switch automatically trips to this position in the event of a
short-circuit. To restore power, the switch must first be turned to 0-off and
then to 1-on.

5.3 Numerical control functions keyboard

CLEAR; (black key) used to update error log displayed in the numerical control software
CLEAR window.

JOG+ soft-key; used to command movement of the axes in the positive direction.

VEL soft-key; used to increase the axis speed during movement in manual mode.
It must be pressed at the same time as the JOG+, or JOG- soft-key.

JOG- soft-key; used to command movement of the axes in the negative direction.

STOP soft-key; used to stop an operation.


STOP

START soft-key; used to perform a step of the program when machining in


START semiautomatic mode.

RESET soft-key; used to reset the numerical control after an emergency.


RESET

BIESSE S.p.A.
(a704h0009.fm-161203)
5-3
Chapter 5.
Controls and signalling devices

5.4 Operator control panel

Emergency button; used to shut down the machine immediately. To


deactivate the button, turn it in the direction indicated by the arrows.

Start button; used to start the machine.

Vacuum indicator; when this lights up it indicates that the vacuum level is
insufficient.

Tooling selector; used to enable the machine setup operating mode. When
this function is enabled, only the voltage required to operate the electrovalves
(24 V) is available, so that operations can be carried out in safety.
Right = function enabled.

Double movement stops selector; used to enable the double movement


stops.
Right = function enabled.

Vacuum system selector; used to prevent unlocking of the piece in the event
of an emergency shut-down. This function is usually enabled when milling
operations are being performed, so that there is no risk of the piece having to
be discarded in the event of an unexpected emergency.
Right = function enabled.

5-4 BIESSE S.p.A.


(a704h0009.fm-161203)
Chapter 5.
Controls and signalling devices

5.5 PLC keyboard

This keyboard has a series of soft-keys with associated symbols. The following illustrates these
symbols and describes the functions of the corresponding soft-keys. The soft-keys that are not
associated with a symbol are not active. On, off and flashing refer to the condition of the LED on
the soft-key in question.

Stop row soft-keys; used to enable the row of stops to be used for the machining
1 operation.
On = row of stops selected.
2

Stop row soft-key; used to select the row of stops to be used for machining.
Off = the first row of stops is selected.
On = the second row of stops is selected.
Flashing = the third row of stops is selected.

Clamp stops soft-key; used to enable the clamp stops function while the program is
running.
On = function enabled;
Flashing = the function is still enabled, but locking with the suction cups is disabled.

Front pushers soft-key; used to enable the front pushers while the program is running.
On = function enabled.

Bar supports soft-key; used to enable the bar or ball supports while the program is
running.
On = function enabled

Magazine Cover soft-key; used to open and close the rear tool magazine cover.
On = the magazine is open.

Reset slot soft-key; used to raise an electrospindle that has been left in the lowered
position following an unforeseen stoppage of the machine.

Semiautomatic soft-key; used during preparation to check the machines movements


with a specific program.
On = function enabled.
Flashing = the machine waits for the soft-key to be pressed before performing a step of
the program.

CLR soft-key; used to cancel the errors that appear on the numerical control software.
On = an error has occurred; solve the problem and then press the soft-key.

BIESSE S.p.A.
(a704h0009.fm-161203)
5-5
Chapter 5.
Controls and signalling devices

Test cones soft-key; used to start a test cycle on the tools in the tool magazine. The
numerical control indicates when it is necessary to carry out this operation.

Reset slot from tool change soft-key; used to return an electrospindle to normal
working conditions, when the former has been left lowered in the tool change position on
the tool magazine following an unforeseen stoppage of the machine.

5.6 Work table button pad

Select origin button; used to select the origin and to start the machining
START 1 (2,3,4)
operation. The various button states indicate the following conditions:
Off = origin can be selected for the machining operation;
On = origin cannot be selected for the machining operation;
Flashing = the origin contains a locked piece; press the button to confirm the
machining operation.

Auxiliary vacuum system selector; used to enable the auxiliary vacuum


STD AUX system.
Right (AUX) = function enabled.
SX 1
(SX 2, DX 2, DX 1)

5.7 Axis speed control button pad

Emergency button; used to shut down the machine immediately. To


deactivate the button, turn it in the direction indicated by the arrows.

Remote override; used to vary the percentage programmed axis movement


speed.

5-6 BIESSE S.p.A.


(a704h0009.fm-161203)
Part 2 - Uses

BIESSE S.p.A.
(a303h003.fm-161203)
BIESSE S.p.A.
(a303h003.fm-161203)
6-

Chapter 6. Starting, stopping and restoring


functions

This chapter describes the procedures used to carry out the main basic operations, such as
start-up, shut-down, stopping and resetting the machine.

6.1 Switching on

1. Turn the main power switch to position 1 (ON).

2. Make sure that all the emergency stop devices are disabled.

3. Close all the doors in the mesh guard.

4. Bring the main factory pneumatic system up to pressure and open the cut-off valve.

5. Activate the chip suction system and make sure that the connection tube sectioning guillotine
is open.

6. Press the start button on the operator control panel. The button will light up.

7. Press the RESET button on the numerical control command module.

8. Carry out a global reset on the machine axes (see page 6 - 5).

9. Perform the warming-up cycles for the electrospindle (see page 9 - 4). and the boring unit
(see page 9 - 5). When the warming-up cycles terminate, the machine is ready for use.

CAUTION
Do not needless switch on and off repeatedly as the vacuum pump blades could get
damaged.

On each start up check that each emergency button is working, as are the cut-out valve, the safety
fence (when door is opened), the contact mats (see procedure below), the photocell barrier (on
access to the area between the photocell supports) and the emergency cord. Should these
devices fail to operate correctly, inform the maintenance technician or the BIESSE service
department.

DANGER
The machine must under no circumstances be used if the safety devices are not working.

BIESSE S.p.A.
(a711h0023.fm-161203)
6-1
Chapter 6.
Starting, stopping and restoring functions

Checking proper operation of the contact mats

1. Along cartesian axis Y, position the operating section towards the back of the machine.

2. Along cartesian axis X, position the operating section (approximately) half way along any one
of the side contact mats.

3. Tread on the side contact mat in correspondence with the operating section; the start button
on the operator control panel should turn off.

4. Restore the machine to normal operation.

5. Along cartesian axis X, position the operating section (approximately) half way along the
other side contact mat.

6. Tread on the side contact mat in correspondence with the operating section; the start button
on the operator control panel should turn off.

7. Restore the machine to normal operation.

8. Tread on any one of the central contact mats; the start button on the operator control panel
should turn off.

9. Restore the machine to normal operation.

10. Tread on the other central contact mat; the start button on the operator control panel should
turn off.

6-2 BIESSE S.p.A.


(a711h0023.fm-161203)
Chapter 6.
Starting, stopping and restoring functions

6.2 Switching off

1. Move the operating section into the park area, on the left hand side, to prevent any tools that
may be fitted on the units from coming into impact with the elements on the work table.

2. Remove the tools from the electrospindles and fit a plug to protect them from dust and to
prevent the springs in the electrospindle from slackening as a result of long periods under
strain, thus losing their ability to lock the collet spindle securely in place.

3. Press the emergency button.

4. Prepare the PC for switching off.

5. Turn the machines main switch to 0-off and lock it.

At the end of the procedure it is possible to


disable (turn OFF) the factory main power
system switch and close the pneumatic circuit at
the point of connection to the main factory A
system.
Yo u s h ou l d t h e n di s c h ar g e a n d l o c k t h e
pneumatic circuit with the cut/out valve (turn
knob A anticlockwise)
that should be padlocked.

6.3 Emergency stop

To stop the machine immediately, press the


nearest emergency stop button A with a hand,
or activate the emergency cord B. A
B

6.4 Deactivating the emergency devices

1. If a button has been pressed, turn it in the direction indicated by the arrows on the button.

2. If the emergency cord has been activated,


press button A on the microswitch of the
cord using a foot.
A

BIESSE S.p.A.
(a711h0023.fm-161203)
6-3
Chapter 6.
Starting, stopping and restoring functions

6.5 Restoring the machine

To restore the machine to normal operation after a sudden stoppage has occurred, whether
accidentally or on purpose, proceed as follows:

CAUTION
Before moving the machine axes, the tool magazines and the electrospindles, remove any
obstructions to ensure that there is no risk of danger.

DANGER
If the stoppage was caused by a power cut, wait at least 30 minutes before approaching the
operating section, to give the tools time to stop rotating.

1. Eliminate the cause of stoppage, resetting any controls or safety devices that may have been
triggered.
If the stoppage was caused by a power cut, immediately turn the machines main switch to 0
off and, after the power supply has been restored, repeat the machine start-up procedure
(see page 6 - 1).

2. Press the start button on the operator control panel.

3. Press the STOP button on the numerical control functions keyboard.

4. Press the RESET button on the numerical control functions keyboard.


In some cases, if stoppage has taken place during automatic tool change operations, it is
possible to run a reset cycle for the operating section and magazine involved.

5. If stoppage has occurred following a power cut during automatic tool change operations,
check that arrangement of the tools in the magazine corresponds with the description given in
the numerical control software.

6. Check the state of the red Reset slot indicator on the PLC keyboard; if it is flashing this
indicates that the electrospindle must be reset. Check that the panel or the tool will not be
damaged when the electrospindle rises (if necessary move the operating section or remove
the panel) and press the relative key.

6-4 BIESSE S.p.A.


(a711h0023.fm-161203)
Chapter 6.
Starting, stopping and restoring functions

6.6 Machine axes reset

Resetting is a procedure using which the machine axes move to a preset position known to the
NC. The axis reset may be global, when all the axes are reset together, or single when the axes
are reset one at a time on different occasions.

Global reset

To carry out a reset of all the machine axes, follow the instructions given below:

1. On the numerical control, enable global machine axis reset mode.

2. Make sure that nothing is likely to obstruct normal movement of the axes, and start the reset
operation by pressing START on the main control panel numerical control functions keyboard.
The first axis to be reset is the Z axis, followed by the remaining axes.

Single reset

To carry out a reset on a single machine axis, follow the instructions given below:

1. On the numerical control, enable single machine axis reset mode and select the axis you wish
to reset.

2. Make sure that nothing is likely to obstruct normal movement of the axes, and start the reset
operation by pressing START on the main control panel numerical control functions keyboard.

INFORMATION
The single reset must follow the order given above for the global reset.

BIESSE S.p.A.
(a711h0023.fm-161203)
6-5
Chapter 6.
Starting, stopping and restoring functions

6-6 BIESSE S.p.A.


(a711h0023.fm-161203)
7-

Chapter 7. Carrying out a machining


operation

This chapter contains a description of the methods to be used and steps to be followed to carry out
the machining operations foreseen. All the procedures described below are given under the
assumption that the operator has started-up and prepared the machine correctly, and that he
knows how to use the numerical control software.

7.1 Warnings regarding machining operations

Before the machining operation:

n Carry out the warming-up cycles for the electrospindle (see page 9 - 4). and the boring unit
(see page 9 - 5).

During the machining operation:

n Set a suitable rotation speed and speed of advance, to prevent chips or parts of tools from
flying out of the machine.
The following gives various reference values regarding the maximum rotation speed to be set
for the electrospindle, according to the weight and diameter of the tool employed.
For additional information, please see appendix B Technical characteristics.

Tool diameter (mm) Tool weight (kg) Max speed (rpm)(*)


150 4 5000 9000
130 4 9000 12000
100 2,5 12000 14000
80 2,5 14000 18000
50 2 18000 24000
(*). The values refer to tools with G. 2.5 balancing levels, in accordance with ISO 1940.

n When using an aggregate, take into account the machining operation suspension times
necessary to prevent it from overheating.

n During machining operations, insert a collet spindle in unused electrospindles, to protect them
from dust.

BIESSE S.p.A.
(a711h0024.fm-161203)
7-1
Chapter 7.
Carrying out a machining operation

n In the event of an emergency stop or sudden stoppage of the machining operation, wait at
least 30 minutes before approaching the operating section, to allow the tools time to stop
turning.

n During loading and unloading of the piece the operator must never lean on the work table or
climb onto the machine, as in this case the contact mat might cease to detect his presence.

n When the machine is used in pendular mode (see page 4 - 1), take into account the safety
limits set in the numerical control (non CE version only) to avoid damaging the piece. If the
operating section reaches this limit while the operator is loading or unloading a piece in the
working area opposite to the one in which machining operations are being carried out, the
machining operations will be paused. To find this limit, consult the machine working field
information in the appendix to this manual, or the Software users manual.

After the machining operation:

n If the machine is not to be used again (for example at the end of a working shift, overnight or
over a holiday), remove the tools from the electrospindles and replace them with a plug. This
procedure serves to prevent the springs in the electrospindle from slackening as a result of
long periods under strain, thus rapidly losing their ability to lock the collet spindle securely in
place.

7.2 Procedure to be used to carry out the machining operation

To carry out a machining operation on a piece, it is necessary to:

1. Tool up the machine; the information required to do this will be provided in the following
chapters.

2. Select the row of stops to be used for the machining operation, using the key provided on the
PLC keyboard.

3. Create a program, using the numerical control software, or open an existing program, and run
it. Please consult the software users manual on how to do this.

4. Select a work table origin (see paragraph 7.5 Selecting a work table origin on page 7 - 3).

5. Lock the piece on the work table (see paragraph 7.6 Locking the piece on page 7 - 4).

6. Start the machining operation (see paragraph 7.7 Starting the machining operation on page
7 - 6).

7. Unload the piece (see paragraph 7.8 Unlocking and unloading the panel on page 7 - 6).

If you wish to carry out the same program on other pieces, repeat steps 4 to 7 on each of the other
pieces required.

If you wish to carry out another working cycle using the same program, repeat the above
procedure from point 4 to point 7.

7-2 BIESSE S.p.A.


(a711h0024.fm-161203)
Chapter 7.
Carrying out a machining operation

7.3 Suspending the program

In a program, it is possible to insert instructions suspending the machining operation to allow


certain operations to be carried out on the piece being machined (for example to turn it, clean it or
move it to another origin). Please consult the Software users manual on how to insert these
suspensions in the program.
To resume the machining operation proceed as described in paragraph 7.7 Starting the
machining operation on page 7 - 6 after (if necessary) locking the piece again (see page 7 - 4).

7.4 Program simulation

The operations performed when running a specific program can be checked before actually
machining the panel.
This simulation can be carried out with the machine stopped, viewing the effect on the numerical
control command unit display. For information on the simulation procedure, please consult the
Software instruction manual.

7.5 Selecting a work table origin

To carry out a machining operation it is necessary to select a work table origin.

According to the dimensions of the piece along


the X axis, which are defined in the program
being run, the machine will automatically enable
the origins on which it is possible to carry out the
machining operation, lighting up the START
buttons (1, 2, 3, or 4), located on the work table
button pads.

According to the origin to be selected, you


should therefore press one of the following
buttons:
for origin 1, 5, 9 or 13 press START 1;
for origin 2,6 or 10 press START 2;
for origin 3, 7 or 11 press START 3;
for origin 4, 8 or 12 press START 4.

After carrying out this operation, if the clamp locking function is not enabled, the stops will rise up.
If the operating section is near to the selected origin wait until it has moved into position and then
stopped before approaching the work table.

BIESSE S.p.A.
(a711h0024.fm-161203)
7-3
Chapter 7.
Carrying out a machining operation

7.6 Locking the piece

According to the characteristics of the piece, the operator may select various locking methods,
which are the standard one (using the shapeable suction cups only), the one using the clamp
stops and finally the one using the jig.

For safe and proper locking it is recommended that you always use a sufficient number of suction
cups, or, if necessary, the clamp stops as well.

Standard locking

Standard locking is the type carried out using the


shapeable suction cups only. This type of
locking is used for sufficiently large, flat pieces,
that can easily be locked using the vacuum
system. If necessary, before locking, clean the
surface of the suction cups involved.

To lock the piece, simply position it correctly in


correspondence with the work table origin
required (as shown in the example) and press
the relative pedal. After locking, press down on
the piece to ensure it adheres perfectly to the
suction cups, and make sure there is a perfect
seal.

Should it be necessary to correct the position of the piece after it has been locked, it can be
temporarily unlocked by pressing and holding the pedal.

Locking with clamp stops

This type of locking is normally used for small


pieces that cannot be adequately locked using A
the suction cups alone.
A
To carry out this type of locking it is first
necessary to install special plates A on the stops
(see 11.4 Fitting the clamp stop plates function A
on page 11 - 5) and then enable the clamp
stops key on the PLC keyboard. This function
can also be enabled directly by the numerical
control software (please see the Software users
manual on how to do this)

7-4 BIESSE S.p.A.


(a711h0024.fm-161203)
Chapter 7.
Carrying out a machining operation

To lock the piece, after having set up the machine as described previously, proceed as follows:

DANGER
During locking operations, keep your hands well away from the plates on the stops.

1. Raise the stops by pressing and holding the


fixing pedal for the origin selected.

2. Position the piece against the raised stops.

3. Release the pedal; the stops will drop down


and lock the piece.

Locking with the aid of a jig

This type of locking is normally used when


carrying out profiling operations on pieces (A) B A
that, because of their shape and size, cannot be
fixed using the standard locking method.

In this case the operator must first prepare a jig


(B) that is to say a piece that can be locked by
the suction cups. The jig must be fitted with one
or more shaped areas, used to lock the piece to
be machined, which must be connected by a C
pipe (C) to the auxiliary vacuum system.

To carry out locking operations, proceed as follows:

1. Rest the jig on the work table, in the area


involved, and connect it to the auxiliary
vacuum system. The connection points on
the machine are located in the base under
the work table.

2. Bring the jig up against the stops.

3. Lock the jig by turning the auxiliary vacuum


system selector, located on the work table
button pad, to the right, and removing the
key to prevent tampering.

BIESSE S.p.A.
(a711h0024.fm-161203)
7-5
Chapter 7.
Carrying out a machining operation

4. Position the piece to be machined on the jig


in the locking area provided.

5. Press the pedal; the piece will be locked.

7.7 Starting the machining operation

To start a machining operation, merely press the flashing START button (1, 2, 3 or 4) located on
the work table button pad.

After pressing the button the operating section moves to the selected origin and starts the
machining operation. In the case of pendular machining operations, the machine will start the new
operation after completing the one in progress.

If, after starting the machining operation, the operator steps onto the contact mats (for example to
check proper locking of the panel), the mats must then be reset again by pressing the START
button (1, 2, 3 or 4), located on the work table button pad, or the start button on the operator
control panel.

7.8 Unlocking and unloading the panel

Normally, at the end of the machining operation, the piece is unlocked automatically, so that to
unload it you simply pick it up from the work table. However, if the piece is locked using the clamp
stops, to unload it these must be raised by pressing on the corresponding fixing pedal.

7-6 BIESSE S.p.A.


(a711h0024.fm-161203)
Part 3 - Tooling

BIESSE S.p.A.
(a309h002.fm-161203)
BIESSE S.p.A.
(a309h002.fm-161203)
8-

Chapter 8. Fitting tools

This chapter contains information on fitting tools, for example a description of the tool types,
minimum and maximum dimensions, rotation speed according to weight and fitting procedures.
This chapter does not contain information on how to input the data required to complete tooling
operations into the numerical control. For this information, please consult the Software users
manual.

8.1 Information on tools

There are many types of tools available on the market. This paragraph contains information on the
type of coupling and maximum dimensions required for tools to enable them to be used on the
machine.

INFORMATION
The data for maximum tool dimensions, provided in this paragraph, are not valid if the tool is to be
used in the magazine. Please consult the chapter describing preparation of the tool magazine to
learn these limits.

Boring tool

The boring tool is divided into 3 categories:

A B C

A - Blind boring tool; used to machine bores that terminate inside the piece without passing all
the way through it.

B - Through boring tool; used to machine bores that pass all the way through the piece.

C - Large diameter blind boring tool; used to machine the blind bores used to house hinges.

BIESSE S.p.A.
(a706h0025.fm-161203)
8-1
Chapter 8.
Fitting tools

The coupling on the boring tools must be cylindrical with a diameter of 10 mm and a minimum
length of 20 mm. The coupling must also have a flat part, which is used to lock the tool in the
spindle.
10

min 20
As regards the diameter (D) and the distance the tool protrudes from the nose of the spindle (L),
always comply with the limits indicated below. Values are expressed in millimetres.

A B C
L
L

D D
D

Unit on which the tool is to be used Tools A - B Tool C


D max L max D max L max
Boring and milling unit 20 77 50 77
Aggregate AGGRE6 10 53 35 53

8-2 BIESSE S.p.A.


(a706h0025.fm-161203)
Chapter 8.
Fitting tools

Milling tool

The milling tool is locked in the spindle using a collet and a lock nut.The tool coupling must by
cylindrical. The diameter and length of the coupling vary according to the type of collet used in the
spindle.

A B C
ERC 25 ERC 32 ERC 40

9 10 6 20 6 25
34

40

46

A - For ERC 25 type collets the diameter of the coupling is between 9 and 10 mm and the
minimum length must be 34 mm.

B - For ERC 32 type collets the diameter of the coupling is between 6 and 20 mm and the
minimum length must be 40 mm.

C - For ERC 40 type collets the diameter of the coupling is between 6 and 25 mm and the
minimum length must be 46 mm.

As regards the diameter (D) and the distance the tool protrudes from the nose of the spindle (L),
always comply with the limits indicated below:.
L

D max = 100 mm;


L max = 120 mm.

BIESSE S.p.A.
(a706h0025.fm-161203)
8-3
Chapter 8.
Fitting tools

Circular blade milling tool

The circular blade milling tool is fitted on a shaft and locked with a flange. The coupling
characteristics vary according to the unit on which it is fitted.

Li

Di
A
A

Unit/Aggregate A Di Li
Boring and milling unit 23 35 26
Aggregate AGGRE4 23 35 2,8

DANGER
Never use circular blade tools that do not have a bore for the lockpin (ref. A).

As regards the diameter (D) the thickness (L) and the maximum working depth (PRF), always
comply with the limits indicated below. The values are expressed in millimetres.

L
D
PRF

PANEL

Unit on which the tool is to be used D max L max PRF max


Boring and milling unit 120 4 26
Aggregate AGGRE4 120 10 26

8-4 BIESSE S.p.A.


(a706h0025.fm-161203)
Chapter 8.
Fitting tools

8.2 Fitting the tool on the boring and milling unit

On the boring and milling unit it is possible to fit 2 different types of tool: boring tool; circular blade
cutting tool.

Fitting the boring tool

DANGER
Before fitting the tool, check the direction in which the spindle turns.

1. Position the operating section at a point on the machine in which it is easiest to access the
boring unit.

2. Turn the tooling selector on the operator control panel to the right and remove the key, to
prevent anybody from re-starting the machine accidentally.

3. Force descent of the spindle involved in the tooling-up procedure.

4. Insert the tool in the spindle, directing the attachment plane A towards the hole B.

5. Lock the tool with the lock screw C.

BIESSE S.p.A.
(a706h0025.fm-161203)
8-5
Chapter 8.
Fitting tools

Fitting the circular blade milling tool

DANGER
Always use the antirotation pin A to lock the tool. Never use circular blade tools that are not
provided with a hole for the antirotation pin.

DANGER
Before fitting the tool, check the direction in which the spindle turns.

INFORMATION
This tool is already fitted on the machine when it is delivered to the client.

1. Lock shaft B using a setscrew wrench.

2. Unscrew flange C.

3. Fit the blade on the spindle.

4. Screw up flange C, locking it completely.

B
C

8-6 BIESSE S.p.A.


(a706h0025.fm-161203)
Chapter 8.
Fitting tools

8.3 Fitting the tool on a collet spindle

DANGER
For safety reasons, all the collet spindles used on the machine must be supplied by
BIESSE S.p.A. or by an authorised dealer.

DANGER
Before fitting the tool, check the direction in which the spindle turns.

1. To carry out this operation a special device A is provided, and this must be anchored to a
work bench using the holes provided.

2. Position the spindle cone B in the device, as shown in the figure.

3. Turn the bracket C until it is over the spindle, and lock it by turnings screws D and E.

C D
E

BIESSE S.p.A.
(a706h0025.fm-161203)
8-7
Chapter 8.
Fitting tools

4. Insert the pincer F in the seating on the ring G.

5. Screw the ring G onto the cone, without locking.

6. Insert the tool shank into the pincer and tighten the ring fully.

8-8 BIESSE S.p.A.


(a706h0025.fm-161203)
Chapter 8.
Fitting tools

8.4 Fitting the tool on the aggregate

To facilitate fitting operations the aggregate can be locked in the same device used when fitting the
tool on a collet spindle (see page 8 - 7). To fit the tool, different procedures are used according to
the type of aggregate (boring, straight milling and cutting).

DANGER
Before fitting the tool, check the direction in which the spindle turns.

Locking an aggregate

1. Unfasten the collet spindle fixing mechanism by unscrewing the screw A.

2. Turn the aggregate upside down and insert it in the device as shown in the figure.

Fitting the tool on a boring aggregate

1. Insert the tool in the spindle, directing the attachment plane A towards the hole B.

2. Lock the tool with the lock screw C.

BIESSE S.p.A.
(a706h0025.fm-161203)
8-9
Chapter 8.
Fitting tools

Fitting the tool on a straight milling and cutting aggregate

DANGER
To lock the tool, always use the antirotation pin A. Never use circular blade tools that do
not have a hole for the antirotation pin.

1. Lock the shaft B using a hexagon wrench.

2. Unscrew flange C.

3. Fit the blade on the spindle.

4. Tighten flange C until it is fully locked.

B
C

8 - 10 BIESSE S.p.A.
(a706h0025.fm-161203)
9-

Chapter 9. Preparing the operating section

This chapter provides the information necessary to set up the units that are present, or can be
installed on the operating section, to carry out a specific machining operation. This chapter does
not contain information on how to input the data required to complete this preparation into the
numerical control. For this information, please consult the Software users manual.

9.1 Installing the collet spindle on the electrospindle

DANGER
For safety reasons, the collet spindles used on the machine must only be supplied by
BIESSE S.p.A. or by an authorised supplier.

CAUTION
In order to protect internal parts from dust produced during machining with other units, the
electrospindle must always be fitted with a collet spindle.

INFORMATION
As regards the maximum diameter and protrusion of the tool on the collet spindle, always comply
with the limits indicated in the paragraph 8.1 Information on tools.

Generally speaking the collet spindle is installed automatically, using the tool magazine. However,
if it has to be installed manually, proceed as follows:

1. Position the operating section in a point on the machine that provides easy access to the
electrospindle, lowering it if necessary.

2. Turn the Tooling selector on the operator control panel to the right and remove the key to
prevent the machine from being put into operation accidentally.

3. Press the Tool unlock soft-key, located in the vicinity of the operating section.

BIESSE S.p.A.
(a706h0026.fm-161203)
9-1
Chapter 9.
Preparing the operating section

4. Insert the coupling completely into the housing provided, and lock it by releasing the soft-key.

5. Insert the key in the Tooling selector on the operator control panel and turn it to the left.

6. Press the start button on the operator control panel. The button will light up.

If the electrospindle has been lowered, proceed as follows to raise it again:

1. Press the RESET soft-key on the numerical control command unit.

2. Press the Reset slot soft-key on the PLC keyboard.The electrospindle will rise.

9-2 BIESSE S.p.A.


(a706h0026.fm-161203)
Chapter 9.
Preparing the operating section

9.2 Installing the aggregate on the electrospindle

When the machine is delivered, each aggregate is set up to be installed on a specific


electrospindle. If an aggregate is to be used in an electrospindle other than the one for which it has
been set up, it will be necessary to adjust the pin. The pin must also be adjusted on all aggregates
purchased after the machine has been delivered.

DANGER
Failure to adjust the lockpin may cause rapid deterioration of the aggregate coupling, with
the consequent risk of it disconnecting from the electrospindle.

To install the aggregate, proceed as described in the paragraph 9.1 Installing the collet spindle on
the electrospindle on page 9 - 1, turning pin A so that it corresponds with the housing on the
electrospindle.

BIESSE S.p.A.
(a706h0026.fm-161203)
9-3
Chapter 9.
Preparing the operating section

Adjusting the lockpin

1. There are 3 types of aggregate. Look at the aggregate and check the figure below to find out
the type of your aggregate.

2. Slightly loosen the lockscrew or screws B, according to the type of aggregate. The pin A will
be pushed upward by a spring located beneath it.

A A A

B B B

3. Install the aggregate on the electrospindle required and check that the pin is perfectly inserted
in the housing.

4. Tighten the lockscrew or screws B once again.

9.3 Warming up the electrospindle

When the machine is started up at the beginning of the day it is necessary to make each
electrospindle perform a brief warm-up cycle so as to allow the bearings to reach an even working
temperature gradually. To do this, create a program in which each electrospindle is used as
described below:

1. 50% of the max rated speed for 2 minutes.

2. 75% of the max rated speed for 2 minutes.

3. 100% of the max rated speed for 1 minute.

It is also recommended that this cycle be repeated every time the machine is stopped for a period
long enough to allow the electrospindle to return to room temperature.

9-4 BIESSE S.p.A.


(a706h0026.fm-161203)
Chapter 9.
Preparing the operating section

9.4 Warming-up the boring and milling unit

In order to ensure precise machining, it is extremely important that the boring and milling unit be
made to carry out a warming-up cycle lasting approximately 15 minutes. As there is no specific
command provided to do this, proceed as follows:

1. Create a simple program in which the boring and milling unit is used, and run it.

2. When the boring unit motor starts, turn the override to the left (to zero) and wait for the
prescribed amount of time.

BIESSE S.p.A.
(a706h0026.fm-161203)
9-5
Chapter 9.
Preparing the operating section

9-6 BIESSE S.p.A.


(a706h0026.fm-161203)
10 -

Chapter 10. Preparing the tool magazine

This chapter describes how to prepare the various tool magazines. In particular it provides
information on the maximum dimensions of tools, on the orientation and assembly position of each
aggregate and on the compatibility of collet spindles and aggregates in adjacent positions.
BIESSE is available for any special requirements or clarification that may be necessary. This
chapter does not contain information on how to input the data required to complete tooling
operations into the numerical control. For this information, please consult the Software users
manual.

INFORMATION
The maximum tool dimensions, provided in this chapter, refer exclusively to the tool magazine in
question, and are not to be considered as limits to the machining operation. Please consult the
chapter describing how the tools are fitted to learn these limits.

10.1 Preparing the tool magazine

This magazine can be used to house collet spindles only, complying with the rules and procedures
described.

Housing collet spindles

It is possible to provide for simultaneous housing of 3 collet spindles with ISO 30 couplings, fitted
with tools having a maximum diameter (D) of 60 mm and a maximum protrusion (L) of 110 mm.
L max 110

D max 60

BIESSE S.p.A.
(a706h0027.fm-161203)
10 - 1
Chapter 10.
Preparing the tool magazine

Housing procedure

1. Move the operating section into a position that allows easy access to the magazine.

2. Turn the Tooling selector on the operator control panel to the right, and remove the key to
prevent anybody from putting the machine into operation accidentally.

3. Open the magazine cover using the soft-key provided on the PLC keyboard.

4. Approach the magazine and select a free location.

5. Insert the coupling in the housing provided,


as shown in the figure.

10.2 Preparing the rack type tool magazine

This magazine can be used to house both collet spindles and aggregates, complying with the rules
and procedures described.

Housing collet spindles

In tool holders 1, 2, and 3 in the magazine, it is possible to house collet spindles, fitted with tools
with a maximum diameter (D) 100 mm. In tool holder 4 it is possible to house a collet spindle fitted
with a tool with a maximum diameter (D) of 120 mm. The maximum tool protrusion (L) is 110 mm.
For the housing procedure, please see page 10 - 4.

X+

1
Y+

2
L max 110

1, 2, 3 = D max 100 - 4 = D max 120


4

10 - 2 BIESSE S.p.A.
(a706h0027.fm-161203)
Chapter 10.
Preparing the tool magazine

Housing aggregates

The aggregates that can be housed in the magazine are the ones illustrated in the figure. It is
possible to house one aggregate at a time in the tool magazine, using tool holder number 4. For
aggregate AGGRE4, it is also necessary to comply with the orientation shown in the figure.

X+

Y+ 1 1

2 2

3 3

4 4
AGGRE4 AGGRE6

For the housing procedure, please see page 10 - 4. As regards the maximum dimensions of tools
fitted on the aggregates, always comply with the limits indicated in paragraph 8.1 Information on
tools on page 8 - 1.

Each aggregate is provided with bores A which are used for precise orientation when it is placed in
the magazine. The number of bores varies according to the type of aggregate. One of these
bores must coincide with the pin B provided in each location.

B
A A
A

BIESSE S.p.A.
(a706h0027.fm-161203)
10 - 3
Chapter 10.
Preparing the tool magazine

Housing procedure

1. If necessary, move the operating section away from the magazine area.

2. Turn the Tooling selector on the operator control panel to the right, and remove the key to
prevent anybody from putting the machine into operation accidentally.

3. Open the magazine cover using the soft-key provided on the PLC keyboard.

4. Using the numerical control, raise the chosen tool holder. For information on how to do this,
please consult the Software users manual.

5. Insert the coupling in the housing provided,


as shown in the figure

10 - 4 BIESSE S.p.A.
(a706h0027.fm-161203)
11 -

Chapter 11. Preparing the work table

This chapter explains how to position or install the various elements forming the work table.
Positioning of these elements must be carried out to allow adequate support and locking of the
piece, and to ensure that there is no interference with tools during machining operations. The
installation of auxiliary locking devices (clamp stops, front pushers) must be evaluated each time,
according to the characteristics of the piece.

11.1 Positioning the mobile elements on the work table

The millimetre rules on the extruded bar and on the mobile piece support front guide allow the
position of the various objects to be established. Always use a sufficient number of suction cups,
which must be suitably prepared and positioned with respect to the piece to be machined.

Positioning the mobile piece support

1. Grasp the handle and press button A.

2. To lock again, release the same button.

The mobile piece supports with centre stops, if


used to provide the machining origin, must be
locked in correspondence with the reference B.

BIESSE S.p.A.
(a706h0028.fm-161203)
11 - 1
Chapter 11.
Preparing the work table

Positioning the side and centre stops

1. Unlock the stop by turning both handles A


to the right.

2. Position the stop as required.

3. To lock the stop again, turn the same


handles to the left. A

Positioning the shapeable suction cup

The method to be used when positioning the shapeable suction cup varies according to its type.

Standard shapeable suction cup

1. Unlock the suction cup by pressing button


A.

2. Position the suction cup as required.


A
3. Lock the suction cup again by releasing the
button.

Small shapeable suction cup

1. Unlock the suction cup by pressing button


B.

2. Position the suction cup as required.

3. Lock the suction cup again by releasing the


button.
B

11 - 2 BIESSE S.p.A.
(a706h0028.fm-161203)
Chapter 11.
Preparing the work table

11.2 Positioning the moving elements on the work table using


the electronic display

Position of the moving elements on the work table using this device is divided into three stages.

n In the first stage, the numerical control software is used to position the various moving
elements on the work table. In this way a new configuration of moving elements is created on
the work table, and this will be associated with the program required. To carry out these
procedures, please consult the Software Users Manual.

n The second stage involves transferring the new work table configuration, created using the
numerical control software, to the electronic displays.

n In the third stage, positioning of the objects takes place using the positions indicated on the
electronic displays.

Transferring the work table configuration

The work table configuration is sent automatically when the program is run.

Positioning the elements

To position the various elements, proceed manually as described in the paragraphs above, reading
the position on the electronic display and using the millimeter rules on the work table.

Reading and use of the electronic display

B C D A

TABLE
S.CUPS
STOP
.............

Display A shows the positions of the various elements on the work table. The position displayed
changes each time soft-key B is pressed. The display C and the LED D, identify the element
selected. For example: if display C shows the number 2 and the LED D S.CUPS is alight, this
means that the display A indicates the Y position of suction cup 2.

BIESSE S.p.A.
(a706h0028.fm-161203)
11 - 3
Chapter 11.
Preparing the work table

The following is a description of the positions shown on display A according to the various
combinations of display C and LED D.

Number on display C Led D alight Position shown on display A


none TABLE X position of the mobile piece support
1 S.CUPS Y position of suction cup 1
2 S.CUPS Y position of suction cup 2
3 S.CUPS Y position of suction cup 3
4 S.CUPS Y position of suction cup 4
1 STOP Y position of stop 1
2 STOP Y position of stop 2

Y position of suction cup 1

Y position of suction cup 2


Y position of stop 1
Y position of suction cup 3

Y position of suction cup 4


Y position of stop 2

X position of the mobile support

11 - 4 BIESSE S.p.A.
(a706h0028.fm-161203)
Chapter 11.
Preparing the work table

11.3 Fitting the gasket on the shapeable suction cup

Fit the gasket in the channels on the suction cup so as to create an area around the vacuum valve.
The following figure gives various examples.

vacuum valve

DANGER
The gasket must meet perfectly at the join.

OK

11.4 Fitting the clamp stop plates function

Fit the plates on the stops if the characteristics of the piece do not allow it to be locked safely using
the suction cups alone.

1. With the aid of a screwdriver, unfasten the


screw plug A. C
A
2. Position the plate B on the stop and fix it
using screw C. B

BIESSE S.p.A.
(a706h0028.fm-161203)
11 - 5
Chapter 11.
Preparing the work table

11 - 6 BIESSE S.p.A.
(a706h0028.fm-161203)
Part 4 - Operations

BIESSE S.p.A.
(a311h002.fm-161203)
BIESSE S.p.A.
(a311h002.fm-161203)
12 -

Chapter 12. Maintenance

This chapter contains all the information required to maintain the machine in perfect working order.

DANGER
Before carrying out any type of maintenance operation on the machine, unless otherwise
indicated, turn the machine off and drain the air from the pneumatic system by activating
the cut-out valve. Lock both the main switch and the cut-out valve using the locks
provided, to prevent anybody from starting the machine.

12.1 Summary and frequency of operations

The following table indicates all the maintenance operations foreseen, also giving the frequency
with which they must be carried out. The column Pag. indicates the page describing the procedure
to be followed when carrying out the operation, where specific procedures are required.

Frequency Parts involved Operation Page


daily Whole machine Cleaning 12 - 7
FRL Unit Check condensation in tray; drain if 12 - 8
necessary
Electrospindle Check tool lock 12 - 8
Curtain guards Check conditions; replace if
necessary
Shapeable suction cup Check the conditions of the gasket;
replace if necessary

BIESSE S.p.A.
(a714h0009.fm-161203)
12 - 1
Chapter 12.
Maintenance

Frequency Parts involved Operation Page


weekly FRL unit Topping up with lubricant 12 - 20
Vac uu m pu m p ( B ec k er Clean 12 - 20
Picchio 2200)
Vacuum pump (Becker VT Clean 12 - 20
4.40)
Guides and racks on axes Cleaning and lubrication 12 - 10
X, Y and Z
Pneumatic and vacuum Check pressures 12 - 11
systems
Operating section Manual lubrication of the slide blocks 12 - 11
and ball screws
every 2 Electrospindle Cleaning 12 - 13
weeks
ISO30 collet electrospindle Cleaning 12 - 14
Aggregates Lubrication and cleaning 12 - 14
Boring and milling unit Lubrication of the circular blade tool 12 - 15
milling unit
monthly Boring unit Lubrication and cleaning 12 - 15
every 2000 Vac uu m pu m p ( B ec k er Lubricate 12 - 16
hours Picchio 2200)
every 3000 Vacuum pump (Becker VT Check wear on blades 12 - 17
hours or 4.40)
once a year
Vac uu m pu m p ( B ec k er Check wear on blades 12 - 19
Picchio 2200)
(*) Central lubrication grease Top-up with lubricant 12 - 21
pump
(*). The unit is fitted with a sensor controlling the lubricant level. If the minimum level is reached a
message appears on the numerical control monitor signalling the operator to top up with lubricant.

12 - 2 BIESSE S.p.A.
(a714h0009.fm-161203)
Chapter 12.
Maintenance

12.2 Lubricants

Use the lubricants indicated by manufacturer, only using equivalent ones if the former are difficult
to obtain. Should it be necessary to replace the recommended lubricant with an equivalent one of
another brand, clean the parts in question thoroughly to remove any residual traces of the previous
product, to ensure that there will be no chemical reactions that might damage the machine.

Lubricants used by the Equivalents Use

name characteristics

KLBER physical state at room product with no equivalent Gears


ISOFLEX temperature (20C): pasty
NBU 15
colour: ivory-fawn

odour: perceptible

density at 20C ASTM D-4052


(g/cm3): approx. 0,99

flammability COC ASTM D-92


(C): over 220C

solubility in water: insoluble

KLBER physical state at room product with no equivalent Gears


ISOFLEX temperature (20C): pasty
TOPAS NB 52
colour: light fawn

odour: perceptible

density at 20C ASTM D-4052


(g/cm3): approx. 0,96

flammability DIN ISO 2176


base oil: 220C

solubility in water: insoluble

drip point DIN 51801/1 (C):


>240C

BIESSE S.p.A.
(a714h0009.fm-161203)
12 - 3
Chapter 12.
Maintenance

Lubricants used by the Equivalents Use

name characteristics

KLBER physical state at room ESSO SPARTAN EP 150 Vacuum pump


LAMORA 150 temperature (20C): liquid EURAL ELTON EP 150
FIAT BAKU R 150 EP
colour: brown FINA GIRAN 150
FUCHS RENEP COMPOUND 104
odour: faintly perceptible IGLEA RILEN EP 150
IP MELLANA OIL 150
density at 20C ASTM D-4052 LEVENIT DELTA EP 118/150
(g/cm3): approx. 0,99 LUBRA DACTA EP 150

flammability COC ASTM D-92


(C): >184C

viscosity at 40C ASTM-D 445


mm2/sec: 150

solubility in water: insoluble

KLBER physical state at room product with no equivalent Protection for


LUSING temperature (20C): aerosol HSK F63
PROTECT couplings
G31 colour: not applicable

odour: perceptible,
characteristic

density at 20C ASTM D-4052


(g/cm3): approx. 0,6

flammability COC ASTM D-92


(C): inflammable in the
presence of live flames

solubility in water: insoluble

drip point DIN 51801/1 (C):


3,2 (7,5 at 50C)

KLBER physical state at room product with no equivalent Vacuum pump


PETAMO temperature (20C): pasty bearings
GY193
colour: fawn

odour: perceptible

density at 20C ASTM D-4052


(g/cm3): approx. 1,03

flammability DIN ISO 2176


base oil: >200C

solubility in water: insoluble

12 - 4 BIESSE S.p.A.
(a714h0009.fm-161203)
Chapter 12.
Maintenance

Lubricants used by the Equivalents Use

name characteristics

METAFLUX physical state: pasty product with no equivalent Tool unlocking


Fett-Paste Nr. device on
70-8508 odour: characteristic electro-
spindles with
colour: grey HSK F63
couplings
flammability (C): >150

density: approx. 1,09 (g/cm3),


20 C

solubility in water: insoluble

MOBIL DTE category: OIL AGIP OSO 32 Pneumatic


24 BP ENERGOL HLP 32 systems
volume mass: 0,869 kg/dmc at CASTROL HYPIN AWS 32
15 C ELF ELFOLNA 32
ESSO NUTO H 32
vapour pressure: <0,1 mm Hg, KLBER LAMORA 32
at 20 C Q8 HAYDN 32
ROL LI 32
viscosity: 32,5 cSt, at 40 C SHELL TELLUS OIL 32
5,5 cSt, at 100 C TAMOIL HYDRAULIC OIL 32
TEXACO RANDO OIL HD 32
slide point: -27 C TOTAL AZOLLA ZS 32

boiling point: >315 C

MOBILTEMP category: GREASE MOBILTEMP SHC 32 Gears


SHC 100
volume mass: 1,0 kg/dmc at
15 C

vapour pressure: <0,1 mm Hg,


at 20 C

viscosity: 87 cSt, at 40 C
13 cSt, at 100 C

drip point: >260 C

boiling point: >315 C

BIESSE S.p.A.
(a714h0009.fm-161203)
12 - 5
Chapter 12.
Maintenance

Lubricants used by the Equivalents Use

name characteristics

MOBILUX - Physical state: grease ESSO BEACON EP 0 Slide blocks,


EP0 - Colour: pale KLBER TRIBOSTAR 0 EP(*) guides and
- Odour: faint racks
KLBER CENTOPLEX 0 EP(**)
- Limit odour: not determined
- Ph: not applicable
- Boiling point C(F): > 316
(600)
- Drip point C(F): > 180 (356)
- Flammability point C(F): >
204 (400) (ASTM D-93)
- Flammability: not determined
- Self-inflammability: not
determined
- Explosive characteristics: not
applicable
- Oxidising characteristics: not
applicable
- Vapour pressure-mm Hg 20
C: not determined
- Vapour density: not
determined
- Evaporated fraction: not
determined
- Relative density, 15/4 C: 1
- Stability in water: negligible
- Distribution coefficient: > 3.5
- Viscosity at 40 C, cSt: 150,0
- Viscosity at 100 C, cSt: >
16,0
- Pour point C(F): not
applicable
- Freeze point C(F): not
determined

(*). Italian market only.

(**). International market.

12 - 6 BIESSE S.p.A.
(a714h0009.fm-161203)
Chapter 12.
Maintenance

12.3 General cleaning of the machine

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

Proper cleaning of the machine and the surrounding area will make the working area safer and
more healthy, and will enable controls and indicators to be identified easily and without errors.

To remove all traces of chips and sawdust, use a vacuum cleaner; if necessary, use a compressor
to remove fine dust, making sure you stand at a safe distance. Chips that fall to the floor must be
removed, either with a vacuum cleaner or with a brush, as they may cause slipping.

CAUTION
To clean the electrical cabinet, use a vacuum cleaner or soft cloth, but never use a jet of
compressed air, as the dust raised might deposit on the electrical contacts and cause
damage.

CAUTION
To avoid damage to the various covers on the operating section (which are made of PVC)
they should be washed with soap and water only; never use thinners, degreasers, alcohol,
gasoline or any other chemical product.

BIESSE S.p.A.
(a714h0009.fm-161203)
12 - 7
Chapter 12.
Maintenance

12.4 Draining condensation from the FRL unit

INFORMATION
To carry out this operation, switch the machine on and turn the Tooling selector to the right.

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

The FRL unit is equipped with a tank to collect condensation. Check the amount of condensation
that has formed and if necessary drain the tank as described below.

1. Place a tin under the bleeder valve A.

2. Press the bleeder valve A upwards, until all the condensation has drained out.

12.5 Checking tool lock on the electrospindle

INFORMATION
To carry out this operation, switch the machine on and turn the Tooling selector to the right.

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

Check that the electrospindle locks the tool properly. To do this, insert a collet spindle with no tool
fitted into the electrospindle and check manually that it is perfectly locked. Also, when doing this,
check that air comes out of the coupling area.

12 - 8 BIESSE S.p.A.
(a714h0009.fm-161203)
Chapter 12.
Maintenance

12.6 Cleaning the vacuum pump (Becker Picchio 2200)

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

Clean the vacuum pump as described below.

B C

A
D D
C
B

B C

1. Unscrew the screw A to eliminate any residual vacuum inside the pump.

2. Remove the filter covers B.

3. Remove each air filter C and clean it using a jet of compressed air and blowing from the
inside out. Replace blocked or greasy filters.

4. Clean the cooling slots D, using a jet of compressed air.

BIESSE S.p.A.
(a714h0009.fm-161203)
12 - 9
Chapter 12.
Maintenance

12.7 Cleaning the vacuum pump (Becker VT 4.40)

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

Clean the vacuum pump as described below.


C

1. Unfasten the screw A to eliminate any residual vacuum from inside the pump.

2. Remove the filter covers B.

3. Remove each of the air filters C and clean by blowing compressed air from the inside
outwards. Replace any blocked or greasy filters.

12.8 Cleaning the guides and racks

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

Clean all the guides and racks moving axes X, Y and Z using clean dry cloths. In case of
particularly stubborn deposits use a bronze wire brush.

Brush a thin layer of MOBILUX EP0 lubricant onto each rack.

12 - 10 BIESSE S.p.A.
(a714h0009.fm-161203)
Chapter 12.
Maintenance

12.9 Checking pressure

The following describes and illustrates the pressure gauges that must be checked periodically.

CAUTION
If the values found are not correct, do not make any adjustments, but call the BIESSE
service department.

C B

Pneumatic system

A - Pressure gauge indicating the supply pressure = 6,5 - 7,5 bar.

B - Pressure gauge indicating the compensation pressure for axis Z = 5 - 6 bar.

C - Pressure gauge indicating the up pressure for boring and milling unit horizontal spindles = 3.5
- 4 bar.

Vacuum system

D - Pressure gauge indicating the vacuum produced by the pump = - 65 cm Hg (approx.).

INFORMATION
To check the vacuum level produced by the pump, turn the machine on and turn the tooling
selector on the operator control panel to the right.

BIESSE S.p.A.
(a714h0009.fm-161203)
12 - 11
Chapter 12.
Maintenance

12.10 Lubrication of the slide blocks and ball screws

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

The machine is fitted with slide blocks and balls screws that only require manual lubrication in the
absence of a central lubrication system.

1. Fill the pump provided with MOBILUX EP0 lubricant.

2. Insert the pump into each greasing nipple and pump in 3 grams of lubricant (approximately 1
or 2 strokes of the pump).

12 - 12 BIESSE S.p.A.
(a714h0009.fm-161203)
Chapter 12.
Maintenance

12.11 Cleaning the electrospindle

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

Clean each electrospindle in the following manner.

1. Clean the guides A using clean, dry cloths. Use a brush with bronze bristles to remove any
encrusted dirt.

2. Clean the outside of the electrospindle using a jet of compressed air.

CAUTION
Never carry out this operation without the collet spindle inserted.

3. Clean surfaces B of the coupling carefully with a clean, soft cloth.

INFORMATION
If the machine is not used for a long time it is essential that the electrospindle coupling be
protected by inserting a collet spindle.

BIESSE S.p.A.
(a714h0009.fm-161203)
12 - 13
Chapter 12.
Maintenance

12.12 Cleaning the ISO 30 collet spindle

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

Clean surfaces A of the collet spindle carefully


with a degreaser..

12.13 Lubrication and cleaning of the aggregate

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

Lubricate every aggregate using the lubricating nipple provided. Proceed as described below.

1. Rest the aggregate on a work bench.

2. Fill the grease pump provided with KLBER ISOFLEX NBU 15 lubricant. For aggregates with
inclining spindle, use the special pressure syringe provided, filling it with KLBER ISOFLEX
TOPAS NB 52 lubricant.

3. Insert the pump into the lubricating nipple and pump in 3 grams (1 or 2 strokes of the pump) of
lubricant.

Clean surface A of the coupling with a degreaser.

12 - 14 BIESSE S.p.A.
(a714h0009.fm-161203)
Chapter 12.
Maintenance

12.14 Lubrication of the circular blade tool unit

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

Lubricate the unit using the lubricating nipple provided. To lubricate, proceed as follows.

1. Fill the grease pump provided with


KLBER ISOFLEX NBU 15 lubricant.

2. Insert the pump into the lubricating nipple A


and pump in 3 grams (1 or 2 strokes of the
pump) of lubricant.

12.15 Lubrication and cleaning of the boring and milling unit

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

Lubricate the boring unit using the greasing nipple A as described below. After lubrication of the
boring unit, clean the outside of the spindles to remove any rust and then coat the area with Teflon
spray. If a spindle is not used frequently it may rust. In this case the spindle will have difficulty in
lowering or may even become blocked.

1. Fill the pump provided with MOBILTEMP SHC 100 lubricant.

2. Insert the pump into the greasing nipple A and pump in 8 grams of lubricant (approximately 3
or 4 strokes of the pump).

BIESSE S.p.A.
(a714h0009.fm-161203)
12 - 15
Chapter 12.
Maintenance

12.16 Lubrication (Becker Picchio 2200)

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

To carry out this operation, remove cover A and cover B, and coat the bearing C with the grease
(KLBER AMBLYGON TA 15/2) in tube D (5 gr).

A
C B

12 - 16 BIESSE S.p.A.
(a714h0009.fm-161203)
Chapter 12.
Maintenance

12.17 Checking wear on the blades (Becker VT 4.40)

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

The blades rub continuously against the interior of the casing, and are therefore subject to wear.
Check the width of the blades and replace them if they have reached the minimum limit of 27 mm.
When carrying out this operation, also clean the blade cylinder with a jet of dry compressed air.

A C

1. Unfasten the screw A to eliminate any residual vacuum from inside the pump.

2. Remove covers B and C.

3. Remove the blades D and check for wear; replace if necessary.

BIESSE S.p.A.
(a714h0009.fm-161203)
12 - 17
Chapter 12.
Maintenance

12.18 Replacing the batteries in the NC 500 numerical control

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

The numerical control is fitted with 3 batteries (1.5 V), located inside the electrical cabinet in the
front right hand area (see figure), which serve to prevent the loss of certain data in the event of a
power cut. These batteries must be replaced at the set times indicated.

CAUTION
To avoid any loss of data, fit the new batteries within minutes of removing the old ones.

12 - 18 BIESSE S.p.A.
(a714h0009.fm-161203)
Chapter 12.
Maintenance

12.19 Checking wear on the blades (Becker Picchio 2200)

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

The blades, which rub continuously against the inside of the pump, are subject to wear. Check the
width of the blades and replace them if they reach the minimum limit of 26 mm. When carrying out
this operation, also check the conditions of the bearing on the inside of the cover C, and if it is dry,
lubricate with KLBER AMBLYGON TA 15/2 type grease.

A E

D B

1. Unfasten screw A to eliminate any residual vacuum inside the pump.

2. Remove covers B and C.

3. Take out the blades D and check them for wear; replace them if necessary.

4. If the bearing on the inside of the cover C is dry, lubricate it with the grease (KLBER
AMBLYGON TA 15/2) in tube E (2 gr).

BIESSE S.p.A.
(a714h0009.fm-161203)
12 - 19
Chapter 12.
Maintenance

12.20 Topping-up lubricant in the FRL unit

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

Check whether the lubricant in the FRL unit has reached the minimum level. If this is the case,
top-up with lubricant as described below.

A
B

D
C

1. Turn off the tap upstream of the FRL unit, to stop the flow of compressed air.

2. Pull the ball knob A upwards and unscrew it completely to eliminate any residual air pressure.

3. Unfasten screw B or remove the cup on lubricating nipple C by lowering lever D and turning
the cup itself by 45 (either to the left or to the right).

4. Pour in MOBIL DTE 24 lubricant until it reaches maximum level.

5. Fasten screw B again or replace the cup on lubricating nipple C.

6. Restore the correct supply pressure.

12 - 20 BIESSE S.p.A.
(a714h0009.fm-161203)
Chapter 12.
Maintenance

12.21 Topping-up lubricant in the central greasing system

To find out how frequently this operation should be carried out, see the table on page 12 - 1.

If the lubricant in the pump reaches the minimum level a message is displayed on the numerical
control. If this is the case, top-up the lubricant as described below.

1. Fill the grease pump provided with MOBILUX EP0 lubricant.

2. Insert the pump into the lubricating nipple A and pump in lubricant until reaching the
maximum level, indicated by the fact that the lubricant starts to come out of drainage hole B.

BIESSE S.p.A.
(a714h0009.fm-161203)
12 - 21
Chapter 12.
Maintenance

12 - 22 BIESSE S.p.A.
(a714h0009.fm-161203)
13 -

Chapter 13. Troubleshooting

13.1 Problems, causes and solutions

Whenever a problem occurs, check for messages on the numerical control. If there are no
messages to help solve the problem, consult the table given below. If the problem is not among the
ones indicated here, contact the BIESSE service department

Problem Cause Solution


The numerical control There is no electrical power Check that the machines main
does not turn on. supply. power switch is turned to 1 (ON).
A thermal cutout switch in the Reset the cutout switch.
wiring cabinet has triggered.
The start button on the There are emergency devices Check the emergency button.
operator control panel active.
does not light up. Check the emergency cords.
The bulb is broken. Replace the bulb.
The panel does not The suction cup tubes If bent, straighten them manually
remain locked on the connected to the vacuum and check sealing capacity. If
work table. system are damaged. broken, replace with new tubes.
Do not attempt to repair them
with adhesive tape or glue.
The vacuum pump motor turns Do not use the machine, and
backwards. report the problem immediately
to BIESSEs Service
Department.
The axis carriages do The Override knob is set to Turn the knob slowly until it is in
not move but no error minimum. the correct position.
messages are
displayed.
During a work cycle, The spindle shaft is dirty or Clean the spindle shaft.
some of the spindles in oxidized. This can happen
the boring unit do not when they are not used very
descend when invoked much.
by the program.
There may be problems in the Refer to the Circuit Diagrams.
electric or pneumatic system.

BIESSE S.p.A.
(a713h0009.fm-161203)
13 - 1
Chapter 13.
Troubleshooting

Problem Cause Solution


During the work cycle There are deposits on the rods. Remove the deposits with a
the stops do not move clean dry cloth or a bronze wire
into position or do not brush.
descend.
The piece has been pressed too Unlock the piece and repeat the
hard against the stops. positioning operation.
There may be problems in the Refer to the Circuit Diagrams.
electric or pneumatic system.
The panel support Deposits have formed along the Remove the deposits with a
cannot be positioned or slide bars. clean dry cloth or bronze wire
cannot be locked. brush.
Problems with the locking Contact the Service department.
piston.
The spindles on the The live wires in the power Turn the machine off and invert
boring unit rotate in the supply terminals, inside the at least two of the three live wires
wrong direction. electrical cabinet, are inserted in the power supply terminals.
in the wrong order.
The quality of results The tool is not suitable for the Replace with a new tool.
obtained on the type of work being carried out,
machine is poor. or the tool is worn.
The tool speed of movement Adjust the parameters of the
and/or the tool rotation speed is speed of movement and/or tool
not suitable for the type of rotation speed.
material being worked.

13 - 2 BIESSE S.p.A.
(a713h0009.fm-161203)
Appendices

BIESSE S.p.A.
(a306h003.fm-161203)
BIESSE S.p.A.
(a306h003.fm-161203)
A-

Appendix A. Safety information

The machine will work safely if it is used by qualified persons in accordance with the
recommendations and instructions provided in this manual. BIESSE will not be liable for any
damage to persons or properly caused by inexperienced and unqualified operators or by failure to
comply with the following recommendations.

Never remove or tamper with guards and protections in order to carry out unforeseen operations,
as this will result in serious risks for the operator. BIESSE declines all responsibility for damage to
persons or goods resulting from incorrect use or deliberate misuse of the machine.

A.1 Transport and moving

1. When lifting and moving the machine, either as a whole or in part, operations must always be
carried out by suitably qualified and experienced personnel, using lifting devices with an
adequate capacity.

2. Never stand within range of the crane when the machine is being lifted.

3. Only lift the machine as described in this manual.

A.2 Installation

1. Installation operations must always be carried out by qualified personnel who have been
authorised to do so by BIESSE.

2. Before starting work, check that the various parts of the machine are free from any physical
damage caused by bumping, tearing or abrasion. Damage to electrical cables or sheathing
will compromise the safety of the machines electrical system.

BIESSE S.p.A.
(a109h019.fm-161203)
A-1
Appendix A.
Safety information

A.3 Tools

When choosing tools to be installed in the machine, the operator is advised to follow the
recommendations given below.

1. Never use deformed or cracked rotating tools.

2. Check for perfect balance of rotating tools and make sure they are perfectly sharp and
suitable for the work to be performed.

3. Never use tools beyond their speed limit, which is impressed on the surface of the tool or
indicated in some way by the manufacturer.

4. Before installing any tool in its seating make sure that the guide and centring surfaces have
no dents and are perfectly clean.

5. In each tool apply only the prescribed torque to screws, bolts, nuts and rings.

6. Always make sure that the direction of rotation of the tool is the same as that of the spindle in
which it is mounted.

7. Never exceed the limits indicated in this manual or otherwise prescribed by BIESSE.

A.4 Preparation and machining

1. Wear protective clothing of the approved type (glasses, gloves, helmet and footwear).

2. Woodworking operations create dust. It is recommended, at the clients discretion, that you
wear a mask with a suitable protection level.

3. Never attempt to modify the programs managing safety devices. BIESSE declines all
responsibility for any damage to persons or goods resulting from unauthorised modifications
of this kind.

4. The machine must be set up by one person only. Ensure that nobody else approaches the
machine during setting up operations.

5. When accessing the area inside the safety fence, remove the key from the limit switch on the
door, after first turning it to the right, to prevent anybody from restarting the machine. Do not
turn the lock back to the rest position when the door is open, to avoid becoming trapped
inside the safety fence.

6. Never leave tools on the machine when setting up has been completed.

7. Before starting work, check that there is nobody within the danger area.

8. Make sure that nothing will obstruct normal movement of the machine along the cartesian
axes and that all the casings, doors and protective covers are in their proper places and
securely fixed.

A-2 BIESSE S.p.A.


(a109h019.fm-161203)
Appendix A.
Safety information

9. Before starting work, check to make sure that the tools installed in the machine have not been
tampered with in any way.

10. Never operate the machine while under the influence of any medicine, drugs or drink that may
reduce levels of vigilance and reflexes.

11. Always keep the working area clean and tidy.

12. Do not climb on the machine.

13. In the event of an unexpected power cut during machining operations the electrospindle might
continue to turn. Wait for at least 30 minutes before approaching the tools fitted on the
electrospindles, or check to ensure that the tool has stopped.

14. Wide Automation type contact mats detect pressures exceeding 13 kg/m2, whereas Gamma
Presse type mats detect pressures exceeding 15 kg/0.5 dm2 (approximately the pressure
exerted by a person weighing over 35 kg.).

A.5 Maintenance

1. Wait at least 1 minute before approaching electronic equipment, to give the condensers time
to discharge any residual energy.

2. Do not smoke, eat or drink when handling lubricants. Always comply with current regulations
regarding handling and use of mineral oils and greases.

3. To prevent irritation or allergy, always wear protective goggles or mask, oil-proof gloves and
oil-proof overalls when handling lubricants.

4. Store lubricants in a room with natural ventilation, well away from heat sources (electrical
panels, open flames, etc.).

5. It is recommended that lubricants should not come into contact with pure oxygen and acids.

6. All used lubricants must be entrusted to the Authorities responsible for disposal of used oils
for treatment.

7. In the event of any spillage of lubricants, use sand to absorb the product from all surfaces,
collect it in a dustpan and send it to an authorised Special Waste collection Authority for
incineration.
To clean the surfaces, use solvents (chlorides or aliphatic solvents), making sure that the
fumes do not accumulate in the room.

8. Those who are particularly sensitive to lubricants may be subject to an allergic reaction or
oil-related acne, particularly if their skin has previously been subjected to damage by abrasive
substances (cleaning paste or injuries) or chemicals (solvents, extremely alkaline detergents,
etc.). Irritations may result from contact with the eyes.

9. Incorrect handling of lubricants may result in overexposure, for example slight irritation of the
eyes or skin; if this occurs, move away from the site of exposure and call a doctor.

BIESSE S.p.A.
(a109h019.fm-161203)
A-3
Appendix A.
Safety information

10. Should lubricants come into contact with the skin, wash well with soap and water.

11. Should lubricants come into contact with the eyes, rinse well with water only.

12. If a lubricant in the oils category is swallowed, do not induce vomiting and call a doctor
immediately.

13. If a small amount of lubricant in the greases category is swallowed, call a doctor
immediately. If the amount swallowed is larger, administer 1 or 2 glasses of water and call a
doctor immediately. Do not induce vomiting or administer anything orally if the person in
question has fainted.

14. One of the pistons moving the electrospindle vertically remains under pressure even when
the cut-out valve has been triggered. Avoid tampering with the relative pneumatic pipes, as
this might cause the electrospindle to drop down suddenly.

A.6 Demolition

1. All operations must be carried out by qualified personnel only.

2. Turn the machine off, disconnect it from the power supply and discharge all the air from the
pneumatic system.

3. Remove any tools that may still be installed and put them away.

4. Fix all parts capable of moving by inertia or by gravity.

A.7 Danger signs

The following describes and illustrates the danger signs present on the machine.

DANGER! Before carrying out any operations on the electrical system,


make sure that the power supply has been turned off.

DANGER! Adjust the lockpin every time the aggregate is fitted on a different
electrospindle. Failure to adjust the lockpin may result in rapid deterioration
of the aggregate coupling, with the consequent risk of it disconnecting from
the electrospindle.

A-4 BIESSE S.p.A.


(a109h019.fm-161203)
B-

Appendix B. Technical characteristics

B.1 General information

Boring and milling unit

Boring data:

n Motor: 1,7 kW (2,3 HP)

n Spindle rotation speed: 4000 rpm

n Transmission ratio: 1,43

Milling data:

n Motor: 1,7 kW (2,3 HP)

n Spindle rotation speed: 5135 rpm

n Transmission ratio: 1,8339

Electrospindle

n Motor: 6,6 kW (9 HP)

n Rotation speed of the electrospindle with ISO 30 coupling: 1000 24000 rpm

Axes X, Y and Z

n Speed
axis X:75 m/min;
axis Y: 45 m/min;
axis Z: 15 m/min.

n Acceleration:
axis X: 3,3 m/s2
axis Y: 5,2 m/s2
axis Z: 5,6 m/s2

BIESSE S.p.A.
(a724h0009.fm-161203)
B-1
Appendix B.
Technical characteristics

B.2 Position of the operating section units along the X-Y axes

X+

Y+

Boring and milling unit

Electrospindle

B-2 BIESSE S.p.A.


(a724h0009.fm-161203)
Appendix B.
Technical characteristics

B.3 Working field along the X - Y axes

X+

Y+

stop

BIESSE S.p.A.
(a724h0009.fm-161203)
B-3
Appendix B.
Technical characteristics

B.4 Working field along the Z axis

The positions along the Z-axis are referenced to the origin of the work table. The maximum stroke
of the operating section is 100 mm. The strokes listed below refer to the movement each unit or
part executes when it positions for machining.

Boring and milling unit Electrospindle with ISO


30 coupling

198 196
60

152
136 136
60

60

269

60
90

B.5 Collet spindle

ISO 30 ISO 30
3,2

3,2

electrospindle nose
49

57

M40 M50

ERC 32 ERC 40

maximum rotation speed (rpm) 24000

B-4 BIESSE S.p.A.


(a724h0009.fm-161203)
Appendix B.
Technical characteristics

B.6 Aggregate AGGRE4

ISO 30

6,5
0
20
Spindle characteristics

size 34 wrench
80
size 8 wrench
107 109,5

59

35

23
71,5 0 50,4 73
2,8

maximum electrospindle rotation speed (rpm) 11500


maximum aggregate rotation speed (rpm) 8050
transmission ratio 0,7
spindle direction of rotation left
electrospindle direction of rotation right
weight (kg) 3
maximum machining depth (mm) 26

Machining suspension time

This aggregate is able to work continuously, without having to suspend machining operations.

BIESSE S.p.A.
(a724h0009.fm-161203)
B-5
Appendix B.
Technical characteristics

B.7 Aggregate AGGRE6

ISO 30 ISO 30
distance between spindle distance between spindle

6,5
6,5 Spindle characteristics
0 0

20 20
M6

wrench

17
74 74
size 3
96 96
10
48 52

maximum electrospindle rotation speed (rpm) 6000


maximum aggregate rotation speed (rpm) 6000
transmission ratio 1
centre spindle direction of rotation right
side spindles direction of rotation left
electrospindle direction of rotation right
weight (kg) 2,2

Machining suspension time

This aggregate is able to work continuously, without having to suspend machining operations.

B-6 BIESSE S.p.A.


(a724h0009.fm-161203)
Appendix B.
Technical characteristics

B.8 Noise level

The correct noise level, measured from the position of the operator, is as follows:

n 80 dB (A), during boring

n 84 dB (A), during milling

Noise level tests were conducted as described in: EN 31202 - ISO 7960 - prEN 848-3.
Materials worked: chipboard covered with melamine, thickness 18 mm.
Instruments: phonometer BK 2230
K1= Background noise correction factor lower than 4 dB (A)
K3= Background environment correction factor lower than 4 dB (A)

The noise levels indicated are output levels and do not necessarily represent safe operational
levels. Although there is a relationship between output levels and exposure levels, the output
levels cannot be reliably used to determine whether additional precautions are necessary or not.
The factors determining the noise levels to which the operative personnel is exposed, include the
length of exposure, the characteristics of the work area, as well as other sources of dust and
noise, etc. i.e. the number of machines and processes concurrently operating in the vicinity. In any
case, the information supplied will help the user of the machine to better assess the danger and
the risks involved.

Working data

Boring Milling
tool rotation speed (rpm) 4000 18000
speed of movement (m/min) 1 6
working depth (mm) 10 5
tools used for operation (n) 10 (8) 1 (25)
tool cutters (n) - 2
tool cutter length (mm) - 40

BIESSE S.p.A.
(a724h0009.fm-161203)
B-7
Appendix B.
Technical characteristics

B-8 BIESSE S.p.A.


(a724h0009.fm-161203)
C-

Appendix C. Transport

DANGER
Before proceeding, read the following warnings with care:

The machine may be shipped using different means of transport (road, rail, air, and sea), and this
is usually established with the customer at the time of purchase. The machine is split into different
parts in order to facilitate transport. This appendix contains a list of the parts that are transported
(see page C - 2), together with their weights.

The lifting and movement operations that are necessary for unloading and setting up the machine
in the definitive area must be carried out by suitably qualified personnel, who shall follow the
indications given in this appendix on pages C - 3 and C - 5.

BIESSE S.p.A.
(a725h0009.fm-161203)
C-1
Appendix C.
Transport

C.1 Parts to be transported

To facilitate transport, the machine is divided into a number of parts. The following is a list of the
dimensions and weight of each of these parts.

A B C D

E F

Machine part Dimensions (mm) Weight (kg)


A - Main structure 4900 x 1700 x H 2000 1700
B - Mesh guard 2250 x 450 x H 1620 200
B - Closing elements for the mesh guard 1050 x 900 x H 300 80
(CE version only)
D - Contact mats 1720 x 80 x H 1220 120
E - Vacuum pump 800 x 470 x H 720 100
F - Box of material supplied with the machine 1000 x 620 x H 640 70

C-2 BIESSE S.p.A.


(a725h0009.fm-161203)
Appendix C.
Transport

C.2 Lifting

The following indicates the procedures to be used to lift each single part of the machine.To carry
out lifting operations, use vehicles and equipment (bars, cables ...) of adequate capacity

Main structure

The main structure is lifted with a crane or bridge crane, using the method described below. The
operator in charge of unloading the machine must provide 4 belts with a length of 2500 mm.
Position the belts as indicated in the figure below

BIESSE S.p.A.
(a725h0009.fm-161203)
C-3
Appendix C.
Transport

Mesh guard

Contact mats

Vacuum pump and box of accessories

C-4 BIESSE S.p.A.


(a725h0009.fm-161203)
Appendix C.
Transport

C.3 Moving

The following indicates how the main structure should be moved. For the other parts, use a fork lift
truck and the lifting method described above.

Main structure

1. Remove the guards on the front of the base.

BIESSE S.p.A.
(a725h0009.fm-161203)
C-5
Appendix C.
Transport

2. Insert the blades of the fork lift truck under the base and lift the machine slowly.

OK

CAUTION
Take particular care to ensure that the blades of the fork lift truck do not damage the X axis
cable-holder box, located at the rear of the base.

C.4 Repositioning the machine support feet

Before setting the machine down on the ground in the final installation area, reposition all the
support feet, screwing them back into their housings. Before carrying out this operation, remove
the materials used to fasten the machine to the means of transport (pieces of wood, boards, etc.)
and the sheets of vibration-damping material.

C-6 BIESSE S.p.A.


(a725h0009.fm-161203)
D-

Appendix D. Installation

DANGER
Before proceeding, read the following warnings with care:

The area in which the machine is installed must be adequately illuminated, ventilated, of a
sufficient size and provided with points for connection to the various systems (electrical,
pneumatic...). In this regard, please consult the paragraph Layout of the machine, connection
points and working dimensions on page D - 2. The systems to which the machine is to be
connected and the environment in which it is positioned must comply with the requirements given
on page D - 5.

The assembly, levelling and connection of the machine must only be carried out by BIESSE
service department staff. Do not remove the packing, open any cases of material or start up the
machine without the prior consent of these expert and qualified technicians.

BIESSE S.p.A.
(a726h0016.fm-161203)
D-1
Appendix D.
Installation

D.1 Layout of the machine, connection points and working


dimensions

The following pages show the layout of the various models, indicating the arrangement of the
machine, the power supply connection points and the working dimensions.
The positions of the various devices that are separate from the machine (electrical cabinet,
vacuum pump ...) are indicated after the machine layouts.

CE version

X+

Y+

pneumatic system connection point (1/2" G, height above ground 500 mm)

operating section suction system connection point ( 200 mm, height above ground 1900 mm)

access door

work table button pad

D-2 BIESSE S.p.A.


(a726h0016.fm-161203)
Appendix D.
Installation

Non CE version

X+

4606
Y+

1135
500

2685
pneumatic system connection point (1/2" G, height above ground 500 mm) 750

operating section suction system connection point ( 200 mm, height above ground 1900 mm)

Electrical cabinet

1200
725

620

1435

electrical system connection point

BIESSE S.p.A.
(a726h0016.fm-161203)
D-3
Appendix D.
Installation

Vacuum pump

Becker VT 4.40 Becker Picchio 2200

0
36
0
28
620

58 71

700
0 0

D-4 BIESSE S.p.A.


(a726h0016.fm-161203)
Appendix D.
Installation

D.2 Installation area requirements

The following describes the essential requirements for the various systems to which the machine
is to be connected and for the room in which it is to be located

Electrical system requirements

The quality of the electrical system must guarantee the basic requirements listed in the following
standards: CEI 60204-1, IEC 204-1, unless otherwise agreed with the client.

n Supply voltage: (see rating plate) tolerance 10%

n Frequency of power supplied: (see rating plate) tolerance 2%

n Maximum absorbed power: (see rating plate)

n Harmonic distortion: from second to fifth < 10% + from sixth to thirtieth < 2%

n Voltage imbalance in three-phase power supply: < 2%

n Pulse rate: duration of under 1.5 ms and < than 200% of the supply voltage

n Voltage breaks: duration < 3 ms; period > 1 second

n Voltage drops: value < 20% of peak supply voltage; period > 1 second

n The system must comply with the following standards: CEI 64-8, IEC 364

For connection voltages up to 400 V, the machines electrical cabinet is fitted with a main
automatic trip switch for short-circuit currents of up to 10 KA R.M.S. or peaks of 17 KA.

For connection voltages exceeding 415 V, the trip switch is capable of supporting short-circuit
currents of up to 5 KA.

If the presumed short-circuit current at the supply point is higher, it must be limited.

Differential protection

No differential type protection is foreseen for the machines electric system. The choice of
differential protection must not contrast with current legal requirement, local regulations or the
characteristics of the factory and machine electric system.
Bear in mind the following machine characteristics to ensure you make the correct choice:

1. Electromagnetic disturbance protection devices (mains filter and screening) may produce
high frequency leakage current sand pulse leakage currents exceeding 30 mA.
The 30 mA differential switches may not guarantee continuous operation under all conditions.

2. The machine may be subject to earth faults even with direct current (IEC 755).
If this is not in contrast with local laws or the characteristics of the system, it is recommended
that you fit differential switches with adjustable currents and trip times, of the type that are not
influenced by high frequencies.

BIESSE S.p.A.
(a726h0016.fm-161203)
D-5
Appendix D.
Installation

It is advisable to use differential switches that are highly resistant to pulse overvoltage caused by
atmospheric conditions and manoeuvres (EN 61008-1), and wave tested 8/20 s >1000A (VDE
0432 T2).

Connection cable

The cable connecting the machine to the power supply must be screened or passed through a
metal raceway to reduce electromagnetic disturbance. The screening or metal raceway must be
earthed. The minimum section of the connection cable is: 10 mm2 (220 V - 230 V), 4 mm2 (400 V).

Installed electrical power

The machine is equipped with a number of electrical components, so please consult the
identification plate to find the exact installed power required.

Pneumatic system requirements

The pneumatic system must guarantee a supply pressure of at least 7.5 bar.

The machine consumes an average of approximately 40 NL/min compressed air.

The compressed air flowing into the machine must comply with the following purity requirements:
- dimensions of solid particles: Class 4 (< 40 micron);
- maximum oil content: Class 3 (1 mg/m3);
- maximum dew point: Class 4 (+10C.).

Suction system requirements

The suction system must be permanently connected to the machine and operate with it, and it
must also be capable of providing a constant minimum flow rate of 30 m/sec.

DANGER
Insufficient performance by this system may result in a health hazard.

A knife valve device must be installed on the pipe connecting the suction system to the machine,
to allow the machine to be cut off from the main system. It must be located in an easily accessible
position within view of the operator.

The consumption of suction air, which it is essential to know in order to adapt the system, is 3392
m3/h.

D-6 BIESSE S.p.A.


(a726h0016.fm-161203)
Appendix D.
Installation

Flooring requirements

Cross-section of flooring

30
A - Concrete. B

300
A
B - Grill.
B

30
B

10
250
250
Vertical forces

n Maximum static load on each support foot: 1500 kg.

n Maximum unitary static load on each support foot: 3 N/mm2.

n Maximum dynamic load on each support foot: 480 kg.

n Maximum unitary dynamic load on each support foot: 1 N/mm2.

n Maximum static load created by tie rod on each support foot: 1500 kg.

n Maximum unitary dynamic load created by tie rod on each support foot: 3 N/mm2.

n Maximum unitary load on each support foot: (3+1+3) N/mm2 = 7 N/mm2.

Horizontal forces

n Tangential dynamic load on each support foot: 250 kg.

Levelling

n Maximum planar error of flooring: 25 mm/m (not cumulative).

n Maximum inclination of the floor in all directions: 0.4%.

Environmental requirements

n Temperature: between 0 and +35 C (with conditioner between 0 and +50 C)

n Maximum relative humidity: 90% (without condensation)

n Maximum altitude: 1000 m (unless agreed otherwise with client)

BIESSE S.p.A.
(a726h0016.fm-161203)
D-7
Appendix D.
Installation

D-8 BIESSE S.p.A.


(a726h0016.fm-161203)
E-

Appendix E. Decommissioning - Demolition

During the life cycle of the machine it may become necessary to dismantle it for transfer to another
site. If this is the case, proceed as indicated below.

1. Turn the machine off and disconnect it from all power sources.

2. Remove and put away all the tools that are in the machine.

3. Clean the machine and protect parts that are subject to corrosion using suitable products.

4. For transport and installation of the machine at the new site, use the methods and procedures
described in this manual.

The machine uses lubricating oil and grease. To neutralize the lubricant fluids which remain
attached to parts of the machine and cannot be re-used, use degradable solvents of an approved
type. For evacuation of recoverable lubricant fluids empty the tanks and deliver the fluids to the
local authority in charge of disposal. Any batteries, accumulators, buffer batteries for electronic
cards and conditioners that may be found in the machine must also be disposed of in a suitable
manner.

When the machine reaches the end of its technical working life it must be totally decommissioned
so that it can no longer be used for the purposes for which it was designed and built. This
procedure allows for re-use of the parts and raw materials contained in the machine. If any parts
are used again it must be for purposes other than those for which the machine was originally
constructed.

BIESSE declines all liability for damage to persons of things that may derive from any secondary
use of single parts of the machine for functions or assemblies other than those originally
contemplated. BIESSE recognizes no implicit or explicit suitability for specific purposes of any
parts of the machine which are used again after final decommissioning in view of demolition.

BIESSE S.p.A.
(a112h005.fm-161203)
E-1
Appendix E.
Decommissioning - Demolition

E-2 BIESSE S.p.A.


(a112h005.fm-161203)
F-

Appendix F. Guarantee and client servicing

F.1 Conditions of the guarantee

BIESSE S.p.A. guarantees that the machine was tested at its own premises and that a positive
result was obtained. The guarantee shall remain valid for a period of 12 months starting from the
date of delivery unless there is an agreement between BIESSE S.p.A. and the purchaser to define
the commissioning of the machine at the latters premises. When, however, it is agreed between
both parties that commissioning shall be performed at the purchasers premises, the guarantee
shall be valid for a period of 12 months starting from the date of commissioning of the machine at
the purchasers premises and, in any case, for a period of no longer than 9 months following the
date of delivery. Working hours over 48 hrs./week shall result in corresponding reductions in the
period of validity of this guarantee.

BIESSE S.p.A. shall be also considered liable for defects in electric and electronic parts of the
machine. The guarantee shall not cover defects caused by normal wear and consumption of those
parts which, by their very nature, are subject to rapid and continuous consumption, (e.g. gaskets,
belts, brushes, fuses etc.). The guarantee for replaced or repaired components shall expire on the
same date as the expiry of the guarantee of the machine itself.

Furthermore BIESSE S.p.A. shall not be liable for any lack of conformity of the machine deriving
from a failure to observe regulations indicated in the instructions manuals and in any case due to
inappropriate use or treatment of the machine. The purchaser may thus demand that any parts
found to be faulty be replaced provided that such faults are not attributed to mishandling and, in
the case of modification, provided that BIESSE S.p.A. has issued prior written consent.

The purchaser shall lose any right to this guarantee if he or she does not provide BIESSE S.p.A.
with a detailed written account of the nature of any defects of conformity found in the machine
within 15 days following discovery of the fact. Moreover, the purchaser shall lose his or her right to
this guarantee if he or she does not allow the vendor to perform all checks required or if, the
vendor having requested the return of a faulty component at its own expense, the purchaser fails
to return the component as soon as possible after such a request.

The technical documents which accompany the machine are prepared with close reference to the
content of the corresponding Directives and current safety regulations. It is therefore of the utmost
importance that the user read completely all volumes of the same in order to obtain from the
machine the best possible performance and to ensure the maximum lifetime to its component
parts.

The configuration of some parts or devices described or illustrated in the documents may differ
from the configuration actually present in the machine in a specific version designed and prepared
for particular requirements or safety standards. In this case, certain descriptions, references or
advised procedure may be of a generic nature although their effectiveness shall remain valid. The
supply of tools or special equipment with the machine is conditioned by the specific characteristics
and safety regulations in force in each country. The drawings and photographs are supplied with

BIESSE S.p.A.
(a728h0002.fm-161203)
F-1
Appendix F.
Guarantee and client servicing

the sole aim of providing examples as a point of reference for a more complete understanding of
the text.

BIESSE products are constantly developed and updated and therefore the firm reserves the right
to modify functional or aesthetic characteristics of its machinery, to make variations in drawings of
any functional part or accessory or suspend production and supply without giving prior notice to
anyone and without incurring any obligation. BIESSE S.p.A. furthermore reserves the right to
make any structural or functional modification besides modifying the supply of spare parts and
accessories without any obligation on its part to inform anyone for any reason whatsoever of such
changes.

F.2 Client servicing

BIESSE S.p.A. has service points throughout the world. The whole structure forms a highly
efficient integrated network, which the client can contact for any problem, information, advice or
news.
The service department employs technicians with a high level of knowledge and experience on the
models manufactured, obtained through special training in our factory, who are able to service
machines on site.

BIESSE's authorised Service Centres are listed on cd-rom InDocs.

F-2 BIESSE S.p.A.


(a728h0002.fm-161203)
Analytical index

Analytical index bar support 2-3


enabling 5-5
base 1-2
batteries
replacing the batteries in the NC 500
numerical control 12-18
boring and milling unit 1-4
displaying horizontal spindle pressure
12-11
fitting the tool 8-5
A lubrication of the circular blade tool unit
aggregate 12-15
adjusting the lockpin 9-4 position along the X - Y axes B-2
AGGRE4 2-4 spindle lubrication and cleaning 12-15
AGGRE6 2-4 technical data B-1
description 2-3 tool characteristics 8-2
fitting the tool 8-9 warming-up 9-5
housing in the rack type tool magazine working field along the X - Y axes B-3
10-3 working field along the Z axis B-4
installing on the electrospindle 9-3 button
lubrication and cleaning 12-14 emergency 5-4, 5-6
tool characteristics 8-2, 8-3, 8-4 select origin 5-6
aggregate AGGRE4 start 5-4
technical characteristics B-5 button pad
aggregate AGGRE6 axis speed control 5-2, 5-6
technical characteristics B-6 work table 5-2, 5-6
aggregate identification plates 2-3
aggregates
advice on overheating during the
machining operation 7-1 C
description of the identification plate
CE mark 1-8
affixed to aggregates 2-3
central greasing system
assembly D-1
topping-up lubricant 12-21
auxiliary vacuum system 7-5
central lubrication system 2-5
enabling selector 5-6
chain guard 1-7
axis
characteristics of workable materials 4-1
description 3-1
clamp stop plate 1-3
manual movement 3-2
piece locking 7-4
maximum speed and acceleration B-1
cleaning
variation of speed 3-2 aggregate 12-14
X 3-1 electrospindle 12-13
Y 3-1 guides 12-10
Z 3-1 ISO 30 collet spindle 12-14
racks 12-10
the machine 12-7
the vacuum pump (Becker Picchio
B 2200) 12-9
ball screws the vacuum pump (Becker VT 4.40)
lubrication 12-12 12-10
ball slide blocks CLEAR 5-3
lubrication 12-12 client servicing F-2
ball support 2-3 CLR, soft-key 5-5
enabling 5-5 collet spindle 1-5

BIESSE S.p.A.
(5801a0225IX.fm-161203)
i
Analytical index

collet types 8-3 curtain guard 1-7


fitting on the electrospindle 9-1 curtain guards
fitting the tool 8-7 periodic control 12-1
maintenance of ISO 30 type 12-14 cut-out valve 1-7
tool characteristics 8-3 cutting 4-3
collet spindles
housing in the rack type tool magazine
10-2
technical characteristics B-4 D
command unit danger area 4-4
NC 1000 numerical control 5-1 danger signs A-4
NC 500 numerical control 5-1 decommissioning E-1
commands demolition E-1
main switch 5-1 safety information A-4
compressed air (see pneumatic system) dimensions
connection D-1 circular blade milling tools 8-4
electrical system connection point D-2 milling tools 8-3
pneumatic system connection point D-2 of boring tools 8-2
suction system connection point D-2 of parts to be transported C-2
connection points on the machine D-2 of the electrical cabinet D-3
consumption of the piece 4-1
compressed air D-6 of the vacuum pump D-4
contact mats 1-7 working dimensions of machine D-2
checking proper operation 6-2 directive 98/37 1-8
lifting C-4
weight and dimensions for transport C-2
control panel 1-2
controls E
auxiliary vacuum system selector 5-6
electric system
axis speed control button pad 5-2, 5-6
differential protection D-5
CLEAR 5-3
frequency 1-8
double movement stops selector 5-4
power 1-8
emergency button 5-4
rated current 1-8
layout of controls 5-1
supply phases 1-8
main switch 5-3
supply voltage 1-8
NC 1000 numerical control command
supply voltage short-circuit cut-out
unit 5-1
power 1-8
NC 500 numerical control command
system requirements D-5
unit 5-1
wiring diagram number 1-8
numerical control functions keyboard
electric system frequency 1-8
5-2
electric system rated current 1-8
operator control panel 5-2, 5-3, 5-4
electric system supply phases 1-8
override 5-2, 5-6
electric system supply voltage 1-8
piece locking pedal 5-2
electrical cabinet 1-2
PLC keyboard 5-2, 5-5
dimensions D-3
select origin button 5-6
weight 1-8
start button 5-4
electrical system
tool unlock soft-key (for electrospindle)
connection cable section D-6
5-2
connection point D-2
tooling selector 5-4
installed power D-6
vacuum indicator 5-4
electronic display 2-1
vacuum system selector 5-4
use 11-3
work table button pad 5-2, 5-6
electrospindle 1-4

ii BIESSE S.p.A.
(5801a0225IX.fm-161203)
Analytical index

advice in case of non-use 7-1 how to use the machine 4-1


aggregate 2-3 humidity in the installation area D-7
checking tool lock 12-8
cleaning 12-13
collet spindle 1-5
fitting the collet spindle 9-1 I
installing the aggregate 9-3 identification plates
position along the X - Y B-2 danger signs A-4
technical characteristics of collet machine identification plate 1-8
spindles B-4 manufacturers identification plate 1-8
technical data B-1 indicator devices
tool characteristics 8-3 emergency indicator light 5-2
tool unlock soft-key 5-2 installation area D-1
warming up 9-4
working field along the X - Y axes B-3
working field along the Z axis B-4
emergency J
button 5-4, 5-6
jig 7-5
deactivating the emergency devices 6-3
power cut 7-2
restoring the machine to normal operation
after an emergency stop 6-4
stopping in an emergency 6-3
L
emergency cord 1-7 layout of the machine D-2
emergency indicator light 5-2 levelling D-1
emergency stop 6-3 lifting
the contact mats C-4
the machine C-3
the mesh guard C-4
F the vacuum pump C-4
loading
fixed piece support 1-3
how to load the piece to be machined
floor in the installation area D-7
4-1
frequency of maintenance operations 12-1
lubricants 12-3
FRL unit 1-2
lubrication
draining condensation 12-8
aggregate 12-14
pressure display 12-11
ball screws 12-12
topping-up with lubricant 12-20
ball slide blocks 12-12
front pusher
boring and milling unit 12-15
enabling 5-5
characteristics of lubricants 12-3
circular blade tool unit 12-15
of the vacuum pump (Becker Picchio
2200) 12-16
G racks 12-10
general description of the machine 1-1
general view 1-2
guarantee F-1
guides M
cleaning 12-10
machine axes
reset 6-5
machine axes reset 6-5
global reset 6-5
H single reset 6-5
horizontal boring 4-3

BIESSE S.p.A.
(5801a0225IX.fm-161203)
iii
Analytical index

machine models N
identification of model 1-8 NC 1000 (see numerical control)
machine serial number 1-8 NC 1000 numerical control 5-1
machine shipment C-1 NC 500 (see numerical control)
machine support feet NC 500 numerical control 5-1
repositioning C-6 replacing batteries 12-18
machine year of construction 1-8 noise level B-7
machining noise produced by the machine B-7
cutting 4-3 numerical control 1-2
horizontal boring 4-3 numerical control functions keyboard 5-2
how to use in pendular mode 4-1
how to use the machine 4-1
paused machine warnings 7-2
power cut 7-2 O
program simulation 7-3
operating section 1-2
repeating the program 7-2
boring and milling unit 1-4
safety information A-2
collet spindle 1-5
suspending the program 7-3
description of parts 1-4
types of machining operation foreseen
electrospindle 1-4
4-3
electrospindle aggregates 2-3
vertical and horizontal milling 4-3
position of the units along the X - Y axes
vertical boring 4-3
B-2
work area 4-4
reset 6-5
workable materials 4-1
spindle direction of rotation 3-6
machining depth
working field along the X - Y axes B-3
maximum machining depth for aggregate
working field along the Z axis B-4
AGGRE4 B-5
operation
machining operation
program simulation 7-3
procedure to carry out 7-2
suspending the program 7-3
start-up 7-6
operator control panel 5-2, 5-3, 5-4
suspension of machining operations with
origin 3-3
aggregates (see suspension time)
machine 3-3
machining pause 7-2
selecting 7-3
machining suspension time
work table 3-3
aggregate AGGRE4 B-5
origins
of the aggregate AGGRE6 B-6
mirror (or symmetrical) origins 3-4
main switch 5-1, 5-3
straight origins 3-4
maintenance
override 5-2
safety information A-3
manufacturer remote 5-6
address 1-8
device 1-8
manufacturers address 1-8
manufacturers device 1-8 P
maximum altitude of the installation area D-7 panel
mesh guard 1-7 unloading from the work table 7-6
lifting C-4 pendular mode (see how to use the machine)
weight and dimensions for transport C-2 photocell barrier 1-7
mobile piece support 1-3 piece
additional supports 2-1 characteristics 4-1
positioning 11-1 how to load/unload 4-1
moving the machine C-5 locking on the work table 7-4
minimum and maximum dimensions 4-1
piece locking 7-4

iv BIESSE S.p.A.
(5801a0225IX.fm-161203)
Analytical index

standard method 7-4 preparing 10-2


with auxiliary vacuum system 7-5 racks
with clamp stops 7-4 cleaning and lubrication 12-10
piece locking pedal 5-2 rear tool magazine
PLC keyboard 5-2, 5-5 opening and closing cover 5-5
bar supports soft-key 5-5 replacing
clamp stops soft-key 5-5 batteries in the NC 500 numerical
CLR soft-key 5-5 control 12-18
front pushers soft-key 5-5 restore
magazine cover soft-key 5-5 of machine 6-4
reset slot from tool change soft-key 5-6 rotation speed
reset slot soft-key 5-5 aggregate AGGRE4 B-5
semiautomatic soft-key 5-5 of collet spindles B-4
stop row soft-key 5-5 of the aggregate AGGRE6 B-6
stop row soft-keys 5-5 row of stops 3-3
test cones soft-key 5-6 selecting 5-5
pneumatic pressure
supply pressure D-6
pneumatic system
air purity D-6 S
compressed air consumption D-6 safety A-1
compressed air requirements D-6 danger signs A-4
connection point D-2 during installation of machine A-1
cut-out valve 1-7 during installation of tools A-2
supply pressure 1-8, D-6 during machine maintenance A-3
system requirements D-6 during machining A-2
pneumatic system requirements during transport and moving A-1
compressed air D-6 machine demolition A-4
positioning safety (see also safety device)
the mobile piece support 11-1 safety device 1-6
the shapeable suction cup 11-2 chain guard 1-7
the side and centre stops 11-2 curtain guard 1-7
power cut-out valve 1-7
of the electric system 1-8 emergency button 1-7
power cut 7-2 emergency cord 1-7
pressure mesh guard 1-7
boring unit horizontal spindles 12-11 safety devices
periodic control 12-11 contact mats 1-7
supply 12-11 selector
supply pressure D-6 auxiliary vacuum system 5-6
vacuum pump 12-11 double movement stops 5-4
Z axis compensation 12-11 tooling 5-4
problems 13-1 vacuum system 5-4
program shapeable suction cup 1-3
repeating 7-2 additional suction cups 2-2
simulation 7-3 fitting the gasket 11-5
suspending 7-3 periodic checking of gasket 12-1
program simulation 7-3 piece locking 7-4
positioning 11-2
short-circuit
supply voltage short-circuit cut-out
R power 1-8
rack type tool magazine 2-4 slot 3-5

BIESSE S.p.A.
(5801a0225IX.fm-161203)
v
Analytical index

soft-key fitting on the boring and milling unit 8-5


tool unlock (for electrospindle) 5-2 fitting to the collet spindle 8-7
spindle direction of rotation 3-6 milling 8-3
aggregate AGGRE4 B-5 tool magazine 1-2
of the aggregate AGGRE6 B-6 preparing 10-1
spindles tools
spindle direction of rotation 3-6 safety information A-2
spindle direction of rotation for aggregate transferring the machine C-5
AGGRE4 B-5 transmission ratio
spindle direction of rotation for aggregate aggregate AGGRE4 B-5
AGGRE6 B-6 of the aggregate AGGRE6 B-6
start transport
button 5-4 safety information A-1
starting
the machining operation 7-6
stop
additional rear stops 2-2 U
centre 1-3 unloading
clamp 1-3 how to unload the piece to be machined
double movement 2-2 4-1
enabling a row of stops 5-5 the panel 7-6
enabling the clamp stop 5-5 unlocking
positioning 11-2 the panel 7-6
preparation of the clamp stop 11-5
rear 1-3
row of stops 3-3
side 1-3 V
suction air (see suction system)
vacuum indicator 5-4
suction system
vacuum pump 1-2
connection point D-2
dimensions D-4
minimum flow rate D-6
pressure display 12-11
suction air requirement D-6
vacuum pump (Becker Picchio 2200)
suction flow speed 1-8
cleaning 12-9
system requirements D-6
lubrication 12-16
summary of maintenance operations 12-1
replacing the blades 12-19
suspending the program 7-3
vacuum pump (Becker VT 4.40)
switching the machine off 6-3
cleaning 12-10
switching the machine on 6-1
replacing the blades 12-17
vertical and horizontal milling 4-3
vertical boring 4-3
T
technical characteristics
aggregate AGGRE4 B-5 W
lubricants 12-3
warming up the electrospindle 9-4
of collet spindles B-4
warming-up
of the aggregate AGGRE6 B-6
the boring and milling unit 9-5
temperature in the installation area D-7
weight C-2
tool
aggregate AGGRE4 B-5
boring 8-1
electrical cabinet 1-8
circular blade milling 8-4
of machine 1-8
dimensions 8-1
of the aggregate AGGRE6 B-6
fitting on the aggregate 8-9
wiring diagram 1-8

vi BIESSE S.p.A.
(5801a0225IX.fm-161203)
Analytical index

work area 4-4


work table 1-2
arrangement of parts 1-3
ball support 2-3
bar support 2-3
button pad 5-2, 5-6
centre stop 1-3
double movement stop 2-2
electronic display 2-1
fitting the gasket on the shapeable suction
cup 11-5
fixed piece support 1-3
mobile piece support 1-3
piece locking 7-4
positioning mobile elements 11-1
positioning the moving elements using the
electronic display 11-3
preparation of the clamp stop 11-5
rear stop 1-3
selecting an origin 7-3
shapeable suction cup 1-3
side stop 1-3
unloading the panel 7-6
unlocking the panel 7-6
workable materials 4-1
how to load/unload the piece 4-1
working area 3-2
working field
along the X - Y axes B-3
along the Z axis B-4

X
X, axis 3-1

Y
Y, axis 3-1

Z
Z, axis 3-1

BIESSE S.p.A.
(5801a0225IX.fm-161203)
vii
Analytical index

viii BIESSE S.p.A.


(5801a0225IX.fm-161203)
BIESSE S.p.A.
Sede legale
Via della Meccanica, 16
61100 Pesaro (PU) Italy
Tel. +39 0721 439100
Fax +39 0721 439150
sales@biesse.it
www.biesse.com

You might also like