Cartea Tehnica SW BAS03A3AGB

____________________________________________________________________________________________________________ A8200Agb

0 Operating Instructions

OPERATING INSTRUCTIONS

VERTICAL PROCESSING CENTRES BAS03-12 and BAS03-22 (A3)

Machine type: .................................... CNC control: ...................................... Order number: ................................... Machine no.: ...................................... Year of manufacture: .........................

VERTICAL MILLING AND DRILLING CENTRES BAS03-12 / BAS03-22 _______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8200Agb

0-2 0.0 Prechapter

0.1 Product Standard processing centres "BAS03-x2" are 3 axle drilling and milling centres with two processing areas, vertical spindles as well as an automatic tool magazine for the automatic execution of CNC work programmes. Currently there is a one spindle model (BAS03-12) and model with a "double spindle" (BAS03-22). The two work areas are integrated in a swivel support system and hold customer-specific workpiece carriers (e.g. tensioning bar or tensioning frame). Every workpiece holder is considered its own independent work room, which offers the advantages of main time parallel loading and unloading. The machines are controlled via the CNC control panel. The proper operation of the machine requires skilled personnel. Significant deviations from the standard model, based on customer-specific requirements, are listed in Chapter 10.

0.2 Manufacturer Schwäbische Werkzeugmaschinen GmbH Seedorfer Straße 91 78713 Schramberg (Ortsteil Waldmössingen), Germany Phone: 0 74 02 / 74-0 Fax: 0 74 02 / 74-211 Service department: Phone: 0 74 02 / 74-240 Fax: 0 74 02 / 74-195

0.3 Supplier

0.4 Copyright The copyright © for the presented documentation belongs to "Schwäbische Werkzeugmaschinen GmbH" as well as partially ot the suppliers of the external documentation. The information contained therein are intended exclusively for the operators of the machine supplied by us and may not be modified, expanded, copied saved/distributed to data processing devices or used for purposes that are not in our interest. There is no claim made regarding the completeness of the information contained in the documentation. We have done our utmost to present the content regarding our products correctly and in an up-to-date fashion. However, we cannot guarantee that this document is free of errors. Especially in photos and other illustrations, components could be shown that are not part of the standard scope of delivery (optionen) or parts that have been modified in the meantime. We reserve the right to make modifications based of further developments or "state-of-the-art". Copyright © "Schwäbische Werkzeugmaschinen GmbH", 2007

VERTICAL MILLING AND DRILLING CENTRES

BAS03-12 / BAS03-22 ______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8200Agb

0.0 Prechapter 0-3

0.5 Intended use The machines "BAS03-xx" are configured and built exclusively as CNC controlled drilling and milling centres and are used for chip processing metal materials, whose spontaneous combustion temperature is not reached in spite of the maximum metal removal rate and unfavourable ambient conditions (temperature, air pressure, oils, cooling and cleaning agents as well as other additives) and that do not emit hazardous vapors, dusts or aerosoles. The operation must take place in closed rooms under normal conditions (permissible temperature and humidity as per specifications). Other prerequisites for proper use include: • adhering to legal regulations as well as to guidelines of authorised institutions • adherence to the information in the included operating and use instructions,

especially the safety and accident prevention instructions • the proper operation of the machine, incl. the components delivered by the

manufacturer by skilled personnel • the punctual and proper execution of maintenance and inspection procedures • the technically flawless condition of the unmodified machine (from the time it

was delivered), especially of all safety equipment Other uses or usage beyond its limits is considered non-purposeful and the risk lies with the operator; so long as no additional protective measures were convened in mutual agreement and installed by "Schwäbische Werkzeugmaschinen GmbH“ (extinguishing unit, filter, suction, monitoring).

Damages caused by illegal use voids any warranties granted by "Schwäbische Werkzeugmaschinen GmbH".

0.6 Machine dangers The machines "BAS03-xx" were designed and built state-of-the-art and conform with the applicable safety regulations and valid machine engineering guidelines. However, not all hazards to the body and life of the user and third parties or damages to the machine and other property can be excluded. The highest possible safety is granted, however, if: • the machine is used solely for its intended purpose • all work is performed by qualified and trained personnel • the generally applicable as well as the specific safety, accident prevention and

operating instructions of the "Schwäbische Werkzeugmaschinen GmbH" are observed

• no self-initiated modifications are made on the machine • the maintenance work is performed responsibly and punctually • the machine is used carefully and responsibly, so that wear and aging signs can

be detected in their early stages and can be alleviated.


____________________________________________________________________________________________________________ A8200Agb

0-4 0.0 Prechapter

0.7 Environmental influences As standard equipment, the machine (without additional customer-specific equipment) requires certain energy types and auxiliary materials, whose production and use can influence the environment negatively and could cause safety hazards for employees. Environmental impact: • Electrical energy as a main supply for the machine operation; type of energy and

volume is indicated on the type plate at the switch cabinet as well as in Chapter "Specifications".

• Pneumatic energy via a compressed air network of the operator. For additional

consumers, such as pneumatic cleaning guns or measurement or tensioning devices, there are connection possibilities inside the machine. Air consumption see "Specifications".

• Hydraulic energy for tool tensioners and tool transport device; the pressure oil is

generated by it own, electrically-driven hydraulic unit. The connection of further hydraulic units is possible. Fill amounts and lubricant / oil qualities can be found in the lubrication schedule and manufacturer documentation.

• The noise level of the machine (without processing) can be found in the

"Specifications". • The lubrication of frequently used bearings and machine parts takes place fully

automated via loss lubrication via central lubricating unitsor by continuous grease lubrication. Fill amounts and lubricant / oil qualities can be found in the lubrication schedule and manufacturer documentation.

• To cool, lubricate and clean tools and workpieces, the machine can be equipped

with an additional cooling lubricant system. Cooling agents and chips (contamination) are separated by the chip conveyor; optional cleaning / filter systems are available as optional items.

• The leaked oil from the loss lubrication and the hydraulic system, etc. flow to the

cooling lubricant.

Depending on the use of the machine and the auxiliary materials and additives used, there will be electromagnetic fields, aerosols (oil vapor), chemical and biological residue as well as noise generation that could reach the environment without additional protective equipment and thus could cause health hazards for the employees.


BAS03-12 / BAS03-22 ______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8200Agb

0.0 Prechapter 0-5

0.8 Warranty / Liability The current, general sale and delivery conditions of the "Schwäbische Werkzeugmaschinen GmbH“ apply; • as well as the following with domestic transactions:

General conditions for the delivery of machines for domestic trade, published by the VERBAND DEUTSCHER MASCHINEN- UND ANLAGENBAU E.V. (VDMA).

• with export transactions: General conditions for the delivery and installation of mechanical, electrical and electronic products, published by ORGALIME, Brussels (... a loose association of economic institutions based in 20 European countries)

Warranty and liability claims for property damage and personal injuries are generally excluded, if the following conditions were their cause: • non-purposeful use, • non-adherence to the general and special safety and accident prevention

instructions, • unskilled or unauthorised handling during: storage, transport, setup, startup,

operation, maintenance, service, repair and removal, • non-adherence to the mandatory (legal) requirements regarding maintenance,

care and testing intervals, • self-initiated construction modifications on electrical, hydraulic, pneumatic and

mechanical systems, including configuration changes of operation systems of electronic controls,

• lack of monitoring of wear and aging signs, • force majeure or external influences.


____________________________________________________________________________________________________________ A8200Agb

0-6 0.0 Prechapter

0.9 Total table of contents Chapter page

0 OPERATING INSTRUCTIONS 0-1

0.1 Product 0-2

0.2 Manufacturer 0-2

0.3 Supplier 0-2

0.4 Copyright 0-2

0.5 Intended use 0-3

0.6 Machine dangers 0-3

0.7 Environmental influences 0-4

0.8 Warranty / Liability 0-5

0.9 Total table of contents 0-6

1 GENERAL SAFETY AND ACCIDENT PREVENTION INFORMATION 1-1

1.1 Explanation of Symbols 1-2

1.2 General 1-3

1.3 Operation safety ordinance / work protection law 1-10

1.4 Skilled personnel 1-10

2 GENERAL DESCRIPTION 2-1

2.1 Preliminary information 2-2

2.2 Description of the mechanics 2-3 2.2.1 General 2-3 2.2.2 Special machine features 2-6

2.3 CNC control: 2-7 2.3.1 Control type 2-7

3 PICTORIAL PART 3-1


3.2 Machine photographs 3-3 3.2.1 Total view 3-3


BAS03-12 / BAS03-22 ______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8200Agb

0.0 Prechapter 0-7

3.2.2 Work room / loading room (two locations) 3-7 3.2.3 Tool magazine 3-9 3.2.4 Groups 3-11 3.2.5 Units 3-15 3.2.6 Individual components 3-24

4 TRANSPORT; LOCATION PREPARATION, SETUP 4-1

4.1 Safety notes for transport and setup 4-3

4.2 Dispatch 4-5

4.3 Transport 4-7 4.3.1 Door lock 4-7

4.3.1.1 Position of the safety switches 4-8 4.3.2 Transporting the machine domestically by crane 4-9

4.3.2.1 Stop positions 4-9 4.3.3 Transport image 4-11 4.3.4 Transport on heavy load rolls 4-12

4.4 Preparing the setup location 4-13 4.4.1 Space requirements and connection data 4-13 4.4.2 Fundation note 4-13

4.5 Erection 4-15 4.5.1 Preparatory work 4-15 4.5.2 Alignment 4-16

4.6 Assembly / Disassembly 4-19 4.6.1 Transportation locks 4-20

4.6.1.1 Mount the safety angle 4-21 4.6.1.2 Round axle / swivelling table 4-22 4.6.1.3 Transport position of swivel support (only for two station machines) 4-22 4.6.1.4 Z axle / work spindle advance 4-22

4.6.2 Hydraulic unit 4-23 4.6.3 Central lubrication / minimum oil quantity lubrication 4-24 4.6.4 Central cooling unit (water return cooler) 4-25 4.6.5 Heat exchanger switch cabinet 4-25 4.6.6 Chip cart (option) 4-26 4.6.7 Chip conveyor / cooling lubricant system (option) 4-27 4.6.8 Initial cleaning 4-29 4.6.9 Initial fill 4-29

4.6.9.1 Hydraulic system 4-30 4.6.9.2 Central lubrication / minimum oil quantity lubrication 4-31 4.6.9.3 Central cooling unit (water return cooler) 4-32 4.6.9.4 Chip conveyor / cooling lubricant system (option) 4-33

4.6.10 Conclusion of the transport preparations 4-34

4.7 Connection (only by skilled personnel) 4-35 4.7.1 Pneumatics 4-35 4.7.2 Power supply 4-36 4.7.3 Chip conveyor / cooling lubricant system (option) 4-36

4.8 Startup 4-37


____________________________________________________________________________________________________________ A8200Agb

0-8 0.0 Prechapter


4.10 Shutting down and storing the machine 4-41

5 DIAGRAMS, DRAWINGS, DIMENSIONS 5-1

6 SPECIFICATIONS 6-1

6.1 Specifications BAS03-x2..(two station machine) 6-2 6.1.1 Performance and torque diagram 6-8

7 UNITS / DEVICES 7-1

7.1 Pneumatic system 7-3 7.1.1 Function 7-3 7.1.2 Adjustment elements 7-5

7.2 Cooling lubricant system (option) 7-9 7.2.1 Function 7-9 7.2.2 Option Interior cooling lubricants 7-9

7.2.2.1 High-pressure pump / filter for interior coolant supply 7-10 7.2.3 Adjustment elements 7-10

7.3 Central lubrication / minimum oil quantity lubrication 7-15 7.3.1 Function 7-15

7.3.1.1 Central lubrication: 7-15 7.3.1.2 Minimal oil lubrication 7-15

7.3.2 Adjustment elements 7-16

7.4 Hydraulic system 7-19 7.4.1 Function 7-19 7.4.2 Adjustment elements 7-20

7.5 Central cooling unit 7-23 7.5.1 Function 7-23 7.5.2 Adjustment elements 7-24

7.6 Option: Emulsion vapor separator system / compact electric filter 7-27 7.6.1 Function 7-27 7.6.2 Adjustment elements 7-27

8 TEST REPORTS, PROTOCOLS, CERTIFICATES 8-1

9 MAINTENANCE / SERVICE 9-1

9.1 Safety instructions for service 9-2 9.1.1 Safety instructions for protective equipment 9-6

9.2 Protective equipment 9-9 9.2.1 Functional safety switches 9-9 9.2.2 Work room / loading room door 9-10

9.2.2.1 Option: Automatic loading room door 9-10


BAS03-12 / BAS03-22 ______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8200Agb

0.0 Prechapter 0-9

9.2.3 roller blinds 9-11 9.2.4 Work room safety window (only with two station models) 9-12 9.2.5 Work room grid 9-13 9.2.6 Magazine loading door (only with two station models) 9-13 9.2.7 Cassette walls 9-14 9.2.8 Panels 9-14 9.2.9 Switch cabinet doors 9-14

9.3 Cleaning 9-15 9.3.1 General instructions 9-15

9.4 List of lubricants BAS-03 9-17 9.4.1 Lubricant list for SW machines 9-18

9.5 Tips for the use of cooling lubricants 9-20

9.6 Maintenance / service 9-21 9.6.1 Lubrication schedule 9-23 9.6.2 Fill volumes 9-24 9.6.3 Maintenance schedule 9-25

9.7 Maintenance photos 9-32

9.8 Service 9-39 9.8.1 Safety windows 9-39

9.8.1.1 Exchanging the polycarbonate window on the work room door 9-39 9.8.1.2 Replacing the polycarbonate windows of the work room door 9-39

9.8.2 roller blind covers 9-40 9.8.2.1 Replacing the "roller blind spindle unit" (X axle) 9-40 9.8.2.2 Replacing "roller blind loading room cover" 9-41 9.8.2.3 Replacing the "side roller blind roof sled" 9-41

9.9 Troubleshooting 9-43

10 OPTIONS / SPECIAL ACCESSORIES 10-1

11 MACHINE OPERATION 11-1

11.1 General safety and accident prevention notes 11-3 11.1.1 Explanation of symbols 11-3 11.1.2 General information 11-4 11.1.3 Use and operation 11-4 11.1.4 Training 11-7

11.1.4.1 Training skilled personnel 11-7 11.1.4.2 Training for production operation 11-7

11.1.5 Operating and programming instructions 11-8

11.2 Operating elements 11-9 11.2.1 Overview Main operating panel 11-10

11.2.1.1 Siemens control panel 11-11 11.2.1.2 Siemens machine control panel 11-11 11.2.1.3 Additional operating panel Schwäbische Werkzeugmaschinen GmbH 11-11

11.2.2 Switches, keys, signal elements 11-12


____________________________________________________________________________________________________________ A8200Agb

0-10 0.0 Prechapter

11.2.2.1 Siemens machine control panel 11-12 11.2.2.1.1 SW function keys with LED 11-13 11.2.2.1.2 Axle selection 11-15

11.2.2.2 Additional control panel SW 11-17 11.2.2.2.1 BAS03-11 / -21 11-17 11.2.2.2.2 BAS03-12 / -22 11-21

11.2.2.3 SW magazine control panel 11-23 11.2.2.3.1 BAS03-x2 11-23

11.2.3 Two station processing 11-24

11.3 Operation 11-25 11.3.1 Switching the machine on 11-25

11.3.1.1 Switching on 11-25 11.3.1.2 Roof sled drive synchronisation 11-26 11.3.1.3 Switching the machine off 11-27 11.3.1.4 Turning the swivel support in the JOG mode 11-27 11.3.1.5 Roof sled 11-28 11.3.1.6 Reference points 11-28 11.3.1.7 Selecting programmes 11-29 11.3.1.8 Test stop 11-30

11.3.2 Tools and magazine 11-31 11.3.2.1 Basics 11-31 11.3.2.2 Oversized tools 11-32 11.3.2.3 Loading the tool magazine BAS03-x1 11-33

11.3.2.3.1 New tool 11-33 11.3.2.4 Loading the tool magazine BAS03-x1 11-35

11.3.2.4.1 New tool 11-35 11.3.2.5 Unloading the magazine 11-37

11.3.2.5.1 Unload tool 11-37 11.3.2.6 Programming notes for tool management 11-38

11.3.2.6.1 Tool change 11-38 11.3.3 Tool monitoring 11-39

11.3.3.1 Standstill monitoring 11-39 11.3.3.2 Quantity monitoring 11-39

11.3.4 Tool magazine 11-41 11.3.4.1 Basics about the tool magazine 11-41

11.3.5 Teleservice (Option) 11-43

11.4 HMI masks 11-45 11.4.1 SW 11-46

11.4.1.1 Tool breakage 11-46 11.4.1.2 Machine 11-47

11.4.1.2.1 NC programme 11-47 11.4.1.2.2 Assigning NC programmes 11-48 11.4.1.2.3 Machine control panel 11-49

11.4.2 Preparation 11-51 11.4.2.1 Type preselection 11-51 11.4.2.2 Adjustment 11-52

11.4.2.2.1 Lubrication 11-52 11.4.2.2.2 Chip conveyor / input 11-53

11.4.3 Manual operation 11-54 11.4.3.1 Individual movement of tool changer 11-55 11.4.3.2 Individual movement tensioning device, table 1 11-56

11.4.4 Processing 11-57


BAS03-12 / BAS03-22 ______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8200Agb

0.0 Prechapter 0-11

11.4.4.1 Tension layer 11-57 11.4.5 Diagnosis 11-58

11.4.5.1 Carrier round table 11-58 11.4.6 Documentation 11-59

11.4.6.1 Workpiece counter 11-59

11.5 SW masks / expansions 11-61 11.5.1 Loading axles / setup positions 11-61 11.5.2 Selecting the device 11-63

11.6 Tool and magazine masks (Siemens) 11-65

11.7 Control tips, tables, lists 11-67 11.7.1 BAG's and channels 11-67 11.7.2 Coordinate system/axle designations/drive distances 11-68 11.7.3 Special functions / BAS03 11-69

11.7.3.1 Error messages 11-69 11.7.3.2 M functions / overview 11-69 11.7.3.3 H functions 11-71 11.7.3.4 Extended M functions 11-72 11.7.3.5 L functions 11-72 11.7.3.6 G commands 11-72

11.8 Programming / examples 11-73 11.8.1 Clamping of round axles 11-73

11.8.1.1 Round axles from NCK status 6.4 11-73 11.8.1.1.1 G1 standard (without round axle interpolation) 11-73 11.8.1.1.2 G1 with 4 or 5 axle interpolation 11-74 11.8.1.1.3 Programming of A or U axle parallel to the tool change. 11-75 11.8.1.1.4 Axle-neutral programming of the round axles A or U 11-75

11.9 Appendix / Option 11-76

11.10 ePS network manufacturer's documentation 11-76

11.11 Groove cycle 11-76 11.11.1 Groove cycle (option) 11-77

11.11.1.1 Inner groove 11-78 11.11.1.1.1 Entering workpiece parameters 11-78 11.11.1.1.2 Input of tool parameters 11-81 11.11.1.1.3 Adjustments for interior circulation 11-82

11.11.1.2 Outer groove 11-83 11.11.1.2.1 Entering workpiece parameters 11-83 11.11.1.2.2 Input of tool parameters 11-86 11.11.1.2.3 Adjustments for exterior circulation 11-87

12 UPGRADING 12-1

12.1 Safety instructions 12-2

12.2 Loading with crane / handling systems 12-5 12.2.1 One station machines 12-5 12.2.2 Two station machines 12-6


____________________________________________________________________________________________________________ A8200Agb

0-12 0.0 Prechapter

13 DISPOSAL 13-1


13.2 Disposal options 13-3

14 FIRES 14-1

14.1 General Information on Fire Procedures 14-2

14.2 Opening the force locked protective doors when there is no power supplied to the machine 14-3

14.3 Opening the safety separating window when there is no power supplied to the machine 14-4

15 EXTERNAL DOCUMENTATION 15-1

16 ELECTRICAL DOCUMENTATION 16-1

17 SPARE PARTS AND WEAR PARTS, DRAWINGS, ILLUSTRATIONS 17-1

17.1 Usage instructions for the electronic spare parts and wear parts lists 17-2

17.2 Drawings, illustrations 17-3

Technical specifications are subject to change.


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8001Agb

1.0 General Safety and Accident Prevention Instructions 1-1

1 General Safety and Accident Prevention Information

Table of Contents

1 GENERAL SAFETY AND ACCIDENT PREVENTION INFORMATION 1-1

1.1 Explanation of Symbols 1-2

1.2 General 1-3

1.3 Operation safety ordinance / work protection law 1-10

1.4 Skilled personnel 1-10

VERTICAL MILLING AND DRILLING CENTRES BAS03-xx _______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8001Agb

1-2 1.0 General Safety and Accident Prevention Instructions

1.1 Explanation of Symbols Graphical symbol are used in the operating instructions to alert the operators of the machine to certain safety and operation situations. These symbols have the following meanings:

Immediate danger to life and health. If these instructions are not observed, this can cause health problems or even life-threatening injuries.

Impending danger for body, life and property. If these instructions are not observed, this can cause health problems or even life-threatening injuries, as well as damages to the equipment and property value.

Important note for the proper handling of the machine. If these notes are not observed, this can lead to damages to the equipment and property value - and sometimes - harbour an injury risk for employees.

Impending danger by electric current. If these instructions are not observed, this can cause health problems or even life-threatening injuries caused by electric current, as well as damages to the equipment and property value.

Impending danger caused by thermal influences. If these notes are not observed, this can lead to burns and scalding by coming into contact with liquids, surfaces and objects (e.g. motors, pumps, hydraulic and cooling units, valves, etc.)

Impending danger by strong magnetic fields. If these instructions are not observed, this could lead to life-threatening affects on humans (e.g. pacemakers, electr. health systems) as well as injuries by magnetic tools and damage or destruction of electronic devices.

Useful tips and work-releated information. These instructions contain information that allows for a better handling of the machine.


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8001Agb


1.2 General The machine is state-of-the-art; the design and manufacturing is performed under observance of the general regulations and legal directives of the machine industry. The highest possible operation safety is only achieved, however, if the machine is used solely by trained, respsonsible personnel and is only used for its intended purpose. Every person that is responsible for the transport, installation, operation, maintenance and supervision of the machines manufactured by "Schwäbische Werkzeugmaschinen GmbH“ as well as the master or department manager, under whose supervision the machine is erected, must have read and understood the chapter "General safety and accident prevention instructions“. Theother country-specific regulations and law, which apply to special handling, must be observed as well and have priority over our instructions. A non-dangerous and flawless performance of activities and interventions is only warranted if special skills are present for these activities and if the information and instructions in our machine documentation as well as the components' instructions are taken into consideration. The cautionary measures required in the documentation of the "Schwäbische Werkzeugmaschinen GmbH“ do not claim to be complete and refer solely to the use of our products.

If unauthorised personnel acts/intervenes without extensive know-how, these situations could result: - Dangers to body and life, - dangers to the machine and other property assets, - danger to the efficient operation of the machine, - danger to the environment. The responsibility of having only trained/skilled personnel work on certain activities lies with the different supervisors of the employees in charge as well as with the safety officer of the operator.

Prior to performing certain tasks, all relevant information as well as the special safety instructions in the respective machine documentation chapter must be observed.


____________________________________________________________________________________________________________ A8001Agb


The operator bears the responsibility for the internal transport of the machine - even if the employees of the "Schwäbische Werkzeugmaschinen GmbH“ are present - and he must ensure that the safety and accident prevention instructions are adhered to. • Depending on the activities to be performed, the respective personal safety

equipment must be worn (e.g. protective gloves, safety shoes, helmet, protective eye goggles, etc.).

• Machine or panel parts with sharp edges in the access area of the transport

workers must be covered by covers (upholstery material). • The prescribed end positions for the load pickup devices must be used.. • The products to be transported must be secured against movement, tilting,

rotating or swivelling of individual parts prior to and during transport. The respective measures must be taken to achieve this (observing the gravity center as well as securing with: positioning rings, chains, securing wooden wedges, screw connections, etc.).

• The transport must be slow, controlled and no other objects must be touched.

If the machine and machine parts are not transported properly, this will endanger your health and life! Neverstep underneath raised loads; secure transported goods sufficiently; when turning/moving the transported goods in small areas, ensure a sufficient safety distance (crushing and severing danger of the head, body and extremities)! Machinesmanufactured by "Schwäbische Werkzeugmaschinen GmbH“ are equipped with various safety systems; e.g. doors and windows (work room, machine room, tool magazine, etc.) are all monitored and locked via the machine control.

The operator is responsible for the machine not being operated if safety systems (such as panel parts) are open, removed, bypassed or taken out of operation - life-threatening danger!

Panel parts and cab sheet metal parts and switch cabinet doors are not monitored.


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8001Agb


With automatically operated doors / windows / openings, there is always a risk of crushing. Persons close to the machine must be warned of this danger by the operator. The operator must check the proper fastening of the tensioning devices, their power supplies (electric, pneumatic, hydraulic) as well as the proper functioning of the tools / tool holders and the processing programme; a walk around the machine as well as an inspection of the machine interior must be conducted to ensure that no persons are within the immediate machine area and that the machine is not colliding with any objects prior to starting the machine. With machinesthat allow the use of two "separate" processing locations by a common spindle performing the processing alternatively, only the work room is monitored or locked, where the processing spindle is located. The other work room can be opened for loading/unloading without having to interrupt the work process in the opposite work room.

The serial work room separating wall which is equipped when the two work room model is used must not be removed - life threatening danger! Reaching across or climbing from the free work room into the active work room is prohibited; danger of injuries by cuts and loss of limbs all the way to life-threatening injuries

Depending on the machine model, certain machine functions or operation settings are protected by key switchesThese key switches are located in the control panel or directly on the respective functional unit. The machine must be set up so that only the required activities are performed by the respective employees. The operator is obliged to remove the key and keep the device locked from unautorized persons. The key switch installed on some machine (e.g. in the control panel), which can interrupt the protective door monitoring, may only be used for setup, maintenance and repair procedures.

As long as the protective door monitoring is disabled, a life-threatening danger exists; axle drives can be activated while the protective door is open.


____________________________________________________________________________________________________________ A8001Agb


The operator must inform himself extensively about the location and the function of the "EMERG OFF" key(s).

If the safety is breached, or if a situation is detected that might lead to a safety breach, the "EMERG OFF" key must be activated immediately.

• When the "EMERG OFF" key is pressed, all machine movements are stopped;

depending on the situation, this can cause damage to the tools, the work piece and perhaps to the machine.

The operator must immediately inform the responsible party of all modifications on the machine that may lead to safety-relevant issues. The CNC controlled machines are equipped with diagnostics system; with functional errors or operational errors, error messages will be generated.The causes of the errors must be eliminated. Severe errors will lead to a shut down of the machine, just like pressing "EMERG OFF".

There is no check of the customer-specific processing programmes regarding these operation errors.. Every operator is responsible for not using commands in programmes that might cause safety issues for persons and materials (e.g. work piece and tool dimensions, advances, speeds, depth of cut).

The operator is responsible for the compliance with work and environmental protection when using hazardous and auxiliary substances.The machines require oils, greases, cooling lubricants and refrigerants, air, hydraulics and electrical energy for their proper operation.The operator is also responsible for choosing the proper manufacturer/supplier as well as for clarifying the safety-relevant issues. Oils, greases, cooling lubricants, detergents and solvents and other materials used for operation contain biological and chemical substances, which may cause hazards to your health if used improperly (toxic and/or flammable vapors, acidic or skin-irritating additives, etc.). Furthermore, the mixing of these materials may create new compounds that may also negatively impact not only human health but also the machine's product life. Generally the information and use instructions of the manufacturer (material safety data sheet) and the applicable national regulations and laws that are binding for the machine's location must be adhered to prior to using auxiliary materials and additives.


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8001Agb


Escaped liquids (leakages) as well as worn or used auxiliary materials must be removed immediately and disposed of as determined by the work and environmental protection regulations. Wear protective clothing.

The service and maintenance staff is expected to be familiar with the general legal accident prevention measures; the responsibility lies with the safety officer of the user or rather with the supervisor of the maintenance and service staff. Prior to beginning maintenance and repair procedures, the machine must be disconnect from the power supply and the pressure must be relieved; furthermore, the non-operational stastus of the machine must be reported by means of "Caution Signs".

After disconnecting the electrical energy (main switch OFF), enough residual energy may remain in the different supply systems - e.g. electrical, electronic, hydraulics, pneumatics - which could lead to hazardous situations, some with fatal consequences - if not handled by an expert.

• Hydraulic and pneumatic systems may only be disconnected from the main line

and the system pressure may only be released after it has been ensured that this will not cause any uncontrollable mechanical reactions (snapping back of spring-loaded tensioning systems or cylinders in idle positions; dropping of tools; sliding off of advance and movement units by the lack of weight balancing, etc.).

• Prior to removing e.g.motors with built-in brakes, toothed gears, couplings or

other movement-inhibiting components, the respective movement units must be secured (supported or hung up) so that these inadvertent movements are prevented.

When working on hard to reach places as well as units that are not clearly visible for design or functional reasons (e.g. chip conveyor, chip box, cooling agent containers, submersion pumps, tool magazine, etc.) there is a danger of cuts, crushing, abrasion and burn injuries. To prevent accidents, you must wear protective clothing during these procedures.

Maintenance, repair and adjustment procedures on active systems must be performed using extreme caution. If the necessary caution is not applied, there is a danger of injuries or even death!


____________________________________________________________________________________________________________ A8001Agb


• Maintenance and repair work that requires adjustments that is only possible

while all systems are ready to operate or by removing or deactivating special safety equipment, must be monitored by responsible employees located near the "EMERG OFF" and "main switch" keys; if danger arises, the machine must be shut down.

The electric switch cabinet may only be opened by qualified and authorised personnel. After disconnecting the machine from the electrical supply (main switch OFF), the following parts still feature life-threatening current: - on the main switch - in the switch cabinets on the terminals L1, L2, L3 - on the connecting cable between the main switch and the terminals - on the power supply line - on electric regulators and their supply modules - on all areas marked with a warning label Switched interventions to modify the hardware or software, as well as electrical and mechanical modifications of the machine's design may only be performed by service technicians of "Schwäbische Werkzeugmaschinen GmbH"; the information in the operating instructions is for informational purposes only. The operator/owner is liable for any damage caused by unauthorized intervention.

After completing maintenance or repair work, the supervisor of the maintenance/service personnel must verify the unlimited operation readiness of the machine. This includes: • the proper fastening of all panel parts and protective equipment, • checking the proper installation of all parts, connections, etc. loosened or

removed in the course of the work performed • the proper filling and pressure application • a function test of the machine with the result, that the machine/its components

are functioning properly and within the prescribed NOMINAL values. • the correct function of the protective equipment and the EMERG OFF key • checking the processing programme, if the executed procedures may have

affected it in any way. A walk around the machine as well as an inspection of the machine interior must be conducted to ensure that no persons are within the immediate machine area and that the machine is not colliding with any objects prior to starting the machine. Only then may the production operation be released.


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8001Agb


All safety-relevant equipment (e.g. ”EMERG OFF” function, light curtains, safety rails, floor mats, door monitors, error current switch, etc.) must be checked for proper function on a regular basis. Here, the respective applicable laws and regulations apply that are legally binding for the operating site.

Adhere to legal regulations: Hydraulic hoses must be regularly checked by an expert for their safe function; the max. use is 6 years - as per the "Safety regulations for hydraulic hoses" (incl. storage time).

Due to the material aging of polycarbonate, the retaining capacity (protection from foreign object impact) of the work rooom protective windows is decreased. Another reduction of safety is caused by mechanical damage, temperature influence, radiation and the contact with chemical and biological auxiliary materials and additives. The usage period of work room protective windows is limited, see Chapter "Maintenance“ Damaged polycarbonate windows must be replaced immediately.


____________________________________________________________________________________________________________ A8001Agb


1.3 Operation safety ordinance / work protection law Notes as per Operational Safety Ordinance and work protection law The machine has been manufactured based on the state-of-the-art technology; its design and manufacturing took place in compliance with the European Machine Directive and the use of the harmonised standards and guidelines for engineering. The machine has been certified with the CE symbol. This also includes the main requirements of the Operational Safety Ordinance. Furthermore, the operator is obliged to integrate this machine into his manufacturing environment as per the Operational Safety Ordinance so that no avoidable hazards or functional errors are created. Based on applicable law, Schwäbische Werkzeugmaschinen GmbH assumes that the operator meets the following requirements. Obligations of the operator / obligations of the personnel

The operator agrees to only let persons work on the machine who are familiar with the basic requirements of work safety and accident prevention, who have been trained in the handling of the machine and who are competent enough to run the work procedures without creating hazardous situations. Furthermore, they must have read and understood all safety and warning notes in the operating instructions and the included (supplier) documentation. The responsibilities of the personnel for the operation, setup, maintenance, repair, cleaning, etc. must be clearly defined.

1.4 Skilled personnel Skilled personnel includes employees who are knowledgeable based on their expert training, experience and on the job training, about the current standards, regulations and accident prevention directives. Furthermore, they must be able to evaluate the tasks given to them and must be able to recognise possibly dangerous situations. These skilled employees must be authorised to perform the respective procedures.


BAS03-12 / BAS03-22 ______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8202Agb

2.0 General description 2-1

2 General description

Table of Contents

2 GENERAL DESCRIPTION 2-1


2.2 Description of the mechanics 2-3 2.2.1 General 2-3 2.2.2 Special machine features 2-6

2.3 CNC control: 2-7 2.3.1 Control type 2-7


____________________________________________________________________________________________________________ A8202Agb

2-2 2.0 General description

2.1 Preliminary information

There is no claim made regarding the completeness of the information contained in the documentation. We have done our utmost to present the content regarding our products correctly and in an up-to-date fashion. However, we cannot guarantee that this document is free of errors. Especially in photos and other illustrations, components could be shown that are not part of the standard scope of delivery (optionen) or parts that have been modified in the meantime. We reserve the right to make modifications based of further developments or "state-of-the-art".


BAS03-12 / BAS03-22 ______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8202Agb


2.2 Description of the mechanics

2.2.1 General Based on the combination of proven design basics (box in box principle) with modern technologies, a machine series was created that stands out because of its compact design and high machine dynamics. The main field of application is the automatic, CNC controlled chip removal of metal materials in wet and dry processing runs. Currently, there is a differentiation between a one station model (with a swivel table, BAS03-x1) and a model with a "double swivel table" (BAS03-x2), which can be called a two station model. The swivel tables are used as machine tables for the placement of workpieces or the tensioning devices; they are fashioned as horizontal NC axle. Generally, both models can be supplied with one (BAS03-1x) as well as with two (BAS03-2x) vertically arranged motor spindles and they are equipped with an automatic tool magazine. The following information refers to the two station model of the processing centres BAS03, with either one or two spindles BAS03-12 (one spindle, two station model) BAS03-22 (two spindle, two station model)


____________________________________________________________________________________________________________ A8202Agb


The basis is the fixed, stiff U-shaped machine stand made of welded steel with cross strut in the rear roof area. The Y sled in "Gantry style" for the lengthwise movement, the X sled for the horizontal movement and the Z sled for the vertical movement of the work spindle(s) are also located in the roof area and make up the three axle unit (as a box in box system). The different sleds are connected to each other via linear guide rails with roller guides. The advance of the individual drive axles (X, Y, Z) is realized via ball roll spindles and servo drives.The distance measuring is done via absolute, direct measuring systems (glass scales). The Gantry system of the Y sled with two drives and two separate distance measuring sytems ensures a regulated, sled-parallel advance movement. Underneath the three axle unit, there is the work room. The machines have two swivel tables with counterbearings, which are defined as independent horizontal NC axles by the control (A1 / U1). This allows processing outside the three main machine axles (room angle processing) without additional effort.The optional planet round tables provide additional NC round axles (C / W); see figure. The swivel tables are built into a swivel support system and make up two areas separated by safety windows.While one table for parts processing is located in the work room, the other table is located in the loading room (main time parallel loading and unloading), so that you could consider this to be a two-station processing. By turning the entire swivel support system by 180°, the two swivel tables change their positions between work and loading room. The chips that are generated during processing (as well as the cooling lubricant - if used) are discharged via declined surfaces into the foot area of the machine stand. As a choice, a chip cart or a cooling lubricant system with chip conveyor - which are adapted to the opening contours in the machine leg - must be used.

If operating without adapted chip catch container (e.g. with central disposal), the operator is obliged to close the foot area of the machine so that there is no bottom access to the hazardous areas of the machine.


BAS03-12 / BAS03-22 ______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8202Agb


The encapsulated tool magazine is located behind the work room. The automatic tool change takes place on the border of the work room via the pickup principle. The tool magazine is loaded and unloaded via the magazine loading station on the left long side of the machine. Synchronuous motor spindles are used as work and tool spindles. Their performance data along with the low mass moment of inertia allow for an economic tool use. The tool tensioning takes place automatically; the release is hydraulic. For the use of tools with "interior coolant supply", the tool tensioner is equipped with a rotating feedthrough (option).

Assembly photo


____________________________________________________________________________________________________________ A8202Agb


2.2.2 Special machine features The standard series machines are delivered in a ready to operate state. Regarding the CNC control, you can select from different, internationally introduced control systems (see further details in the specifications). • Common international CNC control

• Safety Integrated (safety monitoring, control-independent)

• Gantry drive of the Y axles

• direct, absolute distance measuring systems in the linear axles including sealing air protection

in linear and round axles.

• sled guides with roll circulating shoes

• tool magazine with 20 or 32 tools, chip and spray water protected

• Hydraulic unit

• 1 or 2 AC synchronuous motor spindles with rotating insert to use with interior cooling lubricant or minimum amount cooling lubricant (aerosol), automatic spindle orientation; minimum oil quantity lubrication of the hybrid bearings; sealing air protection, automatic spindle core cleaning, tool tensioners;

• CFC free central cooling device for motor spindle, round axle drive, switch cabinet and optional expansions

• automatic central and minimum oil quantity lubrication for guides / bearings

• pneumatic system / sealing air / pneumatic weight balancing

• safety protective panelling; all-round closed chip removal area; unobstructed chip expelling with wet and dry chipping

• swivel support with two swivel tables to place customer-specific tensioning systems

• prepared to attach a chip conveyor and the cooling lubricant systems

• work room illumination

• erection elements (1 set of fixators)

• standard painting

ADDITIONAL DEVICES - MECHANICS (option) • tensioning bridge or measuring bridge with / without T groove(s) and pickup / indexing borings • oil distributor for hydraulic workpiece tensioning (rotating feedthroughs to the tensioning bridge) • expansion of the machine hydraulics up to max. 250 bar; control side pressure switching • Aerosol producer for the interior lubrication by the tools with "dry processing"; dosing

parameters selectable via NC programme • cooling lubricant system (emulsion) with scraper belt conveyor and pumps; expandable to

"interior cooling lubricant" by the tools by means of additional filters

• rinse nozzles in the work room, the loading room, on the tool magazine • air filter systems (e.g. emulsion vapor separator) • plan system control (monitoring for correct tool seating in the spindle) • torque support on the spindle for the boring head indexing • automatic work room / loading room door (open and close), with monitoring • interfaces to handling systems


BAS03-12 / BAS03-22 ______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8202Agb


2.3 CNC control: The processing centres BAS03-xx of the "Schwäbische Werkzeugmaschinen GmbH" can be delivered with different CNC controls suitable for international use. The standard documentation of the control manufacturer (operating and programming guides), are included in the delivery in separate folders. The special operating and programming instructions of the "Schwäbische Werkzeugmaschinen GmbH" regarding the adaptation of the standard control to the SW processing centres (menus, operator guides, operating modes, tool management, messages, M functions, cycles, examples, etc.)are included in "Chapter 11, Operation" in these operating instructions.

2.3.1 Control type The following CNC controls are currently available for the standard use in machine types BAS03-xx:

• Siemens Sinumerik 840D • Fanuc 30i

Special models as well as customer-specific adaptations are possible.


____________________________________________________________________________________________________________ A8202Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8003Agb

3.0 Pictorial part 3-1

3 Pictorial part

Table of Contents

3 PICTORIAL PART 3-1


3.2 Machine photographs 3-3 3.2.1 Total view 3-3 3.2.2 Work room / loading room (two locations) 3-7 3.2.3 Tool magazine 3-9 3.2.4 Groups 3-11 3.2.5 Units 3-15 3.2.6 Individual components 3-24

Technical specifications are subject to change.


____________________________________________________________________________________________________________ A8003Agb

3-2 3.0 Pictorial part

3.1 Preliminary information

There is no claim made regarding the completeness of the information contained in the documentation. We have done our utmost to present the content regarding our products correctly and in an up-to-date fashion. However, we cannot guarantee that this document is free of errors. Especially in photos and other illustrations, components could be shown that are not part of the standard scope of delivery (optionen) or parts that have been modified in the meantime. We reserve the right to make modifications based of further developments or "state-of-the-art".


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8003Agb


3.2 Machine photographs

3.2.1 Total view BAS03-22 (two-spindles, two locations)

Control panel

Option: Cooling lubricant system / chip conveyor

Doors Loading room / work room


____________________________________________________________________________________________________________ A8003Agb


View from the left (two location model)

View from the right

Accumulator for weight balancing Z sled

Tool magazine loading station with control panel

Device room

Additional device room

Switch cabinet

Option: Suction / air filter


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8003Agb


Rear view

Hydraulic unit

Central cooling unit

Panel of tool magazine

Main switch; Type plate

Insert opening for chip conveyor / chip cart


____________________________________________________________________________________________________________ A8003Agb


Control panel

EMERG OFF


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8003Agb


3.2.2 Work room / loading room (two locations)

(Cover removed)

Swivel support

Work room safety disc (open)

Swivel table work room

Lock Safety discs

Swivel table loading room

Loading room door

Option: Device / planet tables (round tables)

Loading room door

Option: Rinse nozzles loading

Option: Rinse nozzles work

Magazine door (lifting door)

Work spindle


____________________________________________________________________________________________________________ A8003Agb


(Magazine door removed)

Drive Magazine door (lifting door)


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8003Agb


3.2.3 Tool magazine Rear view of machine (Panels removed)

Magazine position numbers

Cover of the magazine drive

Magazine opening (to the work room)

Oil distributor Magazine lubrication

BERO, Magazine pliers open

Drain funnel bed rinsing Pneum.

cylinder Loading station Spring

bearing Tool magazine

Pneumatic cylinder Tool change

BERO, Magazine position


____________________________________________________________________________________________________________ A8003Agb


View from the work room (Magazine door open)

Magazine loading station (two location model)

Magazine control panel

Safety it h

Magazine door

Magazine drive

Rinse nozzles Tool cleaning

BERO, Magazine pliers open


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8003Agb


3.2.4 Groups Two location machine View from the left

Magazine loading station

Storage and clamping of swivel support

Magazine door Loading station

Safety switch magazine door


____________________________________________________________________________________________________________ A8003Agb


Drive with gear, swivel support (Q)

Drive / clamping of NC axle / machine table

Cylinder, Release of safety disc



BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8003Agb



Counter bearing swivel support

Option: Suction work room

Machine-specific hydraulic components Door guide

Loading room door

Counter bearing machine table (loading room)

Standard hydraulic components

Mounting plate for optional equipment


____________________________________________________________________________________________________________ A8003Agb


Counter bearing with oil distributor


Untere Türführung Beladeraum-tür

Cam switch swivel support (Q axle)

Valve Release of safety disc


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8003Agb


3.2.5 Units (Device room)

Storage container / unit for central and minimal oil lubrication

Hydraulic unit / components


____________________________________________________________________________________________________________ A8003Agb


Pneumatics

Central lubrication / oil minimum quantity lubrication

Pneumatic connection, pressure reducer, water separator, filter

Filter / pressure regulator air purge glas scales

Pressure reducer, air purge, motor spindles, round table, counter bearing, etc.

Central lubricating unit, (Central lubrication / minimum oil lubrication)

Switching valve Central / minimum oil lubrication


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8003Agb


Hydraulics

(Rear)

Accumulator

Rail guide; extendable unit

Temperature display

Fill level indicator

Motor with pump

Valves tool tensioner

Tank installation filter with fill level limit switch

Fill opening

Pressure switch system pressure

Heat exchanger hydraulic unit


____________________________________________________________________________________________________________ A8003Agb


Central cooling unit (Rear of the machine)

(Metal filter wall removed)


Fill neck, water mixture

Temperature display

Metal filter wall

Cooling unit with refrigerant

Operation displays, temperature regulator

Circulating p mp

Drain hose

Heat exchanger Ventilator


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8003Agb


Central cooling unit (Bottom part open)

Drain hose (Fill level indicator)


____________________________________________________________________________________________________________ A8003Agb


Spindle box (Roof area)

Option: Controller plan system

Lubrication distributor Minimum quantity lubrication

Oil filter and pneum. pressure switch, minimum quantity lubrication

Regulator valve plan system

Pressure adjuster / manometer / ventilation, for pneum. weight balancing

Pneumatic valves Minimum quantity lubrication plan

Lubrication pressure monitoring


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8003Agb


Option: Cooling lubricant system (Example)

Option chip conveyor (Example Link belt conveyor)

Pneum. controlled coolant valves

Connectors, coded; (chip conveyor, filter systems, additional pumps)

Interior cooling lubricant,

Coolant lubrication supply

Activation coolant valves

Supply of coolant gun chip conveyor,

Additional blow-off function via rinse nozzles in the loading room


____________________________________________________________________________________________________________ A8003Agb


Options: Chip cart (for dry processing)

Setup screw

Link belt

Connection Rinse gun


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8003Agb


Switch cabinet

Switch cabinet heat exchanger

Power connection; Main switch;


____________________________________________________________________________________________________________ A8003Agb


3.2.6 Individual components Left roof area

Gantry drive left; Roll circulation guide, motor, ball roll spindle, glass scale

Roof rollo

Accumulator pneum. weight balancing

Loading room door, left

Safety switch


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8003Agb


Front roof area


Pneumatic cylinder weight balancing

Pneum. valve island, blow out spindle, minimum oil lubrication


____________________________________________________________________________________________________________ A8003Agb


Front right roof area

Drain funnel

Rinse rail

Lubricant distributor central lubrication and pressure switch


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8003Agb


Option compact air filter system


Drawer sieve insert

Suction pipe (work room)


____________________________________________________________________________________________________________ A8003Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb

4.0 Transport / Setup 4-1

4 Transport; location preparation, setup

Table of Contents

4 TRANSPORT; LOCATION PREPARATION, SETUP 4-1

4.1 Safety notes for transport and setup 4-3

4.2 Dispatch 4-5

4.3 Transport 4-7 4.3.1 Door lock 4-7

4.3.1.1 Position of the safety switches 4-8 4.3.2 Transporting the machine domestically by crane 4-9

4.3.2.1 Stop positions 4-9 4.3.3 Transport image 4-11 4.3.4 Transport on heavy load rolls 4-12

4.4 Preparing the setup location 4-13 4.4.1 Space requirements and connection data 4-13 4.4.2 Fundation note 4-13

4.5 Erection 4-15 4.5.1 Preparatory work 4-15 4.5.2 Alignment 4-16

4.6 Assembly / Disassembly 4-19 4.6.1 Transportation locks 4-20

4.6.1.1 Mount the safety angle 4-21 4.6.1.2 Round axle / swivelling table 4-22 4.6.1.3 Transport position of swivel support (only for two station machines) 4-22 4.6.1.4 Z axle / work spindle advance 4-22

4.6.2 Hydraulic unit 4-23 4.6.3 Central lubrication / minimum oil quantity lubrication 4-24 4.6.4 Central cooling unit (water return cooler) 4-25 4.6.5 Heat exchanger switch cabinet 4-25 4.6.6 Chip cart (option) 4-26 4.6.7 Chip conveyor / cooling lubricant system (option) 4-27 4.6.8 Initial cleaning 4-29 4.6.9 Initial fill 4-29

4.6.9.1 Hydraulic system 4-30 4.6.9.2 Central lubrication / minimum oil quantity lubrication 4-31 4.6.9.3 Central cooling unit (water return cooler) 4-32 4.6.9.4 Chip conveyor / cooling lubricant system (option) 4-33

4.6.10 Conclusion of the transport preparations 4-34

4.7 Connection (only by skilled personnel) 4-35 4.7.1 Pneumatics 4-35 4.7.2 Power supply 4-36 4.7.3 Chip conveyor / cooling lubricant system (option) 4-36

4.8 Startup 4-37


4.10 Shutting down and storing the machine 4-41


____________________________________________________________________________________________________________ A8004Agb

4-2 4.0 Transport / Setup


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.1 Safety notes for transport and setup Every person that is responsible for the transport, installation, operation, maintenance and supervision of the machines manufactured by "Schwäbische Werkzeugmaschinen GmbH“ as well as the master or department manager, under whose supervision the machine is erected, must have read and understood the chapter "General safety and accident prevention instructions“. Theother country-specific regulations and law, which apply to special handling, must be observed as well and have priority over our instructions.

A non-dangerous and flawless performance of activities and interventions is only warranted if special skills are present for these activities and if the information and instructions in our machine documentation as well as the components' instructions are taken into consideration.

If unauthorised personnel acts/intervenes without extensive know-how, these situations could result: - Dangers to body and life, - dangers to the machine and other property assets, - danger to the efficient operation of the machine, - danger to the environment.

The operator bears the responsibility for the internal transport of the machine - even if the employees of the "Schwäbische Werkzeugmaschinen GmbH are present - and he must ensure that the safety and accident prevention instructions are adhered to. • Depending on the activities to be performed, the respective personal safety

equipment must be worn (e.g. protective gloves, safety shoes, helmet, protective eye goggles, etc.).

• Machine or panel parts with sharp edges in the access area of the transport workers must be covered by covers (upholstery material).

• The prescribed end positions for the load pickup devices must be used.. • The materials used (crane and lifting equipment, forklifts, roll transport carts,

etc.)must be large enough for the loads to be transported. • The products to be transported must be secured against movement, tilting,

rotating or swivelling of individual parts prior to and during transport. The respective measures must be taken to achieve this (observing the gravity center as well as securing with: positioning rings, chains, securing wooden wedges, screw connections, etc.).

• The transport must be slow, controlled and no other objects must be touched.

If the machine and machine parts are not transported properly, this will endanger your health and life! Neverstep underneath raised loads; secure transported goods sufficiently; when turning/moving the transported goods in small areas, ensure a sufficient safety distance (crushing and severing danger of the head, body and extremities)!


____________________________________________________________________________________________________________ A8004Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.2 Dispatch For the dispatch, the processing centres are treated with anti-rusting agents, moving parts and units are locked into place / removed and sent in two transport units (machine as well as a pallet with small parts). The crane transport takes place via attachment eyes (rotating transport eyes). Depending on their size and weight, options and accessories are enclosed with the usual transport units or packaged separately (see delivery note). In accordance with the "environmental" and "hazardous materials transports" rules and regulations, the contents of the units are limited to a permitted volume.

The operating instructions for the machine are packaged in separate boxes and are sent along with the small parts.

Dispatch data - domestic

BAS03-x2 (Two station machine)

Machine (WxDxH) 2.44 x 3.37 x 2.75 m Weight approx. 8,000 kg Chip conveyro (option) (WxDxH)

1.2 x 3.75 x 1.4 m

Weight (max.) approx. 750 kg Chip cart (option) (WxDTxH) 1.00 x 1.30 x 0.45 m Weight (max.) approx. 250 kg Decreasing these dimensions can only be achieved by the elaborate removal of machine parts.


____________________________________________________________________________________________________________ A8004Agb


With seaworthy packaging, all transport units are wrapped with a sealed aluminium foil and are dispatched in transport crates with pallet floors. Dispatch data for seaworthy packagaing

BAS03-x1 BAS03-x2

Machine (WxDxH) Weight Chip conveyro (option) (WxDxH)

Weight (max.) Chip cart (option) (WxDTxH) Weight (max.)


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.3 Transport You can use a crane, forklift and rolling transport cart to transport the machine and the different packaging units.

Generally, machines and other machine-related parts (e.g. hydraulic units, filter units, cooling and air conditioning units, etc.) may only be transported in their upright position or the position they are used in.

The transport must take place taking into consideration the country-specific requirements and laws regarding accident prevention and transport.

4.3.1 Door lock Machine access points to dangerous areas, which must be opened repeatedly, are monitored electrically and are locked via the control depending on the situation.

The safety switches with locks are constructed so that a forced lock will be performed on the respective door when there is no power to the machine.

The manual opening of a forced lock may only be performed when the machine poses no dangers.

After removing the lock screw, a bushing with a front cross groove will be exposed and can be accessed.By turning this bushing by approx. 5 degrees counter clockwise, the lock in the safety switch is released and the machine access can be opened by hand. After closing it once again, the forced lock is reactivated.


____________________________________________________________________________________________________________ A8004Agb


4.3.1.1 Position of the safety switches Work room / loading room The safety switches with lock / monitoring for the work room or loading room doors are built in above the doors behind a metal panel. The two signal lamps are visible through two punchouts (switch status display), which also allow access to the lock screw. In conditions without power, the lock remains active. Safety separating window (only for 2 station models) There is a safety window between the loading room and the work room on both sides of the swivelling support.This safety window can be manually folded open when working in the work room. The lock is activated by two monitored pneumatic cylinders. If the control is turned ON and by pressing the key "safety window", the locks are

released.

Loading the magazine The access to the tool magazine on the left side of the machine (only with two station machines) is locked / monitored by a safety switch. In conditions without power, the lock remains active. The safety switch can be accessed beneath the opening - after removing the cabin panel.


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.3.2 Transporting the machine domestically by crane The machine was factory-prepared for its initial transport. (The corresponding activities are described in Chapter "Assembly / Disassembly".) The following items must be provided by the customer to have the machine transported by crane:

BAS03-21 BAS03-22

4 Transport clevis B4, DIN 82101 (Bolt diameter 30 mm

Weight capacity 4,000 kg)

B4, DIN 82101 (Bolt diameter 30 mm

Weight capacity 4,000 kg)

4 transport ropes without straps L ³ 4,000 mm, Load capacity, each ³ 30 kN

L ³ 4,000 mm, Load capacity, each ³ 30 kN

4.3.2.1 Stop positions There are 4 threaded borings in the roof area of the machine stand to install the attachment eyes (rotating transport eyes) for the transport of the machine. The attachment eyes "LBG(3) M24" are included in the machine's scope of delivery. The rear threaded borings for the attachment eyes are located to the right or left of the motors for the longitudinal drive (y axle) of the sled unit.


____________________________________________________________________________________________________________ A8004Agb


The borings for the two attachment eyes in the front part of the machine are located next to the guide rails of the sled unit. Caution: These attachment eyes must be removed after the crane transport; otherwise there will be a collision with the attachment eyes (or with the roof sled) when the sled unit is moved.

You must check that the attachment eyes are properly screwed in and that they are able to move freely.

The transport ropes are attached to the attachment eyes with clevises.

Prior to as well as while lifting the machine, the rope guides and the rope stop postions must be checked to guarantee a stable transport without the danger of tipping over or damaging the machine. The transport must take place taking into consideration the labor assiocations regulations regarding accident prevention and transport.

The front attachment eyes must be removed after the crane transport; otherwise there will be a collision with the attachment eyes or with the roof sledwhen the sled unit is moved.


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.3.3 Transport image

A (m) B (m) C (m) BAS03-x1 BAS03-x2 2.44 3.37 2.75

A B

C

> 3.0 m


____________________________________________________________________________________________________________ A8004Agb


4.3.4 Transport on heavy load rolls If there is no suitable crane available for the onsite transport of the machine, we recommend the use of sufficiently large heavy load rolls. A prerequisite is that the floor covering is suited for a safe and vibration-free transport regarding its loadbearing capacity and even surface. Load capacity of the heavy load rolls 40 kN Ground clearance of machine, approx. 75 mm The steerable heavy load rolls are positioned under the front right and left machine pedestal so that a proper, safe connection can be made via the anchor hole of the machine stand (e. g. by a screw / bolt) with the heavy load rolls. At the rear of the machine, two heavy load rolls are attached via a spacer and connected with suitable connection elements by means of the anchor holes to the machine stand.

If the heavy load rollers are not properly connected to the machine stand or if there is an uncontrolled transport situation, there is a risk of crushing or cutting for body parts and limbs by slipping or tipping of the machine.


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.4 Preparing the setup location The machine is configured for use in closed rooms under normal conditions (permissible temperature and humidity data can be found in the specifications). We recommend erecting the machine on an oil-resistant floor to prevent possibly leaking fluids from seeping into the groundwater.

4.4.1 Space requirements and connection data You can find information regarding the space requirements and connection data of the machine in Chapter "Diagrams, drawings, dimensions" and "Specifications". The legal safety distances when erecting a machine must be adhered to.

4.4.2 Fundation note • For most of the applications, an approx. 40 cm thick, armed concrete foundation is sufficient;

see machine image or foundation diagram. The necessary installation parts or fastenes for the different machines (e.g. sub plates, support legs, fastening elements, spacer plates) are including in the machine's scope of delivery.

• In the machine image or the foundation diagram, there is information regarding the static and dynamic load on the different erection points, as well as about the max. permissible deflection of the erection area. This data is especially important when setting up the machine on an intermediate ceiling.

• Additional floor coverings (e.g. pavement, tiles, plastic) must be suited for the load point stress. • When preparing the setup area, the evenness (differrence in height between the highest and

the lowest point of this area) must be less than 10 mm.

Generally, we recommend having the foundation and the floor checked by an architect or a structural engineer prior to erecting the machine.


____________________________________________________________________________________________________________ A8004Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.5 Erection

4.5.1 Preparatory work Prior to erecting the machine, the following preparatory work has to be performed: • Foundation / installation area must be ready and dry. • The erection points and the machine dimensions must be marked on the hall floor (exit paths

and assembly areas are taken into consideration). • The surfaces for the setup plates and the fixators must also be ready (filled or poured if

necessary), so that there is a flat, strong connection between the hall floor and the erection elemente.

• Fastening points for fixators must be drilled and the standing bolts for the setup elements must be attached via a mortar cartridge.

• Electrical connection choice with sufficient power is ready to use. • Pneumatic connection with dry, oil-free compressed air is ready to use. • Assembly support such as crane, lifting cart, forklift, pedestals / scaffolding, cleaning cloths are

ready to use. • Auxiliary materials such as hydraulic oil, lubricants, cooling lubricants, nitrogen (accumulator fill)

are ready to use.

option - customer-specific items are prepared (e.g. oil pan, central cooling lubricants and chip disposal, oil mist suctioning, fire protection systems, data processing connections, etc.).

When delivered, the small parts (e.g. subplates with installation or adjusting screws or fixators are inside a carton that is dispatched on a pallet. Larger parts (such as cab parts, metal panels, units, etc.) are shipped on pallet floors, in wooden crates or transport boxes - depending on the country-specific regulations and dispatch type (see delivery note).

The operating instructions for the machine are packaged in separate boxes and are sent along with the small parts.

If skilled personnel is on hand, the following steps can be performed after the shipment has been carefully unpacked and compared to th delivery note or the packing list.

To avoid installation errros, which may negatively influence the machine's quality and which bear accident risks, we generally recommend having the following activities performed only by skilled personnel and under the supervision or assistance of our customer service technicians. Damage caused by non-skilled activities are not covered by our warranty.

• Install the setup elements ("fixators") at the machine site over the previously mounted standing bolts and premount them; see machine image or the setup diagram.

• Adjust the machine installation points on the fixators to the lowest possible height. Use a ruler and a level or a levelling device to preadjust the installation points of all fixators horizontal to each other (max. deviation 0.2 mm); (temporarily remove the ball discs if necessary).

• Transport the machine to its setup location and position it so that the fastening borings in the machine pedestal are aligned above the standing bolts. After lowering the machine, the machine bed must rest securely on the fixators.


____________________________________________________________________________________________________________ A8004Agb


Never put your hands under the machine to position any parts!

• Install the remaining fixator components and tighten the fastening screws to the indicated

torque.

4.5.2 Alignment In the roof area, next to the Y guide rails, there are ground surfaces to attach the measurement devices. We recommend:

2 x machine level (accuracy 0.02 mm/m) 2 x ground spacer blocks (> 140 mm) 1 x ground strip (machine ruler) l = > 1400 mm

• Horizontal deviation:

Place the spacer blocks onto the ground surfaces next to the Y-guide rails and position the machine ruler and the level.

• Vertical deviation:

2. Position the machine level next to the left Y-guide rails.

Read the horizontal deviation in the vertical and horizontal direction and note it with respect to the four machine erection points.


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


• The machine is aligned horizontally using the four fixators. Generally, the machine is always

aligned upward. This means that the machine corners that lie the lowest according to the determined deviations compared to the other corner points are lifted to the level of the highest corner point. The horizontal alignment must be performed by repeatedly checking the vertical and horizontal deviations until the horizontal deviation is ≤ 0.02 mm/m.

After the machine is ready to use, we recommend measuring the tension bridge in the X direction with the machine axle. The permissible deviations can be found in the machine protocol.

If - in spite of the correct static alignment of the machine - there is an excessive deviation from the horizontal alignment during the test run, one can assume that the foundation has been deformed and is therefore not suited. A repeated adjustment would deform the machine bed and would not influence the test run.


____________________________________________________________________________________________________________ A8004Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.6 Assembly / Disassembly

Access by non-authorised persons without extensive knowledge of the machine can cause extensive damage to the machine and, in extreme cases, can lead to dangers for body and life. As a rule, the enclosed documentation by the supplier / manufacturer must be adhered to.

After the processing centre has been set up, the modifications / refittings made for transport must be reversed.Depending on the machine type and the machine model, the following assembly/disassemly procedures must be performed. (The work steps for another machine transport can be performed in the reversed order; compare to the following check lists).

Assembly sequence after the transport

Disassembly for the transport

Transportation locks see information "Shutdown / Storage" Check / install units see "Dispatch" and "Transport" Cleaning see "Concluding the transport

preparation" Initial fill Observe options; chip conveyor / devices Connection Positioning movement units Check / fill / ventilate systems Cleaning Option; e.g. chip conveyors, tensioning

devices, etc. Transportation locks / crane eyes

Startup Disconnect remaining connection, also to foundation (see "Erection")

Empty systems Disconnect connections


____________________________________________________________________________________________________________ A8004Agb


4.6.1 Transportation locks

Depending on the machine type and model, the movement units are equipped with transportation locks. Prior to startup, the these must be informed; otherwise there will be a danger of machine damages.

In the roof area of the machine, there are the transporation locks for the X axle as well as the two transportation locks for th Y axle. If the front attachment eyes are still there, these must be removed! All transportation locks are accessible from above. The disassembly of the transportation locks is done by removing the socket head screws. The following illustrations show the setup location. The transportation lock for the left Y axle is mounted to the left horizontal side of the machine. The transportation lock for the right Y axle is located on the right side of the machine, behind the switch cabinet (top view)

Switch cabinet


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.6.1.1 Mount the safety angle

The X and Y axles are not self-locking and can move due to vibrations when no power is applied. The installation of the transportation locks is mandatory if the machine is to be transported.

The fastening points for the safety angles are located in the roof area of the machine. • Unload the tools from the tool magazine and the work spindle(s). • Remove loose parts / workpieces from the work / loading rooms. • The Y and X axles must be positioned consecutively so that the safety angles can be

assembled.

In order to position the safety angles correctly, a multiple movement of the different advance axles might be required. The machine room / roof area cannot be viewed from the control panel. During the positioning run, no persons may be present in the vicinity of the machine; otherwise, there is a danger of crushing and severing of the head, body and limbs. For safety reasons, the positioning run should only be performed by one person, who takes turns running the machine and then checks its position.

• Machine "ON" (= main switch "ON"; switch machine control on) • Check the work room and determine whether a collision-free run of the main axles (X, Y and Z)

is possible. • Drive the Z axle (work spindle) to the upper limit position • Position the Y axle on the value Y = 0 mm • Position the X axle on the value Y = 0 mm • Machine "OFF" (= switch off machine control, main switch to "OFF" and protect from

reactivation). • Place the two identical safety angles in the rear roof area next to the guide webs and position

against the Y sleds. The boring in the perpendicular section must be congruent to the threaded boring in the Y sled and the two oblong holes must be congruent to the threaded borings next to the guide webs. If no modifications are necessary, fasten the safety angle with three screws.

• 3. Place the safety angle in the roof area, to the left of the spindle unit onto the Y sled and

position against the dome of the X sled. The boring in the perpendicular section must be congruent to the threaded boring in the dome of the X sled and the two oblong holes must be congruent to the threaded borings in the Y sled. If no modifications are necessary, fasten the safety angle with three screws.

After fixing the Y and X axles, these may no longer be moved.


____________________________________________________________________________________________________________ A8004Agb


4.6.1.2 Round axle / swivelling table • Depending on the tensioning device model, horizontal round axles must be turned for transport,

so that the centre of gravity is in the area of the bottom dead centre. The hydraulic clamping pressure - which is maintained for a long time if the valves function properly - ensures a lockdown of the round axle.

4.6.1.3 Transport position of swivel support (only for two station machines) The swivel support is driven by a "brake motor" with a subsequent gear. • For transport, we recommend setting the swivel support (Q) to one of the two working positions

(0° or 180°). Without applied power, the motor brake is active and prevents the self-turning of the swivel support - in combination with the gear.

4.6.1.4 Z axle / work spindle advance The Z axle is moved forward via a "brake motor" • Depending on the tensioning device model or the collision situation, the Z axle should be

moved to the bottom limit position. The motor brake is active when there is no power to the system and prevents a self-activated position change of the Z axle.


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.6.2 Hydraulic unit

In accordance with the laws and regulations for "environmental protection" and "transporting hazardous goods", the contents of the hydraulic unit and the accumulator are kept at a permissible quantity for dispatch

Prior to starting up a machine, the units and the accumulators must be checked regarding their contents and might have to be filled / ventilated by trained staff.

The processing centres are standard equipped with a hydraulic unit that is built into the device room (at the left long side of the machine) above the rail guides. The startup / ventilation of the hydraulic system is only possible after connecting the machine to the power supply; see chapter "initial fill“. The hydraulic system is connected to safety functions of the machine that only function properly with a correctly adjusted system. Disassembly

In accordance with the laws and regulations for "environmental protection" and "transporting hazardous goods", the contents of the hydraulic unit and the accumulator must be kept at a permissible quantity for dispatch The emptying and the depressurising must only be performed by skilled personnel. The respective documentation of the component manufacturers must be adhered to.


____________________________________________________________________________________________________________ A8004Agb


4.6.3 Central lubrication / minimum oil quantity lubrication The automatic lubricating unit is installed in the device room on the left long side of the machine. • There is no assembly required after the

transport.

In accordance with the "environmental protection" and "hazardous materials transports" rules and regulations, the contents of the units are limited to a permitted volume.

Disassembly • There is no disassembly required for the transport. • If you are planning a dispatch, we recommend checking the valid legal situation regarding

"Environmental protection" and "transport of hazardous goods" with the forwarding agent; reduce contents to a permitted value if necessary.


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.6.4 Central cooling unit (water return cooler) The central cooling unit is located on the rear of the machine, in the roof area, and has a system circuit with refrigerant as well as a consumer circuit that is filled with a water mixture. The system circuit is closed and is delivered filled (with refrigerant). The type and volume of the refrigerant are listed in the supplier's documentation, which is included in the delivery. • There is no assembly required after the

transport. • Check the fill level in the consumer circuit, fill if

necessary Disassembly • There is no disassembly required for the transport. • If you plan a dispatch, we recommend emptying the consumer circuit; (anti-freeze).

4.6.5 Heat exchanger switch cabinet The air-water exchanger for the switch cabinet is installed in the floor area and connected to the central cooling unit. • There is no assembly required after the

transport. Disassembly • There is no disassembly required for the

transport.


____________________________________________________________________________________________________________ A8004Agb


4.6.6 Chip cart (option) • The chip cart is slid into the machine from

behind. Disassembly • Pull the chip cart out of the machine. • Clean cooling lubricant container if necessary.


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.6.7 Chip conveyor / cooling lubricant system (option) • The chip conveyor with attached cooling

lubricant container is slid into the back of the machines with the included transport rolls.

• After its placement, the chip conveyor is fixed

onto the hall floor by the laterally attached installation screws.

• Hose lines and their connection locations are

labelled the same.The electrical connection is made via non-mistakable connectors.

Disassembly • Disconnect the electrical connections between

the chip conveyor / coolant system as well as the optionally installed devices (filter, cooling unit, high-pressure pumps, etc.).

• Suction the cooling lubricant from the storage containers (chip conveyor / coolant filter)

• Loosen the screw connections of the cooling lubricant lines to pumps and coolant distributors (as well as the coolant gun in the front area)

• Lower the chip conveyor / cooling lubricant system onto the transport rolls by loosening the articulating legs

• Pull the chip conveyor / cooling lubricant out of the machine • Clean cooling lubricant container if necessary.


____________________________________________________________________________________________________________ A8004Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.6.8 Initial cleaning After the assembly is completed, the machine as well as the included units and devices must be thoroughly cleaned. The factory installed rust protection enamal can be removed with "cold cleaner" or "benzine". Painted surfaces and windows can be cleaned with common household cleaners. Prior to using detergents, the material safety data sheets of the manufacturers must be read to prevent hazardous influences on persons and the machine. Use personal protective gear, such as safety gloves, safety goggles, etc.!

Never use tri or triperchlorethylene, acetone or similar solvents to clean, as these can cause damage to lines, bearings as well as health hazards to the employees. Oil the blank metal surfaces after cleaning.

4.6.9 Initial fill

In accordance with the laws and regulations for "environmental protection" and "transporting hazardous goods", the contents of certain systems and units must be kept at a permissible quantity for dispatch or removed altogether.

In order to make the machine ready to operate, these systems must be filled and ventilated if necessary. Information regarding the required materials and fill volumes are listed in Chapters "Specifications" and "MAINTENANCE / SERVICE", as well as in the documentation furnished by the different suppliers. The filling must take place according to the guidelines of the unit manufacturers (e.g. the filtering of fill contents, ventilating the system, etc.). If there is no other information, the following applies to our machines:

The oil filling for lubrication and hydraulic applications must be done with a filter rating of 10 µm.

The units belonging to a serial machine and the included units must be installed (filled) according to the intended operation; otherwise there will be a danger of destruction of the unit as well as its connected components (e.g. dry run protection on pumps and bearings, overheating of spindle units, malfunctions of hydraulic units).


____________________________________________________________________________________________________________ A8004Agb


4.6.9.1 Hydraulic system

Prior to starting up a machine, the units and the accumulators must be checked regarding their contents and might have to be filled / ventilated by trained staff.

The processing centres are standard equipped with a hydraulic unit that is built into the device room (at the left long side of the machine) above the rail guides. Further hydraulic components (for basic functions and optional devices) are installed into the accessory devices room on the right side of the machine. The startup / ventilation of the hydraulic system is only possible after connecting the machine to the power supply. • Check the fill level in the unit, fill / refill /

ventilate if necessary • Check the accumulator fill, ventilate / refill if

necessary. In addition to the accumulator on the unit, there can be more accumulators; see hydraulic diagram.

• Check the tightness of the hydraulic lines and connections

• Check the safe fastening of all hydraulic components

The information listed in the manufacturer's documentation is mandatory. Also see Chapter "Specifications" as well as "Maintenance/Service".

Safety functions are connected with the hydraulic system on the machine (e.g. weight balancing, etc.) that only function flawlessly with a properly configured system.


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.6.9.2 Central lubrication / minimum oil quantity lubrication The automatic lubricating unit is installed in the device room on the left long side of the machine. The required oil quality is indicated on the container; also see Chapter "Specifications" and "Maintenance/Service" • Check / refill the oil level • If the unit was delivered empty: Check whether

there are larger areas of trapped air in the lubricant lines.

Ventilation: The ventilation may only be performed by skilled personnel (service employees). (loosen the lubrication lines from lubrication location and multiple triggering of lubrication intervals).


____________________________________________________________________________________________________________ A8004Agb


4.6.9.3 Central cooling unit (water return cooler) The central cooling aggregate is located on the rear of the machine, in the roof area and has a system circuit with refrigerant as well as a consumer circuit. The consumer circuit must be filled with water and a corrosion protection agent. Fill volume / corrosion protection - see Chapter "Specifications" or the manufacturer's documentation. Filling • Machine "OFF" (= switch off machine control, main switch to "OFF" and protect from

reactivation). • Check the hoses in the machine room that are connected to the central cooling system; open

the shutoff valves to the connected components (e.g. to the heat exchanger in the cooling lubricant container) if necessary

• Premix corrosion protection agent in a separate container with approx. 4 parts water. • Fill the water mixture in at the central cooling unit • Check the fill level, fill the central cooling device with water • Check the fill level several times during the first days after the machine startup; fill up water if

necessary.

Fill opening


Drain plug (installed)


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.6.9.4 Chip conveyor / cooling lubricant system (option) Depending on the customer's requirements (high-pressure pump, filter unit, cooling unit, etc.), the cooling lubricant container is subdivided into special functional units. The individual chambers have stable cover plates, partially with added components (pumps, overflow, etc.). We recommend filling the cooling lubricant container on the rear of the machine. Filling • (switch control off) • Create the mechanical and electrical

connections (see Chapter "Connections") • Check on the cooling lubricant container

whether all hose/pipe connections as well as the electrical connections have been properly connected; open shutoff valves to the connected components (e.g."interior coolant" or "coolant guns') if necessary.

• Fill the cooling lubricant container via an automatic mixing device (injector mixing device) with the desired emulsion concentrate.

If no automatic mixing device is available:

• Mix the required amount of cooling lubricant concentrate (see Chapter "Maintenance/Service") with approx. 5 parts water.

• Fill the premixed emulsion into the cooling lubricant container. • Fill the cooling lubricant container with water; see fill level indicator

• Check the concentration • Check the fill level several times during the first days after the machine startup; fill up water if

necessary.


____________________________________________________________________________________________________________ A8004Agb


4.6.10 Conclusion of the transport preparations The following prerequisites should be met prior to transport: • Machine tiedown to foundation is loose • (Roof rolo is closed) • Attachment eyes for the crane transport are installed • Work room or loader room door (and magazine door) closed • All connections to the machine are disconnected • Control panel is folded in and clamped • All loose parts have either been removed from the machine or properly stowed. • All panel parts, cables and hose lines, etc.are attached correctly and cleaned up. • All switch cabinet doors are closed; panels / sheet metal plates are either secured or removed. • All machine parts that are subject to the risk of damage during transport, are protected

accordingly (e.g.control panel, etc.) • All keys have been removed • It is ensured that the loading can be performed without danger. After loading the machine, the removed panels are reattached for transport or packed into transport boxes.


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.7 Connection (only by skilled personnel)


4.7.1 Pneumatics The connection for the pneumatic supply is located inside the device cabinet, on the left long side of the machine. • Prior to installation activities, the connection

point to the onsite pneumatic supply must be relieved of pressure.

• Create the connection between the onsite

pneumatic connection point and the machine connection (maintenance unit) via a suitable pressure hose. Connect the hose with a hose clamp.

• Supply the connection line with compressed air and check the pneumatic system for leaks.

Set the required operating pressure (see Chapter "Specifications") on the manometer. • Check the pressure settings of the other manometers; sealing air; weight balancing, options,

see pneumatic diagram


____________________________________________________________________________________________________________ A8004Agb


4.7.2 Power supply The connection is located in the right switch cabinet near the main switch. • Prior to installation activities, the onsite electric

connections must be disconnected from the voltage supply; remove the fuses

• Check connection voltage, see switch

cabinet type plate, electric diagrams and chapter "Specifications".

• Connect the onsite electrical supply to the

machine connection via a suitable connecting cable. The cable can be inserted from the bottom or from the top.

• Switch on the onsite voltage supply, check the right rotation field!

4.7.3 Chip conveyor / cooling lubricant system (option) The connections for the cooling lubricant system and for the possible additionally installed units (cooling unit, filter, band skimmer, etc. are located on the rear of the machine • The machine hoses are marked and are

connected to the same-name connections of the cooling lubricant system.

• The electrical connection of the units including the optional units is done via connectors.Plugs / couplings are coded so they will not be mistaken.


BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.8 Startup

The proper startup procedure requires extensive mechanical and control skills, which are not included in this documentation! The startup may only be performed by a person trained by us (Schwäbische Werkzeugmaschinen GmbH) in mechanics and the control for the respective machine type.

• After switching on the control, all units and devices (control, pneumatics, cooling lubricant

system, cooling system, lubrication, hydraulics, etc.) must be checked for correct function and correct settings of the operational values.

• The hydraulic systems and the lubrication units must be ventilated. • Check the limit positions and the interplay of the individual machine cycles (test programmes). • Test the safety and control units for safe operation. • Perform customer-specific sample programmes without processing as a test; also see:

⇒ Operation and programming instructions of the manufacturer of the control ⇒ Supplemental operation and programming instructions of the "Schwäbische

Werkzeugmaschinen GmbH“ in Chapter "Operation“


____________________________________________________________________________________________________________ A8004Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.9 Environmental influences The main functions of the machine work with electrical energy; the noise level can be found in the "Specifications". The connection to a pneumatic supply is necessary for the actual machine operation; additional consumers such as pneumatic cleaning guns or measurement or tensioning can also be supplied. Standard air consumption - see "Specifications". The lubrication of frequently used bearings and machine parts takes place fully automated via loss lubrication via central lubricating unit(s) or by continuous grease lubrication. Fill amounts and lubricant / oil qualities can be found in the lubrication schedule and manufacturer documentation. An integrated hydraulic unit supplies the tool tensioner and the tool transport unit with pressure oilThe connection of further hydraulic units is possible. Fill amounts and lubricant / oil qualities can be found in the lubrication schedule and manufacturer documentation. To cool, lubricate and clean tools and workpieces, there is an integrated cooling lubricant system. The separation of coolant and chips (contaminations) takes place via the chip conveyor. Options such as filters and cleaning devices (paper band filters, edge splitting filter, oil separator) can be supplied. The leaked oil from the loss lubrication and the hydraulic system, etc. flow to the cooling lubricant. The water return cooler is filled with refrigerant. Depending on the requirements, SW has selected a corresponding refrigerant, so that no general information can be provided regarding the environmental impact. The data regarding the refrigerant and perhaps a material safety data sheet is available as an appendix to the documentation of the water return cooler.


____________________________________________________________________________________________________________ A8004Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8004Agb


4.10 Shutting down and storing the machine If the machine is to be shut down/stored for a longer period of time, the following conditions must be met in addition to the transport preparation: • Machine data is saved; new batteries were installed in the control (see documentation by the

control manufacturer) • Cooling lubricant system, pumps and hoses were emptied • If individual machine parts are to be stored with contents, the machine must be fitted with an

informational sign listing the contained auxiliary materials / additives as well as their volumes. • If the machine systems are stored without contents, the auxiliary materials and additives must

be removed properly, stored or disposed of. • The machine was thoroughly cleaned • Metallic parts were treated with corrosion protection agent • Machine was protected during storage againstr damage / contamination

The storage and transport must be conducted so that no condensation water (dew) is formed in the switch cabinet and on the electrical parts. Therefore we recommend storing the machine in a tempered warehouse. Furthermore, you must make sure that the machine will not be damaged / contaminated by insects or rodents during its storage.


____________________________________________________________________________________________________________ A8004Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8005Agb

5.0 Diagrams / drawings 5-1

5 Diagrams, drawings, dimensions

Table of Contents

Machine image / foundation diagram Work room Tool data sheet


____________________________________________________________________________________________________________ A8005Agb

5-2 5.0 Diagrams / drawings


BAS03-12 / BAS03-22 ______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8206Agb

6.0 Specifications 6-1

6 Specifications

Table of Contents

6 SPECIFICATIONS 6-1

6.1 Specifications BAS03-x2..(two station machine) 6-2 6.1.1 Performance and torque diagram 6-8


____________________________________________________________________________________________________________ A8206Agb

6-2 6.0 Specifications

6.1 Specifications BAS03-x2..(two station machine) GENERAL DATA BAS03-22

(two spindle) ELECTRICAL POWER CONNECTION Connected voltage 3 x 400 V / 50 Hz, grounded, TN-S or TN-C net

no error current protective switch Total connection value approx. 70 kVA PNEUMATIC CONNECTION Compressed air quality as per ISO 8573-1 Purity class 4 Operating pressure min. 5 bar Connected pressure max. 12 bar average air requirement at 5 bar 100 l/min Connection dimensions G 1/2“ DIMENSIONS ( L x W x H ) [m] erection room (without emergency exit paths) 3.90 x 3.26 x 3.10 m Transport dimensions see Chapter Transport WEIGHT Machine ready to operate approx. 8,000 kg Transport weights see Chapter Transport EMISSIONS Noise level with nominal operation (without chip removal)

approx. 78 dB(A)

electromagnetic emissions AMBIENT CONDITIONS perm. geographical height 1,000 m üNN perm. ambient temperature 15-40° C. perm. humidity max. 90% (no condensation) Atmosphere no aggressive air CONTROL CNC control Siemens 840 D

or FANUC 30i


BAS03-12 / BAS03-22 ______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8206Agb


WORK SPINDLES BAS03-12

(one spindle) BAS03-22

(two spindle) Number of spindles 1 2 spindle layout vertical vertical, side by side spindle distance -- 300 mm Design Motor spindle, liquid cooled,

AC-SYNCHRONOUS technique Cooling lubricant (standard) Nozzles on the work spindle Cooling lubricant (option) Interior coolant supply SPINDLE DRIVE BAS03-12

BAS03-22

Model 17500 HSK (Siemens / SW)

Torque range 0 - 17500 1/min Output 15.5 kW each (at 2500 1/min) (S6/40% ED)

15.5 kW each (at 3500 1/min) (S6/100% ED) Torque 60 Nm each (S6/40% ED)

42 Nm each (S6/100% ED) Startup time to: 15000 1/min

approx. 1.65 s Main spindle Ø 70 mm Main spindle seat 3-fold Spindle lubrication Minimum oil quantity lubrication Tool interface Hollow shaft cone DIN 69893-HSK-A63 Tool tensioner tension / release

Retraction force > 18 kN; mechanical / hydraulic


____________________________________________________________________________________________________________ A8206Agb


ADVANCE DRIVES BAS03-12

BAS03-22

Model AC technique, digital Advance / rapid run speed X L 1 75,000 mm, Y L 1 75,000 mm, Z L 1 75,000 mm, Advance force X 4,500 N Y 4,500 N Z 4,500 N medium axle acceleration X 10 m/s² Y 10 m/s² Z 10 m/s² Distance measurement X, Y, Z axle

direct, absolute DRIVE PATHS BAS03-12

(one spindle) BAS03-22

(two spindle) X axle 600 mm 300 mm Y axle (change position) 400 (650) mm Z axle 400 mm ACCURACY Position tolerance Tp 0.010 mm These values can be warranted by the operator as long as our foundation requirements have been met and were determined at a reference temperature of 20°C using the pendulum step procedure as per VDI/DGQ 3441. TOOL MAGAZINE BAS03-21

(two spindle) Chain magazine 2 x 20 tools

(2 x 32 tools) Tool storage location encoded Numbering 2 x 1-20

(2 x 1-32) max. tool diameter 70 mm (160 mm with unused adjacent locations) max. tool length 275 mm (see tool data sheet) max. tool weight 7.5 kg TOOL CHANGE Tool change principle Pickup, automatic medium chip to chip time approx. 3.0 s


BAS03-12 / BAS03-22 ______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8206Agb


WORK AREA BAS03-x2

(two station) Model

Swivel support with 2 separate swivel tables to hold tensioning bridges

Swivel support with two-sided plan teeth

1

max. transport load 1,100 kg Swivel time (0 - 180 degrees) approx. 3.5 sec Main time parallel workpiece loading yes Swivel table as an independent horizontal NC axle (round table with counterbearing)

2

Driving torque 200 Nm Plan disc speed max. 100 1/min Distance measurement Splitting accuracy (angle seconds)

direct, absolute +/- 5 ’’

max. moment of mass inertia 18 kgm² Tangential moment hydr. clamped 2,000 Nm max. transport load 400 kg max. Dimension workpiece / tensioning bridge

450 x 830 mm diam.

Illumination 2 x 13 Luminous flux 2 x 900 lumen


____________________________________________________________________________________________________________ A8206Agb


Units and devices Central lubrication / oil minimum quantity lubrication

Unit Manufacturer Vogel Type MFE 5 Max. operating pressure 27 bar Partial delivery flow 0,5 dm³ / min. (counter pressure 5 bar) Lubricant container 2.7 liters Oil flow switching between central lubrication / minimum oil quantity lubrication

via solenoid valve

Central lubrication Lubrication intervale (standard) 1,800 s (approx. 2/h) self-initiating

adjustable via PLC Lubrication duration 10 s (after pressure build-up) Lubricant consumption approx. 1.9 cm³/interval Supplied devices see Chapter Units / devices Minimum oil quantity lubrication Lubrication intervale (standard) after 600 s spindle run time (n>20 1/min), self-

initiating, adjustable via PLC Lubrication duration 10 s (after pressure build-up) Lubricant transport continuously by air flow Lubricant consumption approx. 0.1 cm³/interval Supplied devices see Chapter Units / devices Hydraulic system Max. operating pressure 250 bar / 8 dm³/min Fill volume hydraulic tank 70 dm³ Oil quality HLP 46 Supplied devices see Chapter Units / devices Central cooling unit (water return cooler)

Cooling performance approx. 5.2 KW at 25 °C ambient temperature recommended temperature setting 25 °C (with middle-European climate) Refrigerant type R134a Fill weight 1.9 kg Cooling water container approx. 40 liters Cooling water additive (corrosion protection)

Tyfocor ( 20 Vol.% )

Nominal volume flow - water circuit approx. 22 dm³ / 3 bar Supplied devices see Chapter Units / devices


BAS03-12 / BAS03-22 ______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8206Agb


Pneumatic system Filter regulating valve: autom. condensate drain / filter 5 µm Operating pressure 5.5 bar Filter insert 0.01 µm Pressure switch 4.5 bar Sealing air: Filter regulating valve: 0.5 bar Minimum oil quantity lubrication: System pressure = Operating pressure Weight balancing: Filter regulating valve: approx. 4 bar Supplied devices see Chapter Units / devices (Option) chip conveyor / cooling lubricant system

Cooling lubricant Emulsion Chip conveyor Model Scraper belt conveyor with coolant container max. chip length 150 mm, no chip balls Ejection height approx. 1,000 mm Separation of chips / coolant Full stream filtering 200 µm, suction pump Cooling lubricant system Fill volume approx. 400 dm³ Feed volume 200 l/min (at 3 bar) Supplied devices see Chapter Units / devices Interior cooling lubricant supply Pressure adjustable, max. 70 bar Feed volume (at 40 bar) 28 l/min Cooling lubricant cleaning Backwash filter Filter insert Steel structure 60 µm Pure water container approx. 100 dm³, integrated into the coolant container Emulsion vapor separator (option) Medium / contaminants Emulsion vapor Air volume 600 m³/h Operating temperature max. 45 °C Supplied devices see Chapter Units / devices


____________________________________________________________________________________________________________ A8206Agb


6.1.1 Performance and torque diagram see following pages


BAS03-xx

______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ A8007Agb

7.0 Units / devices 7-1

7 Units / devices

Table of Contents

7 UNITS / DEVICES 7-1

7.1 Pneumatic system 7-3 7.1.1 Function 7-3 7.1.2 Adjustment elements 7-5

7.2 Cooling lubricant system (option) 7-9 7.2.1 Function 7-9 7.2.2 Option Interior cooling lubricants 7-9 7.2.3 Adjustment elements 7-10

7.3 Central lubrication / minimum oil quantity lubrication 7-15 7.3.1 Function 7-15 7.3.2 Adjustment elements 7-16

7.4 Hydraulic system 7-19 7.4.1 Function 7-19 7.4.2 Adjustment elements 7-20

7.5 Central cooling unit 7-23 7.5.1 Function 7-23 7.5.2 Adjustment elements 7-24

7.6 Option: Emulsion vapor separator system / compact electric filter 7-27 7.6.1 Function 7-27 7.6.2 Adjustment elements 7-27



______________________________________________________________________________ A8007Agb

7-2 7.0 Units / devices


BAS03-xx

______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ A8007Agb


7.1 Pneumatic system

The operator must supply oil-free, dry compressed air to operate the machine.

The pneumatic system is used for the following applications: • Opening the magazine position pliers during manual loading/unloading of the tool magazine • Opening the magazine pliers during automatic tool change and simultaneous blowing off of the

groove in the tool pickup, by nozzles in the magazine pliers • Blowing off the tool bevel and blowing off the work spindle during the automatic tool change • Placing / lifting off the blow cylinder on/from the work spindle • Blowing off the spindle tools during the automatic tool change, prior to placing them into the tool

magazine • Supply to the minimum oil quantity lubrication • Sealing air supply to the round axles (A, U, Q), work spindles, gear, tool magazine and

measuring systems, and • switching the individual coolant valves on and off • Option: Plan system control (monitoring for correct tool seating in the spindle) • Option: Contact control (monitoring for correct positioning of workpieces in the tensioning unit) • Unlocking the work room safety disc (only two station machines) • Weight balancing on the vertical unit (only with two spindle machine) • Roof sled release (only one station machines)

7.1.1 Function The connection for the pneumatic supply is located inside the device cabinet, on the left long side of the machine. The oil-free dry compressed air is routed to the air preparer (water separator, pressure reducer with manometer and filter) via a hose or pipe line. The operating pressure is set at the pressure reducer, see pneumatic diagram. After the fine filter, the compressed air is further distributed to the different application locations. Here, further setting and monitoring elements can be integrated. During the tool change, a pneumatic cylinder is docked within the work spindle.This will be used to supply the compressed air to clean the spindle interior and tool. Another pneumatic cylinder with air supply opens the magazine pliers in the tool magazine and transfers the compressed to blow off the pliers and the tool pickup. For the minimum quantity oil lubrication which is used to lubricate the main spindle bearings, the compressed air is used as a transport medium for the lubricant. The sealing air creates an increased air pressure (overpressure) within certain systems, which largely prevents contaminants from entering. Motor spindles, round table motors, counterbearings and the measuring systems of the linear axles and the round axles (swivelling table / swivel support) are supplied with sealing air. One station machines with common work / loading rooms are equipped with an automatic roof sled with a pneumatically actuated release.


______________________________________________________________________________ A8007Agb


Two-spindle machines are equipped with an additional pneumatic weight balancing system (pneumatic cylinder and accumulator) to balance the gravity on the spindle boxes.


BAS03-xx

______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ A8007Agb


7.1.2 Adjustment elements Air preparer (standard) Set the pneumatic operating pressure on the pressure reducer after the compressed air has been supplied. Two-spindle model Spindle box Set values in the pneumatic diagram. Pneumatic diagram and device list for the different machine types can be found on the following pages.

Pressure reducer, water separator, filter, pressure monitor

Pressure reducer, air purge, motor spindles, round table, counter bearing, etc.

Filter / pressure regulator air purge glas scales



______________________________________________________________________________ A8007Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ A8007Agb



______________________________________________________________________________ A8007Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ A8007Agb


7.2 Cooling lubricant system (option) The chip conveyor and the cooling lubricant container with pumps make up a unit, which is slid into the machine from the rear. The pumps are connected to the cooling lubricant distributor via the cooling lubricant spreader. The following systems are supplied: The cooling lubricant nozzles arranged around the work spindles for the direct cooling of the tools and workpieces, the bed rinse magazine, rinsing of the roof area and manual cooling lubricant gun. Optional expansions: Interior cooling lubricant and loading room rinsing. The addition of the cooling lubricant is regulated via the machine control by pneumatically controlled valves.

Avoid any kind of skin contact with these cooling lubricants and wear the necessary personal protection gear. Please observe the country specific guidelines and laws

7.2.1 Function After switching on the machine control, the cooling lubricant pump starts up and supplies the cooling lubricant gun.The direct cooling on the spindle is selected by manually pressing the key "Coolant on" or by programming the respective M function. Furthermore, machine-related and optional applications such as "Rinse package ALU" depend on the customer-specific requirements. The added cooling lubricant and the chips arrive in the chip conveyor through an opening.The cooling lubricant and chips are separated from each other via perforated sheets and sieves.The cooling lubricant flows back into the storage container and the chips are transported to another location. The electrical connection of the different cooling lubricant components takes place via encoded connectors.

7.2.2 Option Interior cooling lubricants To use tools with "Interior cooling lubricant supply", the tool tensioners are factory equipped with a rotating feedthrough; the cooling lubricant supply takes place through the rear of the spindle via an additional high-pressure pump. Suitable tool pickups and a cooling lubricant filtering system with an additional fine filter are required.


______________________________________________________________________________ A8007Agb


• For tools with interior cooling lubricant supply, you must use • hollow shaft cones as per DIN 69893-HSK-A63 with a cooling lubricant

pipe.

7.2.2.1 High-pressure pump / filter for interior coolant supply The cooling lubricant container is expanded at the factory and will be equipped with an additional ara for cleaned cooling lubricant as well as with a high-pressure pump. The pure water area is connected to the cooling lubricant container via an emergency overflow. The precleaned cooling lubricant is removed from the cooling lubricant container by means of a lifting pump, is recleaned / filtered and transported to the pure water container. If there are no further requirements by the customer, the cleaning / filtering of the cooling lubricant is done via a backwash filter with an automatic self-cleaning function.The fill level in the pure water area is controlled via float switches. The high-pressure pump of the pure water area supplies the tool pickup with cooling lubricant via the rotating insert / tool tensioner (interior cooling lubricant supply). The control for the interior cooling lubricant supply is handled via the M function in the CNC programme or after activation via the control panel. By using additional filtering systems (paper band filters, turbo filters, rotating filters, etc.) the filter performance can be increased and the cleaning effect can be improved.

7.2.3 Adjustment elements

Unauthorised intervention (e.g. by incorrect pressure settings) can cause the exceeding of the existing safety limits, so that certain components can fails and personnel can be injured or equipment can be damaged.(Evaporation and leakage of coolant, motor overload, pressure lines and rotating feedthroughs).

Pneumatically controlled coolant valves


BAS03-xx

______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ A8007Agb


Cooling lubricant container (Example) Further information can be found in the manufacturer's documentation Cooling lubricant diagram and device list on the following pages.


______________________________________________________________________________ A8007Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ A8007Agb



______________________________________________________________________________ A8007Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ A8007Agb


7.3 Central lubrication / minimum oil quantity lubrication These machines are equipped with an automatic lubrication unit. This is connected to all the bearing and roller guides, which must be regularly lubricated to function properly; an exception here are grease-filled bearings. The compact unit (storage container, toothed gear pump and electrical components) is installed in the device room, on the left long side of the machine and used alternatingly to feed the central lubricant distributors as well as the minimum oil quantity dosing units by switching the oil line. The monitoring of the functions, the display of operation messages as well as the adjustment / triggering of lubrication intervals takes place via the machine control.

7.3.1 Function Lubrication cycle on the lubricating unit:

• Start the pump motor (prelubricating) until the set operating pressure is reached (see central lubrication diagram)

• Start of the trail time (lubrication duration) • Start of the set interval time (break time)

After the interval time has elapsed, a new lubrication cycle will start.

7.3.1.1 Central lubrication: The lubricant fed by the toothed gear pump is routed via a feed line to several piston distributor groups. Each distributor (depending on the required lubricant quantity) is equipped with a special insert. These inserts are filled with oil and transfer their oil volume to the lubrication location after the pump has been switched off. The lubrication procedure takes place automatically, depending on the factory set time interval. The supplied lubrication locations, the dosing as well as the set time interval can be found in the lubriation line diagram.

7.3.1.2 Minimal oil lubrication The lubricant fed by the toothed gear pump is routed to the oil and air dosing units, which are also supplied with air by the pneumatic system, via a feed line. The distributors integrated into the oil and air dosing unit are filled with oil and will emit a dosaged oil amount into the different lubrication loctions lines after the pump has been switched off. There, it will be transported continuously to the bearing locations of the work spindle by the constantly flowing compressed air. A lubrication process is automatically triggered once the factory set spindle run time has been reached. An addition of the spindle switch on times is only performed if the speed is > 20 1/min. The supplied lubrication locations, the dosing as well as the set time interval can be found in the lubriation line diagram.


______________________________________________________________________________ A8007Agb


7.3.2 Adjustment elements Central lubrication unit There are no adjustment elements located directly on the unit.The number of lubrication pulses is set via the internal controller or the machine control - depending on the machine model. Lubricant diagram and device list on the following pages.


BAS03-xx

______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ A8007Agb



______________________________________________________________________________ A8007Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ A8007Agb


7.4 Hydraulic system

• Interventions to change hardware or software as well as electrical or mechanical modifications to the hydraulic system must only be performed by authorised personnel.

• As a rule, the enclosed documentation by the supplier / manufacturer must be adhered to.

The hydraulic unit with filter and monitoring sensors is installed on the left long side of the machine in the device room, via rail guides. The switch and control elements for the different hydraulic applications are located in the additional device room on the right side of the machine and some of them are equipped with LEDs and displays for functional control.

7.4.1 Function After pressing "Control ON / Hydraulic system ON“, the pressure oil is available for the following hydraulic systems: • Open / close lifting door tool magazine • Loosen tool tensioner • Lock / lift off swivel support (two station model

only) • Swivel table (round table axle) - lock / lift off;

clamp counterbearing • Oil distributor for customer-specific applications

Options:

• expanded, customer-specific hydraulic system • Heat exchanger to cool the hydraulic system The sequence of hydraulic functions is regulated via the machine control. The monitoring takes place via pressure switches, Beros, etc.(A direct activation of the valves, e.g.during service calls, is only possible by means of special interventions into the machine control and by using special functions.) Error messages are shown on the control panel display and evaluated by the machine control.

Prior to switching off the hydraulic system, all devices connected to it must be in stable condition; hydraulic devices can still move after switching off the oil supply (e.g.lowering the lift cylinders, opening/closing tensioning devices, etc.); also see "Safety instructions".


______________________________________________________________________________ A8007Agb


7.4.2 Adjustment elements

Modifications to hydraulic systems may only be performed by specially trained skilled personnel. Improper interventions can make the machine exceed its safety limits and this can cause pressures that are too high or too low, the failure of certain components and this can have a life-threatening impact on the personnel and severe damage to the machine (explosive material breakage by overload as well as uncontrolled movement by loss of force).

The factory settings on the hydraulic unit, for the basic functions of the machine, may not be changed by the customer. For customer-specific functions (e.g. tensioning devices), the serial hydraulic unit is expanded. For adjustment values see the (expanded) hydraulic diagram The hydraulic diagrams and device lists for the basic unit and its expansions are listed on the following pages.


BAS03-xx

______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ A8007Agb



______________________________________________________________________________ A8007Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ A8007Agb


7.5 Central cooling unit The central cooling unit is located on the rear of the machine, in the roof area, and has a system circuit with refrigerant as well as a consumer circuit that is filled with a water mixture. The water mixture allows a heat exchange between the connected components and the central cooling device.

7.5.1 Function Standard use: • Cooling of the motor spindles

(The housing of the motor spindles is connected to the consumer circuit.) • Cooling the switch cabinet air

(The switch cabinet is connected to the consumer circuit via an air water exchanger) Athermostat regulates the connection to the consumer circuit.

• Cooling of the round table motor (A / U axle) (The drive of the swivel tables is connected to the consumer circuit). Optional use: • Cooling of hydraulic oil

(An additionally installed heat exchanger on the hydraulic unit is connected to the consumer circuit and cools the hydraulic oil) A thermostat regulates the connection to the consumer circuit.

• Cooling the cooling lubricant

(The cooling lubricant is exchanged via a plate exchanger that is installed in the chip conveyor.) A thermostat regulates the connection to the consumer circuit.


______________________________________________________________________________ A8007Agb


7.5.2 Adjustment elements The digital temperature gauge with setup keys is located directly on the unit. In middle-European climates and with normal ambient conditions, a temperature setting of 25°C should be selected on the central cooling device. In other climates, you might have to adapt this setting. Switch cabinet heat exchanger The air water exchanger for the switch cabinet is mounted in the floor area. Cooling water diagram and device list on the following pages.


BAS03-xx

______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ A8007Agb



______________________________________________________________________________ A8007Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ A8007Agb


7.6 Option: Emulsion vapor separator system / compact electric filter In the roof area, above the switch cabinet, there is an optional air filter system. Depending on the model, oil or emulsion vapor or softening vapors, smoke and fine airborne particles can be suctioned in the work room and filtered.

7.6.1 Function The unit is connected to the grid sieve in the work room via a hose and pipe line and routes the contaminated air to the filter system. Permissible ambient temperature approx. 5 - 45° C. The condensate that is emitted during cleaning is routed to the drain funnel (in the roof area) via a hose line and is discharged into chip carts / chip conveyors. The solid particles remain in the filter.

7.6.2 Adjustment elements No functional settings can be selected in the unit itself. You can find further information in the Chapter "External documentation"


______________________________________________________________________________ A8007Agb



BAS03-xx

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8008Agb

8.0 Protocols, certificates 8-1

8 Test reports, protocols, certificates

Table of Contents

CE Conformity Declaration Geometry of the Acceptance Protocols DIN 8615 (Laser measuring protocol VDI DGQ 3441) (Measuring protocol test piece VDI DGQ 3444) (UVV Certificate (§ 5 Sect.4)) Accumulator documentation


____________________________________________________________________________________________________________ A8008Agb

8-2 8.0 Protocols, certificates


BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb

9.0 Maintenance / service 9-1

9 Maintenance / service

Table of Contents

9 MAINTENANCE / SERVICE 9-1

9.1 Safety instructions for service 9-2 9.1.1 Safety instructions for protective equipment 9-6

9.2 Protective equipment 9-9 9.2.1 Functional safety switches 9-9 9.2.2 Work room / loading room door 9-10 9.2.3 roller blinds 9-11 9.2.4 Work room safety window (only with two station models) 9-12 9.2.5 Work room grid 9-13 9.2.6 Magazine loading door (only with two station models) 9-13 9.2.7 Cassette walls 9-14 9.2.8 Panels 9-14 9.2.9 Switch cabinet doors 9-14

9.3 Cleaning 9-15 9.3.1 General instructions 9-15

9.4 List of lubricants BAS-03 9-17 9.4.1 Lubricant list for SW machines 9-18

9.5 Tips for the use of cooling lubricants 9-20

9.6 Maintenance / service 9-21 9.6.1 Lubrication schedule 9-23 9.6.2 Fill volumes 9-24 9.6.3 Maintenance schedule 9-25

9.7 Maintenance photos 9-32

9.8 Service 9-39 9.8.1 Safety windows 9-39 9.8.2 roller blind covers 9-40

9.9 Troubleshooting 9-43

VERTICAL MILLING AND DRILLING CENTRES BAS03-22 _______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb

9-2 9.0 Maintenance / service

9.1 Safety instructions for service Every person that handles service work for machines manufactured by "Schwäbische Werkzeugmaschinen GmbH", must at least have read and understood the chapters "General safety and accident prevention instructions" and "Safety instructions for service" gelesen und verstanden haben. Theother country-specific regulations and law, which apply to special handling, must be observed as well and have priority over our instructions. A non-dangerous and flawless performance of activities and interventions is only warranted if special skills are present for these activities and if the information and instructions in our machine documentation as well as the components' instructions are taken into consideration. • The machine and control functions must be handled in a way that the machine and the attached devices can be operated error-free and without safety hazards. • A machine may not be operated if safety equipment (incl. panelling and doors) are open, bypassed or rendered non-functional. • Maintenance, adjustment and repair work may only be performed by trained and authorised skilled personnel. • Depending on the activities to be performed, the respective personal safety equipment must be worn (e.g. protective gloves, safety shoes, helmet, protective eye goggles, etc.).



BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


In order to prevent injuries and machine damage, the machine should be properly cleaned prior to maintenance and service work.

• When working on hard to reach places as well as units that are not clearly

visible for design or functional reasons (e.g. chip conveyor, chip box, cooling agent containers, submersion pumps, tool magazine, etc.) there is a danger of cuts, crushing, abrasion and burn injuries.

• Never clean the machine with compressed air, high-pressure devices or steam.

An uncontrolled spreading of solid, liquid or gaseous substances can cause them to permeate the system components, which may lead to malfunctions (short circuit, contamination, lack of oil, corrosion, etc.).

• Do not use cleaners containing solvents, which themselves or in combination

with other substances, liquids, atmospheres (gases), can lead to fire or explosion hazardous. Do not change or dissolve, etc. the used materials.

Oils, greases, cooling lubricants, detergents and solvents and other materials used for operation contain biological and chemical substances, which may cause hazards to your health if used improperly (toxic and/or flammable vapors, acidic or skin-irritating additives, etc.). Furthermore, the mixing of these materials may create new compounds that may also negatively impact not only human health but also the machine's product life. Generally the information and use instructions of the manufacturer (material safety data sheet) and the applicable national regulations and laws that are binding for the machine's location must be adhered to prior to using auxiliary materials and additives.

Escaped liquids (leakages) as well as worn or used auxiliary materials must be removed immediately and disposed of as determined by the work and environmental protection regulations. Wear protective clothing. Prior to beginning maintenance and repair procedures, the machine must be disconnect from the power supply and the pressure must be relieved; furthermore, the non-operational stastus of the machine must be reported by means of "Caution Signs".


____________________________________________________________________________________________________________ A8009Bgb




and the system pressure may only be released after it has been ensured that this will not cause any uncontrollable mechanical reactions (snapping back of spring-loaded tensioning systems or cylinders in idle positions; dropping of tools; sliding off of advance and movement units by the lack of hydaulic weight balancing, etc.).

• Prior to removing e.g. motors with built-in brakes, toothed gears, couplings or

other movement-inhibiting components, the respective movement units must be secured (supported or hung up) so that these inadvertent movements are prevented.

Maintenance, repair and adjustment procedures on active systems must be performed using extreme caution. If the necessary caution is not applied, there is a danger of injuries or even death! • Maintenance and repair work that requires adjustments that is only possible

while all systems are ready to operate or by removing or deactivating special safety equipment, must be monitored by responsible employees located near the "EMERG OFF" and "main switch" keys; if danger arises, the machine must be shut down.

The electric switch cabinet may only be opened by qualified and authorised personnel. After disconnecting the machine from the electrical supply (main switch OFF), the following parts still feature life-threatening current: − - on the main switch − - in the switch cabinets on the terminals L1, L2, L3 − - on the connecting cable between the main switch and the terminals − - on the power supply line − - on electric regulators and their supply modules − - on all areas marked with a warning label Switched interventions to modify the hardware or software, as well as electrical and mechanical modifications of the machine's design may only be performed by service technicians of "Schwäbische Werkzeugmaschinen GmbH"; the information in the operating instructions is for informational purposes only. The operator/owner is liable for any damage caused by unauthorized intervention.


BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


After completing maintenance or repair work, the supervisor of the maintenance/service personnel must verify the unlimited operation readiness of the machine. This includes: • the proper fastening of all panel parts and protective equipment, • checking the proper installation of all parts, connections, etc. loosened or




Please inform us about extraordinary malfunctions / errors in the course of the product observation.


____________________________________________________________________________________________________________ A8009Bgb


9.1.1 Safety instructions for protective equipment

The operator is responsible for the machine not being operated if safety systems (such as panel parts) are open, removed, bypassed or taken out of operation - life-threatening danger!

• The separating protective equipment (work room door, loading room door,

magazine loading door/panels/cassette walls) are used to keep away the chips, cooling lubricants and ejected material and tool parts - thus to protect the operator.

• All protective equipment must be fully functional and properly fastened. • Repair and service work on the safety equipment may only be performed by SW

personnel.

All safety-relevant equipment (e.g. ”EMERG OFF” function, light curtains, safety rails, floor mats, door monitors, error current switch, etc.) must be checked for proper function on a regular basis. Here, the respective applicable laws and regulations apply that are legally binding for the operating site.

Depending on the machine model, certain machine functions or operation settings are protected by key switches These key switches are located in the control panel or directly on the respective functional unit. The machine must be set up so that only the required activities are performed by the respective employees. The operator is obliged to remove the key and keep the device locked from unautorized persons. The key switch installed on some machine (e.g. in the control panel), which can interrupt the protective door monitoring, may only be used for setup, maintenance and repair procedures.

As long as the protective door monitoring is disabled, a life-threatening danger exists; axle drives can be activated while the protective door is open.


BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


Due to the material aging of polycarbonate, the retaining capacity (protection from foreign object impact) of the work rooom protective windows is decreased. Another reduction of safety is caused by mechanical damage, temperature influence, radiation and the contact with chemical and biological auxiliary materials and additives. The usage period of work room protective windows is limited, see Chapter "Maintenance“ Damaged polycarbonate windows must be replaced immediately. Option: Automatic loading room doors Depending on the customer requirements, the loading room doors can be opened and/or closed automatically. The activation takes place via the function keys on the control panel. To protect against crushing of body parts, the closing edges are covered with rubber strips. If an obstacle is encountered, a safety feature will interrupt the door movement (also see manufacturer's documentation).

There is a risk of crushing on the closing edge and in the "rear driving range".


____________________________________________________________________________________________________________ A8009Bgb



BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


9.2 Protective equipment The vertical milling and drilling centres BAS03-xx are standard equipped with different protective systems. These are:

• fixed, attached protective equipment • manually locked protective equipment • electrically monitored protective equipment • electrically monitored and locked protective equipment

9.2.1 Functional safety switches Machine access points to dangerous areas, which must be opened repeatedly, are monitored electrically and are locked via the control depending on the situation.

The safety switches with locks are constructed so that a forced lock will be performed on the respective door when there is no power to the machine. The manual opening of a forced lock may only be performed when the machine poses no dangers.

The currently used safety switches have two signal lamps to show the switch status as well as a lock screw to access them for manual unlocking. As far as possible, breakthroughs were installed in the cabin panel, which allow a monitoring of the visual switch status display as well as access to the release screw. Green lamp: Safety switch circuit closed;

protective function is active Red lamp: Safety switch circuit interrupted,

no protective function Aux. release: In case of an interruption of

power, releasing this aux. release will open the mechanical lock.

After removing the lock screw, a bushing with a front cross groove will be exposed and can be accessed. By turning this bushing by approx. 5 degrees counter clockwise, the lock in the safety switch is released and the respective mechanical system can be moved (opened). After closing it once again, the forced lock is reactivated.


____________________________________________________________________________________________________________ A8009Bgb


9.2.2 Work room / loading room door The two-part protective door is a sliding door and consists of a steel sheet metal frame with a clamped in polycarbonate window. The closed protective door is a prerequisite for the production release by the control (also see Chapter Operation). The safety switches with lock / monitoring for the work room or loading room doors are built in above the doors behind a metal panel. The two signal lamps are visible through two punchouts (switch status display), which also allow access to the lock screw. In conditions without power, the lock remains active. To open the protective door, press the key "Open loading door" (on the control panel) and then open it by hand. The protective door is closed by hand and locks automatically.

9.2.2.1 Option: Automatic loading room door The loading door is moved by a regulated torque motor. To protect against crushing body parts, the closing edge is fitted with a contact strip. If an obstacle is encountered, a safety feature will interrupt the door movement (also see manufacturer's documentation). The door automatics are controlled via the key "Open loading door" and "Close loading door" at the loading control panel.


BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


9.2.3 roller blinds roller blinds are used to protect the moving machine parts and guides as well as to discharge cooling lubricant and chips.

The covers and the corresponding fastening elements must always be installed tightly and correctly.

When removing / installing covers, there is a danger of cut and crushing injuries by harp edges, tight installation conditions and spring loaded systems. Please use safety gloves!

Two roller blinds are located left and right of the spindle unit (X axle). (The illustration shows the roller blinds in premounted condition)

roller blind cover (roof area) Only for one station machines Lateral roller blind cover (roof sled open)


____________________________________________________________________________________________________________ A8009Bgb


9.2.4 Work room safety window (only with two station models)

There is a risk of crushing when opening the two prefriction locks of the work room safety window.

Independent of their visual condition, safety windows must be replaced at least every three years. An immediate replacement is necessary, if the holdback capacity is decreased by damage (scratches or cracks) or if the proper visibility is not longer ensured.

There is a safety window between the loading room and the work room on both sides of the swivelling support. The safety window consists of a steel sheet metal frame and a polycarbonate window. This safety window can be manually folded open when working in the work room. The locks / monitoring function via two safety switches each. If the control is turned ON and by the pressing the

"Safety window" key, this window will be unlocked and can be opened by hand. The safety switches with locks / monitoring of the safety windows installed between the work and loading rooms, can be accessed from the left and right machine sides - after removing the panelling.


BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


9.2.5 Work room grid The processing centres BAS03-xx have a grid in the work room of the one station model and in the loading room of the two station model. This will prevent: • larger parts (workpieces and aux. materials)

from falling into the chip cart or the chip conveyor.

• the access from below into this hazardous area.

When operating without a chip conveyor / cart, the openings in the machine pedestal must be closed by different means - suitable metal sheets - so that the access from below to the work and loading rooms is prevented.

9.2.6 Magazine loading door (only with two station models) The access to the tool magazine on the left machine side (only with two station models) consists of a polycarbonate window and is locked / monitored by a safety switch. The closed protective door is a prerequisite for the production release by the control (also see Chapter Operation). The safety switch with lock / monitoring for the magazine door is located under the door, behind the cabin panel. The two signal lamps are visible through two punchouts (switch status display), which also allow access to the lock screw. In conditions without power, the lock remains active. The key switch "Release magazine" on the main control panel must be switched on to open the magazine door. After that, the lock is released by pressing the key "Release magazine door" on the magazine control panel, and the door can be opened manually.


____________________________________________________________________________________________________________ A8009Bgb


9.2.7 Cassette walls The cassette walls are sheet metal panels, which are hooked into guides around the machine and are attached with prefriction locks. Prefriction size: 8 mm square

The prefriction locks must always be closed; the cassette walls must always be installed flush with each other, so that there will be no gaps and all cassette walls can be installed.

9.2.8 Panels The machine parts that must be worked on directly, are protected by fixed panels.The panels consist of steel sheet metal and are fastened to the prefriction locks by screws. Prefriction size: 8 mm square

Make sure that the panels and their fasteners are completely and properly fastened.

9.2.9 Switch cabinet doors The switch cabinet doors and terminal boxes are protected by padlocks or prefriction locks against unauthorized access. Prefriction size: 5 mm double beard for medium voltage Prefriction size: 3 mm double beard for low voltage

Always keep all switch cabinet doors closed, if you are not working directly in the switch cabinet for inspection, maintenance or service reasons.Remove the keys.


BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


9.3 Cleaning A regular cleaning of the machine not only preserves its value - but also allows for early detection of wear and tear and damages. Therefore we recommend (independent of the requirements listed in the maintenance schedule) cleaning the machine thoroughly at least twice a year (after removing covers and panel parts).

In order to prevent injuries and machine damage, the machine should be properly cleaned prior to maintenance and service work.

9.3.1 General instructions

• There must not be any tools in the the work spindle(s) • The tools should be unloaded from the tool magazine • Move the work spindle(s) to the edge of the work room; max. right, max. toward

the rear, max. toward the top • Remove the workpieces from the work room and the loading room • Preclean the tensioning devices by rinsing them • open all moving work room doors / windows • Switch the machine / control off; main switch OFF; protect from switching on • remove the cabin insert sheet metal • (remove covers / guide rail covers orloosen them and slide them together) • Using a broom, chip hooks, lint-free cloths and industrial vacuum cleaner,

remove dirt from the machine starting at the top.Check the different components for scratches, abrasions or other damage during the cleaning process.

• Remove dirt and chips from the chip conveyor / cooling lubricant system; pump off cooling lubricant if necesary and clean the different chambers thoroughly

• Do not wipe the protective windows with a dry, but with a moistened cloth!

Never clean the machine with compressed air, high-pressure devices or steam. An uncontrolled spreading of solid, liquid or gaseous substances can cause them to permeate the system components, which may lead to malfunctions (short circuit, contamination, lack of oil, corrosion, etc.) .

Do not use cleaners containing solvents, which themselves or in combination with other substances, liquids, atmospheres (gases), can lead to fire or explosion hazardous. Do not change or dissolve, etc. the used materials.


____________________________________________________________________________________________________________ A8009Bgb



BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


9.4 List of lubricants BAS-03 To fill the shared storage container for the central lubrication and the minimum oil quantity lubrication, only products with the following features must be used:

• Mineral oil as per ISO VG 68 with EP additives • no mixed oils • no MoS2 additives

As far as we know, the following products currently have the required features. We did not perform a capability test. We recommend requesting a relevant confirmation with the supplier during your purchase.

Viscosity as per DIN 51519

ISO VG 68 68 mm²/s (cSt) at

40°C

ID as per DIN 51502

---

Manufacturer

Esso Spartan EP 68

Shell Omala-Öl 68

Mobil Pressure oil KLP 68-C

ARAL Deol BG 68

BP Emergol HLP-D68


____________________________________________________________________________________________________________ A8009Bgb


9.4.1 Lubricant list for SW machines Contact surface oil Contact surface oil Lubricating oill /

hydraulic oil



40°C


40°C


40°C

ID as per DIN 51502

CG LP 220 CG LP 68 C LP 10 (H-LP 10)

Manufacturer

ARAL ARAL

DEGANIT B 220 DEGANIT BW 220

DEGANIT B 68 DEGANIT BW 68

VITAM GF 10 VITAM DE 10

AVIA AVILUB RSL 220-SU AVILUB RSL 68-SU AVILUB RSL 10

BP

MACCURAT 220 D MACCURAT 68 D ENERGOL HLP-HM10

CASTROL

MAGNAGLIDE D 220

MAGNAGLIDE D 68

HYSPIN SP 10 HYSPIN AWS 10

DEA NOVAN CGLP 220 NOVAN CGLP 68 ASTRON HLP 10

Esso FEBIS K 220 FEBIS K 68 NUTO H 10

FINA HYDRAN G 220 HYDRAN G 68 GIRAN L 10

FUCHS RENEP 5 K RENEP 2 K RENOLIN B5

MOBIL MOBIL

VACTRA Oil 4 track oil 20

VACTRA Oil 2 track oil 68

DTE 21

SHELL SHELL

TONNA T 220 TONNA TX 220

TONNA T 68 TONNA TX 68

TELLUS 10

TEXACO WAY LUBRICANT 220 WAY LUBRICANT 68 RANDO Oil HD A 10

Zeller+Gmelin Divinol T 12 EP Divinol T 6 EP Divinol DHG 10

Q8 Q8 Wagner 220 Q8 Wagner 68 Q8 Haydn 10

NOTE: The data in the different product descriptions in the lubricant list is entered because of the capability information of the respective mineral oil supplier, with reference to the required DIN qualities. We did not perform a capability test.


BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


Hydraulic oil Hydraulic oil Hydraulic oil



40°C


40°C


40°C

ID as per DIN 51502

H LP 68 H LP 46 H LP 22

Manufacturer

ARAL ARAL




AVIA AVILUB RSL 68 AVILUB RSL 46 AVILUB RSL 22

BP BP

ENERGOL HLP-HM 68

ENERGOL HLP-HM 46

ENERGOL HLP-HM 22

CASTROL CASTROL




DEA ASTRON HLP 68 ASTRON HLP 46 ACTIS HLPD 22

Esso NUTO H 68 NUTO H 46 NUTO H 22

FINA HYDRAN 68 HYDRAN 46 HYDRAN 22

FUCHS RENOLIN B 20 RENOLIN B 15 RENOLIN B 5

MOBIL MOBIL

DTE 26 DTE 25 DTE 22

SHELL SHELL

TELLUS 68 TELLUS 46 TELLUS 22 HYDROL DO 22

TEXACO RANDO Oil HD C 68 RANDO Oil HD B 46 RANDO Oil HD A 22

Zeller+Gmelin Divinol HLP ISO 68 Divinol DHG ISO 68

Divinol HLP ISO 46 Divinol DHG ISO 46

Divinol HLP ISO 22 Divinol DHG ISO 22

Q8 Q8 Haydn 68 Q8 Haydn 46 Q8 Haydn 22

NOTE: The data in the different product descriptions in the lubricant list is entered because of the capability information of the respective mineral oil supplier, with reference to the required DIN qualities. We did not perform a capability test.


____________________________________________________________________________________________________________ A8009Bgb


9.5 Tips for the use of cooling lubricants

Escaped liquids (leakages) as well as worn or used auxiliary materials must be removed immediately and disposed of as determined by the work and environmental protection regulations. If necessary, wear your protective gear when working with the above-mentioned substances.

Oils, greases, cooling lubricants, detergents and solvents and other materials used for operation contain biological and chemical substances, which may cause hazards to your health if used improperly (toxic and/or flammable vapors, acidic or skin-irritating additives, etc.). Furthermore, the mixing of these materials may create new compounds that may also negatively impact not only human health but also the machine's product life. Generally the information and use instructions of the manufacturer (material safety data sheet) and the applicable national regulations and laws that are binding for the machine's location must be adhered to prior to using auxiliary materials and additives.

The machine is designed to use "low water mixture, mineral oil containing cooling lubricants". The cooling lubricant concentrate should have a mineral oil content of approx. 40 %. To mix a useable emulsion, the water must be mixed with at least 6% lubricant or coolant concentrate.

When selecting suitable cooling lubricants and their maintenance and care, we recommend using the consulting services of the suppliers. Special attention must be paid to the compatibility with the other aux. materials, such as lubricating oil, track oil, gear oil, greases, cleaners, etc., which have been shown to contaminate the cooling lubricant.Therefore, we cannot make any recommendations regarding certain cooling lubricants.

We do not recommend using fully synthetic or mineral oil-free cooling lubricants, as the machine is equipped with a loss lubrication system, where used lubricant is channeled into the cooling lubricant.


BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


9.6 Maintenance / service

The listed activities are only mandatory for parts manufactured by us! All other data marked with an "*" refer to external products and are only intended to remind you. The maintenance instructions by the external parts suppliers as well as the documentation regarding customer-specific expansions can be found in the enclosed separate documentation; see Chapter External documentation.

Maintenance and repair work may only be performed by trained and authorised skilled personnel. The service and maintenance staff is expected to be familiar with the general legal accident prevention measures; the responsibility lies with the safety officer of the user or rather with the supervisor of the maintenance and service staff. Generally, all activities must be performed while the machine is turned off, if there is not an immediate need for the machine to be turned on for control or adjustment purposes.


____________________________________________________________________________________________________________ A8009Bgb



BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


9.6.1 Lubrication schedule Times refer to 3-shift operation

Central lubrication

Oil air lubrication

Machine parts BAS03

Guides, bearings, etc.

Main spindle Hydraulic unit

Cooling lubricant

Central cooling device

Tooth crown Q

axle No of the invention location

* 1 * 2 * 3 * 4 * 5 6

Pictoral symbol of the intervention

Type of intervention

Lubricant as per DIN 51502

Mineral oil with EP additives ISO VG 68

(keine MoS2-Zusätze)

H LP 46 Emulsion Water / Tyfocor

Grease (KE2K)

Check / fill (h) 100 100 100 4001200 4800 Fill (h) Clean (h) 2400 4800 Replace (h) 9600 Container capacity (l) 2.7 12 400 40 * see external operating instructions


____________________________________________________________________________________________________________ A8009Bgb


9.6.2 Fill volumes Initial fill of machine

BA S03-xx

Lubricant ID

(DIN)

Fill volume

Central lubricating / minimum oil quantity lubrating unit

Mineral oil

with EP additives-Zusätzen

(MoS2 additives mixed oils are not approved)

CLP 68

ISO VG 68

2.7 dm³

Hydraulic unit Hydraulic oil H LP(D) 46

ISO VG 46

12 dm³

Central cooling unit see manufacturer's documentation

(Tyforop, Hamburg)

Water with 20 Vol.% corrosion protection

(Tyfocor)

approx. 40 dm³

Magazine gear (SEW)

see manufacturer's documentation

CLP PG ISO VG 220 (Tribol 800/220)

0.16 dm³

Swivel support gear; Q axle (Neugart)


KLÜBER Klüberplex BEM

34/132

Chip conveyor gear motor



BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


9.6.3 Maintenance schedule General requirements / notes

• If damages are detected during the machine maintenance, the machine may not be switched back on until all problems have been fixed.

• Protective equipment must be fully functional and must be checked regularly as prescribed by the applicable regulations. This also includes glass (glass / polycarbonate windows), whose retaining capacity is reduced by damages.

• The intervals to clean the entire machine depend on the process and should be defined by the operator; however, they should take place at least 2 x per year.

Maintenance intervals The listed maintenance intervals (h) refer to operating hours in 3 shift operation with a 5 day work week and represent the following rough structure: 20 h = 1 day 100 h = 1 week 400 h = 1 month 2400 h = 6 months 4800 h = 1 year 9600 h = 2 years 14400 h = 3 years

No. h Illustration

Object / activity Note

According to the applicable laws, relevant devices such as ”EMERG OFF” function, light curtains, safety rails, floor mats, door monitors, error current switch, etc. must be checked for their function at least once a year.

20 General Check the condition and function of protective devices / roller blinds. If damages are detected, the machine may only be used after these damages have been fixed and the protective equipment is fully functional.

20 W110 Loading room / work room (Option) door drive safety strip perform functional test. By applying force to the telescoping doors during the automatic movement (e.g. holding them) and light tapping on the safety strip on the closing edge (e.g. with the handle of a screwdriver), the movement must be interrupted and the doors must open automatically.

20 W120 * W121

Work room / tool spindle Cooling lubricant rotating feedthrough visual inspection; with permanent leakage flow, an immediate exchange of the tool spindle rotating feedthrough is necessary to avoid spindle and subsequent damages!

Documentation "Kessler�


____________________________________________________________________________________________________________ A8009Bgb


No. h Illustration


Aux. materials, such as lubricants and coolants have chemical, biological and synthetic characteristics, which can cause influences that are negative for health and environment. The work and environmental protection regulations must be adhered to; wear protective gear.

20 * Cooling lubricant system (Option) paper band filter; check filter fleece for correct transport and damage.

Documentation �Knoll� / �Interlit�

The oil filling for lubrication and hydraulic applications must be done with a filter rating of 10 µm.

100 * Coolant system (Option) chip conveyor / coolant container Check the function of chip conveyor, pumps as well as the proper function of the filter systems. Check the cooling lubricant as well as its contamination level (dirt freight). Remove the chips as well as residue in the sieve box. Check the gear motors (chip conveyor) oil level.

Documentation "KNOLL" / �Interlit� Dirt freight max. 40 mg/l

During the functional control of the chip conveyor, there is a risk of cutting, crushing and severing for fingers, hands and limbs by the circulating conveyor system. Interventions are only permitted while the machine is turned off. When replacing the cooling lubricant, all contamination, such as chips, sludge and other residue from all the cooling lubricant containers must be removed; otherwise, there is a risk of damaging the motor spindles, the rotating feedthroughs, valves and other active and passive components.

100 W130 W131 W132

Work room / additional device room (Option) suctioning system Clean the suction location in the work room Check/clean exhaust air sieve insert in the additional device room (optional on the opposite side of the machine).

400

W140 *

Hydraulic unit Check / clean / replace the oil return filter

Documentation "Lotz hydraulics"

400 W150 *

Central cooling unit Check the fill level in the consumer circuit / fill water

Documentation �Lahntechnik�


BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


No. h Illustration


400 W122 W123 W124 W125

Work room and roof area General check of all components for fastening, damages, leakages and contamination. Position the X and Y axle at the largest and smallest values, respectively.Check the roller blinds for contamination and damage. Clean the roller blinds and the scrapers in the work room and the roof area; retension or replace if necessary. Remove chips / contamination from the scrapers of the X and Y axles.

Documentation "SW�

The functional check of the tool tensioner and the tool magazine can only be performed while the machine is running. This results in an increased risk of injury due to automatic processes and the functional readiness of the work spindle and the advance units. Activities of this kind must be monitored by a second person positioned by the EMERG OFF key. Otherwise there is a risk of collision, cut, crushing and severing injuries for the fingers, hands and other body parts.

400 * Work room, tool spindle Check the spindle cone and tool pickup for damage. Clean the tensioning set of the tool tensioner - do not use compressed air - for function and wear; replace if necessary. Replace the grooved ring in the tensioning set(Viton O-ring to seal for interior cooling lubricant supply). Do not apply oil, grease the clamping spigot pickup / sliding parts with high-performance grease. Measure the retraction force and document it; max. 27kN; min. 15 kN. Check the adjustment dimension of the tensioning unit in the loosened position (see spindle drawing, with HSK63 = 10,5 mm +/- 0,1).

Documentation "Kessler�

1200 W160 W161 *

Pneumatic system Check function / adjustments. Sealing air: Check function / adjustments.

Documentation "Festo" �Heidenhain�

1200 W162 *

Pneumatic system Cylinder weight balancing: Check / replace muffler.

Documentation "Festo"


____________________________________________________________________________________________________________ A8009Bgb


No. h Illustration


A high amount of pressure energy remains in the hydraulic circuits even after the machine has been turned off. Unauthorised, improper interventions can cause oil to be expelled with high pressure and can result in severe, deep injuries, even death. Oil hydraulic systems may only be worked on by trained specialists, after the system has been depressurised. Prior to that, it must be checked whether this pressure relief did not cause any undesired movements, such as the backlash of tensioning systems or the sliding off of moving units.

1200 W140 W141 W142 W123 *

Hydraulic unit Check the hydraulic components for contamination / clean. Clean the heat exchanger Perform a safety inspection of the accumulator / hydraulic hoses / safety valves, etc. Check the accumulator for gas pretension pressure; refill if necessary.


1200 W150 *

Central cooling unit Check the concentration of the corrosion protection agent with a full unit; minimum volume 25%. Clean the airways on the central cooling device; remove the metal filter walls and clean them; replace if necessary.

Documentation �Lahntechnik�

1200 W125 Roof area Remove chips and residue behind the 3-axle unit and the drain funnel; check the function of the rinse bars.

1200 End limit switch, limit and measuring key Check the fastening as well as the function - remove dust or chips.

Check all "EMERG OFF" keys and safety equipment for their proper function (door lock, etc.).

2400 General cleaning of the machine The work spindle(s), ball thread drive, guide rails, rotary encoders, etc. must be visually and acoustically checked for scratch or abrasion traces as well as external noise development.

In case of wear / damage, consult SW.

2400 Pipes and hoses of pneumatics, coolant, cooling lubricant, central lubrication and hydraulics must be checked for leakage and proper fastening / function.

2400 W126 Loading room / work room Clean / check the door guide.

(Option) automatic door drive Clean the drive, toothed belt, mechanical connections as well as the safety rail and check them for function and damages.


BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


No. h Illustration


2400 Work room, tool spindle Check the axial and radial play as well as the circulation. Check the function of the pneumatic blowout as well as plan position control (option); detection from 0.04 mm distance.

2400 W170 W171

Machine room Energy supply / Q axle (Remove the left sheet metal insert; open the additional device room); check the energy supply lines for damage, leakage and correct routing. Check energy chain. Check measurement systems / rotary distributors (A / U and Q axle), clean if necessary.

2400 W172 W173 W174

TOOL MAGAZINE Magazine locations; check the lock for damage and function as well as guide rollers; clean if necessary. (Machine rear) replace defective elements.

2400 W160 *

Pneumatic system Replace the very fine filter for "sealing air measurement systems".

Documentation "Heidenhain"

2400 W180 W161 W125 W181 *

Central lubrication system Check the function of the central lubrication unit; check the lubricant metering via the lubricating oil distributors (central lubrication) and on the metering units (minimum oil lubrication).

Documentation "Vogel�

2400 W140 W141 *

Hydraulic system Take an oil sample from the unit, replace the hydraulic oil if is dirty or worn; clean the return filter and tank interior if necessary.

Documentation "Lotz"

Oberve the notes issued by the labor associations: Hydraulic hoses must be checked for their safe operation at least once a year by an expert; max. use is 10 years - as per the "Safety regulations for hydraulic hoses" (incl. storage time).

2400 * (Option) suction / air filtering system Maintenance as instructed by the manufacturer (e.g. emulsion vapor separator or compact electric filter Replace/clean filter.

Documentation Losma

2400 * Coolant system (Option) chip conveyor; chain tension, drive shaft, guide rollers, removal strips and scrapers must be checke for function and wear / adjusted / replaced.

Documentation "Knoll", �Interlit�


____________________________________________________________________________________________________________ A8009Bgb


No. h Illustration


4800 W160 W161 *

Pneumatic system Maintenance unit; replace prefilter and fine filter of the main maintenance unit; clean the water separator (filter) (observe chemical durability; check function.

Documentation "Festo"

4800 W120 W121*

Tool spindle / roof areas Replace the cooling lubricant rotary feedthrouhgh on the work spindle.

Documentation "Kessler

4800

Switch cabinet / control Check the ventilator of the PCU, NCU, regulator package and heat exchanger for function and contamination; clean. Test the motor protection triggering device: Press the reset / test key for > 2 sec, red LED will illuminate. Press the reset / test key briefly, red LED will turn off. Save data and create NC and PLC archives; we recommend saving the hard drive to a CD once per year.

Control "OFF", turn main switch on switch cabinet OFF = "0". Discharge voltage / watch for time of drive assemblies! Connections of current rail, intermediate circuit, connections and bus connections, regulator board and I/O. Check the regulator board for contamination, clean if necessary Check the serial terminals (random sample)

4800 W170* Swivel support (only two station machines) Clean / grease the tooth crown of the Q axle.

Gear Q axle; check the shaft seal rings for tightness, replace if necessary (check grease content).

Documentation "Neugart"

9600 W122 W123 W124 W125

Cover / guides / drive spindles Remove the covers / roller blinds, check for function; slightly oil the metal covers; checking sealing lips. Remove chips (also on the ball thread drives). Check the guide rails as well as the ball thread drives and lightly oil them after the cleaning.

9600 W140* Hydraulic unit Replace hydraulic oil

Have the hydraulic hoses / pressure lines checked by an expert



BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


No. h Illustration


9600 W175 *

Tool magazine gear Check the grease filling and fill if necessary (for grease type - see manufacturer's documentation).

Documentation "SEW"

14400

Independent of their visual condition, safety windows must be replaced at least every three years. An immediate replacement is necessary, if the holdback capacity is decreased by damage (scratches or cracks) or if the proper visibility is not longer ensured.


____________________________________________________________________________________________________________ A8009Bgb


9.7 Maintenance photos (also see Chapter 3) W110 W120 W121

Safety strip


BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


W122 W123

W124 W125

W126 W127


____________________________________________________________________________________________________________ A8009Bgb


W130 W131

W132

Sieve insert (work room door

closed)


BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


W140 W141

W142

Fill level control

Return filter Fill neck


____________________________________________________________________________________________________________ A8009Bgb


W150 W160 W161

W162

Metal filter wall removed


BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


W170 W171

W172 W173

W174 W175


____________________________________________________________________________________________________________ A8009Bgb


W180 W181


BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


9.8 Service

9.8.1 Safety windows

Independent of their visual condition, safety windows must be replaced at least every three years.

9.8.1.1 Exchanging the polycarbonate window on the work room door Only with two station machines Replace the window as follows: 1. Fold open the work room door 2. Remove the screws M 5 x10 and remove

the cover sheet metal plate 3. Remove the window and the seal strips 4. Clean the bottom part and the sheet metal cover 5. Check springs for function 6. Attach new seal to the bottom part 7. Place the window in its postion (attach from the outside through the seal) 8. Install a new seal between the window and the sheet metal cover 9. Screw on the sheet metal cover with screws M5x10

9.8.1.2 Replacing the polycarbonate windows of the work room door Only with one station machines These windows may only be replaced by skilled SW personnel.

Cover plate

Screws M5 x10

Spring loaded sealing plastic


____________________________________________________________________________________________________________ A8009Bgb


9.8.2 roller blind covers

9.8.2.1 Replacing the "roller blind spindle unit" (X axle)

The two roller blinds are located to the right and left of the work spindles. Replace the roller blind as follows: 1. Open the loading room doors all the way 2. Unlock the work room door and fold toward the

front 3. Remove the aperture, two-part, galvanised

zinc, left and right from the Z sled 4. Loosen 3 screws on each side of the scrapers 5. Remove the toothed belt for synchronising 6. Unscrew the top support angle of the roller blind 7. Pull the roller blind out of the bottom bearing 8. Refit the toothed belt disc and the bearing to the new roller blind 9. Install the new roller blind with the top holder and affix loose end to the scraper 10.Reinstall the belt 11.Manually retension the roller blind spring by hand and tighten tensioning set 12.Install the aperture


BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


9.8.2.2 Replacing "roller blind loading room cover" 1. Drive the roof sled back

2. "Unscrew the lateral roller blinds on both sides

of the roof sled

3. Remove the cover from the roller blind box

4. Slacken the roller blind on the right side

5. Unscrew the roller blind band from the Y sled

6. Remove both roller blind holders

7. Remove the roller blind

8. Insert new roller blind

9. Install the left holder

10. Attach the roller blind band to the sled

11. Move the roller blind box against the Y sled stop

12. Pretension roller blind with 15 rotations

13. Install the roller blind box cover

14. Attach the side roller blinds

9.8.2.3 Replacing the "side roller blind roof sled" 1. Drive the roof sled back

2. Unscrew the roller blind band

3. Unscrew the roller blind box

Assembly in reverse order


____________________________________________________________________________________________________________ A8009Bgb



BAS03-22

______________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________ A8009Bgb


9.9 Troubleshooting Error messages are displayed as PLC errors and PLC operation messages on the screen. The error message mainly points out the cause (e.g. protective door open) or can be derived from this. See Chapter 11 and the control manufacturer's operating instructions.

A correct troubleshooting procedure is part of SW's operator training and therefore may only be performed by a personnel trained by SW.

• If errors cannot be clearly identified / localised, please contact our service

department to clarify the error cause and eliminate the error.

• Please inform us about extraordinary malfunctions / errors in the course of the product observation.


____________________________________________________________________________________________________________ A8009Bgb



BAS03-xx

______________________________________________________________________________________________________________________________________________

_______________________________________________________________________________________ A8010Agb

10.0 Options / special accessories 10-1

10 Options / special accessories

Table of Contents


_______________________________________________________________________________________ A8010Agb

10-2 10.0 Options / special accessories

Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx

______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB

11.0 Machine operation 11-1

11 Machine operation

Please consult the user documentation and operating instructions we furnish to operate the control. The proper operation of the machine requires the knowledge of the operating and programming instructions issued by the control manufacturer as well as a programming training by the "Schwäbische Werkzeugmaschinen GmbH".

11 MACHINE OPERATION 11-1

11.1 General safety and accident prevention notes 11-3 11.1.1 Explanation of symbols 11-3 11.1.2 General information 11-4 11.1.3 Use and operation 11-4 11.1.4 Training 11-7

11.1.4.1 Training skilled personnel 11-7 11.1.4.2 Training for production operation 11-7

11.1.5 Operating and programming instructions 11-8

11.2 Operating elements 11-9 11.2.1 Overview Main operating panel 11-10

11.2.1.1 Siemens control panel 11-11 11.2.1.2 Siemens machine control panel 11-11 11.2.1.3 Additional operating panel Schwäbische Werkzeugmaschinen GmbH 11-11

11.2.2 Switches, keys, signal elements 11-12 11.2.2.1 Siemens machine control panel 11-12 11.2.2.2 Additional control panel SW 11-17 11.2.2.3 SW magazine control panel 11-23

11.2.3 Two station processing 11-24

11.3 Operation 11-25 11.3.1 Switching the machine on 11-25

11.3.1.1 Switching on 11-25 11.3.1.2 Roof sled drive synchronisation 11-26 11.3.1.3 Switching the machine off 11-27 11.3.1.4 Turning the swivel support in the JOG mode 11-27 11.3.1.5 Roof sled 11-28 11.3.1.6 Reference points 11-28 11.3.1.7 Selecting programmes 11-29 11.3.1.8 Test stop 11-30

11.3.2 Tools and magazine 11-31 11.3.2.1 Basics 11-31 11.3.2.2 Oversized tools 11-32 11.3.2.3 Loading the tool magazine BAS03-x1 11-33 11.3.2.4 Loading the tool magazine BAS03-x1 11-35 11.3.2.5 Unloading the magazine 11-37 11.3.2.6 Programming notes for tool management 11-38

11.3.3 Tool monitoring 11-39 11.3.3.1 Standstill monitoring 11-39 11.3.3.2 Quantity monitoring 11-39

11.3.4 Tool magazine 11-41 11.3.4.1 Basics about the tool magazine 11-41

11.3.5 Teleservice (Option) 11-43

Supplemental operating and programming instructions for the control SINUMERIK 840D (PCU50/08) for BAS03-xx _______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB

11-2 11.0 Machine operation

11.4 HMI masks 11-45 11.4.1 SW 11-46

11.4.1.1 Tool breakage 11-46 11.4.1.2 Machine 11-47

11.4.2 Preparation 11-51 11.4.2.1 Type preselection 11-51 11.4.2.2 Adjustment 11-52

11.4.3 Manual operation 11-54 11.4.3.1 Individual movement of tool changer 11-55 11.4.3.2 Individual movement tensioning device, table 1 11-56

11.4.4 Processing 11-57 11.4.4.1 Tension layer 11-57

11.4.5 Diagnosis 11-58 11.4.5.1 Carrier round table 11-58

11.4.6 Documentation 11-59 11.4.6.1 Workpiece counter 11-59

11.5 SW masks / expansions 11-61 11.5.1 Loading axles / setup positions 11-61 11.5.2 Selecting the device 11-63

11.6 Tool and magazine masks (Siemens) 11-65

11.7 Control tips, tables, lists 11-67 11.7.1 BAG's and channels 11-67 11.7.2 Coordinate system/axle designations/drive distances 11-68 11.7.3 Special functions / BAS03 11-69

11.7.3.1 Error messages 11-69 11.7.3.2 M functions / overview 11-69 11.7.3.3 H functions 11-71 11.7.3.4 Extended M functions 11-72 11.7.3.5 L functions 11-72 11.7.3.6 G commands 11-72

11.8 Programming / examples 11-73 11.8.1 Clamping of round axles 11-73

11.8.1.1 Round axles from NCK status 6.4 11-73

11.9 Appendix / Option 11-76

11.10 ePS network manufacturer's documentation 11-76

11.11 Groove cycle 11-76 11.11.1 Groove cycle (option) 11-77

11.11.1.1 Inner groove 11-78 11.11.1.2 Outer groove 11-83


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.1 General safety and accident prevention notes

11.1.1 Explanation of symbols The operating instructions include graphic symbols to alert the machine operator about special safety and operating situations. The different symbols have the following meaning:

Direct danger for life and health. Non-adherence to these notes will have severe health effects as well as possibly life-threatening injuries.

Threat for body, life and property assets. Non-adherence to these notes can lead to health risks as well as possible life-threatening injuries and damage to the equipment and property assets.

Important note for the proper handling of the machine. Non-adherence to these instructions can cause damage to the equipment and the property assets and - in some cases - might lead to injuries of the employees.

Threatening danger by electrical energy. Non-adherence to these notes can lead to health risks as well as life-threatening injuries and damage to the equipment and property assets caused by electrical energy.

Impending danger by thermal influences. Non-adherence to these instructions can cause burns and scalding by contacting liquids, surfaces and objects. (I.e. motors, pumps, hydraulic and cooling units, valves, etc.)

Impending danger by strong magnetic fields. Non-adherence to these instructions can lead to life-threatening situations for humans (e.g. pacemakers, electrical health care equipment) as well as danger of injuries by magnetic tools and damages or even destruction of electronic devices.

Helpful hints and work-related information. These hints contain information regarding better handling of the machine.


______________________________________________________________________________ 03G11AGB


11.1.2 General information Every person involved in the transport, installation, operation, maintenance, repair and monitoring of machines in the "Schwäbische Werkzeugmaschinen GmbH", as well as the manager or department manager of the area where the machine is installed, must have at least read and understood the chapter "General safety and accident prevention instructions".

A non-adherence will lead to - dangers for body and life, - dangers for machine and other assets, - dangers for efficient operation of the machine, - dangers to the environment. The cautionary instructions required in the documentation of the "Schwäbische Werkzeugmaschinen GmbH" do not claim to be complete and refer solely to the handling of our products. The national and international regulations and laws that extend beyond these and that are valid for specific actions must also be adhered to and must take priority over our instructions.

11.1.3 Use and operation The machine's design complies with the current state-of-the-art technology; the design and manufacture takes place in accordance with the general requirements and legal regulations of the machine industry. The highest possible operation safety is only achieved if the machine is used and operated only for its intended purpose by skilled, responsible personnel. • Machines manufactured by the "Schwäbische Werkzeugmaschinen GmbH“ are

series-equipped with numerous safety equipment choices; e.g. doors and windows (for workroom, machine room, tool magazine, etc.) are monitored and locked via the machine control. An unlimited processing is only possible with the doors/windows locked.

This excludes the setup operation.

During setup, different motions can be initiated with open workroom doors. NC axles as well as working spindles can be driven at reduced speeds. Danger of cutting, crushing and burning injuries by tool and advance movements as well as by thrown chips and workpieces.


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


• Panel parts such as cabin sheet metal panels with locks and switch cabinet doors are not monitored as a standard.

The user is responsible for the machine not being operated while safety equipment (including panel parts) are open, removed, bypassed or taken out of operation; life-threatening danger! • Automatically operated doors/windows/openings represent a crushing hazard;

persons present in the machine vicinity must be informed of this danger by the operator.

• Prior to starting work, the operator must check the proper attachment of the tensioning devices, the energy supply (electrical, pneumatic, hydraulic) and their function as well as the tools/tool holders and the processing programme; a walk around the machine and a check within the machine must be conducted to ensure that nobody is locked inside the machine when it is started and that no collision with non-machine parts can take place.

• On machines, whose use is possible from two "separate" processing locations

working with one common spindle, only the work area with the working spindleis monitored or locked. The other workroom can be opened for loading/unloading without interrupting the processing in the other workroom.

The workroom separating wall installed during two-location operation must never be removed: life-threatening danger! The intervention or entering of the occupied workroom is prohibited; danger of cut injuries and loss of limbs or even life-threatening injuries.

• The operator must learn about the location and the function of the EMERG

STOP key(s).

If a safety hazard occurs, or if a situation is recognised which may indicate a safety risk, the EMERG STOP key must be activated immediately.

• When activating the EMERG STOP key, all movements of the machine are

stopped; depending on the situation, this can cause damage to the tools, workpiece and possibly to the machine.

• All changes on the machine that cause safety-technical hazards to it, must be

immediately reported to the supervisor by the operator.


______________________________________________________________________________ 03G11AGB


• The CNC-controlled machines have a diagnostics system; in case of

malfunctions or operator errors, error messages will be displayed. The reasons for these errors must be eliminated. Severe errors will lead to an interruption of operation, just like when activating EMERG STOP.

There will be no check of the customer-specific processing programmes in relation to operation errors. Every operator is responsible for not using commands in the programmes, which may lead to safety hazards for personnel or machine based on environmental conditions (e.g. workpiece and tool dimensions, advances, chip depth).

The operator is responsible for the adherence to the work and environmental protection when using hazardous and auxiliary equipment. The machines require oils, greases, cooling lubricants and refrigerants, air, hydraulics and electrical energy to function properly. The selection of the proper manufacturer/supplier as well as the clarification of the safety-relevant connections is handled by the operator.


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.1.4 Training In the course of the start-up of the machine, SW will conduct a training session, which will include the following content:

11.1.4.1 Training skilled personnel By SW for the preparation, setup and production operation as well as for the inspection/maintenance/repair. • Function of the machine, equipment and additional units • Function of the protection equipment (see chapter 9) • Position and function of the EMERG STOP keys • Setup and function of the operating panel • Functions of the machine • Preparation • Production operation • Danger sources and safety instructions • Error messages • Contents of the operating instructions • Programming examples • Performance of inspection/maintenance/repair and cleaning

A prerequisite for the preparation and the setup of the machine is the operator training for the used control by SW and the documented training session.If this work is to be performed by other employees of the company, they must be trained by SW as well.

The user documentation for the control and the operating instructions of the component manufacturers are part of the delivered total documentation of this machine. The instructions and recommendations given in the user documentation of the control manufacturer are mandatory, if not expressly specified otherwise in these operating instructions.

11.1.4.2 Training for production operation The training of the operating personnel can be conducted by a skilled SW employee. The training should include at least the following contents: • Function of the machine and the machine elements • Function of the protection equipment (see chapter 9) • Position and function of the EMERG STOP keys • Danger sources and safety instructions • Operating with errors • Setup and function of the control panel; permitted and blocked functions • Processing sequence • Processing the work task • Using personal protective equipment


______________________________________________________________________________ 03G11AGB


11.1.5 Operating and programming instructions The vertical processing centres BAS03-xx are currently produced in four different model types: BAS03-11 one-spindle model with a swivelling table controlled as a horizontal NC axle in

the workroom BAS03-21 two-spindle model with a swivelling table controlled as a horizontal NC axle in

the workroom BAS03-12 one-spindle model with swivelling support system, where both swivelling

tables installed as horizontal NC axles shuttle back and forth - separated by a safety window - between the workroom and the loading room.

BAS03-22 two-spindle model with swivelling support system, where both swivelling tables installed as horizontal NC axles shuttle back and forth - separated by a safety window - between the workroom and the loading room.

Depending on the additional equipment and the work task at hand, the control and the control panel were customised to the customer's specifications. The symbols found here may include functions that your machine is not equipped with, or your machine might have functions that are not depicted here. If the machine should differ, you will find supplemental information as an enclosure of these operating instructions; see chapter "Additions/supplements". The standard operation takes place according to the current operating and programming instructions of the control manufacturer.

This chapter includes exerpts of the operating instructions for the Siemens 840D control. We will not be held liable for the completeness and up-to-dateness of this information!

Mandatory prerequisites for the safe and accident-free operation of the processing centre as well as its programming are: • Knowledge of the operating and programming instructions of the control

and component manufacturers. • Knowledge of the SW operating instructions. • The participation in a operator and programmer training session at SW. • The use of the machine and control by exclusively skilled and trained

personnel familiar with the functions of the machine, the control and the work task at hand so that errors and hazards can be avoided.


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.2 Operating elements


______________________________________________________________________________ 03G11AGB


11.2.1 Overview Main operating panel

Siemens control panel A display B Alpha- / numeric block

C Correction / cursor block / control keys

D Machine control panel 1 Recall (jump back) 2 Machine range key 3 Soft key bar, horizontal (HSK) 4 Key, etc. (menu expansion 5 Area switch 6 Soft key bar, vertical (VSK) 7 Mouse/USB Siemens machine control panel with SW function keys

Additional control panel SW

0

0 1

0 1

C / W

A / U


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


To operate and program the machine, the control panel is subdivided into several operating fields or function groups.

11.2.1.1 Siemens control panel

Monitor Screen to display: Operating functions, programmes, messages, menus

Soft keys Selection keys to select certain screen displays and menus Alpha block Numeric block

Keyboard with letters from A to Z, keyboard with digits from 0 to 9 as well as mathematical functions, special characters and input/correction keys

Cursor block Cursor keys to control the input mark (cursor) on the screen, as well as for paging within certain screens and special function keys.

11.2.1.2 Siemens machine control panel

EMERG STOP Key for the stopping of all drives and performance components Function block operating modes

Preselection keys for: Operating modes, step measure dimensions, reference point and repositioning function

Function block „SW“

Preselection keys for: Work area, chip conveyor, cooling agent, etc.

Function block NC axles

Preselection keys for: NC axle selection, keys for step dimension and rapid gear

Function block override

Rotary switch for the change in percent of programmed advance and spindle speeds as well as start and stop keys for advance and spindle

11.2.1.3 Additional operating panel Schwäbische Werkzeugmaschinen GmbH

Function block control

Control, cooling agent and hydraulic on, special operation with reduced movement, key switch, confirmation key

Function block device

Special keys for optional use, e.g. tensioning device

Function block acknowledge

Equipment acknowledgment, work area, magazine special keys

Function block hand wheel

Option: electronic handwheel


______________________________________________________________________________ 03G11AGB


11.2.2 Switches, keys, signal elements Depending on the additional equipment and the work task at hand, the control and the control panel were customised to the customer's specifications. The symbols found here may include functions that your machine is not equipped with, or your machine might have functions that are not depicted here. If the machine should differ, you will find supplemental information as an enclosure of these operating instructions.

11.2.2.1 Siemens machine control panel

EMERG OFF KEY Press the red key in emergency situations:

• if human lives are in jeopardy,

• if there is a danger of the machine or the component being damaged. Generally, all drives will be stopped with the highest possible braking effect when EMERG-OFF is initiated.


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.2.2.1.1 SW function keys with LED

T

Test stop After "main switch ON" as well as after the time span set by the control (> 8 operating hours) and selecting the operating mode "JOG", the request to conduct the test stop function will be placed via the control display.

Acknowledgment load/unload tool After the menu-guided loading/unloading of tools, the key "tool acknowledgment" must be pressed.

Interior cooling lubricant/high-pressure pump The cooling lubricant dispensing via the processing tool will be turned on or off.Suitable tools and tool pickups are required. The system can be switched on while the NC programme is running. Following a programme interruption (NC stop), the settings that were valid before the interruption, will be restored.

Cooling lubricants/spindle nozzles The cooling lubricant dispensing via nozzles on the work spindles is switched on or off. The system can be switched on while the NC programme is running. Following a programme interruption (NC stop), the settings that were valid before the interruption, will be restored.

Cooling lubricant/rinsing The cooling lubricant dispensing via additional rinsing nozzles will be turned on or off. The system can be switched on while the NC programme is running. Following a programme interruption (NC stop), the settings that were valid before the interruption, will be restored.

T


______________________________________________________________________________ 03G11AGB


Chip conveyor

• By activation, the chip conveyor will be turned on and off

• During its activation, the chip conveyor is driven back (time-limited) The system can only be switched on while the NC programme is running. Following a programme interruption (NC stop), the settings that were valid before the interruption, will be restored.

Home Position

Option: Reserve/home position

Stop after end of programme

Special function with automatic loading/unloading By switching on the function, the tensioning device remains in the workroom after the CNC programme is ended. The automatic swivel support movement in the loading room will not be executed.

Lamp test

By activating the key in the operating mode "JOG", all signal lamps on the control panel are switched on for testing.

Rotate swivel support

Only with two station model: By activating the key in the operating mode "JOG", the swivel support is rotated by 180°.This will switch the tables (1 and 2) or the round axles (A and U) positions between the workroom and the loading room.

Caution: Collision hazard between spindle tool and swivel support or device

Tool changer - basic position

By pressing the key (several times) in the operating mode "JOG", the tool change basic position is driven, e.g. after terminating a tool change or after a long standstill. The basic position is reached when the respective LED is turned off.

Safety window

Only with two station model: The safety protection window between the loading room and the workroom is locked by two monitored pneumatic cylinders. When the key is pressed, the lock is released and the safety window can be opened. Prerequisite: operating mode JOG or .AUTO

no spindle/advance movement (NC STOP is active)

Channel


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.2.2.1.2 Axle selection

By first activating the shift key, the second function is selected with double-function keys.

..

Axle selection and directional keys The desired axle is selected by pressing the respective key X, Y, Z, etc. .

..

Moving the selected axle in the positive or negative direction. Other occupied axles are moved in the same manner. If an NC function is set, only one increment is moved when the direction key is pressed (cursor key) - no matter if it is pressed briefly or for a long time (1/10/100/1000/10000 Inc., depending on the setting). If no INC function is selected, the presetting "continuous" will prevail. The axle will be moved as long as the directional key is pressed. If the safety locks are open, only the simple movement movement via the JOG keys or or via the handwheel is possible (also see agreement key).

Quick run overlap If this key is activated together with one of the keys described above, the axle is driven in rapid gear (not in setup mode).


______________________________________________________________________________ 03G11AGB



______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.2.2.2 Additional control panel SW The standard key functions are shown. Other keys might be used for customer-specific/optional functions.

11.2.2.2.1 BAS03-11 / -21

1

Confirmation key By pressing this continuously, axle movements can be performed with the workroom open. Prerequisite: Key switch (15) on setup (1); operating mode "JOG", axle selected.

• While using this in connection with the "plus or minus" keys, the selected axle is driven.

Axle movements are limited to 2,000 mm/min.

2

Close door The open roof area is closed when activating this key; see chapter "roof sled". With the optional extension "automatic workroom door", this door will be closed.

3

Tensioning The function depends on the application: e.g.: close tensioning device or tension the workpiece. Prerequisite: Device is in basic position and work or loading room door is closed.

4

0

Basic position of round axle Turns the NC axles (and possibly setup planets) in the loading room (workroom) into the basic position. (The determination of the basic positions is done in the “SW menu“)

00 1

A

0 1


______________________________________________________________________________ 03G11AGB


5 C

Cycling the C axle Option: Rotates the planet (C) by a previously set angle value. (The determination is made in the “SW menu“)

6

Magazine position Loading and unloading of the tool magazine takes place first at the control in the control panel; including magazine location selection. By activating the key, the previously selected magazine location is automatically driven to the loading or the unloading position.

7

0 1

Circling Special operating mode: By switching this on, the work spindle can be rotated by hand. Prerequisite: Key switch (15) on setup (1); operating mode "JOG".

8

Control ON Drive regulator, pumps, valves as well as connected aux. units are switched on. Performance components that are monitored by safety equipment only become active, if certain safety instructions (such as workroom doors closed) are fullfilled.

9

Equipment acknowledgment Acknowledges the completed equipment and starts the automatic operation. (With active automatic loading cycle, automatic functions such as: open door, release, keep cycling, etc. can be run. After the equipping is completed, the automatic loading cycle is terminated and this will lead to e.g. tensioning, closing door and finished message to the control.)

10

Unlock/open door By activating the key, the loading room door is unlocked; (with optional extension "automatic loading door", additionally opened automatically). At the same time, the roof area will open - depending on the Y position of the work spindle; see also chapter "roof sled".

11

Release The function is application-dependent; e.g. open tensioning device or release workpiece. Prerequisite: Device is in basic position and work or loading room door is closed.

12 A

Cycling A axle Rotates the round axle (A) by a previously set angle value. (The determination is made in the “SW menu“)

13

Rinsing Option: The function depends on the device. Possibilities include: Rinsing the device with cooling lubricant; cleaning the device with compressed air; switch on oil minimum lubrication volume; etc.

14

Magazine cover The magazine door (between the workroom and the tool magazine) is alternately opened/closed.


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


15

0 1

Setup Special operating mode: In connection with the confirmation key, the different advance axles can be moved with the workroom door open. Prerequisite: Key switch on setup (1); operating mode "JOG", axle selected.

16

Control OFF Drive regulator, pumps, valves as well as connected aux. units are switched off.

18

Unlocking magazine location For the manual tool change the magazine location is unlocked using the foot switch. A tool can be inserted or removed while this switch is pressed.

Functions involving a higher safety risk are protected by the Siemens key switch and deactivated selection options (greyed out soft keys). Also see the menu "machine control panel" and the listed selection options.


______________________________________________________________________________ 03G11AGB



______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.2.2.2.2 BAS03-12 / -22

1

Confirmation key By pressing this continuously, axle movements can be performed with the workroom open. Prerequisite: Key switch (15) on setup (1); operating mode "JOG", axle selected.

• While using this in connection with the "plus or minus" keys, the selected axle is driven.

Axle movements are limited to 2,000 mm/min.

2

Close door Option: By pressing this key, the loading room door is closed automatically.

3

Tensioning The function depends on the application: e.g.: close tensioning device or tension the workpiece. Prerequisite: Device is in basic position and work or loading room door is closed.

4

0

Basic position round axles / planets Turns the NC axles (and possibly setup planets) in the loading room into the basic position. (The determination of the basic positions is done in the “SW menu“)

5 C / W

Cycling the C/W axles Option: Turns the planets (C/W) in the loading room by a preset angle value. (The determination is made in the “SW menu“)

7

0 1

Circling Special operating mode: By switching this on, the work spindle can be rotated by hand. Prerequisite: Key switch (15) on setup (1); operating mode "JOG".

0

0 1

0 1

C / W

A / U


______________________________________________________________________________ 03G11AGB


8

Control ON Drive regulator, pumps, valves as well as connected aux. units are switched on. Performance components that are monitored by safety equipment only become active, if certain safety instructions (such as workroom doors closed) are fullfilled.

9

Equipment acknowledgment Acknowledges the completed equipment and starts the automatic operation. (With active automatic loading cycle, automatic functions such as: open door, release, keep cycling, etc. can be run. After the equipping is completed, the automatic loading cycle is terminated and this will lead to e.g. tensioning, closing door and finished message to the control.)

10

Unlock/open door By activating the key, the loading room door is unlocked; (with optional extension "automatic loading door", additionally opened automatically).

11

Release The function is application-dependent; e.g. open tensioning device or release workpiece. Prerequisite: Device is in basic position and work or loading room door is closed.

12 A / U

Cycling A/U axle Turns the round axle in the loading room(A/U) by a preset angle value. (The determination is made in the “SW menu“)

13

Rinsing Option: The function depends on the device. Possibilities include: Rinsing the device with cooling lubricant; cleaning the device with compressed air; switch on oil minimum lubrication volume; etc.

15

0 1

Setup Special operating mode: In connection with the confirmation key, the different advance axles can be moved with the workroom door open. Prerequisite: Key switch on setup (1); operating mode "JOG", axle selected.

16

Control OFF Drive regulator, pumps, valves as well as connected aux. units are switched off.

Functions involving a higher safety risk are protected by the Siemens key switch and deactivated selection options (greyed out soft keys). Also see the menu "machine control panel" and the listed selection options.


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.2.2.3 SW magazine control panel Two-station machines have a magazine loading station with magazine control panel

11.2.2.3.1 BAS03-x2

EMERG STOP Key for the stopping of all drives and performance components When activating the “EMERG STOP“ key, all movements of the machine are stopped; depending on the situation, this can cause damage to the tools, workpiece and possibly to the machine.

Errors Every malfunction (e.g. doors, swivel supports, tensioning device, control, etc.) are signalled by an illuminated error indicator lamp

Loading panel active The lamp illuminates if "release magazine" has been selected on the "SW magazine operating panel". Entries can only be made in the magazine control panel; the main operating panel is deactivated.

Unlock magazine door During operation, the magazine door is unlocked and can be opened manually.

0 1

Release magazine Switching (key switch) between main operating panel and magazine operating panel. Entries can only be made on the activated unit; see "loading panel active".

Magazines turn forward The magazine is moved forward while the key is pressed in the direction of increasing magazine location numbers (up). Prerequisite: Magazine door closed.

Rotate magazine reverse The magazine is moved backwards while the key is pressed in the direction of increasing magazine location numbers (down). Prerequisite: Magazine door closed.

Unlocking magazine location The magazine location in the loading/unloading position is unlocked by using the key.

Acknowledgment load/unload tool With the menu-guided loading/unloading of tools, machine-internal processes are combined with manual activities. To confirm that the operator has executed a manual activity and further processes can be started, the acknowledgment key must be activated.

Termination of loading/unloading tools If the loading/unloading process malfunctions, this key must be pressed. (termination of loading/unloading cycle)

0 1


______________________________________________________________________________ 03G11AGB


11.2.3 Two station processing The vertical processing centres BAS03_x2 are equipped with a swivel support system with two separate work areas (table 1 = A axle / table 2 = U axle), so that two (of the same or different) customer-specific devices can be used as tool pickups. While one table for parts processing is located in the work room, the other table is located in the loading room (main time parallel loading and unloading), so that you could consider this to be a two-station processing. In JOG mode, the area or table change (turn swivel support system) takes place by pressing the respective key on the SW additional control panel (see chapter "Turning the swivel support in JOG mode"). In the MDA/automatic mode, the swivel support system is turned automatically. Prerequisite: • Each table / area is assigned their own CNC programme. • The automatic processing is run (NC start) • The device in the loading station is loaded/unloaded and acknowledged. After the CNC programme for one of the tables in the work room is completed, the swivel support is rotated automatically and the CNC processing of the other table is started.


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.3 Operation A prerequisite for an economic processing method is the skill to use the operating processes as well as the understanding of the memory organisation. See Siemens operating instructions "managing programmes and NC data".

11.3.1 Switching the machine on

11.3.1.1 Switching on

Main switch ON The control will execute a self-test, several messages will appear on the display consecutively

Wait No more entries may be made until the message "Loading door not calibrated" (JOG mode) is displayed.

Key control ON

Activation of the machine - controls, valves, hydraulics, etc. are switched on. After that, activate "open door" on the SW additional control panel, open the door and reclose it; (unlock EMERG STOP if applicable). Option: If the "automatic loading/workroom door" is present, the door is automatically opened after the key is pressed. After reaching the end position, activate the key "close door". After the automatic opening/closing, the automatic door drive is synchronised.

Press the „Test stop“ key

T

After the main switch has been turned ON, the safety-relevant self-test for the drives must be performed by pressing the "TEST STOP" key. Prerequisite: Spindle not in magazine area; loading/workroom door closed.


______________________________________________________________________________ 03G11AGB


11.3.1.2 Roof sled drive synchronisation One-station machines (BAS03-x1) generally are equipped with an automatic roof sled with a shutter cover. The processing centres BAS03-xx can be (optionally) equipped with an automatic loading/workroom door. Both systems are opened and closed via "Landert drives". These drives will have be synchronised after turning the machine on (main switch ON). During this synchronisation, the drives are run at lower speeds.

Prerequisite: Machine ON; control ON; operating mode "JOG"; EMERG STOP unlocked. Advance/rapid gear override is "open" and > 0

Roof sled When opening the workroom door the roof area will also open - depending on the Y position of the work spindle; see chapter "roof sled". To perform the synchronisation, the work spindle must be located outside the workroom.

Driving the work spindle

Select the operating mode MDA; enter the following commands (in two consecutive lines) on the keyboard: T 0 L 6 Activate NC start; the spindle will be moved to the magazine area

Synchronising Activate the key "Open door" on the SW additional control panel; when opening the workroom door, the roof area is also opened. After reaching the end/final position, press the key "Close door" (close the workroom door if operating it manually). After the roof area has been closed, the synchronisation is completed and the message on the control panel will be deleted


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.3.1.3 Switching the machine off

Press the key "control OFF“ on the "SW additional control panel"

Main switch The machine is switched off via the main switch.

11.3.1.4 Turning the swivel support in the JOG mode

Prior to turning the swivel support, you must make sure that the will be no contact or collisions between the moving and stationary components. Observe malfunction areas of work spindle(s), tools, measuring and auxiliary equipment, devices, swivel supports, or swivel tables as well as their movements!

Prerequisites:

• Loading door closed

• Y axle outside malfunction area

• Z axle outside malfunction area

• Tensioning device tensioned (close)

Advance release

Switch on the advance release / override is "open" > 0

Driving the work spindle

Select the operating mode MDA; enter the following commands (in two consecutive lines) on the keyboard: T 0 L 6 Activate NC start; the spindle will be moved to the magazine area

Press key "turn swivel support" (SW function key block)


______________________________________________________________________________ 03G11AGB


11.3.1.5 Roof sled One-station machines (BAS03-x1) generally are equipped with an automatic roof sled with a shutter cover. When opening the workroom door the roof area will also open - depending on the Y position of the work spindle, which will allow unobstructed access to the workroom (also for crane and handling systems). Depending on the Y position of the work spindle, the roof sled can take on three different positions:

Y position Work spindle

Y = 0 to -401 (workroom)

Y = +1 (workroom limit)

Tool magazine change area (L6)

Opening the workroom door Roof area remains closed

Roof area opens to centre position

Roof area opens completely

11.3.1.6 Reference points The processing centres BAS03-xx have absolute distance measuring systems. Therefore, the different axle positions are displayed as the correct number value immediately after turning on the control.A user-side reference point run is not required.

The balancing of the measurement systems and the transfer of the required data into the machine control takes place when the machine is taken into operation at the plant. Skilled personnel must eliminate errors or replace measurement systems.


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.3.1.7 Selecting programmes

Select the operating mode "JOG"

Switch to the "basic image menu bar" using the area switch

⇒ Select the menu "NCProg" via the masks

"HMI", "SW", "machine" VSK6 select the desired area/table (1 or 2),

which the programme is to be allocated to

VSK1 press "assign programme". The existing

files/directories are listed in a new mask. Mark the desired file (WKS/MPF) using the cursor. (Directories are opened or closed using the "INPUTkey“)

VSK5 If "cancel" is pressed, the masks are

closed without saving the changes. VSK6 By pressing "transfer", the marked

programme is assigned to the selected area/table and the mask is closed.

With two areas, a programme must

also be selected for the other area.

The “machine key“ is used to jump back to the basic menu

VSK2 The existing programme allocation is deleted VSK3 "table release" can only be changed in the loading room. With a deactivated table

release, the programme assignment becomes ineffective and the table is skipped during the subsequent programme execution.

start programmes With two-station processing centres: The area/table that is to be processed, must be located in

the workroom; (possibly "turn swivel table"). Select the operating mode "AUTO"; the CNC programme run is started via "CYCLE START". Acknowledgment key By pressing the acknowledgment key, the control will receive the release for a new automatic

programme start - after a successful programme sequence. With two-station machines: After the CNC programme for one of the tables in the work room is

completed, the swivel support is rotated automatically and the CNC processing of the other table is started.

More automatically run functions (loading cycles) can be executed for the table in the unloading station after the end of processing via separate programmes ("device selection").

NCPROG

NCPR_EG


______________________________________________________________________________ 03G11AGB


11.3.1.8 Test stop According to the data indicated by the control, safety-relevant monitored drives must be checked for proper function regularly by performing a self-test "test stop function". With the updated controls, the possibility was created to manually start the test stop function, which used to run automatically in the background.

T

On the machine control panel, there is a key with an LED to initiate the TEST STOP function. After "main switch ON" as well as after the time span set by the control (> 8 operating hours), the request to conduct the test stop function will be placed via the control display.

Operating message:

• 700248 perform TEST STOP (key); (A currently running NC programme is not interrupted by this. After switching operating modes, or after "main switch ON", the safety doors remain locked until the test stop function is completed.)

Prerequisite:

• Operating mode "JOG"

• Doors / safety protection windows (with two-station models) closed

• Position of the Y axle < 0 mm

Process:

• Using the "test stop" key; during the run of this function, the LED on the keys are illuminated. After the LED turns off, the self test is completed.


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.3.2 Tools and magazine To use different tools (drills, lathes, reamers, milling tools, etc.), which can be interchanged depending on the task at hand, a tool management programme is necessary. The tool management within the machine takes place via the NC control. Basics for the operation of the tool management are the instructions issued by the control manufacturer. For certain, machine-specific expansions, the functions of the tool management were revised/expanded by the "Schwäbische Werkzeugmaschinen GmbH". The following information is to be considered a supplement to the operating and programming instructions of the control manufacturer. As is the case with modern controls nowadays, certain inputs/modifications can be made in different menus/screen masks. The following descriptions are used for basic knowledge and show mostly only one of the possible operating sequences.

11.3.2.1 Basics Before a tool can be used for automatic processing, its tool data must be transferred to the tool management/machine control. The entered tool data is saved in a database, the individual values/parameter can be modified via different masks.

Basically, only one tool magazine or one spindle tool is managed via the machine control, regardless whether one or two processing spindles are used. With two-spindle processing centres, identical tools will have to be used in both processing spindles. This also applies to the tool loading of the same-name magazine locations.

Only use clean and undamaged tools. The tools must be inserted into the tool magazine in the correct position (see label on the insertion position). Observe the permissible tool diameters, tool weights, tool lengths and revolutions. The retaining capacity of the protection devices used as standard (protection doors, separating walls, panels) meets the requirements of the DIN prEN 12417. If you wish to use larger tools, such as for open side locations in the tool magazine, please keep in mind that the protection devices might have to be reinforced (larger diameter, higher revolution speed).


______________________________________________________________________________ 03G11AGB


11.3.2.2 Oversized tools A normal sized tool is defined as 1:1 by the control. This means that this tool will take up one half position on the left and one on the right (regarding its space requirements in the magazine). Tools that vary from this requirement are titled oversized tools.

By using oversized tools, the additional locations in the tool magazine are blocked/covered and can no longer be used for other tools; collision hazard.

Additional limitations (with two-spindle processing centres) arise from the design-related placement sequence of the different tools. Some of the direct additional locations might differ by up to 3 magazine location numbers.

When using several oversized tools, you must generally make sure that the next oversized magazine location is different from the previous one by at least 4 magazine location numbers. Magazine locations to be preferred for the placement of oversized tools include: 2,3, 6,7 10,11, 14,15, 18,19, etc. (with a distance of 4 each). If the control suggests other magazine locations, we recommend placing the selection marker (cursor) on the subsequent magazine location and to conduct a new empty location search. The check for open additional locations must be performed during loading.


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.3.2.3 Loading the tool magazine BAS03-x1

11.3.2.3.1 New tool

Selection: ☞ ☞ "Parameter" ☞ ☞ "Magazine list" ☞ "Mag list 1" ☞ "tool management" HSK3 Press "load" If the line cursor (blue bar) is in a certain

position within the magazine list before the empty location search is started, this magazine location is used if it is available and can take the tool size. Otherwise, the next higher suitable magazine location is selected.

VSK5 press "search for empty location" ⇒ Enter the tool size; the number of

required tool semi-locations; 1:1 is preset (also see "oversized tools"); list box selection: Preplacement = "normal" for 1.1 The entries are saved with the "save key".

VSK8 Confirm with "OK", empty location search

will be conducted and the new tool is assigned a magazine location. The tool master data is entered directly via the marked magazine location. The different fields are selected via the cursor keys and the entries are transferred via the "save key".

Tool ID enter the tool name Duplo enter 1, other values for sister tools Type short symbol for type of tool (drill, lathe,

special tool, etc.); see prorgramming instructions

GrL GrR Tool size was already entered during magazine location search

Geo length enter tool length Geo radius enter tool radius ⇒ Close loading door VSK8 press "Start"; the entries will be checked and transferred into the machine. "Loading/unloading

active" will appear in the alarm/message line on the control panel. At the same time "tool movement running" will appear in the dialog line and the key "magazine position" will illuminate on the additional SW control panel.

WBEL-F

WBEL-LS

WBEL-F


______________________________________________________________________________ 03G11AGB


Press the key "magazine cover" (14) on the "additional SW control panel"; the magazine door between the workroom and the tool magazine will open.

Press the key "magazine position" (6) continuously; the magazine will drive the previously found free magazine location to the loading position automatically and will stop.

Press the key "unlock workroom door" and open the workroom door at the same time.

Press the footswitch "unlock magazine" - the magazine location lock will be opened

⇒ Insert the tool properly into the magazine location

⇒ Release the footswitch

Press the key "tool acknowledgment" (on the SW function key block) to acknowledge the completion of the manual tool loading.

⇒ Close the workroom door; the tool loading is complete.

0 1

0 1


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.3.2.4 Loading the tool magazine BAS03-x1

11.3.2.4.1 New tool

Selection: ☞ ☞ "Parameter" ☞ ☞ "Magazine list" ☞ "Mag list 1" ☞ "tool management" HSK3 Press "load" If the line cursor (blue bar) is in a certain

position within the magazine list before the empty location search is started, this magazine location is used if it is available and can take the tool size. Otherwise, the next higher suitable magazine location is selected.

VSK5 press "search for empty location" ⇒ Enter the tool size; the number of

required tool semi-locations; 1:1 is preset (also see "oversized tools"); list box selection: Preplacement = "normal" for 1.1 The entries are saved with the "INPUT key".

VSK8 confirm with "OK", empty location search

will be conducted and the new tool is assigned a magazine location. The tool master data is entered directly via the marked magazine location. The different fields are selected via the cursor keys and the entries are transferred via the "save key".

Tool ID enter the tool name Duplo enter 1, other values for sister tools Type short symbol for type of tool (drill, lathe,

special tool, etc.) ; see prorgramming instructions

GrL GrR Tool size was already entered during magazine location search

Geo length enter tool length Geo radius enter tool radius VSK8 press "Start"; the entries will be checked

and transferred into the machine. "Loading/unloading active" will appear in the alarm/message line on the control panel. At the same time "tool movement running" will appear in the dialog line and the key "tool acknowledgment" will illuminate on the additional SW function block.

WBEL-F

WBEL-LS

WBEL-DE


______________________________________________________________________________ 03G11AGB


⇒ The further tool loading (manual placement of the

tools into the tool magazine) must take place directly on the magazine loading station, via the magazine control panel.

⇒ Site change on the magazine control panel

Switch on the key switch "release magazine" on the SW magazine operating panel.

Press the key "magazine forward" continuously; the magazine will drive the previously found free magazine location to the loading position automatically and will stop.

Press the key "unlock magazine door" and open the magazine door at the same time.

Continuously press the key "unlock magazine location"; the magazine location in the loading position will be unlocked.

⇒ Insert the (first) spindle tool properly into the unlocked magazine location ⇒ Release key ⇒ check correct tool locking (pull on tool) ⇒ Close magazine door

---------------------------------------------------------------------------------------------------------------------------------------------------------

Only with two-spindle machines:

Press the key "magazine back" continuously; the magazine will drive the previously found free magazine location to the loading position of the second tool automatically and will stop.

• Press the key "unlock magazine door" and open the magazine door at the same time.

• Continuously press the key "unlock magazine"; the magazine location in the loading position will be unlocked.

• Insert the second spindle tool properly into the unlocked magazine location • Release key • check correct tool locking (pull on tool) • Close magazine door

---------------------------------------------------------------------------------------------------------------------------------------------------------

Press the key "tool acknowledgment" to acknowledge the completion of the manual tool loading

Switch off the key switch "release magazine"

0 1

0 1

0 1


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.3.2.5 Unloading the magazine

11.3.2.5.1 Unload tool

Selection: ☞ ☞ "parameters" ☞ ☞ "tool management" ☞ "magazine list" By unloading, the data of a tool are removed from the magazine list. Here, you can select whether the tool data including their usage data (standstill time, corrections, etc.) should remain in the "tool list", be moved to the "tool cabinet" or be completely deleted.

⇒ Mark the desired tool with the cursor keys HSK4 Press "unload" ⇒ Select the unloading function:

VSK4 Unload the tool from the magazine and archive the respective tool data in the cabinet

VSK6 Unload the tool from the magazine and delete the tool data VSK8 Unload the tool from the magazine and move the tool data to the tool list

The selected unloading function is executed. "Loading/unloading active" will appear in the alarm/message line on the control panel. At the same time "tool movement running" will appear in the dialog line and the key "magazine position" will illuminate on the additional SW control panel.

Depending on the machine model (with or without magazine loading station), the manual unloading from the magazine takes place.

Without magazine loading station: (1-station machine) The further tool unloading (manual removal of the tools) is controlled via the keys on the "SW additional control panel". ⇒ Press the key "magazine position"; the magazine will drive the tool to be unloaded to the loading/unloading position

automatically and will stop. ⇒ Open the loading door ⇒ Open the magazine door ⇒ Press the (foot) switch "unlock magazine" and remove the tool; release the (foot) switch. ⇒ Press the key "acknowledge load/unload tool" to acknowledge the manual tool loading ⇒ Close the loading door; the tool loading is complete.

With magazine loading station: (2-station machine) The further tool loading (manual removal of the tools into the tool magazine) must take place directly on the magazine loading station, via the magazine control panel. ⇒ Switch on the key switch "release magazine" on the SW magazine operating panel. ⇒ Press the key "magazine forward"; the magazine will drive the tool to be unloaded to the loading/unloading position

automatically and will stop. ⇒ Press the key "unlock magazine door" and open the magazine door at the same time. ⇒ Keep the tool in the load/unload position, press the key "unlock magazine" and remove the tool; release key, close

magazine door. ⇒ Press the key "magazine back" and repeat the unloading process for the second tool. ⇒ Press the key "acknowledge load/unload tool" to acknowledge the completion of the manual tool loading; switch off

the key switch"release magazine".

WENT


______________________________________________________________________________ 03G11AGB


11.3.2.6 Programming notes for tool management

11.3.2.6.1 Tool change The SW processing centres BAS03-xx have technical and software tool magazines, also in the two-spindle models. The magazine location management is fixed coded. This means that the individual tools are fixed to a certain magazine location and will be placed there again after use. For a tool change, the following functions are available:

Tool change "L6" or "M6"

The programmed cycle "L6" (or "M6") will initiate a tool change in automatic mode (MDA or Auto).The tool selection "TXX" (tool retrieval) as well as the actual change command "L6" must be retrieved in two consecutive sentences; e.g.

.... T XX T= tool retrieval / XX = tool number or tool name

.... L6 (xx,xx) Command to change tools (possibly with parameters)

The activation of a tool change can take place in a main or a subprogramme. For each NC set, only one tool change command is permitted. After a tool change (except with "T00"), the "release from the magazine" run takes place automatically (spindle is between the workroom and the magazine doors) and the settings prior to the tool change become active once again. Exception: Spindle = off, coolant = off

L6 parameter With the tool change command "L6", parameters for further functions can be transferred; L6(a,b,c).

a = spindle speed; start/speed transfer after the tool change; during "release drive" (magazine room)

b = rotation direction after tool change; 3 = right, 4 = left c = * Plan system control; 0 = OFF; 1 = ON

Examples: L6(3000,3,1) Change with plan system control, speed 3000 1/min, rotation direction to the right

* The plan system control is an optional expansion and monitors whether a tool has been correctly pulled into the tool spindle after the tool change.

Special function "T00 L6"

Via the function "T00", an existing spindle tool is placed into the magazine, without changing in a new tool. After the placement, the tool spindle remains in the tool changing position.

With a tool change with "speed transfer", the work spindle will already be started in the work spindle. Disadvantage: With contaminated tools, the particles are spread around the magazine room and can cause malfunctions.


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.3.3 Tool monitoring

11.3.3.1 Standstill monitoring The time indication for the max. use time (standstill time) of a tool (or of a blade) is entered as a minute value in "Maglist-2", in the column "Ist_Zeit" (actual time). With every active tool placement (e.g. work advance, but not G00), this indicated value is reduced by the usage time of the tool (counted in milliseconds). If the standstill time reaches or does not reach the value "0", this tool is considered used and is blocked for future use; marked in Maglist-3 by a "G". If desired, a prewarning can be issued prior to blocking the tool. If the remaining standstill time does not reach the value entered under "warn time", the tool is marked accordingly in the Maglist-3 with a "V". As an option, customer-specific functions can be derived.

11.3.3.2 Quantity monitoring With the quantity control, the number of the maximum tool uses is monitored. Generally, it is determined how often a tool can be placed into the work spindle or how many workpieces can be processed with this tool (if multiple equal workpieces are processed simultaneously). In the Maglist-2, in column "Ist-Stück" (actual piece), a whole number is entered. The programme command "SETPIECE (X,Y)" will subtract the quantity entered under "X" from the "IstWert Stk" (actual value piece). SETPIECE (X,Y) X = number of workpieces Y = spindle number; (main spindle = 0, if main spindle tool is monitored, "Y" does not have to be entered)

With the SETPIECE function, the user can update the quantity monitoring data of the tools used for the processing sequence. All tools are captured, which were replaced since the last update of SETPIECE.

If the "actual value piece" reaches or does not reach the value "0", this tool is considered used and is blocked for future use; marked in Maglist-3 by a "G". If desired, a prewarning can be issued prior to blocking the tool. If the remaining standstill time does not reach the value entered under "warn time", the tool is marked accordingly in the Maglist-3 with a "V". As an option, customer-specific functions can be derived. Further information can be found in the Siemens control documentation


______________________________________________________________________________ 03G11AGB



______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.3.4 Tool magazine

11.3.4.1 Basics about the tool magazine The SW processing centres BAS03-xx have technical and software tool magazines, also in the two-spindle models. The magazine location management is fixed coded. This means that the individual tools are fixed to a certain magazine location and will be placed there again after use. The loading and unloading of tools must generally take place via the control side "tool management"; after the control panel entries are completed, the operator will be asked to place the selected tool into the defined magazine location or to remove it from a certain magazine panel.

All tools in the tool magazine must be properly registered in the machine control. A manual new placement, adding or removal of tools without the support of the control's tool management, can lead to collisions between tools and machine or device parts. Furthermore, there is a danger of injuries for the employees caused by blown off / broken parts.

With multi-spindle machines, you must ensure that the same tools are in the same tool locations. By using different tools on the work spindles, there is a danger of damages to the tool, the workpiece and the tensioning device, as only one tool is defined per magazine location in the tool management and only one can be corrected.

Depending on the machine type, the magazine loading is conducted via the operator station or via the magazine loading station, which is located on the left long side of the machine.


______________________________________________________________________________ 03G11AGB


Tool magazine BAS03-11 (operator position) Magazine loading station (BAS03-x2) Left machine side

Magazine control panel

Tool magazine / magazine doors

Workroom

Magazine door

Control panel

Workroom door

Safety switch tool magazine


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.3.5 Teleservice (Option) The Siemens control 840D with PCU50 has a standard serial ethernet connection to communicate with data networks. This connection allows the exchange of data and events (together with the software from the „ePS-Network“) between the customer and the "Schwäbische Werkzeugmaschinen GmbH" via the world wide web (internet) = (teleservice). Here, the internet server of ePS is used as a continuously available communication manager. Prerequisite: • When taking the machine into operation, an internet access was created via the ethernet

connection of the control. • The release for common use of the ePS network was realised via "SW". Process:

Step 1 Starting with the Siemens basic menu and by pressing the extension ">" - select the soft key "ePS network". For safety reasons, there will always be an access authorisation check with every login. Step 2 Now start the ePS Network Services by pressing the soft key "online services". The function of the soft key video is described in the following under "login instructions". Step 3 Now enter your access data on the login page and press the soft key "OK". You will receive the access data by the responsible service organisation. If you enter false information three times, your access will be denied for safety reasons. To unblock your access, you must contact the respective eP dynamic administrator. Further information regarding the "ePS network" can be found in the appendix to this chapter 11.


______________________________________________________________________________ 03G11AGB



______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.4 HMI masks Starting with the Siemens basic menu, you will transfer to the HMI area by pressing the horizontal soft key (HSK) "HMI".

The horizontal soft keys of the HMI masks feature two lines. Main menus are listed on the bottom line, the respective selections for the main menus are pictured above, in the first line. Depending on the setup level of the machine/control, only certain menus or menu paths are displayed. Standard assignment Horizontal Soft Keys:“

HSK 1 Operating area "SW" HSK 2 Operating area "Preparation" HSK 3 Operating area "Manual operation" HSK 4 Operating area "Processing" HSK 5 Operating area "Diagnosis" HSK 8 Operating area "Documentation"

You can use the Help key to retrieve descriptions and help for the different masks.

WERKZBR


______________________________________________________________________________ 03G11AGB


11.4.1 SW

11.4.1.1 Tool breakage

WERKZBR

Selection: ☞ ☞ "HMI" ☞ "SW" ☞ "Tool breakage" A prerequisite for the use of the mask is the expansion of the machine by an external tool breakage monitoring system. After a tool breakage message via the external monitoring system, the processing programme is automatically interrupted by "NC STOP" and the tool breakage mask is displayed on the control panel display. The message must be acknowledged by means of the vertical soft keys. Function keys:

Tool Ok. The control receives the signal that the message "tool breakage" is an erroneous alarm and can be ignored. The automatic processing can be restarted via "NC START".

Tool broken The tool breakage is acknowledged.

The processing programme should be interrupted and the damaged tool should be replaced. If the process is continued by pressing "NC START" without eliminating the error, the spindle tool will be marked as "invalid" by the control.


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.4.1.2 Machine

11.4.1.2.1 NC programme This mask is used to assign NC programmes and table releases to the work tables for production.

NCPROG

Selection: ☞ ☞ "HMI" ☞ "SW" ☞ "machine" ☞ "NC Prog" VSK 2 "Assign programme"; a new mask will open (see following page). VSK 3 "Delete programme"; causes the deletion of the programme assignment for the

displayed table. The entry for the directory and the programme path will be "without assignment" after the deletion.

VSK 4 Changing the "table release"; with deactivated table release, the programme

assignment is invalid. The CNC programme for this table/area is not executed. VSK 7 "Switch table"; display switching between table 1 and table 2.


______________________________________________________________________________ 03G11AGB


11.4.1.2.2 Assigning NC programmes

This mask lists the NC programmes present on the control. Pressing the respective keys will transfer or terminate the programme assignment.

NCPR_EG

Selection: ☞ ☞ "HMI" ☞ "SW" ☞ "Maschine" ☞ "NC Prog" ☞ "assign programme" Function keys:

VSK 6 Terminating the input VSK 7 Transfer the entered data.


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.4.1.2.3 Machine control panel In addition to the mechanical key switches, certain user functions can be switched on/off via this menu. The consideration of protective levels/authorisations to change individual functions can be saved in the control.

MSTT

Selection: ☞ ☞ "HMI" ☞ "SW" ☞ "Maschine" ☞ Key switch ☞ MSTT"

You can page up and down using the keys "PageUp" and "PageDown". The selection of the desired function is made via two arrow keys. The listed functions have two switch positions (ON/OFF). Effective functions (ON) are marked in green.

Function keys: VSK 1 The switch position is changed via this key.


______________________________________________________________________________ 03G11AGB



______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.4.2 Preparation

11.4.2.1 Type preselection The selection of all workpiece types, which can be processed on the entire system, are shown in the workpiece type list in the left large window.

TYPVORW

Selection: ☞ ☞ "HMI" ☞ "Preparation" ☞ "Type preselection"

The tensioning devices on the workpiece carriers are assigned tension layers. A max. of 8 tension layers are possible on one table. Each tension layer on table 1 or table 2 can be assigned its own workpiece type.

Without this assignment, the workpiece counting will not work!

Select the desired workpiece type using the cursor key and enter the table and tension layer number in the input field for the respective workpiece type. The

selected type is transferred to the input field with the key "to the right".

Input: Table numbers values 1 to 2 are permitted Tension layer numbers values 1 to 8 are permitted

After an entry, the soft key‚+’ must be pressed to assign the workpiece to the

corresponding table and the respective tension layer. With the soft key‚-’ this assignment can be reversed.

The tension layers with their assigned workpiece types are listed in the mask "process tension layer".


______________________________________________________________________________ 03G11AGB


11.4.2.2 Adjustment The following masks show the adjustments for the lubrication times and the chip conveyor.

11.4.2.2.1 Lubrication The setup interval times for spindle lubrication and central lubrication as well as the counter status are displayed. Changes to the factory defined values are not possible in this mask.

EIN_SCHM

Selection: ☞ ☞ "HMI" ☞ "Preparation" ☞ "Adjustment" Function keys:

Lubrication Operating area "lubricating spindles and central lubrication"

(preset) The counter value shows the remaining time until a new

lubrication pulse is initiated (in seconds) and is constantly updated. When "0" is reached, a lubricating pulse is initiated and the counter status will restart at the preset adjustment value.

Chip conveyor Operating range "chip conveyor".


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.4.2.2.2 Chip conveyor / input The selected run and stop times are displayed that the chip conveyor processes periodically after it has been switchd on. The remaining time until the change into the other operating mode (ON/OFF) is constantly updated and shown as a counter display.

EIN_SPAE

Selection: ☞ ☞ "HMI" ☞ "Preparation" ☞ "Adjustment"

The run and stop times are entered in seconds (0 ...9998 /9999) via the keyboard;

Run time = 0 no run Stop time = 0 no stop, continuous run with run time >0

The yellow Siemens input key transfers the values into the display.

Function keys:

Lubrication operating area "lubricating spindles and central lubrication"

(preset) Chip conveyor Operating range "chip conveyor".


______________________________________________________________________________ 03G11AGB


11.4.3 Manual operation Different functions can be selected via the mask "manual operation", in which "individual movements" can be executed. The current signals/statuses of the changeable units are displayed. The use of individual movements (dividing automatic process sequences into several individual sections) is only necessary if extraordinary movements (such as for the setup of the machine, devices or additional units) or service work must be performed. A prerequisite for the "individual movement" is the release of the "cursor keys".

The use of the "individual movement" is only permitted for authorised skilled personnel. Contrary to sequences stored in the machine control, no monitoring functions are effective when using the "individual movement".

When retrieving individual movements - certain operating sequences must be adhered to depending on the design conditions. Otherwise, there is a danger of collisions and movement sequences, which may cause damage to the equipment and property assets all the way to life-threatening injuries of employees..


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.4.3.1 Individual movement of tool changer After selection, certain signals/conditions of the tool changing system will displayed. Two-spindle machines have a two-column display; spindle 1 and spindle 2. Set commands generally apply to both spindles. Spindle-independent (common) signals are shown in single columns.

WKZBW1

Selection: ☞ ☞ "HMI" ☞ "manual operation" ☞ "WKZW EZB" The signal conditions are distinguished by coloured markings: Signal OK / normal background grey, font colour black Signal disturbed background red, font color white With multi-page menus, the previous or subsequent pages are displayed by paging

through them using (Page up / down).

An identical status for the return messages of the two adjustment possiblities of a movement unit (e.g. top and bottom, tensioned and released, front and back) is not realistic and indicates that there is a malfunction (pair monitoring).

To use the special operating mode "individual movement", the lateral soft keys (cursor keys) in the mask "machine control panel" must be released via the function "INDIVIDUAL MOVEMENT".


______________________________________________________________________________ 03G11AGB


11.4.3.2 Individual movement tensioning device, table 1 Depending on the customer's equipment, the signals of the tensioning device (separated into table 1 and table 2) as well as the possible individual movements are displayed.

EZBW_VS1

Selection: ☞ ☞ "HMI" ☞ "manual operation" ☞ "SV EZBT1" (or SV EZBT2) The operation takes place in the same way as with the "individual movement of tool changer"


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.4.4 Processing

11.4.4.1 Tension layer

SPANNLAG

Selection: ☞ ☞ "HMI" ☞ "Processing" ☞ "tension layer" The tensioning devices on the workpiece carriers are assigned tension layers. A max. of 8 tension layers are possible on one table.

Table here, you will find the descriptors for tables TI_1 (table_1) and TI_2 (table_2).

Tension layer contains the numbering of the tension layers (1..8) for table_1 and (1..8) for table_2.

Quantity the number of workpieces per tension layer is displayed here. OK (in order) shows whether the parts were processed properly. vorh. (existing) displays whether there are parts in the tension layer. beab. (processed) displays whether the parts in the respective tension

layer have been processed. Workpiece shows the current workpiece types.

Each tension layer on table 1 or table 2 can be assigned its own workpiece type in the mask type preselection.

Entries: Select the desired workpiece type using the cursor key and enter the table and tension layer number in the input field for the respective workpiece type. Enter the number of workpieces per tension layer into the quantity column! This value is used as an increment during the workpiece counting! Without this assignment, the workpiece counting will not work!


______________________________________________________________________________ 03G11AGB


11.4.5 Diagnosis

11.4.5.1 Carrier round table

TR_RUNDT

Selection: ☞ ☞ "HMI" ☞ "Diagnosis" ☞ "carrier round" In this mask, the status of the carrier round table (raised or lowered) and the table position (0 or 180 degrees) is displayed.


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.4.6 Documentation

11.4.6.1 Workpiece counter For all workpiece types together, as well as separately for every workpiece type, there is a total, a daily and a shift counter. Each counter captures the total number of processed parts, the number of the correct (IO = OK) and the incorrect (NIO = not OK) parts at the output belt of the entire machine.

WERK_ZAE

Selection: ☞ ☞ "HMI" ☞ "Documentation" ☞ "Workpiece counter"

The counter field can be selected using the arrow keys to the left and right Function keys:

This key can be used to reset the counter.

Function not used


______________________________________________________________________________ 03G11AGB



______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.5 SW masks / expansions

11.5.1 Loading axles / setup positions The mask offers the possibility to define customer-specific positions (basic position, loading position with and without robot, rinse position, etc.) for each round axle of the work tables. The determination can be defined differently for each saved device programme (see "device selection"). By pressing the "round axle" keys on the "loading control panel" as well as during the automatic series process - depending on the programmed loading cycles - the work table and/or its additional axles are positioned in their indicated positions in the loading room.

Example illustration

BELAD_A

Selection: Operating mode "AUTO" ☞ ☞ ☞ "machine" ☞ "loading axles"

Select the desired table area (A/U) via the soft keys. Depending on the selected device, the values for the used setup positions are displayed. The designation "ABL1_" refers to the first device programme; ABL2_ to the second, ABL3_ to the third, and so forth.

You can switch between the input fields via the arrow keys (cursor keys); additional explanations will be displayed in the header line. Values can be changed via the keyboard.

The displayed input fields depend on the machine equipment and the customer requirements.


______________________________________________________________________________ 03G11AGB


Example: Setup positions

ABL1_A_POS1 A axle, basic position 1, (degrees) ABL1_A_POS2 A axle, basic position 2, (degrees) ABL1_A_ROBPOS1 A axle, basic position 1 with robot ON, (degrees) (with robot OFF, POS1 is used) ABL1_C1_POS1 C1 axle, basic position 1, (degrees)

ABL1_xx_INK xx axle, angle value for "rotate round axle"; can be predetermined for table and/or additional axle (A, U, C, W)

ABL1_U_ARBPOS1 U axle, preset for work position (degrees) (Prepositioning for more rapid work start after swivelling)

When using "loading cycles", the saved positions must be considered with regard to the selected device.


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.5.2 Selecting the device The application-specific device programmes are selected via the mask. The programmes contain command sequences, which will replace the superfluous manual operator actions during loading/unloading with automatic sequences with an optimised serial production.

Vor_Anw

Selection: "Machine" ☞ " " ☞ "SW GmbH" ☞ "device selection x" Up to 8 device programmes with the respective setup positions for loading axles

can be selected via the mask (also see "loading axles/setup positions" and "loading cycles")

By selecting these, saved command sequences (e.g. drive to setup position, rinse device, open door, open device, etc.) are executed following CNC processing when the device is located in the loading room.

The activation/deactivation of a device only becomes effective by the next "NCK POWER ON" or with the next "CONTROL ON".

You can switch between the input fields (nominal) via the

arrow keys (cursor keys). The select key is used to activate/deactivate the device. (The device programme is saved in the PLC)

If necessary, every device programme can be marked with a

designation; entries are transferred via "input".


______________________________________________________________________________ 03G11AGB



______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.6 Tool and magazine masks (Siemens)

Access takes place - from the Siemens basic menu - by selecting the horizontal soft key "PARAMETER". The interface shown next can be used to retrieve different lists and changes can be made to tools, tool data and the magazine assignment; see Siemens operating and programming documentation.

see Siemens operating and programming documentation

EPS_01

MAGL_1


______________________________________________________________________________ 03G11AGB



______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.7 Control tips, tables, lists

11.7.1 BAG's and channels The Siemens control has the ability to execute independent operating and control tasks as if multiple independent controls were used simultaneously. For this, the control is subdivided into several operating mode groups by the machine manufacturer (so-called BAG's), which may have their own self-contained work channels.

BAG, channels

The SW two-station processing centres use exclusively BAG 1 with one channel:

BAG 1, channel 1 for NC-programmes/applications


______________________________________________________________________________ 03G11AGB


11.7.2 Coordinate system/axle designations/drive distances The coordinate system used complies with DIN 66217.

X1 = horizontal, transverse to the operator position, to the left = minus, to the right = plus. X1 = horizontal, lengthwise to the operator position, forward = plus, backwards = minus. Y2 = Gantry axle to Y1 Z1 = vertical axle, up = plus, down = minus SPIND_1 = work or tool spindle, tool rotation, to the right = plus, to the left = minus SPIND_2 = work or tool spindle, tool rotation, to the right = plus, to the left = minus MAGAZINE = tool magazine; magazine location increasingn = plus Q = swivel support (only with 2-station machines) A / U = swivel table (U only for 2-station machines) C.. / W.. = planets on swivel table A/U (option)


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.7.3 Special functions / BAS03

11.7.3.1 Error messages If a control error occurs, its error number and a brief text will be shown on the operator control display.

By pressing the key INFO/HELP, you will switch to the machine control's online help system. The display "i" in the dialog line points out this possiblity.

11.7.3.2 M functions / overview

Code Description BAS 03 (09/07)

M 00 Stop M 01 like M 00, but selectable M 02 Programme end M 03 Right rotating spindle M 04 Left rotating spindle M 05 Stop spindle M 06 Tool change M 07 Coolant 2 ON (inner cooling) *see H function Option M 08 Coolant 1 ON (exterior cooling) Option M 09 Coolant 1 +2 OFF Option M 10 Clamping ON (monitoring ON)/axle: A / U M 11 Clamping OFF (monitoring OFF)/axle: A / U M 12 Open clamping until the end of next drive command A /U Option M 13 Clamping ON (monitoring ON)/axle: C C2 / W W2 M 14 Clamping OFF (monitoring OFF)/axle: C C2 / W W2 M 15 Open clamping until the end of next drive command C C2/W W2 Option M 16 M 17 Subprogramme end M 18 M 19 Adjust spindle M 20 M 21 Tension circuit / device 1 open Option M 22 Tension circuit / device 2 open Option M 23 Tension circuit / device 3 open Option M 24 Tension circuit / device 4 open Option M 25 M 29 Rapid gear limit 30%: OFF M30 Programme end M 31 Tension circuit / device 1 tension Option M 32 Tension circuit / device 2 tension Option M 33 Tension circuit / device 3 tension Option M 34 Tension circuit / device 4 tension Option M 35 M function 1 with external return (advance and reading stop) Option M 36 M function 1 with external return (advance and reading stop) Option M 37 M function 1 with external return (advance and reading stop) Option


______________________________________________________________________________ 03G11AGB


M 38 M function 1 with external return (advance and reading stop) Option M 39 Rapid gear limit 30%: ON M 40 Deletion position M 41 / M 42 (reserved system) impossible M 41 Main spindle star operation (reserved system) impossible M 42 Main spindle triangle operation (reserved system) impossible M 43 reserved system M 44 reserved system M 45 reserved system M 46 Tension hydraulics circuit 1 Option M 47 Tension hydraulics high-pressure circuit 1 Option M 48 Tension hydraulics low pressure circuit 2 Option M 49 Tension hydraulics high-pressure circuit 2 Option M 50 Tension hydraulics low pressure circuit 3 Option M 51 Tension hydraulics high-pressure circuit 3 Option M 52 Tension hydraulics low pressure circuit 4 Option M 53 Tension hydraulics high-pressure circuit 4 Option M 54 M 55 used M 56 Open tool magazine cover (premature) M 57 Flow monitor OFF until tool change IK (M7) Option M 58 Flow monitor OFF until tool change AK (M8) Option M 59 Pressure monitor OFF until tool change IK (M7) M 60 Measuring key 2 ON (door open, if available) M 61 Measuring key ON (door open, if available) Option M 62 Rinse bed ON Magazine sheet

metal M 63 Rinse shutter ON Option M 64 M 65 Blockage air angle drill head ON Option M 66 Blockage air angle drill head OFF Option M 67 Device rinse ON workroom Option M 68 M 69 Device rinse OFF workroom Option M 70 reserved system M 71 All measuring keys OFF (door open, if available) Option M 72 Rinsing OFF Magazine sheet

metal M 73 Minimum volume lubrication ON Option M 74 Minimum volume lubrication OFF Option M 75 ARTIS monitoring ON Option M 76 ARTIS: Monitoring OFF Option M 77 ARTIS: Monitoring only ON with G 01 Option M 78 ARTIS: Oscillation monitoring ON Option M 79 ARTIS: Oscillation monitoring OFF Option M 80 Tool breakage control: ON/test M 81 Tool breakage control: Measuring 1 M 82 Tool breakage control: Measuring 2 M 83 Device rinse start, when table is on loading side Option M 84 reserved EPS M 85 Part finished processing Option M 86 Start loading/unloading robot impossible


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


M 87 Increment workpiece counter Option M 88 Close cover 1-station M 89 Open cover (depending on Y position) 1-station M 90 Loading door open 1-station M 91 Open workpiece grabber 1 Option M 92 Open workpiece grabber 2 Option M 93 Close workpiece grabber 1 Option M 94 Close workpiece grabber 2 M 95 Adaptive regulation ON M 96 Adaptive regulation OFF M 97 Coolant pumps ON Option M 98 Home cycle end M 99 Safe programme end M 100 Ensure H function M122 Rinse valve loading side ON (channel 2 only) impossible M123 Rinse valve loading side OFF (channel 2 only) impossible M125 Open loading door (channel 2 only) impossible M126 Close loading door (channel 2 only) impossible M140 Set equipping acknowledgment (channel 2 only) impossible M150 Start: Release, total (channel 2 only) see M60= impossible M152 Finished message: Tensioned, total (channel 2 only) see M63= impossible M156 ERV ON M158 ERV OFF M160 Message output: Loading axle not in release position impossible M186 PREStart robot

11.7.3.3 H functions

Code Description BAS 03 H 01 ASI-Bus H1=1 ... H1=100 possible in steps % Option H 02 Programme number on ext. device (Telesis / Roboter / .. Option H 03 Prop value 1 tensioning device (standardisation in bar) Option H 04 Prop value 2 tensioning device (standardisation in bar) Option H 05 MDE-BDE - INTERFACE


______________________________________________________________________________ 03G11AGB


11.7.3.4 Extended M functions

Code Description BAS 03 M 2 = 3 Right rotating spindle2 M 2 = 4 Left rotating spindle2 M 2 = 5 Stop spindle2 M 3 = 3 Right rotating spindle 3 M 3 = 4 Left rotating spindle 3 M 3 = 5 Stop spindle 3 M 4 = 3 Right rotating spindle 4 M 4 = 4 Left rotating spindle 4 M 4 = 5 Stop spindle 4

11.7.3.5 L functions

Code Description BAS 03 L 6 Tool change with free drive / BA03: with T0 without free drive L 20 Query swivel table in position impossible L 21 Query axle name round axles (A/U) possible L 23 Query current table possible L 29 Thread coupling ON possible L 30 Thread coupling OFF possible

L6 parameter; syntax: L6(a, b,c) a = transfer speed after tool change b = rotation direction after tool change; 3 = right, 4 = left c = *Plan system control; 0 = OFF; 1 = ON (*plan system control is an optional machine feature)

11.7.3.6 G commands

The G commands are listed in the original machine documentation issued by the control manufacturer (programming guide).


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.8 Programming / examples

11.8.1 Clamping of round axles Work table(s) as well as added planets are fashioned as NC round axles.

If the movement capability (interpolation) of the round axles is not needed during a process, these must be clamped.

This clamping can be executed with or without monitoring and also in connection with "reading stop". Depending on the software status of the control, the newer models include clamping sequences which used to have to be activated/selected via M functions in the previous software versions.

11.8.1.1 Round axles from NCK status 6.4

11.8.1.1.1 G1 standard (without round axle interpolation) The M functions M10, M11, M12 or M13, M14, M15 are no longer needed because the round axles are clamped and monitored automatically. (Processing interpolation "G1" between the main and round axles is thus blocked.)

If the automatic clamping/monitoring of the round axles is active, an error message will be generated with "G1 + interpolation of main and round axles".

Rapid gear (G0) will be executed automatically and time-optimised with the interpolation of the main and round axles. With G64 (track control operation), the clamping for a later drive command is opened prematurely (up to 2 G0 sets earlier). The G0 movements of the main axles are driven without round axle clamping; after G1, the clamping, monitoring as well as the further processing will take place. Example: Comment G0 G64 Z-200 X-300 A=0 G64 is mandatory Z-50 Clamping of A will be opened prematurely X-200 A=90 Z-200 clamping A will close automatically G1 F2000 X-220 advance = 0% until A is clamped M30


______________________________________________________________________________ 03G11AGB


11.8.1.1.2 G1 with 4 or 5 axle interpolation If the G1 interpolation of main and round axles is required for a process, this interpolation opportunity must be released via a PLC-MD (machine date).

The automatic clamping/monitoring of the round axles is no longer effective, after the G1 interpolation of main and round axles has been released.

For a processing without moving round axles, the respective clamping/monitoring must be switched on via the following M functions A- / U axle C- / W axle Function M 10 (default)

M 13 (default)

Clamping is closed and monitored. During the function execution a "reading stop" applies. A set change is prevented until the return message of the clamping has taken place. (Reset by Reset / M30)

M 11 M 14 The clamping is permanently open. (Serves i.e. for the interpolation between the 4th axle and the main axles - or to process items that do not require clamping).


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.8.1.1.3 Programming of A or U axle parallel to the tool change.

DO POS [U]=DC (180) FA[U]=36000 Txy L6

Load GUD variable with position value of the axle (e.g.180°) Start axle Retrieve tool xy Conduct tool change

11.8.1.1.4 Axle-neutral programming of the round axles A or U

N30 L21(_AU,_CW,_CW2) N20 L23(_ATISCH) DO POS [_AU]=DC(0) FA[_AU]=10000 DO POS [_CW]=DC(180) FA[_CW]=10000 DO POS [_CW2]=DC(180) FA[_CW2]=10000 N180 T1 N190 M6 N250 g0 g54 g95 AX[_AU]=DC(0) AX[_CW]=DC(180) AX[_CW2]=DC(180) S2000 M3 N320 G1...

if present if present IMPORTANT: Check round axle position Processing


______________________________________________________________________________ 03G11AGB


11.9 Appendix / Option Significant variations from the serial model due to special customer requirements are listed in the following or attached.

11.10 ePS network manufacturer's documentation

11.11 Groove cycle


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.11.1 Groove cycle (option) The groove cycle is a factory programme extension and is used to manufacture radial grooves (grooves) in connection with special tools. The processing sequence "circular interpolation" can be compared to a lathe, in spite of the "fixed workpiece". Two semi-circle tracks are created with the tool spindle by interpolating X and Y advance. At the same time, the tool is turned by a coupled spindle speed so that the tool blade always has the same angle (orthogonal) to the circular track. A chip removal (advance of the tool blade) is created (like with a lathe) when the interpolated circular track is continuously changed with regard to the radius and the tool blade enters the workpiece in a spiral fashion. Depending on the tool and the used parameters, interior and exterior grooves can be created. The workpiece/groove parameters and blade data with regard to the radial conditions are defined via the following masks. The cycle retrieval takes place in the CNC programme by "groove" [groove number (1...8)], [tool number (1...8)] and controls the automatic creation of the groove - depending on the saved values. Prerequisite:

• Tool blade is aligned to 3 o'clock in the tool pickup (looking at the tool; when viewing from the tool spindle, the blade will be positioned at 9 o'clock)

• Tool type and length were properly saved in the tool administration during tool loading (e.g. special tool 900).

• Tool was replaced in the tool spindle prior to cycle retrieval

• Groove position was addressed prior to cycle retrieval via the CNC programme


______________________________________________________________________________ 03G11AGB


11.11.1.1 Inner groove

11.11.1.1.1 Entering workpiece parameters (Mask can only be selected in operating mode "JOG")

INZIRK

Selection: Operating mode JOG ☞ ☞ ☞ "machine" ☞ "circulate" ☞ "circulate on inside" Function keys:

HSK1 Mask groove tool / tool parameter HSK2 circulate on the outside / circulate on the inside VSK1/2 Paging groove + / groove - VSK7 Transferring the changed values VSK8 Reading back the most recently saved values

Entries: If the input limits are exceeded or not reached, a message is displayed in the bottom status line.

N NUT Count number 1-8; max. 8 different grooves can be defined D_BOHR drilling diameter / opening in the workpiece, via which the

tool will arrive at the groove position without collision. D_EINST nominal diameter of the groove (indicated value = drawing

dimension)


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


D_KORR correction value for nominal diameter; e.g. to balance tool displacement (with long shaft), tool wear or tolerances.

V_SCHRUPP Roughing speed (interpolation torque = circular track speed of the blade)

AP_SR assignment of roughing; advance or chip depth per circular

track (360 °) U_ENTSPAN factor for cut interruption / empty cut. Depending on the blade advance, the machine will need a

certain number of circular movements/rotations until the required groove depth has been reached. This value is calculated internally. The factor "U_ENTSPAN" subdivides the calculated numbers of rotations and results in a (rounded) rotation limit value. Everytime this limit value is reached, a rotation without advance is executed to release.

Example: U_ENTSPAN = 3, required rotations = 120. Therefore, 120 / 3 = 40; after every 40 roations, an empty step is performed.

U_UEBERG Number of rotations for speed adaptation between

V_SCHRUPP and V_FERTIG Inertia, drive system and mechanical circumstances can

lead to a change in diameter of the blade track (groove depth) in case of abrupt changes in the track speed (circular interpolation) and thus destroy the blade.

The numeric value "U_UEBERG" indicates how many circular tracks are available to the control in order to perform the speed change.

Example: U_UEBERG = 4; V_SCHRUPP = 8000mm/min, V_FERTIG = 1000 mm/min. The acceleration/delay is selected on the control so that the new web speed (1000 mm/min) is achieved after four rotations.

V_SCHLICHT Smoothing speed (interpolation speed = circular web speed

of the blade); also see "T_SCHLICHT" AP_SL assignment of smoothing; advance or chip depth per circular

track (360 °) T_SCHLICHT Material difference to the groove diameter (D_EINST), which

is chipped by smoothing. (With "0", only roughing takes place during the processing)


______________________________________________________________________________ 03G11AGB


X_OSZ Distance for the oscillating centre point migration; serves for

chip removal - depending on the material properties - or for the clearing during roughing. This value must not exceed 70% of "AP_SR".

U_OSZ Number of oscillation movements per circular web U_FERTIG Number of rotations for final lathing. The numeric value "U_FERTIG" determines how many

circular webs the tool blade will execute after the nominal diameter has been reached (D_EINST) in order to form the groove.

V_FERTIG Finished rotated speed (interpolation speed = circular web

speed of the blade), which is used to form the groove after the nominal diameter (D_EINST) has been reached.

V_Z Driving out speed (interpolation speed = circular web speed

of the blade) that is used to exit the groove. AP_Z assignment of driving out; advance or chip depth per circular

track (360 °) Is used in connection with "V_Z" to create a smoothing surface with a shallow rough depth on the groove flanks when "driving out".

U_ABH Number of rotations for speed adaptation to drive out speed

"V_Z" The numeric value "U_ABH" indicates how many circular

tracks are available to the control in order to reach the drive out speed.

X_KORR Correction dimension of the X axle to balance the centre

point migrations of the blade trajectory Y_KORR Correction dimension of the Y axle to balance the centre

point migrations of the blade trajectory L_LAENGS Distance difference/drive path to widen the groove (= groove

width minus blade width) or to create a contour AP_LAENGS Axial advance per circular web (360°) to widen the groove or

to create a contour V_LAENGS Cutting speed (interpolation speed = circular web speed of

the blade)


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.11.1.1.2 Input of tool parameters (Mask can only be selected in operating mode "JOG")

INZIRK_W

Selection: Operating mode JOG ☞ ☞ ☞ "machine" ☞ "circulate" ☞ "xxx circulation" ☞ insertion tool

Function keys: HSK1 mask workpiece / groove parameter VSK1/2 Paging tool number + / - VSK7 Transferring the changed values VSK8 Reading back the most recently saved values


WZ_NR Count number 1-8; max. 8 different tools (tool sets) can be defined

W_SCHN1 Positioning angle of blade in spindle 1; viewed from the tool spindle, the tool blade should be aligned with 9 o'clock. An entered angle value causes a turning counter clockwise.

W_SCHN2 Positioning angle of blade in spindle 2; see above W_SCHN3 Positioning angle of blade in spindle 3; see above W_SCHN4 Positioning angle of blade in spindle 4; see above With 2-spindle machines, the value -1 (not present) must be entered into W_SCHN3 and W_SCHN4!

WZ_RADIUS tool radius; distance between the rotating point and the blade tip

PKD_TIEFE Blade depth; is max. groove depth.


______________________________________________________________________________ 03G11AGB


11.11.1.1.3 Adjustments for interior circulation Variable Name Minimum value Maximum value

N_NUT [No.] Groove number 1 8

D_BOHR [mm] Drill diameter 20

D_EINST [mm] Groove diameter 21

D_KORR [mm] Correction measure of groove

V_SCHRUPP [mm/min] Max. roughing speed 1

AP_SR [mm] Assignment of roughing 0.001

U_ENTSPAN [n] Number of release cycles 0

U_UEBERG [n] Number of transitions 0 5

V_SCHLICHT [mm/min] Advance for smoothing 1

AP_SL [mm] Assignment for smoothing 0.001

T_SCHLICHT [mm] Smoothing measure

X_OSZ [mm] Withdrawal with oscillation 0

U_OSZ [n] Number of oscillations 0 4

U_FERTIG [n] Rotations during finishing rotation 0 10

V_FERTIG [mm/min] Advance for finished rotation 1000 2000

V_Z [mm/min] Maximum drive out speed 1000 50000

AP_Z [mm] Assignment for driving out 0.001

U_ABH [n] Slowly lift off rotations 1 4

X_KORR [mm] Correction measure X axle -0.1 0.1

Y_KORR [mm] Correction measure Y axle -0.1 0.1

L_LAENGS [mm] Longitudinal rotation incremental Z axle

AP_LAENGS [mm] Assignment longitudinal rotation of Z axle -0.25 0.25

V_LAENGS [mm/min] Advance longitudinal rotation of Z axle 1000 10000

WZ_NR [No.] Groove tool number 1 8

W_SCHN1 [degrees] Positioning angle blade spindle_1 -1 360




WZ_RADIUS [mm] Tool radius 10

PKD_TIEFE [mm] Blade depth 1 5


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.11.1.2 Outer groove

11.11.1.2.1 Entering workpiece parameters (Mask can only be selected in operating mode "JOG")

AUZIRK

Selection: Operating mode JOG ☞ ☞ ☞ "machine" ☞ "circulate" ☞ "outer circulation"

Function keys:

HSK1 Mask groove tool / tool parameter HSK2 circulate on the inside / circulate on the inside VSK1/2 Paging groove + / groove - VSK7 Transferring the changed values VSK8 Reading back the most recently saved values


N NUT Count number 1-8; max. 8 different grooves can be defined D_AUSSEN outer diameter / bolt diameter, via which the tool will arrive at

the groove position without collision D_EINST nominal diameter of the groove (indicated value = drawing

dimension)


______________________________________________________________________________ 03G11AGB


D_KORR correction value for nominal diameter; e.g. to balance tool displacement (with long shaft), tool wear or tolerances.

V_SCHRUPP Roughing speed (interpolation torque = circular track speed of the blade)

AP_SR assignment of roughing; advance or chip depth per circular

track (360 °) U_ENTSPAN factor for cut interruption / empty cut. Depending on the blade advance, the machine will need a

certain number of circular movements/rotations until the required groove depth has been reached. This value is calculated internally. The factor "U_ENTSPAN" subdivides the calculated numbers of rotations and results in a (rounded) rotation limit value. Everytime this limit value is reached, a rotation without advance is executed to release.

Example: U_ENTSPAN = 3, required rotations = 120. Therefore, 120 / 3 = 40; after every 40 roations, an empty step is performed.

U_UEBERG Number of rotations for speed adaptation between

V_SCHRUPP and V_FERTIG Inertia, drive system and mechanical circumstances can

lead to a change in diameter of the blade track (groove depth) in case of abrupt changes in the track speed (circular interpolation) and thus destroy the blade.

The numeric value "U_UEBERG" indicates how many circular tracks are available to the control in order to perform the speed change.

Example: U_UEBERG = 4; V_SCHRUPP = 8000mm/min, V_FERTIG = 1000 mm/min. The acceleration/delay is selected on the control so that the new web speed (1000 mm/min) is achieved after four rotations.

V_SCHLICHT Smoothing speed (interpolation speed = circular web speed

of the blade); also see "T_SCHLICHT" AP_SL assignment of smoothing; advance or chip depth per circular

track (360 °) T_SCHLICHT Material difference to the groove diameter (D_EINST), which

is chipped by smoothing. (With "0", only roughing takes place during the processing)


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


X_OSZ Distance for the oscillating centre point migration; serves for

chip removal - depending on the material properties - or for the clearing during roughing. This value must not exceed 70% of "AP_SR".

U_OSZ Number of oscillation movements per circular web U_FERTIG Number of rotations for final lathing. The numeric value "U_FERTIG" determines how many

circular webs the tool blade will execute after the nominal diameter has been reached (D_EINST) in order to form the groove.

V_FERTIG Finished rotated speed (interpolation speed = circular web

speed of the blade), which is used to form the groove after the nominal diameter (D_EINST) has been reached.

V_Z Driving out speed (interpolation speed = circular web speed

of the blade) that is used to exit the groove. AP_Z assignment of driving out; advance or chip depth per circular

track (360 °) Is used in connection with "V_Z" to create a smoothing surface with a shallow rough depth on the groove flanks when "driving out".

U_ABH Number of rotations for speed adaptation to drive out speed

"V_Z" The numeric value "U_ABH" indicates how many circular

tracks are available to the control in order to reach the drive out speed.

X_KORR Correction dimension of the X axle to balance the centre

point migrations of the blade trajectory Y_KORR Correction dimension of the Y axle to balance the centre

point migrations of the blade trajectory L_LAENGS Distance difference/drive path to widen the groove (= groove

width minus blade width) or to create a contour AP_LAENGS Axial advance per circular web (360°) to widen the groove or

to create a contour V_LAENGS Cutting speed (interpolation speed = circular web speed of

the blade)


______________________________________________________________________________ 03G11AGB


11.11.1.2.2 Input of tool parameters (Mask can only be selected in operating mode "JOG")

AUZIRK_W

Selection: Operating mode JOG ☞ ☞ ☞ "machine" ☞ "circulate" ☞ "xxx circulation" ☞ insertion tool

Function keys: HSK1 mask workpiece / groove parameter VSK1/2 Paging tool number + / - VSK7 Transferring the changed values VSK8 Reading back the most recently saved values


WZ_NR Count number 1-8; max. 8 different tools (tool sets) can be defined

W_SCHN1 Positioning angle of blade in spindle 1; viewed from the tool spindle, the tool blade should be aligned with 9 o'clock. An entered angle value causes a turning counter clockwise.

W_SCHN2 Positioning angle of blade in spindle 2; see above W_SCHN3 Positioning angle of blade in spindle 3; see above W_SCHN4 Positioning angle of blade in spindle 4; see above With 2-spindle machines, the value -1 (not present) must be entered into W_SCHN3 and W_SCHN4!

WZ_RADIUS tool radius; distance between the rotating point and the blade tip

PKD_TIEFE Blade depth; is max. groove depth


______________________________________________________________________________________________________________________________________________

______________________________________________________________________________ 03G11AGB


11.11.1.2.3 Adjustments for exterior circulation Variable Name Minimumvalue Maximumvalue

N_NUT [No.] Groove number 1 8

D_AUSSEN [mm] Bolt / exterior diameter 20

D_EINST [mm] Groove diameter 21

D_KORR [mm] Correction measure of groove

V_SCHRUPP [mm/min] Max. roughing speed 1

AP_SR [mm] Assignment of roughing 0,001

U_ENTSPAN [n] Number of release cycles 0

U_UEBERG [n] Number of transitions 0 5

V_SCHLICHT [mm/min] Advance for smoothing 1

AP_SL [mm] Assignment for smoothing 0,001

T_SCHLICHT [mm] Smoothing measure

X_OSZ [mm] Withdrawal with oscillation 0

U_OSZ [n] Number of oscillations 0 4

U_FERTIG [n] Rotations during finishing rotation 0 10

V_FERTIG [mm/min] Advance for finished rotation 1000 2000

V_Z [mm/min] Maximum drive out speed 1000 50000

AP_Z [mm] Assignment for driving out 0.001

U_ABH [n] Slowly lift off rotations 1 4

X_KORR [mm] Correction measure X axle -0.1 0.1

Y_KORR [mm] Correction measure Y axle -0.1 0.1

L_LAENGS [mm] Longitudinal rotation incremental Z axle

AP_LAENGS [mm] Assignment longitudinal rotation of Z axle -0.25 0.25

V_LAENGS [mm/min] Advance longitudinal rotation of Z axle 1000 10000

WZ_NR [No.] Groove tool number 1 8





WZ_RADIUS [mm] Tool radius 10

PKD_TIEFE [mm] Blade depth 1 5


______________________________________________________________________________ 03G11AGB



BAS03-12 / BAS03-22

______________________________________________________________________________________________________________________________________________

_______________________________________________________________________________________ A8012Agb

12.0 Upgrading 12-1

12 Upgrading

Table of Contents

12 UPGRADING 12-1


12.2 Loading with crane / handling systems 12-5 12.2.1 One station machines 12-5 12.2.2 Two station machines 12-6


_______________________________________________________________________________________ A8012Agb

12-2 12.0 Upgrading

12.1 Safety instructions Every person that is responsible for the transport, installation, operation, maintenance and supervision of the machines manufactured by "Schwäbische Werkzeugmaschinen GmbH“ as well as the master or department manager, under whose supervision the machine is erected, must have read and understood the chapter "General safety and accident prevention instructions“. Theother country-specific regulations and laws, which apply to special handling, must be observed as well and have priority over our instructions. A non-dangerous and flawless performance of activities and interventions is only warranted if special skills are present for these activities and if the information and instructions in our machine documentation as well as the components' instructions are taken into consideration. The cautionary measures required in the documentation of the "Schwäbische Werkzeugmaschinen GmbH“ do not claim to be complete and refer solely to the use of our products.


Prior to performing certain tasks, all relevant information as well as the special safety instructions in the respective machine documentation chapter must be observed.

The operator is responsible for the machine not being operated if safety systems (such as panel parts) are open, removed, bypassed or taken out of operation - life-threatening danger! Panel parts and cab sheet metal parts and switch cabinet doors are not monitored.


BAS03-12 / BAS03-22

______________________________________________________________________________________________________________________________________________

_______________________________________________________________________________________ A8012Agb

12.0 Upgrading 12-3

If the safety is breached, or if a situation is detected that might lead to a safety breach, the "EMERG OFF" key must be activated immediately.

Prior to beginning maintenance and repair procedures, the machine must be disconnect from the power supply and the pressure must be relieved; furthermore, the non-operational stastus of the machine must be reported by means of "Caution Signs".



and the system pressure may only be released after it has been ensured that this will not cause any uncontrollable mechanical reactions (snapping back of spring-loaded tensioning systems or cylinders in idle positions; dropping of tools; sliding off of advance and movement units by the lack of hydaulic weight balancing, etc.).

The refitting of workpieces, tools, tensioning devices and work procedures that were not designed for the respective machine, is prohibited; also prohibited are interventions that could cause direct or indirect hazards. In order to avoid damages caused by chips, etc. , we recommend cleaning the machine before upgrading it. Wear the required protective gear for cleaning and upgrading, e.g. protective gloves, safety shoes, protective eye goggles, etc.

Use transport help devices for the transport of large, heavy or bulky objects. The products to be transported must be secured against movement, tilting, rotating or swivelling of individual parts prior to and during transport. The respective measures must be taken to achieve this (observing the gravity center as well as securing with: positioning rings, chains, securing wooden wedges, screw connections, etc.). No do stand under suspended loads and avoid hazardous areas


_______________________________________________________________________________________ A8012Agb

12-4 12.0 Upgrading

Switched interventions to modify the hardware or software, as well as electrical and mechanical modifications of the machine's design may only be performed by service technicians of "Schwäbische Werkzeugmaschinen GmbH"; the information in the operating instructions is for informational purposes only. The operator/owner is liable for any damage caused by unauthorized intervention. The responsible party must be immediately informed of all modifications on the machine that may lead to safety-relevant issues. Upgrade procedures that require adjustments that is only possible while all systems are ready to operate or by removing or deactivating special safety equipment, must be monitored by responsible employees located near the "EMERG OFF" and "main switch" keys; if danger arises, the machine must be shut down.

After concluding the work, the unlimited operation readiness of the machine must be checked and confirmed by a responsible party appointed by the operator. This includes: • the proper fastening of all panel parts and protective equipment, • checking the proper installation of all parts, connections, etc. loosened or





BAS03-12 / BAS03-22

______________________________________________________________________________________________________________________________________________

_______________________________________________________________________________________ A8012Agb

12.0 Upgrading 12-5

12.2 Loading with crane / handling systems

12.2.1 One station machines One station machines (BAS03-x1) are generally equipped with an automatic roof sled. When opening the work room door - depending on the Y position of the work splindles - the roof area of the machine will also open and will thus allow unobstructed access to the work room (also for crane and handling systems). Depending on the Y position of the work spindle, the roof sled can take on three different positions. Y position Work spindle

Opening the work room door

Y = 0 to -399 mm (work room)

Roof area remains closed

Y = -400 mm (work room limit)

Roof area opens to centre position

Tool magazine change area (L36)

Roof area opens completely


_______________________________________________________________________________________ A8012Agb

12-6 12.0 Upgrading

12.2.2 Two station machines Two station machines (BAS03-x2) are equipped with a loading room and a work room. After opening the protective doors, the loading room can be accessed. If a crane loading process is required, the panel sheet metal can be removed in the roof area by opening the prefriction locks.


BAS03-xx

______________________________________________________________________________________________________________________________________________

_______________________________________________________________________________________ A8013Agb

13.0 Disposal 13-1

13 Disposal

Table of Contents

13 DISPOSAL 13-1


13.2 Disposal options 13-3


_______________________________________________________________________________________ A8013Agb

13-2 13.0 Disposal

13.1 Safety instructions

The machine, its contents and the packaging material must be disposed of in an environmentally friendly manner and as demanded by the current regulations.

Please observe the applicable environmental regulations as well as the requirements put into place by the labor association(s) and the material safety data sheets and the safety and accident prevention instructions in this operating manual! Please wear you personal protective gear, such as safety gloves, safety goggles and a respiratory protection, if needed.


BAS03-xx

______________________________________________________________________________________________________________________________________________

_______________________________________________________________________________________ A8013Agb

13.0 Disposal 13-3

13.2 Disposal options

The list below will show a selection of the materials contained in the machine and does not claim to be complete. Depending on the customer-specific equipment, changes and supplemental information might be required. Please get information on the contents of the machine by consulting the included external documentation.

Material

Disposal method Disposal key no. EWC

/ EAK -Code:

Aluminium components – free of oil

12 01 03

Lubricating oil (non-chlorinated)

13 02 xx

Please adhere to the enclosed data sheets and the data provided

Processing emulsions (free of halogens)

12 01 09

Please adhere to the enclosed data sheets and the data provided by the supplier!

Hydraulic oil 13 01 xx

Please adhere to the enclosed data sheets and the data provided by the supplier!!

Contents of oil/water separators

13 05 xx


Water return cooler Refrigerant R 134A

16 05 05


Antifreeze / corrosion protection TYFOCOR


Protective discs - polycarbonate

12 01 05

The indicated codes are not binding and refer to "pure substances". By mixing the substances (mixing leakage oil and cooling lubricant), these disposal key codes can change.


_______________________________________________________________________________________ A8013Agb

13-4 13.0 Disposal


BAS03-xx

______________________________________________________________________________________________________________________________________________

_______________________________________________________________________________________ A8014Agb

14.0 Fires 14-1

14 Fires

Table of Contents

14 FIRES 14-1

14.1 General Information on Fire Procedures 14-2

14.2 Opening the force locked protective doors when there is no power supplied to the machine14-3

14.3 Opening the safety separating window when there is no power supplied to the machine 14-4


_______________________________________________________________________________________ A8014Agb

14-2 14.0 Fires

14.1 General Information on Fire Procedures The machine is not designed for use in explosion or fire hazard environments.Furthermore, no materials, auxilairy materials, etc. should be used, which could cause fires or explosions if combined with other substances (see Chapter 0 "Intended use"). The machine design itself does not create any special dangers (overcurrent trigger, DIN standard cable cross sections, avoiding friction spots, inspection guidelines, etc.) from today's perspective. The machine contains: • Hydraulic oil • in the cooling system: the non-chlorinated refrigerant

R134a • Cooling lubricant • Lubricants

Based on the safety concept, the closed protective doors remain closed when the machine is not powered.

• The protective doors in the work room or the loading room also offer resistance

against exterior attempted access.

• In case of a fire, the power supply to the machine must be interrupted. Extinguishing attempts into the work room from the front are difficult due to the locked protective door; but the protective doors can be opened manually (see next chapter).

• With critical materials and processes, we recommend using a fire extinguishing system.

When fighting a fire, you must wear a respiratory mask with independent air supply. Fire fighters must wear the respective gear to protect their eyes and skin.

The decomposition products of polycarbonate (protective windows) are mainly H2O and CO2 when burned, as well as small amounts of CO (depending on the oxygen content).

Please adhere to the material safety data sheets for the used liquids, oils as well as to the respective legal requirements!

Fill volumes are listed in the Specifications and the external documentation of the manufacturers!


BAS03-xx

______________________________________________________________________________________________________________________________________________

_______________________________________________________________________________________ A8014Agb

14.0 Fires 14-3

14.2 Opening the force locked protective doors when there is no power supplied to the machine (The door can be opened by hand if the main switch is turned on and the "EMERG OFF" key is activated.) In a no power state (main switch off), the lock is active. The safety switches with locks / monitoring of the: • Work room door (with one station machines -

BAS03-x1) • Loading room door (with two station machines

BAS03-x2) are built in above the doors behind a metal panel. The two signal lamps are visible through two punchouts (switch status display), which also allow access to the lock screw. In conditions without power, the lock remains active. After removing the lock screw, a bushing with a front cross groove will be exposed and can be accessed. By turning this bushing by approx. 5 degrees counter clockwise, the lock in the safety switch is released and the machine access can be opened by hand. After closing it once again, the forced lock is reactivated.


_______________________________________________________________________________________ A8014Agb

14-4 14.0 Fires

14.3 Opening the safety separating window when there is no power supplied to the machine Safety separating window (only for 2 station models) There is a safety window between the loading room and the work room on both sides of the swivel support. The respective safety window to the active work room can be opened manually. If the "Control is ON" (JOG or AUTOMATIC with

NC stop), the locks are released if the "Safety window" key is pressed.

(The locking is done via two monitored pneumatic cylinders, which are installed on the left and right machine sides.The lock blocks that are located on the support of the safety window, are the counter pieces.) With no power to the machine (main switch OFF), the safety windows are locked. Another way to open the work room window is to remove the two lock blocks. 1. Open the protective door of the loading room (see previous chapter) 2. Remove the two socket screws from the

support of the safety window in the right and left lock block.

3. Hold the safety window and remove the lock blocks.

4. Press the cylinder rod of the pneumatic cylinder in until flush and open the safety window.


BAS03-xx

______________________________________________________________________________________________________________________________________________

_______________________________________________________________________________________ A8015Agb

15.0 External documentation 15-1

15 External documentation

The following pages show the documentation of the component manufacturers. Basically, the information and the described procedures of the manufacturers apply to work on units, unless this is expressly stated otherwise in these operating instructions.

Pneumatics

Very fine filter LFM / manometer Festo Pressure switch PEV Festo Regulating valve LRP Festo Switch on valve Festo CP valve island Festo

Central lubrication

Central lubricationr unit MFE5 Vogel Pressure switch DS-W Vogel

Hydraulics see Chapter 7 Lotz

Measuring systems Rotary encoder, RCN 220 EnDat Heidenhain Length measuring system, LC481 EnDat Heidenhain Pressure sensor, PN7, PN5 IFM

Erection elements Fixator Bertuch

Cooler Central cooling device, LM040-19 Lahntechnik

Air filter (option) Oil vapor separator, Darwin 600 Losma

Cooling lubricooling system (option) Hyfra

Mechanics

Gear WPLS (swivel support) Neugart Gear (tool magazine) Heynau


_______________________________________________________________________________________ A8015Agb

15-2 15.0 External documentation

Safety

safety switch TZ Euchner

Motors Synchronous motor TMA 210/100 (xxxxxxx) Etel Torque servo motor 1FK6 (xxxx) Siemens Synchronous installation motors 1FE1 Siemens

- Minicoder GEL244 Lenord + Bauer Other devices / options

Door drive Servax Motor spindle

- Spindle drawing SW - Spindle / tensioner detail SW - Tool tensioning system Röhm - Rotary feedthrough Deublin


BAS03-xx

______________________________________________________________________________________________________________________________________________

_______________________________________________________________________________________ A8016Agb

16.0 Electrical documentation 16-1

16 Electrical documentation

Table of Contents


_______________________________________________________________________________________ A8016Agb

16-2 16.0 Electrical documentation


BAS03-xx

______________________________________________________________________________________________________________________________________________

_______________________________________________________________________________________ A8017Agb

17.0 Spare / wear parts 17-1

17 Spare parts and wear parts, drawings, illustrations

Table of Contents

17 SPARE PARTS AND WEAR PARTS, DRAWINGS, ILLUSTRATIONS 17-1

17.1 Usage instructions for the electronic spare parts and wear parts lists 17-2

17.2 Drawings, illustrations 17-3


_______________________________________________________________________________________ A8017Agb

17-2 10.0 Spare / wear parts

17.1 Usage instructions for the electronic spare parts and wear parts lists The spare and wear parts lists are compiled by our electronic data processing centre and they are laid out as trees. The interpretation of these lists takes some getting used to, but it has the advantage that also the installation site or rather the superior assemblies can be taken from the electronic lists. For its use, there are these column headers: "Pos / Stuf" and "Id-Nr / EK" (Item/level and ID no. / Purchasing).

(Pos) Item number within the parts list level value or structure position in reference to the total machine:

0 = total machine, 15 = single part in the lowest structure. The combination of several installation parts, e.g. of level 5 will make up one installation part (assembly) of the next higher level 4; level 4 is part of level 3, level 3 is part of level 2, etc.

ID no. or data processing number issued by "Schwäbische Werkzeugmaschinen

GmbH S/W Part: column for spare or wear part identification; the abbreviations have the

following meaning: "EE" = Ersatzteil (spare part) "EV" = Verrschleißteile (wear part)

In spite of the data processing supported spare parts management, we ask you to indicate the follwing information when ordering individual parts or in case of questions Order / machine number issued by "Schwäbische Werkzeugmaschinen GmbH". When in doubt, this will give us the opportunity to adapt your order to the machine in question (possible upgraded by service calls).


BAS03-xx

______________________________________________________________________________________________________________________________________________

_______________________________________________________________________________________ A8017Agb

17.0 Spare / wear parts 17-3

17.2 Drawings, illustrations


_______________________________________________________________________________________ A8017Agb

17-4 10.0 Spare / wear parts

Documents

Cartea Tehnica SW BAS03A3AGB