DATRON D5

Operating instructions
Name Operating instructions

Product DATRON D5

Language en

Target group User, machine operator

DATRON AG Tel.: +49 - (0) 6151 - 1419 - 0

In den Gänsäckern 5 Fax: +49 - (0) 6151 - 1419 - 29
D-64367 Mühltal www.datron.de

© Copyright by DATRON AG 2013

It is not permitted to distribute or copy these operating instructions, or to utilize or communicate their contents, without the ex-
press permission of DATRON AG. All rights regarding the registration of patents, utility models or registered designs remain re-
served.

Registered trade marks

Apple, the Apple Logo and iPad are registered trademarks or trademarks of Apple Inc.
All other company and product names may be trademarks of the companies to which they are connected.
 i
Contents

Contents

1 Introduction.................................................................................................................. 1-1
1.1 How to use these operating instructions....................................................................................... 1-1
1.2 Explanation of the used symbols....................................................................................................1-2
1.3 DATRON D5.......................................................................................................................................1-2
1.4 Correct use........................................................................................................................................ 1-2

2 Safety instructions.......................................................................................................2-1
2.1 Safety instruction labels...................................................................................................................2-1
2.2 Safety devices................................................................................................................................... 2-2
2.2.1 Emergency stop switch............................................................................................................ 2-2
2.2.2 Other machine protective equipment..................................................................................... 2-2
2.2.3 Safety and warning symbols...................................................................................................2-3
2.3 Basic safety regulations................................................................................................................... 2-7
2.4 Selection and qualifications of personnel...................................................................................... 2-7
2.5 Conditions at the setup site.............................................................................................................2-8
2.6 Safety requirements when operating the machine....................................................................... 2-8
2.6.1 Dry machining...........................................................................................................................2-9
2.6.2 Machining with minimum-quantity cooling lubrication system (optional)........................2-10
2.6.3 Handling different materials.................................................................................................. 2-11
2.6.4 Machining titanium.................................................................................................................2-11
2.6.5 Automatic production.............................................................................................................2-12
2.7 Notes on fighting fires................................................................................................................... 2-12
2.8 Safety instructions for cleaning.................................................................................................... 2-13
2.9 Safety instructions for maintenance and repair.......................................................................... 2-14

3 Scope of Delivery.........................................................................................................3-1
3.1 Scope of delivery of the basic machine......................................................................................... 3-1
3.2 Application-specific equipment (options).......................................................................................3-1
3.3 DATRON HSCpro control................................................................................................................. 3-2

4 Minimum quantity cooling lubrication system (optional)....................................... 4-1

5 Commissioning.............................................................................................................5-1
5.1 Setting up the machine....................................................................................................................5-1
5.1.1 Dimensions and weight........................................................................................................... 5-1
5.1.2 Transport................................................................................................................................... 5-2
5.1.3 Setup site...................................................................................................................................5-3
5.1.4 Room climate............................................................................................................................ 5-3
5.1.5 Installation................................................................................................................................. 5-5
5.2 Connecting the supply media..........................................................................................................5-6
5.2.1 Voltage supply.......................................................................................................................... 5-6
5.2.2 Internet connection...................................................................................................................5-8
5.2.3 Network integration..................................................................................................................5-8
5.2.4 Notes regarding the control computer................................................................................... 5-8
5.2.5 Compressed air supply............................................................................................................ 5-9
5.2.6 Connection for deduster........................................................................................................ 5-10

6 Operation...................................................................................................................... 6-1

Operating instructions D5 DATRON AG i-1

3.0
 i
Contents

6.1 Operating terminal............................................................................................................................6-1

6.2 Switching on the machine............................................................................................................... 6-2
6.3 Fix blank in the blank holder...........................................................................................................6-3
6.3.1 Fixing blank (thickness 8 mm)................................................................................................ 6-5
6.3.2 Fixing blank (thickness 10 mm - 26 mm)............................................................................... 6-6
6.4 Loading the machine........................................................................................................................6-7
6.5 Start milling operation..................................................................................................................... 6-8
6.6 Remove blank....................................................................................................................................6-8
6.7 Change tool....................................................................................................................................... 6-9
6.7.1 Clamp the milling tool into the HSK collet chuck..................................................................6-9
6.7.2 Inserting tool in the machine................................................................................................ 6-10
6.8 Cleaning and maintenance............................................................................................................ 6-12
6.9 Switching Off the Machine............................................................................................................ 6-12

7 Accessories................................................................................................................... 7-1
7.1 Spindle cooling unit......................................................................................................................... 7-1
7.2 Automatic tool changer....................................................................................................................7-3
7.3 Camera for LiveView display (optional)......................................................................................... 7-3
7.4 Compact deduster (optional)........................................................................................................... 7-3

8 Maintenance................................................................................................................. 8-1
8.1 Maintenance...................................................................................................................................... 8-1
8.2 Lubricating instructions..................................................................................................................8-10
8.2.1 Lubricating the A axis............................................................................................................ 8-10
8.2.2 Lubricating the B axis............................................................................................................ 8-12
8.2.3 Lubricating the lubricating nipples on the back side of the machine................................ 8-13
8.3 Disposal............................................................................................................................................8-14
8.3.1 Disposal of consumable materials........................................................................................8-14
8.3.2 Dismantling and disposal of the machine............................................................................8-14

9 Troubleshooting........................................................................................................... 9-1

10 EC Declaration of Conformity for a machine........................................................ 10-1

i-2 DATRON AG Operating instructions D5

3.0
 1
Introduction
How to use these operating instructions

1 Introduction
Document The technical documentation, including these original operating
instructions, are a component of the DATRON D5 milling/grinding
machine. It reflects the status of July 2012. Another component of
the technical documentation is a software manual. (Right to make
technical amendments reserved. Error cannot be ruled out.)

Manufacturer DATRON AG
In den Gänsäckern 5
D-64367 Mühltal
Tel.: +49 - (0) 6151 - 1419 - 0
Fax: +49 - (0) 6151 - 1419 - 29
Email: [email protected]
www.datron.de

1.1 How to use these operating instructions

Target group These operating instructions are intended for trained, instructed
and expert personnel.
Read these operating instructions through completely before
starting the machine for the first time in order to be able to operate
the machine safely and as intended.
In order to be able to make full use of the performance of the
machine, training by DATRON is strongly recommended. Please
contact us:

DATRON Dental Application

Tel.: +49 - (0) 6151 - 1419 - 86
Fax: +49 - (0) 6151 - 1419 - 69
E-mail: [email protected]
www.datron.de

Archiving These operating instructions should be accessible at all times at

the site of operation of the machine. Safety instructions should be
passed on to all other users.

Read and observe all safety information before you work on or

near this machine.
Read all the safety instructions in this manual and on the safety
WARNING
notices affixed to this machine. Failure to observe the safety
instructions can lead to severe or fatal injuries.

Operating instructions D5 DATRON AG 1-1

3.0
 1
Introduction
Correct use

1.2 Explanation of the used symbols

 This symbol indicates that you must take some action.

✓ This symbol indicates that the machine has taken some action
or a result has been reached.

NOTE Here, you can find information about the subject.

The safety instructions are labelled as described in Chapter 2.1,

"Safety instruction labels".

1.3 DATRON D5

Fig. 1-1: DATRON D5

The DATRON D5 is a compact milling/grinding machine* for

the 5-axis simultaneous machining of all established dental
materials. The machine offers a high degree of precision, a
comprehensive range of functions and simultaneously simple
operating characteristics.

* The "wet machining" option is required for the grinding function.

1.4 Correct use

Milling machining of blanks made of all established dental

materials, such as

1-2 DATRON AG Operating instructions D5

3.0
 1
Introduction
Correct use

■ Zirconium oxide
■ Nano-composites
■ PMMA/wax
■ Plaster
■ NEM/CoCr
■ Titanium*
■ Ceramics (in combination with the wet machining option)

* Observe the safety instructions for this in Chapter 2.6.4,

"Machining titanium".

The machine is intended exclusively for the above-mentioned

applications. Any use above or beyond this is considered incorrect.
The manufacturer is not liable for damages resulting from such
incorrect use. The user bears the full risk in such cases.
Correct use also includes understanding and observing the
operating instructions and adherence to the service instructions.

Operating instructions D5 DATRON AG 1-3

3.0
 1
Introduction
Correct use

1-4 DATRON AG Operating instructions D5

3.0
 2
Safety instructions
Safety instruction labels

2 Safety instructions

Failure to observe the safety instructions can lead to severe or

fatal injuries.
Read and follow all safety instructions before working on or in
WARNING
the vicinity of this machine. Read all the safety instructions in this
manual and on the safety notices affixed to this machine.

2.1 Safety instruction labels

Following warning signs and signal words are used in this manual
to call the user's attention to hazards.

Safety notice ATTENTION

This warning indicates a possible dangerous situation which can
lead to moderate and minor bodily injuries. This can also warn
CAUTION
about possible material damage.

Safety notice WARNING

This warning indicates a possible danger. Failure to observe it can
lead to severe physical injuries or death.
WARNING

Safety notice DANGER

This warning indicates a direct danger. Failure to observe it will
lead to severe physical injuries or death.
DANGER

Safety notice WARNING - Electricity

This warning indicates a possible danger from high voltage.
Failure to observe it can lead to severe physical injuries or death.
WARNING

Safety notice DANGER - Electricity

This warning indicates a direct danger from high voltage. Failure
to observe it will lead to severe physical injuries or death.
DANGER

Operating instructions D5 DATRON AG 2-1

3.0
 2
Safety instructions
Safety devices

Safety notice WARNING - Fire

This warning indicates a potential fire hazard. Failure to observe it
can lead to severe physical injuries or death.
WARNING

2.2 Safety devices

2.2.1 Emergency stop switch

Position

Actuation When the EMERGENCY STOP button is pressed, all axes are shut
down and the high-frequency spindle is braked to a standstill
(approx. 5 - 10 s.). The frequency converter is also disconnected
from the power after a delay of 10 s. Other components, such as
the controller, control system and spindle cooling unit, remain
switched on.

Restarting the Machine To switch the machine on again after an abort with the
EMERGENCY STOP switch, proceed as follows:

 Eliminate the cause of the abort; If applicable, check the milling

job to see whether it contains any errors.
 Unlock EMERGENCY STOP switch
 Call up Overview in the operating menu.
 Press the ON key on the iPad.
 In the main Settings menu, execute the start macro.
 Restart the aborted job.
✓ The aborted job is started again from the beginning.

2.2.2 Other machine protective equipment

Danger of crushing and lacerations from hurled parts!

The machine may only be started up with machine's protective
equipment installed and the safety devices correctly connected.
WARNING

The machine has the following additional protective equipment:

■ door lock:
The machining area is protected by a door lock while the

2-2 DATRON AG Operating instructions D5

3.0
 2
Safety instructions
Safety devices

machine is in operation. The door cannot be opened until it has

been released via the user interface.
■ Safety switches:
The operating flaps for the tool changer and blank changer
are equipped with contactless safety switches. The operating
flaps can only be opened following a corresponding request.
Otherwise, the machining process stops and an error message
appears.
■ Maintenance locks:
The maintenance flaps can only be opened with a special
maintenance key.

2.2.3 Safety and warning symbols

Damaged or missing safety labels increase the risk of serious or

fatal injuries.
Missing or damaged safety labels must be replaced immediately.
WARNING

NOTE After installation and maintenance, make sure that all labels are
undamaged and are correctly arranged. Missing or damaged
labels must be replaced immediately.

The tables list all the safety labels and notices affixed to this
machine:

ISO label (worldwide) ANSI label (USA)

Danger of getting caught

Keep hands away. Moving parts

Dangerous high voltage

In case of contact, electric shock or burns can result. Before beginning
maintenance work, switch off the power and disable it.

Tab. 2-1: Safety labels on the machine

Operating instructions D5 DATRON AG 2-3

3.0
 2
Safety instructions
Safety devices

Note: Maximum permissible tool length

Use the gauge in the flap to check that the
new tool conforms to the permitted total
length of 65 mm.
Tab. 2-2: Notices on the machine
Note on the spindle cooling unit
CAUTION! Potential damage to the spindle! Never operate the cooling
device without DATRON coolant additives!

Tab. 2-3: Warning sign on the spindle cooling unit

2-4 DATRON AG Operating instructions D5

3.0
 2
Safety instructions
Safety devices

Note on the water separator

Potential damage to components through which air flows! If water
builds up in the water separator, improve the quality of the compressed
air! Consult the operating instructions for the required level of air purity.

Tab. 2-4: Warning sign on the compressed air supply

Operating instructions D5 DATRON AG 2-5

3.0
 2
Safety instructions
Safety devices

Arrangement of the machine stickers

4
1

3
1

1
1

1
5

Fig. 2-1: Arrangement of the machine stickers, DATRON D5

1 7x Danger of getting caught (tool changer, blank changer, beneath the covers: machine interior,
chip tray)
2 Dangerous electric voltage (behind cover, right side of machine)
3 Note - water separator (behind cover, rear side of machine)
4 Note on tool length (in the tool changer flap)
5 Note on the spindle cooling unit
6 CE marking with DATRON type plate (right side of machine)

2-6 DATRON AG Operating instructions D5

3.0
 2
Safety instructions
Selection and qualifications of personnel

2.3 Basic safety regulations

■ Check the safety devices prior to each machine commissioning.

■ The machine should only be used in technically perfect
condition in accordance with its designated use, observing
safety and risk factors and the instructions set out in the
operating instructions!
■ Remedy any malfunctions immediately which could impair
safety.
■ The operating instructions should always be kept close at hand
at the place of use of the machine.
■ In addition to the operating instructions, observe all other
generally applicable legal and other mandatory regulations
relating to accident prevention and environmental protection.
■ Ensure that safety instructions and warnings affixed to the
machine are always complete and perfectly legible.
■ In the event of changes to the machine or to its mode of
operation that have an impact on safety, shut the machine
down immediately and report the fault to the responsible body/
person!
■ Without the approval of the manufacturer, do not undertake
any modification, expansion or conversion work on the
machine that could have a negative impact on safety! This also
applies to the installation and adjustment of safety devices. If
the operator undertakes modification, expansion or conversion
work on the machine, he must draw up an updated set of
operating instructions.
■ Become familiar with the site and the operation of fire
extinguishers!
■ At the place of installation, take preventive measures to ensure
that the machine cannot be accidentally damaged, e. g. by
vehicles such as fork-lift trucks.
■ Protect electrical systems from moisture, chips and external
damage.

2.4 Selection and qualifications of personnel

■ Work on the machine should be executed by reliable personnel

only. Observe the legally permissible minimum age.
■ Only use trained or instructed personnel.

Operating instructions D5 DATRON AG 2-7

3.0
 2
Safety instructions
Safety requirements when operating the machine

■ Clearly define the responsibilities for personnel for operation,

setup, maintenance and repairs.
■ Only hand out the key for the maintenance flaps to trained and
qualified operators.
■ Ensure that only authorised personnel work on or with the
machine.
■ Persons who require training or instruction or persons taking
part in a general training course should not be permitted
to work on or with the machine without being continuously
supervised by an experienced person!
■ Work on the electrical systems and equipment of the machine
should only be carried out by a skilled electrician or by
instructed persons under the supervision and guidance of a
skilled electrician and in accordance with electrical engineering
rules and regulations.

2.5 Conditions at the setup site

Observe the information regarding the conditions at the setup

site in Chapter 5.1.3, "Setup site" and in Chapter 5.1.4, "Room
climate".

2.6 Safety requirements when operating the machine

■ The machining area is secured by safety devices (e.g. door's

locking safety device). Check the safety devices prior to each
machine commissioning.
■ The actuator on the door's locking safety device should be
checked every time the machine is turned on or daily. When
the actuator breaks off and is stuck in the locking safety device,
the machine can indicate that it is safe, although it's not.
■ The maintenance flaps are lockable and should be kept locked
by the maintenance personnel or the one who did the set-up.
■ Ensure that the workpiece is properly secured before starting
up the machine.
■ When the "Abort milling process" key is pressed on the iPad,
the axes are stopped and the machining spindle is braked to a
standstill. The components are not de-energized!
■ When machining materials which release harmful dusts, the
dusts which are formed must be suctioned off. Observe the
information in the substance-specific data sheets here.

2-8 DATRON AG Operating instructions D5

3.0
 2
Safety instructions
Safety requirements when operating the machine

■ The safety instructions of the coolant and material

manufacturer must also be observed!
■ The interior of the machine must not be cleaned using
compressed air, because the function of components can be
impaired by loose chips and residual material flying around.

Danger of hearing loss due to noise!

The noise level on the machine for standard applications is < 80
dB(A). If, however, noise levels greater than 80 dB(A) occur during
WARNING workpiece machining, suitable hearing protection must be worn.
At lower levels, ear protection must be kept readily available.

Danger of eye injuries caused by ejected chips!

Wear eye protection when using compressed air to suction off
chips outside the machine.
WARNING

Blank holder and seat

Possible damage to the machine due to hurling parts!

Before each program start, ensure that the work piece is securely
clamped so that it cannot work itself loose during machining.
CAUTION

2.6.1 Dry machining

The following dental materials are dry machined:

■ Zirconium oxide
■ PMMA/wax
■ Nano composite
■ Other materials only after consulting with DATRON

In dry machining, the material is machined without the cooling

spray function. The released dusts must be suctioned by a
deduster.

Operating instructions D5 DATRON AG 2-9

3.0
 2
Safety instructions
Safety requirements when operating the machine

Danger due to hazardous dusts!

During dry machining of materials, dusts can be released which
are hazardous to health and must be vacuumed. For this, observe
WARNING
the information on the safety data sheet of the respective material.

Possible damage to the machine due to released dusts!

During machining, the dusts that are released have to be suctioned
off by a suitable vacuum cleaner. Check the compatibility of the
CAUTION
vacuum cleaner and the material to be machined. If the dusts are
not suctioned off, the machine can be damaged.

2.6.2 Machining with minimum-quantity cooling lubrication system (optional)

The following dental materials are machined using the minimum

quantity cooling/lubricating system:

■ NEM
■ Titanium alloys*/Titanium*
■ Other materials only after consulting with DATRON

* (With regard to this, observe the information in Chapter 2.6.4,

"Machining titanium")

Observe the following when using cooling lubricants:

■ Canisters with cooling lubricants must be labelled.
CAUTION ■ Only use the cooling lubricants recommended by DATRON,
since these are optimally suited for the system. Non-
recommended cooling lubricants can lead to poor results and
damage of the machine.
■ When using cooling lubricants, make sure there is sufficient
ventilation at the setup site.
■ Observe the safety data sheet of the used cooling lubricant.
■ When using cooling lubricants which have not been explicitly
recommended by DATRON, observe the manufacturer
specifications with regard to fire and explosion hazards. If in
doubt, consult a safety professional.

Danger of blockage in the vacuum cleaner!

Suctioning is not allowed when machining with cooling lubricants.

CAUTION

2-10 DATRON AG Operating instructions D5

3.0
 2
Safety instructions
Safety requirements when operating the machine

2.6.3 Handling different materials

For every machining operation, only load the machine with

materials with are either dry or are machined with the minimum
quantity lubricating system. Do not mix these two milling
technologies during one machining operation.

Potential damage to machine due to contamination!

Clean the machine thoroughly before you change from dry
machining to wet machining or machining with the minimum
CAUTION
quantity lubricating system and vice versa. Also empty the chip
tray. Observe the information regarding cleaning in the Operating
Instructions of the machine, in Chapter 8.1, "Maintenance".

Potential fire hazard due to mixing materials!

When switching from the machining of metallic materials to
flammable materials (e.g. PMMA, wax, plastics, etc.), and vice
WARNING
versa, the machine must be thoroughly cleaned. Empty the chip
tray in this case as well.

Also observe the notes with regard to fighting fires (see Chapter
2.7, "Notes on fighting fires")

2.6.4 Machining titanium

Make sure you observe the following safety instructions when

machining titanium:

Fire hazard posed by material!

When machining titanium or other reactive materials, there is a
general fire hazard due to the kind of material. DATRON therefore
WARNING
recommends that you install a suitable automatic extinguishing
system if you machine titanium. When machining titanium, be
sure to consult a safety professional or someone who has been
trained accordingly to evaluate the fire hazard and the specific
situation at your site. A corresponding extinguishing system can
be purchased from DATRON.

Also observe the notes with regard to fighting fires (see Chapter
2.7, "Notes on fighting fires")

Operating instructions D5 DATRON AG 2-11

3.0
 2
Safety instructions
Notes on fighting fires

2.6.5 Automatic production

When operating the machine without supervision, make sure you

observe the following safety information:

This constitutes a fire hazard under unfavourable conditions!

When the tool wears out or breaks, this can cause nests made of
flammable materials to ignite in the chip tray. DATRON therefore
WARNING
urgently recommends that a suitable automatic extinguishing
system is installed for unsupervised machine operation. When
the machine is operated without supervision, be sure to consult a
safety professional or someone who has been trained accordingly
to evaluate the fire hazard and the specific situation at your site.
A corresponding extinguishing system can be purchased from
DATRON.

Also observe the notes with regard to fighting fires (see Chapter
2.7, "Notes on fighting fires")

2.7 Notes on fighting fires

Optional: Using an automatic
extinguishing system

Danger of suffocation due to automatic extinguishing system!

If your machine is equipped with an automatic extinguishing
system, this is activated as soon as a fire is detected.
WARNING
Once the automatic extinguishing system has been tripped, you
must leave the room immediately!
Also observe the information in the original operating instructions
of the extinguishing system.

If your machine is not equipped with an automatic extinguishing

system, the following applies:

Extinguishing agent Observe the safety instructions of the coolant and material
manufacturers! Keep fire blankets and fire extinguishers of classes
A, B, C, D ready for extinguishing fires. Metal fires can start,
especially when machining aluminium, titanium and magnesium.
Metal fires are to be extinguished with a class D fire extinguisher.
Do not extinguish with water under any circumstances. This poses
a danger of explosion!

2-12 DATRON AG Operating instructions D5

3.0
 2
Safety instructions
Safety instructions for cleaning

Extinguishing flap

Fire-fighting tip!
If you want to extinguish the machine with a fire extinguisher and
the machine door is locked, feed the extinguishing agent through
NOTE the flap for the tool changer.

2.8 Safety instructions for cleaning

Every time the machine is loaded, make sure that the blank
holders, grippers and seat are free of contaminants.

Health hazards!
When doing cleaning work and when there is contact with milling
scrap, wear protective gloves, protective goggles and light
WARNING breathing protection, especially when you come into contact with
zirconium oxide dusts or with coolants/lubricants.
When cleaning the machine and when in contact with milling
scrap, observe the information in the safety data sheet of the
respective material.

Empty the chip tray daily; at latest when it is more than half-full.
Observe the information regarding cleaning in the Operating
Instructions of the machine, in Chapter 8.1, "Maintenance".
Clean the machine thoroughly and always empty the chip tray
when you:

Operating instructions D5 DATRON AG 2-13

3.0
 2
Safety instructions
Safety instructions for maintenance and repair

■ change from dry machining to wet machining or machining

with a minimum quantity lubricating system, and vice versa.
■ change over from machining metallic materials to flammable
materials (e. g. PMMA, wax, plastics, etc.) and vice versa.

2.9 Safety instructions for maintenance and repair

Also observe the safety instructions in Chapter 8.1, "Maintenance".

2-14 DATRON AG Operating instructions D5

3.0
 3
Scope of Delivery
Application-specific equipment (options)

3 Scope of Delivery

3.1 Scope of delivery of the basic machine

The scope of delivery of the DATRON D5 usually includes the

following components:
■ DATRON D5
■ DATRON HSCpro control system with drives
■ DATRON HSCpro software
■ Operating terminal with Apple iPad
■ Rotary-swivel axis for five-axis-simultaneous machining
■ Integrated 2x automation with blank feed
■ Automatic 6x tool changer with tool length sensor and tool
breakage check
■ Spindle cooling unit for cooling the high-frequency spindle and
the torque drive (depending on machining spindle)
■ Circuit diagram, pneumatic diagram
■ Operating instructions

Please see your order confirmation for the specific scope of

supply.

3.2 Application-specific equipment (options)

■ Grinding application/wet machining option

■ Integrated 8x automation with blank feed
■ Other blank holders, incl. software extension
■ Automatic 13x tool changer with tool length sensor and tool
breakage check
■ Minimum quantity cooling lubrication system
■ Integrated camera for LiveView display on the Apple iPad
■ Deduster
■ Various CAD and CAM programs for dental machining

and many more options.

For more information please ask for our complete catalogue.

Operating instructions D5 DATRON AG 3-1

3.0
 3
Scope of Delivery
DATRON HSCpro control

3.3 DATRON HSCpro control

Description The DATRON HSCpro control system is a powerful 5-axis
continuous-path control. It is enclosed internally in the machine
housing.

Functions The DATRON HSCpro control system comprises the following

functions:
■ 3D linear interpolation
■ Circular interpolation
■ Numerous drilling and milling cycles
■ Automatic tool changer with tool length correction

Apple iPad functions:

■ Operation of the milling machine
■ Data transfer via network
■ Software interfaces to CAD/CAM programs (optional)

3-2 DATRON AG Operating instructions D5

3.0
 4
Minimum quantity cooling lubrication system (optional)

4 Minimum quantity cooling lubrication system (optional)

Description The integrated minimum-quantity cooling lubrication system
guarantees optimum results in the machining of base metals and
titanium.

Correct use Cooling and lubricating during the milling machining of NEM and
titanium.

Cooling lubricants Ask DATRON about the recommended cooling lubricants for your
application.
Other cooling lubricants may only be used with the prior consent
of DATRON.
Cooling lubricants with high solid content and such which tend to
flocculate (milky emulsion) are not suitable.

Potential material damage when using drilling emulsions!

Do not use any drilling emulsions or similar media. The DATRON
machine is not designed for use with such coolants. Problems
CAUTION
with the cooling system caused by use of unsuitable coolants will
invalidate the warranty!

Potential hazard due to the use of cooling lubricants!

Observe the safety instructions in Chapter 2.6.2, "Machining with
minimum-quantity cooling lubrication system (optional)".
CAUTION

Danger of blockage in the vacuum cleaner!

It is not permitted to suction the chips when the spray cooling
system is in use.
CAUTION

Operation The minimum-quantity cooling lubrication system is activated

automatically via the machine's control system for the machining
of base metals and titanium.

Filling level status display The level of the coolant container is electronically monitored and
displayed on the Apple iPad. If the filling level is low, the following
error message appears.

Change canister The replacement of the coolant container is done easily and
cleanly with a quick-change system.

Operating instructions D5 DATRON AG 4-1

3.0
 4
Minimum quantity cooling lubrication system (optional)

Please observe!
Canisters containing coolant must be labelled accordingly.

CAUTION

Remove canister 2

1 3
Fig. 4-1: Position of the canister with cooling lubricant
1 Maintenance flap
2 Closing lid
3 Holder

 Open the maintenance flap to the left on the machine.

 Swing out the quick-changing system with canister
 Push the integrated closing lid upward, together with the
suction hose.
 Open the holding bracket: move upward, pull toward you, fold
down
 Remove canister

 Check the sinter filter on the suction hose for contamination.

Clean, if necessary (see Chapter 8.1, "Maintenance", minimum-
quantity cooling lubrication system)

Insert canister  Proceed in the opposite order.

✓ Now you can continue to work.

Maintenance Every time you change the canister, at least 1 x per month:
Check the sinter filter on the suction hose for contamination.
Exchange or clean, if necessary (see Chapter 8.1, "Maintenance",
minimum-quantity cooling lubrication system)

4-2 DATRON AG Operating instructions D5

3.0
 5
Commissioning
Setting up the machine

5 Commissioning

5.1 Setting up the machine

5.1.1 Dimensions and weight

Dimensions DATRON D5 Dimensions (mm)

Weight approx. 900 kg
Width/depth 790/1190
Height 1910
Width with flaps open 1980
Depth with flaps open 1370
Height, machining area 1120
Height, operating terminal 1560
Distance between supporting feet 669/950
Distance between supporting feet Outer edge 46/96/110

Operating instructions D5 DATRON AG 5-1

3.0
 5
Commissioning
Setting up the machine

1193 mm
803 mm
1886 mm

1548 mm

1414 mm
875 mm

90 mm
669 mm 46 mm
A 96 950 mm 110 mm

1981 mm
1944 mm
1362 mm

10 - 15 mm

409 mm

DETAIL A
MAßSTAB 1 : 2

Fig. 5-1: DATRON D5

5.1.2 Transport

For safe transport to the setup site, the transport route must be
checked. In all areas, make sure that the width, height and load-
bearing capacity are sufficient. Check the following:

• Entrance and parking options for a truck

• Access inside the building (stairs, doors, passageways)
• Stairwells and elevators

5-2 DATRON AG Operating instructions D5

3.0
 5
Commissioning
Setting up the machine

• Floor conditions and surfacing

5.1.3 Setup site

Check the permissible floor load at the setup site!

When setting up the machine in residential buildings, the
permissible floor load must be checked by a structural engineer.
CAUTION
Here, observe the machine weight (see table in chapter
"Dimensions and weight") and also note that the machine
generates dynamic loads of approx. 500 N with a frequency of 0 to
5 Hz.

The machine is installed on-site on a solid supporting surface.

The floor of the setup site must have a sufficient load-bearing
capacity, rigidity and evenness. The height of the supporting
feet is adjustable and the feet aren't screwed to the floor. The
machine requires a minimum all-round clearance of 60 cm to its
surroundings to allow access to components within the cover.
Also observe the legal regulations with regard to work safety and
escape routes.

Observe!
Open flames, smoking, eating and drinking are prohibited in
the vicinity of the machine. Please also adhere to the safety
CAUTION instructions of the coolant and material manufacturer!

5.1.4 Room climate

NOTE Air should be free of aggressive dusts and gases.

Required room climate:

Temperature 18 - 30° C
Humidity < 65 % rel.

Operating instructions D5 DATRON AG 5-3

3.0
 5
Commissioning
Setting up the machine

Make sure the room temperature is sufficient. The ideal room

temperature is 20 - 23 °C. The machine must be completely at
room temperature before commissioning. For perfect operation,
the spindles require a coolant temperature of at least 18 °C, ideal
would be 25 °C.
If there is a risk of frost during storage or transport of the DATRON
machine, the cooling water must be completely drained out of the
machine and the cooling device beforehand.

Venting the set-up location Make sure there is good ventilation in the set-up environment.
When machining materials which release harmful dusts, the dusts
which are formed must be suctioned off. Observe the statutory
regulations.

The following must be observed when the machine is operated

with cooling lubricant:
When the machine is operated continuously, the set-up
environment should be kept well-ventilated or a room exhaust
system for the coolant mist is to be installed. When installing the
room exhaust system, note whether the used cooling lubricant is
lighter or heavier than air. Install the room exhaust system at the
top or bottom of the room accordingly. The AGW values (MAK
values - maximum workplace concentration values) of the used
coolant must be complied with.
In HVAC technology, the following general empirical values are
used for the air exchange numbers (i.e. exchanged air per hour):

Exchanged air
Location
per hour
Workshops 3-6
Workshops where especially high levels of fumes
10 - 18
develop
Laboratories 5 - 15
Garages 3-5

Danger of hearing loss due to noise!

In the idle state, the noise level of the CNC machine is < 80
dB(A). However, when workpieces are being machined, noise
WARNING levels exceeding 80 dB(A) might occur. In this case, suitable ear
protection must be worn. At lower levels, ear protection must be
kept readily available.
Workpieces which tend to vibrate (e.g. sheet material) should be
clamped over as large an area as possible (e.g. with a vacuum
plate) to prevent noise.

5-4 DATRON AG Operating instructions D5

3.0
 5
Commissioning
Setting up the machine

5.1.5 Installation

First-time commissioning is performed by DATRON. If you would

subsequently like to install the machine in a different location,
proceed as follows:

Potential damage to the machine!

If the machine is subject to hard impacts during transport, a
transportation securing device for the axes inside the machine
CAUTION
is required. In this case, only allow DATRON to transport the
machine.

Fig. 5-2: Front and rear view

1 Suction opening
2 Exhaust opening

 Select a suitable setup location.

 Check the load-bearing capacity and the firmness of the ground
at the desired place of installation.
The suction and exhaust openings for the spindle cooling unit
on the side and rear of the machine may not be obstructed and
require sufficient space all the way around for air exchange.
 Remove the casing from the bottom of the machine (casings
are magnetically fastened).
 Transport the machine with a suitable forklift.

 Set up the machine at the desired location.

Operating instructions D5 DATRON AG 5-5

3.0
 5
Commissioning
Connecting the supply media

Fig. 5-3: Adjustable screw foot

1 Lock nut
2 Adjusting nut

 Adjust the gap running around the protective door so that it

is uniformly wide using the adjustable screw feet so that the
function of the door safety switch is ensured.
 Align the machine using a spirit level using the adjusting nuts
(2) on the screw feet. When doing so, make sure that the screw
feet are approximately uniformly loaded and the gap around
the protective door is uniformly wide so that the function of the
door safety switch is ensured.
 Afterwards, counter the screw feet with lock nuts (1).

 Remount the bottom coverings.

✓ The machine is now set up correctly!

5.2 Connecting the supply media

Connection options The machine can be connected from below, e.g. through a cable
duct in the floor, or from above, through an opening in the cabin
roof.

5.2.1 Voltage supply

To guarantee smooth system operation, the basic disturbances of

the power supply must lie below the required limit value curves in
accordance with EN 55011.

Information concerning personal If personal protection is required for setting up systems, frequency
protection converters must be safeguarded in acc. with EN 50178 as follows:

• 1-phase devices by means of RCDs, type A (RCDs sensitive to

pulse current) or type B (RCDs sensitive to all types of current)

5-6 DATRON AG Operating instructions D5

3.0
 5
Commissioning
Connecting the supply media

• 3-phase devices (with B6 bridge rectifier) by means of RCMAs

with disconnectors (preferable) or RCDs, type B (RCDs sensitive
to all types of current)

The release current of the RCDs should be 300 mA or more to

avoid premature tripping by leakage current from the converter
(approx. 200 mA). The valid local regulations are to be observed
when connecting.
Depending on the existing type of network (TN, IT, TT), other
measures are required in acc. with VDE 0100 part 410 (part 4; chap.
41). In the case of TN networks, this would be protection by means
of an overcurrent mechanism, for example, and for IT networks,
isolation monitoring with pulse-code measurement methods. For
all types of networks, protective isolation can be used, as far as the
required power and line length permit this.

The DATRON machine must be connected to a separately fused

electric circuit (3x16 A) .

NOTE No other consumers or vacuum cleaner may be connected to this

power circuit!

Fig. 5-4: Voltage supply connection 3 x 400 V

Data Voltage 3 x 400 V /16 A

Frequency 50 Hz / 60 Hz
Power consumption 4,0 kW

Operating instructions D5 DATRON AG 5-7

3.0
 5
Commissioning
Connecting the supply media

5.2.2 Internet connection

An Internet connection for the control computer integrated in

the machine is absolutely necessary to be able to make use of
remote maintenance. This is the only way DATRON can access the
machine control if support is needed, making immediate analysis
and help possible.

5.2.3 Network integration

Including the DATRON machine in the customer network is the

responsibility of the customer, done at his own risk: If improperly
integrated in the customer network, the performance of the
DATRON machine can be negatively influenced. Group guidelines
on the network side can limit the machine's performance and lead
to errors.
To be able to optimally prepare for the integration of the DATRON
machine in the customer network, we require that you send
information from the checklist for network integration (see
Chapter , "Checklist"). Please send the filled-out checklist back to
us immediately.
Please understand that for failures and damage to the machine
caused by improper integration in the customer network, DATRON
must bill you for all service and repair costs (even if it's within the
warranty period).

5.2.4 Notes regarding the control computer

Observe the following points to ensure the process reliability of

the machining system and quick help in the event repairs are
needed:

• The DATRON machine may only be operated with the control

components included in delivery. These are an integral part of
the system.
• Do not install any other applications, and also no virus
scanners on the control components, which are not expressly
approved of by DATRON. Additionally installed applications
can lead to non-reproducible, sporadically occurring errors.

5-8 DATRON AG Operating instructions D5

3.0
 5
Commissioning
Connecting the supply media

5.2.5 Compressed air supply

The compressed air must meet the requirements of the spindle

manufacturer (see the original spindle operating instructions).
It must be dry, clean and oil-free. Otherwise, the components
through which the air flows could be damaged (especially the
spindle).

Required air purity Max. particle size 5 µm

Solid contaminants Class 3
max. Particle content 5 mg/m³
Water content Class 4 Max. pressure dew point +3 °C
Total oil content Class 3 Max. oil content 1 mg/m³

NOTE DATRON urgently recommends that an air treatment system be

connected in front of the system!

Any air treatment system available on the market can be used

which fulfils the above requirements. Our commissioning
personnel is instructed to use a suitable air dryer when there is
moisture in the compressed air. This is available for purchase.
If the machine is operated with insufficiently pure compressed air,
the warranty for the spindle and components through which air
flows is invalid.

Data

Fig. 5-5: Compressed air connection 1/2" rapid action hose

coupling

Required pressure 7 to 10 bar

Connection 1/2" rapid action hose coupling (NW 7.2 mm)
Compressed air max. 200 Nl/min Machine
consumption approx. 100 Nl / min Compressed air gun

Compressor Design your compressed air supply so that there is a continuous

supply available to the DATRON machine. Depending on the
type of compressor, the capacity must lie much higher than the

Operating instructions D5 DATRON AG 5-9

3.0
 5
Commissioning
Connecting the supply media

consumption of the machine and the supply buffered via a boiler,

so that the compressor has sufficient cooling-off time available.
Please have the manufacturer help you with the design of the
compressor.

5.2.6 Connection for deduster

There is a connection port in the base of the machine for

connecting a deduster.
To make the connection, proceed as follows:

Fig. 5-6: Rear view

1 Opening for suction hose

 Open the lower side doors on the left side of the machine
 Guide the suction hose through the termination opening in the
lower rear wall of the machine.
 Push the suction hose onto the connection port in the machine
base and fasten with a hose clamp
 Close the side doors on the left side of the machine.

✓ The suction hose is now connected.

5-10 DATRON AG Operating instructions D5

3.0
 6
Operation
Operating terminal

6 Operation
The machine is operated via the iPad and is controlled by the
DATRON HSCpro software. A software manual is also available for
this software.
In order to be able to make full use of the performance of the
machine, training by DATRON is strongly recommended. Please
contact us:

DATRON Dental Application

Tel.: +49 - (0) 6151 - 1419 - 86
Fax: +49 - (0) 6151 - 1419 - 69
E-mail: [email protected]
www.datron.de

6.1 Operating terminal

Description The operator controls the DATRON D5 via the Apple iPad. Here,
current data and program menu items are displayed. To operate
the machine, the Apple iPad must be inserted in the holder on
the machine. Removing the Apple iPad from the holder does not
interrupt the milling process and jobs that have already been
started continue to be carried out. Although you can continue
to view the menus on the Apple iPad, you cannot perform any
activities.

Fig. 6-1: Operating terminal D5

Working with the iPad Observe the operating instructions of the Apple iPad, see also
http://www.apple.de. Take particular note of the cleaning
instructions.

Operating instructions D5 DATRON AG 6-1

3.0
 6
Operation
Switching on the machine

Loading the iPad The Apple iPad battery is charged automatically as soon as the
iPad is fully inserted in the holder on the machine.

Data exchange The DATRON D5 is equipped with a control computer. This

receives the milling data from your CAD-CAM system. To do this,
synchronise the CAD-CAM system output with the D5 control
computer's predefined import directory.

6.2 Switching on the machine

LED strip The LED strip on the door displays the machine statuses:

Colour of the LED strip Status

white System ready, software not yet
booted
yellow Machine in service mode
green Machine is performing machining
red Malfunction, abort
blue Machine ready
blue flashing Software booted, app on iPod not
yet started

4
1
3

Fig. 6-2: Front and rear view

1 Main switch
2 Emergency stop switch
3 LED strip
4 Apple iPad
5 Door

6-2 DATRON AG Operating instructions D5

3.0
 6
Operation
Fix blank in the blank holder

To switch on the machine, proceed as follows:

 Switch on the compressed air supply

 Close the door and all operating flaps on the machine.
 Push the iPad into the holder
 Unlock the EMERGENCY STOP switch (pull), if necessary
 Switch the main switch to 1 ON
✓ The computer is booted up
✓ The LED strip flashes yellow
 Turn on the iPad, unlock, and start the DATRON App (not until
the LED strip flashes yellow)
✓ The machine performs the reference run
✓ The software is now started up and the machine components
are initialized
✓ You are now in the user interface's main menu

6.3 Fix blank in the blank holder

Required auxiliary aids Torque screwdriverISK 4 (Art. no. 0198088)

Permissible blank dimensions The DATRON machine can machine blanks up to 26 mm thick. The
following standard blanks can be fixed into the DATRON blank
holder:

Fig. 6-3: Standard blanks with thickness 10 mm - 26 mm

Fig. 6-4: Standard blanks with thickness 8 mm

Operating instructions D5 DATRON AG 6-3

3.0
 6
Operation
Fix blank in the blank holder

Blank thickness h1 Edge thickness h2 Diameter d1 Diameter d2 Symmetry

at offset s
8 mm (+/- 0.25 mm) - - 98 mm - 99 mm -
10 mm - 10 mm (+/- 0.25 mm) 93 mm - 94.5 mm 98 mm - 99 mm (+/- 0.1 mm)
max. 26 mm
Tab. 6-1: Blank dimensions and allowed tolerances

Blank materials The DATRON technicians recommend the following maximum

thicknesses when using blanks of different materials:

Material Blank thickness

Plaster up to max. 26 mm
Zirconium up to max. 26 mm
PMMA up to max. 20 mm
CoCr up to max. 18 mm

Clamping rings for different Always use the correct clamping rings to fix blanks made from
materials different materials. Check the clamping rings for wear before every
use. Also observe the maintenance information in Chapter 8.1,
"Maintenance".

Clamping ring For blank material

Clamping ring, black 75 Sh (Art. no. 0069890A) NEM, titanium
Clamping ring, red 45 Sh (Art. no. 0069890B) Zirconium, PMMA
Clamping ring, yellow * (Art. no. 07020847) Zirconium

* If there should be flaking on the zirconium blank when using the

red clamping ring, the yellow clamping rings have an even softer
degree of hardness available as an alternative.

Risk of damage to the machine!

Incorrectly fixed blanks can slip out of position during machining
and damage the machine. Make sure you observe the following:
CAUTION
■ Before fixing, clean all components of chips!
■ Select the correct fixing method for the respective edge
thickness of the blank!
■ The maximum permitted blank thickness is 26 mm
■ Select the correct clamping ring for the material being
machined (pay attention to colour!) and check the clamping
ring for wear!
■ Check the blank holder for defective parts or loose screws. If
there are defective parts, make sure you exchange them!

6-4 DATRON AG Operating instructions D5

3.0
 6
Operation
Fix blank in the blank holder

6.3.1 Fixing blank (thickness 8 mm)

5
6

Fig. 6-5: Inserting blank (thickness 8 mm) in blank holder (item no.
0695009A)
1 3x screws, M5x10 DIN ISO 4762, 8.8 (item no. 0071604P)
2 Blank holder, top part
3 Spacer ring, top (item no. 07020358)
4 Clamping ring (black/red)
5 Blank (thickness 8 mm)
6 Insertion ring (item no. 07014981)
7 Blank holder, bottom part

To fix the blank, proceed as follows:

 Before fixing, clean all components of chips!

 Insert insertion ring in the bottom part of the blank holder.
 Insert blank in the bottom part of the blank holder.
 Insert top spacer ring in the top part of the blank holder.
 Join the clamping ring into the top part of the blank holder
(make sure the colour is correct!)
 Put on the top part of the blank holder and tighten the three
screws with 5 Nm.
Check that the blank is positioned tightly in the blank holder!

Operating instructions D5 DATRON AG 6-5

3.0
 6
Operation
Fix blank in the blank holder

6.3.2 Fixing blank (thickness 10 mm - 26 mm)

Fig. 6-6: Inserting blank (thickness 10 mm - 26 mm) in blank holder

(item no. 0695009A)
1 3x screws, M5x10 DIN ISO 4762, 8.8 (item no. 0071604P)
2 Blank holder, top part
3 Clamping ring
4 Blank (thickness 10 mm - 26 mm)
5 Blank holder, bottom part

To fix the blank, proceed as follows:

 Before fixing, clean all components of chips!

 Insert blank in the bottom part of the blank holder
 Join the clamping ring into the top part of the blank holder
(make sure the colour is correct!)
 Put on the top part of the blank holder and tighten the three
screws with 5 Nm.
Check that the blank is positioned tightly in the blank holder!

6-6 DATRON AG Operating instructions D5

3.0
 6
Operation
Loading the machine

6.4 Loading the machine

Risk of damage to the machine!

Dirty blank holders can lead to the milling program aborting and
damage to the machine. Make sure you observe the following:
CAUTION
Before inserting in the machine, clean the blank holder thoroughly
of chips and dust:

■ Chips and dust can settle in the recesses in the blank holders;
clean these thoroughly with a toothbrush every day.
■ Clean thoroughly all around the blank holder with a brush.
■ Clean the seat for the blank holder in the machine with the
cleaning brushes included in delivery.

Fig. 6-7: Insert loaded blank holders in the machine

1 Marking ^

 In the operating menu, call up Blanks

 Select the desired free position no by tapping it.
 Select Insert blank.
✓ Message appears: Insert blank
 Open flap for blank feeder by pressing
 Load blank holder in blank feeder so that the marking on the
blank holder is facing the blank feeder (see Fig. 6-7).
Carefully push the blank holder as far as the limit stop.
 Close the flap for the blank feeder,
and confirm message with OK
 Assign blank name and blank type, and confirm with OK

Operating instructions D5 DATRON AG 6-7

3.0
 6
Operation
Remove blank

✓ Message appears: Blank in the magazine

 confirm message with OK

6.5 Start milling operation

 Call up Jobs in the operating menu

 Mark the desired job and select Activate
 Select the job Execute
Other functions are available for managing the jobs. More
information about this can be found in the software manual.

6.6 Remove blank

Risk of shearing injuries from sharp edges!

The milling process creates outlines with sharp edges. Take special
care and pay particular attention when touching machined blanks.
CAUTION

Completely machined blanks can be removed as follows:

 Call up Blanks in the operating menu

 Select desired position No by touching
 Select Eject blank menu item
 Message appears: Please remove blank
 Open flap for blank feed by pressing
 Remove blank holder
 Close flap for blank feed; confirm with OK

6-8 DATRON AG Operating instructions D5

3.0
 6
Operation
Change tool

6.7 Change tool

6.7.1 Clamp the milling tool into the HSK collet chuck

Potential machine damage!

• It is imperative that you observe the maximum permissible tool

CAUTION length of 65 mm! (See Fig. 6-9)
• Make sure that the milling tool is correctly clamped into the
HSK collet chuck!

Use the length ruler and the Tribos clamping fixture to insert the desired tool into the HSK collet
chuck:

Fig. 6-8: Clamp the milling tool into the HSK collet chuck. Using the Tribos clamping fixture,

 stick the HSK collet chuck with flat part (1) all the way into the reducing insert (2) and turn to the
right until it engages (3). Make sure that the HSK collet chuck is pushed all the way in and that
there is no more backlash!

Operating instructions D5 DATRON AG 6-9

3.0
 6
Operation
Change tool

 Insert the reducing insert in the Tribos clamping fixture (4).

 Close the valve (turn to the right) (5)
 Pump to 180 bar with the lever (6). Danger of destroying the collet chuck! Do not exceed 180 bar
(7)!
 Stick the milling tool into the HSK collet chuck and bring to the right dimension using the length
ruler (8). The milling tool may project a maximum of 25 mm out of the HSK collet chuck.
 Open the valve (turn to middle position) (9) and removed clamped tool from the reducing insert.

✓ The tool is now ready to be inserted in the machine!

< 65 mm!

Fig. 6-9: Maximum permissible tool length

1 Length template
Total length = Length of HSK collet chuck + length of milling tool

6.7.2 Inserting tool in the machine

Potential machine damage!

Tools which are too long or inserted incorrectly or the entry of an
incorrect tool type in the DATRON HSCpro software can lead to
CAUTION
damage to the machine, the tools and the workpiece.

■ Always check the total length of the tool before inserting in the
tool changer using the gauge, which is located in the flap for
the tool changer.
■ Clean the taper of the HSK collet chuck, inside and out, of chips
with a cloth before inserting the HSK collet chuck in the tool
changer. Pay special attention to the inner ledge, behind which
chips can hide.
■ Correctly set up all tools.

6-10 DATRON AG Operating instructions D5

3.0
 6
Operation
Change tool

Fig. 6-10: Cleaning HSK collet chuck of chips.

1 Clean the outside of the tapered surface of chips with a cloth.
Pay attention to the ledge!
2 Clean the inner taper surface of chips with a cloth. Pay
attention to the inner ledge!

Fig. 6-11: Inserting tool in the machine

1 Tool changer flap
2 Gauge to check total length
3 Tool changer magazine with clamps

 Call Tools in the operating menu

 Select the Position to be loaded
 Select Manual change

Operating instructions D5 DATRON AG 6-11

3.0
 6
Operation
Switching Off the Machine

 Open the tool changer flap by pushing it.

 Remove the old tool from the magazine.
 Clean the taper of the new tool thoroughly of chips.(see Fig.
6-10)
 Clean the clamps of the tool changer magazine thoroughly with
a paintbrush.
 Check the new tool using a gauge in the flap for the
permissible total length of 65 mm and insert in the clamp of
the tool changer magazine (see Fig. 6-11)
 Close the flap for the tool changer

 Confirm with OK
 Select correct tool type of the new tool from the TypeNo table
 Confirm with OK
✓ The exact tool length is measured under program control with
the integrated tool length sensor and saved.
✓ The tool change is now complete.

6.8 Cleaning and maintenance

For cleaning and maintaining the machine, observe the

information in Chapter 8.1, "Maintenance".
Also observe Chapter 2.9, "Safety instructions for maintenance
and repair" and Chapter 2.8, "Safety instructions for cleaning".

After every milling operation  sweep out/vacuum chips from the machine and components
pay particular attention to brushing/suctioning off chips from
the seat on the rotary swivel axis
 Check the filling level of the chip bin and empty it if required

6.9 Switching Off the Machine

The rotating high-frequency spindle can trap body parts or cause

shearing injuries!
If the machine is switched off at the main switch while the high-
WARNING
frequency spindle is running, it continues to run after shut-down
and is not decelerated!
Therefore, end the milling program first!

To switch off the machine, proceed as follows:

6-12 DATRON AG Operating instructions D5

3.0
 6
Operation
Switching Off the Machine

 Call up Settings in the operating menu

 Select Switch off
 Confirm message with Yes
✓ The program is shut down
 Wait for two minutes and set the black main switch to 0 OFF
✓ Switching the main switch to 0 OFF de-energises the entire
milling machine

Operating instructions D5 DATRON AG 6-13

3.0
 6
Operation
Switching Off the Machine

6-14 DATRON AG Operating instructions D5

3.0
 7
Accessories
Spindle cooling unit

7 Accessories

7.1 Spindle cooling unit

Description

The spindle cooling unit serves to cool the water-cooled high-

frequency spindle and the torque drive.

Observe the specifications in the original operating instructions of

the device.

The following items provide additional information:

coolant To fill the spindle cooling unit, only use distilled water with a
suitable coolant additive, if another one isn't expressly required
by the spindle cooling unit manufacturer (also observe the
manufacturer specifications).

The following coolant mixtures can be used on your machine:

■ Distilled water with DATRON coolant additives AO-100 and
B-100.
You can obtain these cooling additives from DATRON. (for
dosing, see Chapter 8.1, "Maintenance").
■ Distilled water with at least 20 % max. 25 % Antifrogen-N
(coolant hoses with an outer diameter >= 8 mm).
You can purchase ready-to-use coolant from DATRON.
(DATRON item No. 0069266X) (see Chapter 8.1,
"Maintenance")

Operating instructions D5 DATRON AG 7-1

3.0
 7
Accessories
Spindle cooling unit

Potential damage to the high-frequency spindle!

Operation of the spindle cooling unit without suitable coolant
additives reduces the service life of the cooling water and shortens
CAUTION
the service life of the components it flows through.

• Always operate the spindle cooling unit with suitable coolant

additives.
• Do not change the settings on the coolant unit.
• Check the filling level of the coolant every week and refill, if
necessary.

If the device is operated without the coolant additives, the

warranty on the components the cooling water flows through is
void.
You can obtain these cooling additives from DATRON.
If not already integrated in the spindle cooling unit, we
recommend using an additional water filter at the coolant outlet
(DATRON item no. 0069259B).

Filling To fill the spindle cooling unit, observe the original operating
instructions of the manufacturer.

Damage inside the high-frequency spindle!

The coolant must never be below room temperature, otherwise
condensation forms inside the spindle. Danger of rusting!
CAUTION
• Pay attention to condensate on the spindle housing. This is an
indication of moisture inside the spindle.
• Allow coolant to reach room temperature before starting.
• Check the control temperature on the device display during
operation (approx. 25 °C).

Malfunction A malfunction on the spindle cooling unit is indicated by an error

message on the DATRON machine. In the event of a fault, look at
the display and eliminate the fault.

Maintenance Observe the information in the original operating instructions

of the device. Observe the instructions in the Chapter 8,
"Maintenance" in these operating instructions.

7-2 DATRON AG Operating instructions D5

3.0
 7
Accessories
Compact deduster (optional)

7.2 Automatic tool changer

Fig. 7-1: Automatic tool changer

1 Tool changer flap
2 Gauge to check total length
3 Tool changer magazine with clamps

Description The automatic tool changer is for machining workpieces with

different tools without the machine operator having to intervene.
A total of up to 13 toolscan be used and managed by the DATRON
HSCpro software.

Tools Only use tools recommended by DATRON. For more information,

see Chapter 6.7, "Change tool".

7.3 Camera for LiveView display (optional)

Description The machine has a built-in camera for the LiveView display: This
way, you can watch blank machining directly on the Apple iPad.

LiveView function The LiveView function is started via the operating menu on the
Apple iPad (see Software help, LiveView display) and can also be
executed when the Apple iPad is not in the holder. Observe the
range of the wireless connection.

Maintenance As needed, at latest when the LiveView display is blurry:

 Clean the protective glass in front of the camera lens with a

soft cloth.

7.4 Compact deduster (optional)

Description The compact deduster can be moved and is installed ready to use.

Operating instructions D5 DATRON AG 7-3

3.0
 7
Accessories
Compact deduster (optional)

Intended use
■ Suctioning of released dusts during dry machining

Danger of clogging in the deduster!

The deduster may only be used for dry machining! Observe the
safety instructions in Chapter 2.6.1, "Dry machining".
CAUTION

Check the compatibility of the deduster and the material to be

machined based on the original operating instructions of the
device.

Connection The deduster is connected to the connection nozzle of the

machine using the hose included in delivery. (See Chapter 5.2.6,
"Connection for deduster")

Operation The deduster is automatically activated via the D5 control during

dry machining.

Fig. 7-2: Compact deduster

7-4 DATRON AG Operating instructions D5

3.0
 7
Accessories
Compact deduster (optional)

Technical data Compact deduster Technical data

Dimensions LxWxH (mm) 600 x 770 x 1350
Weight 103 kg
Power 1,1 kW
Voltage 400 V
Negative pressure 2100 Pa
Air output max. 1220 Nm³/h
Sound level 74 dB(A)
Movable dust container 30 l
Filter category M
Hose length DIN 125 3 M00

Maintenance Maintain the deduster as described in the operating instructions

of the device. If the yellow warning light is illuminated, you
must clean or exchange the filter cartridges (see Chapter 8.1,
"Maintenance", compact deduster).

Operating instructions D5 DATRON AG 7-5

3.0
 7
Accessories
Compact deduster (optional)

7-6 DATRON AG Operating instructions D5

3.0
 8
Maintenance
Maintenance

8 Maintenance

8.1 Maintenance
Maintenance intervals The maintenance intervals were conceived for one-shift operation,
which corresponds to 40 hours per week. Shorten the maintenance
intervals accordingly if your machine runs for a longer time. The
intervals for regular checks, maintenance and inspections specified
in the operating instructions must be complied with.

Electric systems Electrical equipment and devices must be checked at least every 4
years by qualified electrical personnel to make sure that they are in
proper working condition (see UVV7 (German Accident Prevention
Legislation), VBG4). The electrical systems are to be protected
from moisture, chips and external damage.

Spare parts Spare parts must comply with the technical requirements specified
by the manufacturer. This is always guaranteed with DATRON
original spare parts.

Consumable materials We recommend that you obtain consumables, cooling lubricants

and care products from DATRON.

Maintenance by DATRON To keep the machine in working order and to avoid machine
Service damage, the machine must be maintained by DATRON Service at
latest after 2000 operating hours, but at least once a year.
Shortened waiting interval for grinding application/wet
machining (option):
To keep the machine in working order and to avoid machine
damage, the machine requires maintenance by DATRON Service
at latest after 500 operating hours, but at least once every three
months.

Maintenance contract We recommend that you sign a maintenance contract for your
machine. Your DATRON Service department would be happy
to give you information regarding the services included and the
scope of the maintenance contract.
Ask for an offer:

DATRON-Service
Tel.: +49 - (0) 6151 - 1419 - 99
Fax: +49 - (0) 6151 - 1419 - 91
E-mail: [email protected]
www.datron.de

Operating instructions D5 DATRON AG 8-1

3.0
 8
Maintenance
Maintenance

Please observe the following!

The "Maintenance" chapter might change significantly due to our
quality management. Please request an updated maintenance
CAUTION
chapter from DATRON Service at least once a year, indicating your
machine type.

Danger of damage to the axis guides!

For machining operations which are executed with small
traversing paths (X < 30 mm, Y < 30 mm, Z < 15 mm), grease must
CAUTION
be distributed at regular intervals. To do this, traverse the machine
in X / Y > 100 mm and in Z > 50 mm.

Potential damage due to penetrating chips!

Remove chips and dirt from the maintenance flaps and the
components before opening them for maintenance purposes.
CAUTION
Otherwise, chips and dirt can penetrate to the inside and impair
the component functions.

Danger of injury!
Maintenance and servicing work is done in the movement space
of the machine or its components. They interfere in the operating
WARNING
state of the machine and require measures for avoiding damage:

■ Before maintenance and servicing work, shut down the

machine.
■ De-energize the system.
■ Carry out work on the electrical equipment only when it is de-
energized.
■ Switch off the main switch and secure it from being switched
on again with a lock.
■ Check the function of all safety devices after ending work.
■ After the exchange or repair of electrical components, check
the function which the component affects.
■ After work, make sure that all safety and warning signs are
undamaged and in place.
■ Immediately replace missing or damaged signs.

8-2 DATRON AG Operating instructions D5

3.0
 8
Maintenance
Maintenance

Health hazards!
When doing cleaning work and when there is contact with milling
scrap, wear protective gloves, protective goggles and light
WARNING breathing protection, especially when you come into contact with
zirconium oxide dusts or with coolants/lubricants.
When cleaning the machine and when in contact with milling
scrap, observe the information in the safety data sheet of the
respective material.

Operating instructions D5 DATRON AG 8-3

3.0
 8
Maintenance
Maintenance

Component Part Maintenance Interval

Check for correct function,
Door lock, cabin, EMER- check that the screws are
1 week
GENCY STOP switch tight, and check for cracks
Safety or mechanical damage.
equipment
Front door: Actuator on Check whether OK, check Daily
the N/O contact of the for cracks or every time switched on
locking safety device
Visual inspection: Ex-
change immediately when
there are
Every day
– cracks

– plastic deformation
Polycarbonate discs Exchange
Polycarbonate discs are
Protective cover wear parts. They age due
to being hit by chips and
2 years
from contact with cool-
ing lubricants. This makes
them lose their support
capability.
Check,
Air filter in the roof venti- 1 month
clean, if necessary
lator
Replace 1 year
Move machine to cleaning Every day
position (safe position).
Clean with paintbrush Additionally when:
(cleaning set, Art. no.
0695046). – Changing from
Vacuum out with vacuum dry machining to
cleaner (suitable for wet machining with
and oily chips). minimum quantity
Do not use compressed
lubricating system or
air!
Do not use ethanol, since wet machining and
this attacks the seals for vice versa
the wet machining option!
– Switching over from
When changing from wet
Machine interior Machining area machining or machining the machining of
with minimum quantity metallic workpieces to
lubrication system to dry flammable materials
machining: Remove lubri- (e.g. PMMA, wax,
cant residue with cleaning plastics, etc.) and vice
fluid (cold cleaner). versa

For grinding applica-

tion/wet machining:

– Clean the machine

every week with a
descaling agent.

8-4 DATRON AG Operating instructions D5

3.0
 8
Maintenance
Maintenance

Component Part Maintenance Interval

Check for cleanliness, suc- Daily,
tion and clean with paint- possibly more often when
Blank holder seat
brush (cleaning set, Art. machining zirconium
no. 0695046) and rag.
As needed, at latest when
Protective glass in front of Clean protective glass
Camera (optional) the LiveView display on
the lens with soft cloth.
the iPad is blurry
Check and empty. 3 months
In the event of water for-
mation, the quality of
the compressed air must
be improved (observe
compressed air quality:
Water separator (at the
see Chapter 5.2.5, "Com-
Pressure reducer rear in the machine cover-
pressed air supply").
ing, top left)
DATRON urgently recom-
mends that an air treat-
ment system be connect-
ed in front of the system.
Set pressure to approx.
6.5 bar.
Every day

At latest when half full

Additionally when:

– For every change

between dry
machining, machining
with minimum
Chip tray (large, below quantity lubrication
Chip tray Empty
the machining area) system or wet
machining

– Switching over
from machining of
metallic materials to
flammable materials
(e. g. PMMA, wax,
plastics, etc.) and vice
versa
Chip tray (small, rear side
of the front covering, un-
Chip tray Empty 2 weeks
derneath the protective
door)

Operating instructions D5 DATRON AG 8-5

3.0
 8
Maintenance
Maintenance

Component Part Maintenance Interval

For milling application:
6 months/1 year
(depending on the lubri-
cating nipple, for exact in-
formation, refer to Chap-
ter 8.2, "Lubricating in-
structions".)

For grinding applica-

tion/wet machining,
shortened lubrication in-
terval:
3 months/6 months/1 year
A axis Lubricate with high-qual- (depending on the lubri-
B axis ity, high-performance cating nipple, for exact in-
grease in accordance with formation, refer to Chap-
Lubricating nipples on DIN 51825, Dynalub 510 ter 8.2, "Lubricating in-
Machine axes
back of machine from Rexroth. structions".)
Permitted alternative
(see Chapter 8.2, "Lubri- grease:
cating instructions") Castrol Longtime PD2. Recommendation:

– Lubricating nipples
with an interval of 1
year: have lubricated
by DATRON Service,
within the term of the
maintenance contract

– Lubricating nipple
with shorter interval:
lubrication by the
customer
Move the machine to the
"cleaning position". De-
posit blank.
With the cleaning taper in-
HSK (hollow-shaft taper)
cluded in delivery, clean Every day
/ inner taper
the hollow-shaft taper by
hand.
Do not use compressed
air!
Important:
High-frequency Maintain according to the
Maintain according to the
Spindle Spindle original spindle operating
original spindle operating
instructions.
instructions.
Do not use compressed
air!
Spindle Clean with cloth or paint- Every day
brush with the air purge
switched on.
Arrange for a replacement
Spindle bearings -> notify the DATRON Ser- 2000 operating hours
vice Team.
Clamps of the tool chang- Clean thoroughly with Every time before using a
Tool changer
er magazine paintbrush. new tool

8-6 DATRON AG Operating instructions D5

3.0
 8
Maintenance
Maintenance

Component Part Maintenance Interval

– Check coolant level

and refill, if necessary.
Suitable coolant: see
below.

– Check control
temperature; set to
approx. 25°C.

– Clean from the

outside.

– Check the fins of the

Spindle cooling unit liquefier (in front of 1 week
fan at air outlet) for
contamination. If
there are deposits,
blow off with
compressed air.

– Check the air

inlet filter for
contamination. If
there are deposits,
blow off with
compressed air.
Spindle cooling unit
Refill coolant

when using
Antifrogen-N:

– Refill the coolant with

distilled water with at
least 20%, but at most
25% Antifrogen-N.

Ready-to-use mixture
is available at
DATRON, (DATRON
Tank item no. 0069266X). 4 weeks

when using A0-100

and B-100:

– Fill half a bottle of

coolant additive
B-100, making sure
the expiration date
hasn't been reached.

Coolant additive
is available from
DATRON.

Operating instructions D5 DATRON AG 8-7

3.0
 8
Maintenance
Maintenance

Component Part Maintenance Interval

Exchange the coolant

Separate instructions
are available from
DATRON for changing
the coolant type.

when using
Antifrogen-N:
1 year
– Distilled water with
at least 20%, at most
25% Antifrogen-N.

Ready-to-use mixture
is available at
DATRON, (DATRON
item no. 0069266X).
when using A0-100 and
B-100:

– Drain, clean, fill with

new coolant: distilled
water plus a half a
bottle each of the
coolant additives 6 months
AO-100 and B-100.
Pay attention to the
expiration date!

Coolant additive
is available from
DATRON.
Check: replace if the filter
is discoloured or if there
is sediment in the inspec-
Water filter at the cooling 1 week
tion glass or interference
circuit outflow to circulation in the filter
insert.
Replace 6 months
Maintain according to the Maintain according to the
original spindle cooling original spindle cooling
Spindle cooling unit
unit operating instruc- unit operating instruc-
tions. tions.
Check for contamination.
Clean, if required. 1 month
Screw off or pull off the
Minimum quantity cool- sinter filter. Additionally for:
Sinter filter at end of suc-
ing lubrication system Exchange sinter filter or
tion hose
(optional) clean with cleaning fluid
(cold cleaner). – every time the
Screw or stick the sinter canister is changed
filter back on again.
Recesses in blank holder Clean thoroughly of chips
blank holder Every day
and dust with toothbrush.

8-8 DATRON AG Operating instructions D5

3.0
 8
Maintenance
Maintenance

Component Part Maintenance Interval

Complete blank holder Clean thoroughly of chips
Every day
and dust with brush.
Clamping rings for blanks Check for wear and con-
tamination, exchange, if
necessary, or clean thor-
oughly of chips and dust
with a brush. Whenever performing
ATTENTION: Do not use clamping
any solvent-containing
cleaners since this will
damage the clamping
ring!
If there is wear, but at lat-
est after:

– 25 clamping
Exchange operations or

– 100 operating hours

or

– 3 months
Accessible interior spaces Switch off the machine
Accessible interior
of the machine behind the and vacuum out with a 1 month
spaces of the machine
maintenance flaps suitable vacuum cleaner.
Maintenance according to See original compact de-
the original operating in- duster operating instruc-
Compact deduster
structions of the compact tions.
deduster.
Clean off the filter car- if the yellow warning
tridge: Turn the crank ap- lamp is illuminated
prox. 10-20x slowly in
Compact deduster
the direction of the arrow
(optional)
marking (see the original
Filter cartridge operating instructions of
the compact deduster)
Exchange (see the original if the yellow warning
operating instructions of lamp is illuminated in
the compact deduster) shorter and shorter time
intervals
See original extinguishing See original extinguishing
system operating instruc- system operating instruc-
Extinguishing system tions. tions.
Extinguishing system
(optional) If extinguishing system If extinguishing system
was triggered: Inform DA- was triggered
TRON Service Department

Operating instructions D5 DATRON AG 8-9

3.0
 8
Maintenance
Lubricating instructions

8.2 Lubricating instructions

This symbol indicates the position of the

screws to be undone.

This symbol indicates the position of one lubri-

cating nipple.

For lubrication, please use the grease press

with flexible hose supplied (flow volume 1
cm³/stroke).

NOTE Clean the lubricating nipples with a cloth before you pump in
grease. Otherwise, dirt can get into the bearings.

NOTE Hold onto moving machine parts when lubricating them.

Danger of injury!
Before starting lubrication work, open the door and then switch the
machine off at the main switch and lock the main switch!
WARNING

8.2.1 Lubricating the A axis

Lubricating the fixed bearings

Fig. 8-1: Removing the maintenance flap

1 Pulling out plug

8-10 DATRON AG Operating instructions D5

3.0
 8
Maintenance
Lubricating instructions

Remove the maintenance flap on the left-hand side of the machine:

 Screw out 6 screws (with size 4 Allen wrench)

 With the help of another person, fold out the maintenance flap
and hold onto it securely!
ATTENTION: Danger of injury! The tool changer flap may open
 Remove the cable (1) from the maintenance flap: Undo the cap
nut and remove the cable
 Push the maintenance flap upwards and remove it

Fig. 8-2: Fixed bearing lubricating nipples

1x per year  Attach grease press to the lubricating nipple, pump 5x

 Lubricate both lubricating nipples in this manner

Lubricating floating bearings

Fig. 8-3: Opening the control cabinet

Remove the maintenance flap on the right-hand side of the

machine:

Operating instructions D5 DATRON AG 8-11

3.0
 8
Maintenance
Lubricating instructions

 Open the control cabinet

 Loosen 6 screws
 Remove maintenance flap

Fig. 8-4: Floating bearings lubricating nipples

For milling application, once per  Attach grease press to the lubricating nipple, pump 3x
year / for wet machining, every 3
months  Lubricate both lubricating nipples in this manner

8.2.2 Lubricating the B axis

a b

Fig. 8-5: B-axis lubricating nipples

For milling application, once per  Open the machine door

year / for wet machining, every 3
months  Attach grease press to the lubricating nipple, pump4x
 Lubricate all 3 lubricating nipples in this manner

8-12 DATRON AG Operating instructions D5

3.0
 8
Maintenance
Lubricating instructions

NOTE Lubricating nipples a and b do not receive maintenance. These are

only lubricated when they are first filled in the factory and do not
require any additional maintenance.

8.2.3 Lubricating the lubricating nipples on the back side of the machine

The lubricating nipples for the rail vehicles and the ball screw
spindles are located behind the maintenance flap on the rear
machine panel.

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16

Fig. 8-6: Lubricating nipples on back side of machine

Remove the maintenance flap at the back of the machine:

 Open the 4 sash locks using a wrench

 Remove maintenance flap

every 6 months Lubricating nipples no. 5, 7, 14, 15

 Attach grease press to the lubricating nipple, pump 3x

1x per year Lubricating nipples no. 1, 2, 8, 9

 Attach grease press to the lubricating nipple, pump 3x

1x per year Lubricating nipples no. 3, 4, 6, 10, 11, 12, 13, 16

 Attach grease press to lubricating nipple, pump 4x

 Remount all maintenance flaps in the opposite order

Operating instructions D5 DATRON AG 8-13

3.0
 8
Maintenance
Disposal

✓ The machine is now ready for use

8.3 Disposal

8.3.1 Disposal of consumable materials

Coolant, dust and machined material waste should be disposed of

environmentally friendly in accordance with the manufacturers'
instructions. Here, observe the valid regional and national
regulations in your region.

8.3.2 Dismantling and disposal of the machine

Once the service life of your DATRON machine has expired,

dispose of it in an environmentally-friendly manner.

NOTE If necessary, have a professional company from the machine

scrap/dismantling sector dispose of the machine.

Please observe the following!

Only use trained or instructed personnel. Wear the appropriate
protective gear for each type of dismantling work. Use suitable
CAUTION
tools and lifting gear for dismantling.

Dismounting Dismantle as follows:

 Put the machine out of operation

 Disconnect the machine from the electrical and pneumatic
mains
 Vent any existing pressure accumulators and pressure-
conducting lines
 Disassemble all components and sort them according to
material

Disposal Dispose of the individual materials in an environmentally-friendly

manner (observe the data sheets, if necessary). During disposal,
observe the valid regional and national regulations in your region.

Material list You can find the materials used in the DATRON machine in the
following list:

8-14 DATRON AG Operating instructions D5

3.0
 8
Maintenance
Disposal

Material Contained in components

Electronic components, cables, computers, moni-
Electronics
tor, etc.
Stand, cabin, axes, clamping elements, screws,
Steel
etc.
Gray cast iron Machine bed
Stainless steel Axes, covers, clamping elements, etc.
Aluminium Axes, covers, handling system, etc.
Cast aluminium Moving column, rotary swivel axis
Brass Screw joints, small parts, etc.
Plastics Covers, cable conduits, hoses, plugs, seals, etc.
Polycarbonate Cabin windows
Coolant Spindle cooling unit
Cooling lubricants Cooling lubricant storage tank, in the hoses
Lubricants Axis guides, central lubrication system

Disposal of additional When disposing of other machine components (e. g. spindle,

components spindle cooling unit), observe the notes on disposal in the relevant
operating instructions.

Operating instructions D5 DATRON AG 8-15

3.0
 8
Maintenance
Disposal

8-16 DATRON AG Operating instructions D5

3.0
 9
Troubleshooting

9 Troubleshooting

The following table lists possible error and fault conditions which
can be experienced with the machine, most of which can be
remedied by the user.
Please contact our Service Department if it should prove
impossible to locate an error using this list.

DATRON-Service
Tel.: +49 - (0) 6151 - 1419 - 99
Fax: +49 - (0) 6151 - 1419 - 91
E-mail: [email protected]
www.datron.de

Inform us as precisely as possible of the operating conditions

under which the fault has arisen and what effect it has had.
Replacement components can be hired from DATRON to ensure
that your machine can also be operated in the event of repairs
being carried out on components.
While troubleshooting, make sure you observe the safety
information in the Chapter 8.1, "Maintenance".

Danger from electric shock, burns or fatal injuries!

Checks which may involve coming into contact with the power
supply may only be carried out by electrical personnel!
DANGER

Operating instructions D5 DATRON AG 9-1

3.0
 9
Troubleshooting

Malfunction Cause Remedy

Insert mains power plug
Machine cannot be switched on,
No mains power Turn on the main switch
the machine lighting is off
Check external socket and fuse
You can find information about the You can find information about the
iPad indicates malfunction cause by touching the displayed remedy by touching the displayed
malfunction on the iPad. malfunction on the iPad.
Protective glass in front of the cam- Clean protective glass with soft
LiveView display on iPad is blurry
era lens is dirty cloth.
Collet chuck loose Check
Noticeable noise or running behav-
iour of the milling spindle Inform DATRON Service Depart-
Spindle bearing defective
ment
Spindle blocked or can only be
Inform DATRON Service Depart-
No spindle running turned manually with difficulty
ment
(possible bearing damage)
Check the air pressure and set to 6.5
Air pressure has dropped below 6 bar on the pressure reducer (rear
The tool is not inserted correctly bar side of machine behind the top cov-
in the magazine in automatic tool er at the upper left).
change. Clean the collet chuck (see also
Collet chuck dirty Chapter 6.7.2, "Inserting tool in the
machine")
Check machine origin, mill a test die
Machine origin is incorrect (see instructions:Checking the D5
machine origin)
Check CAM settings, mill a test cone
Poor milling result, work piece di-
Incorrect CAM settings (see instructions: Checking the CAM
mensions exceed the tolerance
settings)
There are chips between the HSK Remove tool, clean taper surface of
collet chuck and the HSK seat on the HSK collet chuck and HSK taper
the spindle. on the spindle with a cloth.
Poor milling result, work piece di-
mensions exceed the tolerance al- Check the scanner and calibrate it if
Incorrect scanner settings
though test die and test cone are required
within the tolerance
Check Tool path and enter the cor-
Milling tool breakage Worn milling cutter rect value, if necessary. See Soft-
ware help, main tool menu

9-2 DATRON AG Operating instructions D5

3.0
 9
Troubleshooting

Malfunction Cause Remedy

See Chapter 6.3, "Fix blank in the
blank holder":

Observe the permissible dimension

and tolerances of the blank!

Check proper fixing of the blank:

Blank is not properly fixed in the
blank holder: ■ Make sure the screws are tight
■ Make sure the clamping rings
■ Screws are loose are used correctly
■ Blank holder is defective ■ Pay attention to clamping ring
■ Abort of milling program wear, and exchange if necessary
■ Chips hinder fixing
■ "Overcurrent" error message (maximum of 25 milling cycles!)

■ Poor milling result ■ Make sure that no chips are

between the clamping positions
■ Milling tool breakage and the blank seat
■ Machine crash ■ Check blank holder and fix blank
properly, if necessary

■ Thoroughly clean the recesses

in the blank holder with a
toothbrush
Blank holder or blank holder seat is ■ Thoroughly clean all around the
dirty blank holder with a brush
■ Clean the blank holder seat in
the machine with the cleaning
brushes included in delivery
For the wet machining option: A
puddle is forming under the ma- Splash guard is not inserted Insert splash guard
chine
For the wet machining option: Check coolant level and refill, if nec-
Coolant level is too low
Grinding operation is interrupted essary
Close the machine door (if it is
open)
Danger of suffocation! Leave the
For the extinguishing system op-
room immediately!
tion: A fire or overheating was detected
After the extinguishing operation is
Siren and signal lamps are trig- in the machine
finished, ventilate thoroughly and
gered
inform DATRON Service.
See extinguishing system operating
instructions.

Operating instructions D5 DATRON AG 9-3

3.0
 9
Troubleshooting

9-4 DATRON AG Operating instructions D5

3.0
 10
EC Declaration of Conformity for a machine

10 EC Declaration of Conformity for a machine

according to Appendix II 1A Directive 2006/42/EC

DATRON AG
In den Gänsäckern 5
D-64367 Mühltal

certifies that the following described machine meets all relevant provisions of the machinery directive
2006/42/EC. The machine also meets all provisions of the directives for electrical equipment 2006/95/
EC and for electromagnetic compatibility 2004/108/EC.

CNC machining system

DATRON D5, , 2013

The technical documentation belonging to the machine was drawn up according to Appendix VII Part A
2006/42/EC. Mr. Hofmeister (for address, see manufacturer) is authorized to compile the technical documenta-
tion.

EN 349, EN 953, EN 954-1, EN 1037, EN 1088, EN 12100-1, EN 12100-2, EN 13850, EN 13855

EN 13857, EN 14121-1, EN 60204-1

The versions of the directives and standards apply which were valid when this declaration was creat-
ed. If changes are made that are not agreed upon with DATRON AG, this declaration of conformity is
void.

Date Board

06.02.2013

Signature

Operating instructions D5 DATRON AG 10-1

3.0