TDC-510S

VER:IM-Q080900
NO:P20ABES510
LEADWELL TDC-510S INSTRUCTION MANUAL P20ABES510
PERFACE

Thank you for purchasing the CNC MACHINE TOOL CENTER. We at Leadwell are
confident your purchase will greatly expand your work capacity and efficiency. This issue
has been prepared to assist you on ordering replacement, servicing parts, technical
problem for the type of TDC-510. Due to constant improvement in design, you may find
slight variations from the machine delivered to you. This merely indicates that equipment
improvements have been made to better meet your requirements. If you have any question
on your machine or this publication, please contact your Leadwell dealer or local agent.

I PERFACE
BRIEF INTRODUCTION OF LEADWELL

Founded in 1980, Leadwell CNC Machines Mfg., Corp., is now the largest CNC machine
tool maker in Taiwan. Leadwell is constantly searching for perfection by upgrading the
performance, product quality, and reliability of it‘s products, which range from CNC
Vertical / Horizontal Machining Centers, Turning Centers, Plastic Injection Molding
Machines, Grinders, Tapping / Drilling Machines to Laser Cutting Machines, 5-face
Machining Centers and Flexible Manufacturing Systems (FMS).

In 1993 Leadwell received the Outstanding Product Award--SYMBOL OF

EXCELLENCE and its quality passed ISO recognition. Hence, Leadwell products are
recognized as highly reliable. In October, 1997 Leadwell has received the National
Quality Award by the Executive Yuan, R.O.C. We have developed our products total
quality management with outstanding result.

II PERFACE
CHANGES AND COPYING

Leadwell reserves the right to make any change or modification to this

manual without giving previous notice and without incurring any obligation.
You may not reproduce or transmit in any form or by any means without the
written permission of Leadwell.

@ Copyright 2008 Leadwell CNC Machines Mfg., Corp..

All rights reserved.

III PERFACE
 CONTENT
I. PREFACE, INTRODUCTION, COPYRIGHT
PAGES

1. SAFETY PRECAUTIONS

1-1 SAFETY RULES.......................................................................................................... 1-1

1-2 GENERAL SAFETY INSTRUCTIONS....................................................................... 1-3

1-3 THE DIAGRAMS AND DRAWINGS OF SAFETY................................................... 1-5

1-4 DANGER AREAS........................................................................................................ 1-7

2. MACHINE VIEWING

2-1 BASIC INTRODUCTION............................................................................................ 2-1

2-2 MACHINE COMPONENT.......................................................................................... 2-1

2-3 MACHINE FEATURE................................................................................................. 2-2

2-4 SPECIFICATIONS OF MACHINE.............................................................................. 2-4

2-5 TABLE SPECIFICATION............................................................................................ 2-6

2-6 TOOL SPECIFICATION.............................................................................................. 2-6

3. PREPARATION

3-1 ENVIRONMENTAL REQUIREMENT....................................................................... 3-1

3-2 POWER SUPPLY......................................................................................................... 3-1

3-3 TRANSPORTATION................................................................................................... 3-4

4. INSTALLATION

4-1 PRECAUTION............................................................................................................. 4-1

4-2 THE PROCEDURE OF INSTALLATION................................................................... 4-1

4-3 POSITION AND PREPARATION............................................................................... 4-2

4-4 REMOVE THE FIX BLOCKS..................................................................................... 4-3

4-5 POWER ON.................................................................................................................. 4-3

5. KEY PARTS FEATURE

5-1 LUBRICATION SYSTEM........................................................................................... 5-1

5-2 COOLANT SYSTEM................................................................................................... 5-4

0D-CONTENET
 CONTENT
5-3 SPINDLE OIL COOLER SYSTEM........................................................................... 5-6

5-4 PNEUMATIC SYSTEM............................................................................................. 5-11

5-5 HEAT EXCHANGER SYSTEM................................................................................ 5-14

6. COORDINATION SYSTEM

6-1 PROGRAMMING ZERO POINT................................................................................. 6-1

6-2 THE FLOWCHART OF ATC OPERATION............................................................... 6-1

7. CLEAN AND MAINTENANCE

7-1 DAILY MAINTENANCE............................................................................................ 7-1

7-2 WEEKLY MAINTENCE.............................................................................................. 7-2

7-3 SEMIANNUAL MAINTENANCE............................................................................... 7-2

7-4 ANNUAL MAINTENANCE........................................................................................ 7-3

【APPENDIX】CAUTION：SPINDLE OPERATION

0D-CONTENET
1 SAFETY PRECAUTIONS
This machine is provided with a number of safety devices to protect personnel and
equipment from injury and damage. Operators should not, however, rely solely upon
these safety devices but should operate the machine after fully understanding what
special precautions to take by reading the following statements thoroughly.

1-1 However, safe operation cannot be ensured if operators use a CNC Machine
Center improperly or do not follow safety rules properly. Failure to comply
with these rules may result in death, injury, or damage to the machine and/or
products. In addition to the safety information in this manual, common sense
tells us there are many "Don'ts" when operating a machine. Unless an
operation is specifically stated in this instruction manual, consider that
operation a "Don't".

1-1-1 The basic conditions given below must always be strictly followed.

‧ Only qualified personnel are permitted to maintain and/or operate this machine.

‧ Read the instruction manual thoroughly and make sure the contents are
completely understood in order to operate a machine efficiently and safely.

‧ Always keep this safety paragraph and the instruction manual at a designated
place near the machine so that they can be easily accessed whenever required.

‧ Use safety shoes which are not damaged by oil, safety goggles with side covers,
safety clothes and other safety protection.

‧ Keys must be kept by a senior qualified person.

‧ Be sure there are no articles around the machine.

‧ Turn off the power source before leaving, checking and daily work.

‧ All persons concerned with operation and maintenance of this machine must be
aware of the emergency stop buttons and switches' location, functions and
operation.

01-TDC-510S-1E 1-1
 ‧ In the event of power failure, turn off the main circuit breaker immediately.

‧ Use the recommended hydraulic oils, lubricants and grease or acceptable

equivalents.

‧ Replacement fuses should have the proper current ratings.

‧ Protect the NC unit, operating panel, electric control panel, etc., from shocks,
since this could cause a failure or malfunction.

‧ Do not change parameters, volumes and other electrical settings unnecessarily. If

such changes are unavoidable, record the values prior the change so that they can
be returned to their original settings if necessary.

‧ Do not soil, scratch or remove the caution plate. Should it become illegible or be
missing, order another caution plate from the supplier.

‧ Whenever operating a forklift truck, over crane similar equipment, special care
should be taken to prevent collisions and damage to surroundings.

01-TDC-510S-1E 1-2
1-2 GENERAL SAFETY INSTRUCTIONS
1-2-1 CAUTIONS OF OPERATING MACHINE :

‧ Only well-trained personnel may operate this machine.

‧ Always wear helmet, protecting glasses, safety shoes and other protecting equipment as
required while operating this machine.

‧ Do not wear loose clothing or jewelry that can be caught by moving parts of machine.

‧ Do not touch the chip and blade tip of the cutter with naked hands or the moving parts
with gloves.

‧ During operating, do not take the chip away or touch the rotating portion parts with
naked hands and other tools.

‧ When performing heavy-duty machining, carefully prevent chips from being

accumulated since hot chips can catch fire.

‧ Do not touch any switches with wet fingers.

‧ Always remember the position of the emergency stop button, so that you can press the
button immediately if accident occurred.

‧ Never operate the machine, unless everything is completely set down.

‧ Do not use fuses other than those are specified.

‧ Pay attention to the high voltage devices and keep away from them as possible as you
can.

‧ When the machine is operating, do not put your hands into the rotating and moving
objects.

‧ Stop the machine before adjusting the position of coolant nozzle or disposing the chips.

‧ Always turn off the power before performing maintenance or inspection.

‧ Cables, cords or electric wires whose insulation is damaged can produce current leaks
and electric shocks. Before using, please check their condition.

‧ Do not operate switches with gloves. This could cause malfunctions, damage, etc..

‧ Do not cut the kind of material which are easy to cause fire on this machine, such as
magnesium, magnesium ally or other material with lower melting point.

‧ During automatic operating, never open the machine door occasionally.

‧ During the time of worming, do not touch or operate the machine parts.

01-TDC-510S-1E 1-3
1-2-2 ROUTINE INSPECTIONS :

‧ Check pressure gauges for proper readings.

‧ Check motors and other parts for being abnormal noises or not.

‧ Check the motor lubrication, sliding parts for evidence of proper lubrication.
‧ Check safety covers and safety devices for proper operation.
‧ Make sure the emergency stop button is under the release condition.

‧ Before the first time to use, each sliding parts must be freshly lubricated after unpacking
or keeping the machine idle for a period. For the lubricant and so on, keep the
lubricating oil pump working unite oil oozes out from wiper. Contact our service
station or agents in connection with what procedure should be taken since it depends on
the type of machine.
‧ Clean the tank so that any abnormalities can be found easily.

‧ Make sure that the gauges for hydraulic pressure, air pressure, lubricating oil pressure
indicated the correct values.
‧ Make sure that lubricating oil and hydraulic oil are properly supplied to the correct
places.
‧ Oil reservoirs should be filled to indicated levels. Check and fill it up, if necessary.

‧ Check the coolant level on the tank, and fill it with coolant, if necessary.

‧ All parts and waste oils should be removed by the operator and placed far enough away
from the machine in safety.
‧ Make sure each of pipe and joint are connected tightly.

1-2-3 WARM UP AND PREPARATION :

‧ The power cable from the factory feeder switch to the machine main circuit breaker
check if there is a sufficient sectional area to handle the electric power used.

‧ Warm up the machine, especially the spindle and feed shaft by running for ten or twenty
minutes at about half or one-third the maximum speed under the automatic operation
mode.

‧ Wire ropes or slings should be strong enough to handle the loads to be lifted and should
conform to the specified provisions.
‧ Tooling should be conformed to the machine specifications, dimensions and type.

‧After installing a tool, you‘d better make a trial run.

01-TDC-510S-1E 1-4
1-3 THE DIAGRAMS AND DRAWINGS OF SAFETY

1-3-1 WARNING SIGNS AND LABELS :

There are several specific signs and labels on the machine. These signs and labels are
attached to the machine at easy-to-see locations. Please take the time to familiarize
yourself with these safety signs.
DANGER : Indicated an imminently hazardous situation which, if not avoided, could result
in death or serious injury.

WARNING : Indicated a potentially hazardous situation which, if not avoided, could result
in death or serious injury.

CAUTION : Indicated a potentially hazardous situation which, if not avoided, might result in
moderate danger to the machine and death or serious injury to operator.

LABELS : Indicated some special purpose or production information examined by Q.C. dept.

Make sure that you can read all warning and instruction labels. Clean or replace these labels
if they are too dirty to read or see the label signs. By using a cloth, water and soap to clean
them. Do not use solvent, gasoline or unknown solution. You must replace the new labels
if they are broke, missing or the words cannot be recognized. In addition to the information
given on safety labels, there is a variety of other cautionary information which must be
observed by operators during machine installation, operating and maintenance. Read all
safety-related information carefully. Failure to observe the danger of caution information
can lead operators to serious injury or damage to the machine. Always observe this
information during machine installation, operation and maintenance. These warning signs and
labels as shown as following pages.

01-TDC-510S-1E 1-5
01-TDC-510S-1E 1-6
1-4 DANGER AREAS

1-4-1 AREA WITH MOVING PARTS :

When no safety guarding, the inside of machine is an extremely dangerous area due to
High-speed spindle‘s rotation, tool X, Y and Z axes movements, tool magazine rotation,
tool arm rotation and quill motions. In addition to chips and coolant are constantly
bouncing and splashing in a wet, very hot environment. In electric controlling cabinet,
it is touched, can produce current leak and electric shock without protection or
insulation articles. So we had stacked labels on the cabinet but also warning
statements in the instruction manual.

AXES MOVING DIRECTION

1-4-2 ELECTRIC COMPONENTS OF HIGH VOLTAGE AREA :

01-TDC-510S-1E 1-7
2 MACHINE VIEWING

2-1 BASIC INTRODUCTION :

‧ For the safety concern, it is designed with full guarding to protect the people from the
moving elements while operation. The door of the guards is interlocked with NC controller
to stop the spindle revolution and the axes movement while the door opened in operating
mode.

‧ It is designed that only a skilled person is allowed to operate this machine, otherwise he
must be trained until he know how to operate it safely.

‧ It is designed having automatic mode and handle mode, any settings and adjusting only can
be done under handle mode or shut off the power source.

‧ Well-ribbed base, saddle and column can achieve the maximum rigidity in this class of
machine.

‧ Thermal deformations are minimized for its symmetric structure designed.

‧ Extremely rigid spindle headstock construction achieve heavy duty cutting and high
precision machining.

‧ Each set of linear guide ways are finely adjusted to ensure smooth travel and high precision
after a long period of machining.

‧ Specially designed HTD (High Torque Drive) pulleys mean both non-slip transmission and
lower noise level.

‧ The ergonomically designed controls are easily accessible to the operator.

‧ Under normal operating condition and with well maintenance, it will not necessary to renew
many components except those are consumable.

The intended life of this machine is counted by :

8 hrs X 6 days X 4 weeks X 12 months X 10 years = 23040 hrs

2-2 MACHINE COMPONENT :

The MCV-760/1000BP machines basically consists of base, column, saddle, table,

transmission system of three axes, A.T.C system, operation cabinet, headstock with spindle,
chip tank, coolant tank, electric controlling cabinet, pneumatic system, lubrication system,
etc..
02-TDC-510S-2E
2-1
2-3 MACHINE FEATURE :
2-3-1 NOMENCLATURE :

2-3-2 MACHINE OUTLINE AND MAJOR DIMENSIONS :

02-TDC-510S-2E
2-2
02-TDC-510S-2E
2-3
02-TDC-510S-2E
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2-4 SPECIFICATION OF MACHINE TDC-510S

SPECIFICATIONS
Capacity
X-axis travel mm(in) 510(20.1)

Y-axis travel mm(in) 350(13.8)

Z-axis travel mm(in) 310(12.2) 400(15.7)

Distance from table(pallet) top to spindle end mm(in) 150(5.9)~460(17.7) 150(5.9)~550(21.7)

Distance from column front to spindle center mm(in) 370(14.6)

Table（pallet）
Table dimensions mm(in) 600(23.6)x350(13.8)

Permissible mass of workpiece kg(lbm) 250(551)

Table working surface configuratin mm 18(0.7)x125(4.9)x3

Height from floor to table top mm(in) 868(34.2)

Spindle FANUC
-1
min
Spindle speeds 10000
Number of spindle speed ranges ---

Spindle nose(nominal size,NO.) 7/24 Taper,NO.30

mm 45
Spindle bearing inner diameter

Cont.rated spindle torque N․m(lbf-ft) 47.7(35.2)

Feedrate
Rapid traverse m/min(IPM) 48 (1890)
Feedrate m/min(IPM) 10 (394)
Jog feedrate mm/min(IPM) ---
A.T.C Drum type Arm type
Tool shank(nominal size,NO.) BT-30

Retention knob(nominal size,NO.) MAS-P30T-1

Tool storage capacity 12 20

Max. tool diameter(with adjacent tools) mm(in) 75(3) 68(2.6)

Max. tool diameter(without adjacent tools) mm(in) 100(3.9)

Max. tool mass kg(lb) 3(6.6)

Max. tool length mm(in) 200(7.9)

Tool change time（tool to tool） sec 1.5 0.87

Tool change time（chip to chip） sec 3.0 1.6

Tool selection Random

Motors FANUC Motor type
KW(HP) 11(14.7)
Spindle motor（30min） α8/8000i
KW(HP) 1.6(2.1)
X-axis feed motor α8/3000i

02-TDC-510S-2E
2-5
 KW(HP) 3.0(4.0)
Y-axis feed motor α12/3000i
KW(HP) 3.0(4.0)
Z-axis feed motor α12/3000i
Hydraulic pump motor KW(HP) ---

Lubricant pump motor W 4

Coolant pump motor KW(HP) 0.86(1.15)

Power sources FANUC

Electrical power supply KVA 25
Compressed air pressure Mpa（psi） 0.6(87)
Compressed air flow rate L/min 200
Tank capacity
Hydraulic oil tank L ---
Lubricant tank L 2
Coolant tank L 180
Machine size
Height of machine mm(in) 2504(98.5)
Floor space mm(in) 1500×2724(59.1×107.2)
Mass of machine Kg(lb) 3000(6610)
Miscellaneous
Positioning accuracy X,Y,Z VDI(3441) mm 0.01/Full
Repeatability X,Y,Z VDI(3441) mm 0.007/Full

02-TDC-510S-2E
2-6
2-5 TABLE SPECIFICATION :

2-6 TOOL SPECIFICATION :

02-TDC-510S-2E
2-7
3 PREPARATION

3-1 ENVIRONMENTAL REQUIREMENT :

(1) Where the machine tool avoid exposing to the direct sunlight and/or near to a heat source,
etc.. Ambient temperature during operation : 0 thru 40 ℃ (32℉ to 104℉).

(2) Avoid a location where the humidity is considerable fluctuating and/or it is highly humid;
normally within 30％to 75％ in relative humidity.

(3) Avoid using the machine tool under such environments as to be specially dustful and/or to
have a vaporous organic corrosive gas highly concentrated.

(4) where there is no vibration source in the surroundings.

(5) Flat and smooth ground without dust or other particles. The required bearing pressure of the
floor is at least 5000 kg/m2.

(6) The machine must be protected from electrical noise sources, such as electric welders and an
electric discharge machines.

(7) Always ground machines independently, the ground resistance is 100 ohms or less and the
length of ground cable is as short as possible.

(8) The sound pressure level at the operator‘s position is under 80dbA. (According to JIS B6004,
1980; Method of sound measurement for machine tools.) It is the policy of the company to
remedy the machine if the sound is over 80 dbA while running test.

(9) Foundation should be constructed of either reinforced or non-reinforced concrete with

thickness and consistency compatible to industry standards for machine weight.

(10) Protect the machine from exposing to the source of electromagnetic interfering or radiated
emission. All signal cables and wire have been connected to ground and protected by
cabinet or isolate conduit.

3-2 POWER SUPPLY :

The current standard voltage in the Republic of China is AC 220V of power system. It is
recommended that the electrical equipment of a machine only has one power supply
connection. When other voltages are required within the machine, then these should be

03-TDC-510S-3E
3-1
 supplied by equipment which is part of machine such as transformer, motor generator.
3-2-1 POWER REQUIREMENTS :

General voltage supply : ±10％

Frequency deviations : ±2％

Voltage loss : up to 10ms

Voltage peaks : up to 200％ of the rate r.m.s. supply voltage

3-2-2 WIRING :

The connecting cable to main power source specified as following table :

POWER WIRE LENGTH

φ8
4M
FOR AC220V
25KVA
(FANUC) φ8
4M
FOR AC380V

3-2-3 POWER CAPACITY :

DESCRIPTION SPECIFICATION/ FANUC

Power Required 25 kva

Frequency 50/60 Hz ±1％

Spindle Motor Power(15min.) 11 kw (14.7Hp)

X/Y/Z Axes Servo Motor Power 1.6/3.0/3.0 kw

NC Switch power 1 kw

Lubrication Pump Power 4w

Coolant Pump Power 860 w (220V)

03-TDC-510S-3E
3-2
 Tool Changer Motor Power 90 w (220V)

Chip Conveyor Motor Power (Option) 93 w (1/8Hp)

3-2-4 TRAVEL RANGE :

3-2-5 SPINDLE OUTPUT DIAGRAM :

03-TDC-510S-3E
3-3
 TDC-510S(α8/8000i) (△connection))

80 16
70.03N-m
1500pm

60 11kW 6000rpm
12

47.75N-m

11kW 連續主軸扭力(N-m)
7.5kW
N-m 40 8
30分主軸扭力(N-m)

α15連續定格出力(KW)

30分定格出力(KW)
5.5kW

20 4

0 0
0 625 1250 1875 2500 3125 3750 4375 5000 5625 6250 6875 7500 8125 8750 9375 10000
rpm

3-3 TRANSPORTATION

3-3-1 PRECAUTION :
1. Only trained, qualified workers should operate forklift trucks, cranes or similar equipment
and apply slings.
2. Only an authorized technician should perform work with the machine hoisting.
3. Use only wires of dimensions specified in the manual. They must be strong enough to
support the weight of the machine.
4. Before hoisting the machine, make sure that each of the units is fixed securely.

3-3-2 TRANSPORTATION :
The following is the drawings of hoisting machine and equipments.

03-TDC-510S-3E
3-4
03-TDC-510S-3E
3-5
4 INSTALLATION
4-1 PRECAUTION :
1. Always the authorized personnel can remove the wooden cage.
2. Be careful during remove the wooden cage or vacuum package and keep away from
damage onto the machine inside or people around will get injured.

3. Keep clean around the machine and floor, especially pay attention to the nails and other
particles before install.

4. Check the rope used to lift the machine, if it is both strong enough and in good condition
for the weight of machine.
5. Ensure that there is a little clearance between the back panel of machine and forklift apron.
6. Be sure electrical cables and wire will not be damaged during lifting the machine from the
skid.

4-2 THE PROCEDURE OF INSTALLATION :

1. Take off the plate around the wooden cage and volatile corrosion inhibiting film, until the
machine left on the shipping pallet.

2. Remove the other accessories on the machine such as hydraulic tank, chip tank, chip guard,
etc.. Then take off the packing bag.

3. Release the bolts and nuts fixed on the wooden skid.

4. Make sure that the wooden block for supporting is fixed securely.

04-TDC-510S-4E
4-1
4-3 POSITION AND PREPARATION :
1. After settling down the machine and accessories ports on adequate site, put the foundation
pads under the foundation bolts. Then position the machine. (Refer to the foundation
drawing)

04-TDC-510S-4E
4-2
 2. All the bare parts of the machine which have been coated with a rust inhibitor for transport
must be carefully cleaned by rags with paraffin or fuel oil and wrung out. Toluene
compounds must not be used.

3. After installation and cleaning, connect the wire to the power source and ensure the
requirement of power capacity is proper.
4. Power on the main power and switch on the machine then check if it is any unusual things
occurred.
4-4 REMOVE THE FIXED BLOCKS :
1. Refer to the drawing of fixed blocks, take them off when install machine done.

04-TDC-510S-4E
4-3
 2. Except authorized personnel, do not remove the shipping support from beneath the machine
as you like anytime. Our service engineer will do with the job, if you need.

4-5 POWER ON :

1. Make sure the main power supplier switch is turned off before the power cable connected to
the power source.
2. Connect the wire of chip conveyor with the socket on the bottom of electric controlling
cabinet.
3. Connect the main cable of machine with the terminal in power source box of factory.
4. Check if the voltage capacity is matched with the power source and machine system
requirement .
5. Check if the phrases of motors and pump are correct or by phrase-meter.
6. After everything settle down, power on and turn on the main switches of machine which are
on the top of power cabinet door and the side of operation panel. Then check there are any
abnormal signal or alarm appeared on the CRT or operation panel.
7. Let the spindle headstock downward a little and ensure the upward wind is from the cool
fan of spindle motor.
8. If there is no deployment on the screen after power on, please refer to the parameter tables
of electric manual to input them and restart again.
9.The well-trained, authorized operator could operate the machine.

04-TDC-510S-4E
4-4
5 KEY PARTS FEATURE

5-1 LUBRICATION SYSTEM :

5-1-1 OUTLINE DIMENSION :

5-1-2 FILL UP LUBRICATION OIL :

a. After opening the cap of oil inlet, fill up the clean fresh oil till to the top line of high level.

b. The oil tank should always preserve clean lubricant.

c. In case of impurity remains in the oil tank, please take the oil away and wash the tank, oil
net immediately. Then refill up new oil or it will fail the oil feeding.
d. Adjust oil discharge by taking off the plastic cup and three E type retainers first.
e. Pull the rod up or down till the requirement volumn of discharge is up to the scale on rod,
then fix with the E type retainers.
f. It is necessary to refill up lubricant oil if oil level is below the lower line during operating.

NOTE : 1. The oil quantity will reduce gradually under normal application.
2. Be careful whether the motor is running normally or abnormally, if not, contact to the
local agent or Leadwell service department.
05-TDC-510S-5E
5-1
 -19-
5-1-3 THE FILTER OF LUBRICATION SYSTEM :

a. OUTLINE DIMENSION :

CAUTION : When assembling the straight adaptor, please use sealing tape.

FILTER CHARACTER
Filter type FX-1
Max. using pressure 10 kgf/c ㎡

Filter accuracy 40 μm

NOTE : The FX-1 filter should be changed once year or it will fail application.
05-TDC-510S-5E
5-2
 b. OIL RECOMMENDATION :

The following drawing is a plate of oil usage recommendation .

05-TDC-510S-5E
5-3
5-2 COOLANT SYSTEM

5-2-1 OUTLINE DIMENSION OF COOLANT PUMP :

5-2-2 TECHNICAL DATA :

TYPE GRUNDFOS CH4-20

10 bars (0℃ - +40℃)
Max. operating pressure
6 bars (+41℃ - +90℃)
0.75 bar (20℃/ 50Hz)
Min. inlet pressure
0.68 bar (20℃/ 60Hz)
Liquid temperature range 0℃ - +90℃
Max. ambient temperature +55℃

5-2-3 POSITION OF TERMINAL BOX :

a. The terminal box can be changed to any one of 0°, 90°, 180°. It is not allowed to be
changed by user or owner of this machine.

5-2-4 PIPEWORK :
a. The pipe should be fitted so that any tension caused by variations in temperature does not
affect the pump. A strainer is recommended in cases where solids could enter the suction
pipe and block the pump.

b. The pump suction port must be below the lowest coolant level, for the pump is not
self-priming.

c. If a hose is used as suction pipe, it must be non-collapsible and every joint of the suction
pipe should be completely tight.

d. The discharge pipe should be at least the same diameter as the discharge port of the pump to

05-TDC-510S-5E
5-4
 minimize pressure drop, high flow velocities and noise.

5-2-5 ELECTRICAL CONNECTIONS :

a. The electrical connections should be carried out in accordance with local regulations.
b. The operating voltage and frequency are marked on the nameplate mounted on pump.
c. The pump must be connected to an external on/off switch.

NOTE : Never make any connections in the pump terminal box unless the electricity supply has
been switched off.

5-2-6 PHASE OF THE PUMP :

a. Signal- phase motor (1x110/220V, 60Hz), do not incorprate motor protection and must be
connected to an approved motor starter. The other incorporate a thermal overload switch
and require no additional motor protection.

b. Three-Phases motor must be connected to a motor starter, the set nominal current of which
must correspond to the electrical data on the nameplate.

NOTE : 1. Do not start the pump at first time using until it has been filled with coolant.
2. Every connection are made as shown on the inside of the terminal box cover.
3. The pump should rotate counter0clockwise when viewed from the motor end and
arrows on the motor fan‘s cover indicated the correct direction of rotation.
4. To reverse the direction of rotation, switch off the power supply and interchange any
two of inputing supply wire.

5-4-7 TROUBLESHOOTING :
FAULT CAUSE
Pump does not start. Supply failure.
Control circuit has cut out or is defective.
Motor is defective.
Pump is blocked by impurities.
Pump runs but gives no coolant. Pump is not filled with coolant.
Suction or discharge pipe is blocked by
impurities.
Leakage in suction pipe.
Foot or check valve is blocked.
Pump runs at reduced capacity. Wrong direction of rotation(three-phase).
Suction lift is too great.
Suction or discharge pipe is blocked.
Pump is blocked by impurities.
Foot or check valve is partly blocked.
Pumpstops during operation. Thermal overload switch in motor or external
motor protection cuts out.
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 Control circuit has cut out.

5-3 SPINDLE OIL COOLER SYSTEM (OPTION)

5-3-1 OUTLINE DIMENSION :

TYPE CO-4PT(L0500R134A)

5-3-2 CIRCUIT DIAGRAM :

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5-3-3 WIRE CONNECTION :

1. Be sure R.S.T are in phase after turning on.

2. Check insulation of compressor and pump before running.

3. 23C temperature meter must set at 25℃.

4. Operation switch should be “ON” position.

5. When the negative phase relay is triggered, reconnect two of R.S.T three lines of power
wire.

5-3-4 GENERAL CAUTION :

1. The oil cooler is designed for reducing heat and cooling spindle of CNC machinery. It can
not be used out of the range as following illustration.

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5-7
 2. Oil cooler usse mineral hydraulic oil or lubrication oil and the viscosity is 22-32 Cst.
Phosphoric ester, chlorinated, hydrocarbon type fluids, cutting oil, grinding oil, medicine
or corrosion liquids, gasoline, kerosene fuel and water-soluble liquid can not use on this
unit.

3. Do not fall it flat and strike it as moving and put it on a level and solid floor.

4. Locate the oil cooler at well ventilation place where is free from fire hazard and from
direct sunlight or heat.

5. Be sure the pressure of oil pump is set from 4 to 8 kg/cm2.

6. The pressure loss of outlet pipe should be below 3 kg/cm2.

7. Be sure the installation place of oil cooler unit where exhausting and air suction can be
well performed.(Refer to the following sketches)

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5-8
 8. Fit a suction strainer to the suction end of oil piping which is of 100 to 150 mesh(10-15mm
metal net), therefore, it will be free from damage of compressor and drop of cooling
capacity. Both suction and discharge pipes outside must be designed that the size larger
than the size of outlet and inlet of oil cooler.

9. Before removing the air filter must wait for more 10 minutes after turning off switch.

10. When the refrigerator once stops, wait for more 3 minutes. If not necessary, do not
ON-OFF of the refrigerator.

5-3-5 MAINTENANCE :

1. Be sure to turn off the main power switch when the oil cooler is checked or maintained.

2. Do not brush or use polishing powder, acid, solvent, benzine and hot water to clean the
surface of case. It is necessary, clean with dry cloths and neutral detergent.

3. Clean the suction strainer at the suction end of the oil cooler, oil pipes after work.

4. Wash the air filter once a week.

5. Clean up the dirt on radiator of oil cooler with compressive air once half year.

5-3-6 TROUBLESHOOTING :
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 SITUATION CAUSE REMEDY
Main power turned on, but the Negative phase relay is Reconnect the wiring.
indicate lamp is not lit. triggered Replace the fuse.
Control circuit protector is
blown.
Pump runs but no oil flow and Joint of oil piping is loosened Check the joint of oil pipe at
lower oil circulation rate of air. from suction side. suction side and tighten the
loose joint.
Suction strainer clogged. Clean the suction strainer.
Change the oil of oil tank if the
oil is contaminated.
The oil level in tank is too low. Trace and refill up oil.
undue pressure loss in oil pipe Enlarge the oil pipe diameter
cause actuation of relief valve. or trim shortly the piping.
Oil viscosity too high. Choose the appropriate oil.
Pump runs but the refrigerator Thermostat is OFF. Shift the thermostat setting to
does not work. the lower side until the
refrigerator starts.
Both pump and refrigerator stop. Control circuit protector failed. Replace the fuse.
Power failure. Check the power source.
Buzzer comes out while Air filter clogged. Clean the air filter.
refrigerator runs. Obstacle block the suction or Remove the obstacle.
exhausting port.
High pressure switch actuated. Ambient temperature is too Move the machine to the lower
Thermostat is OFF. high. temperature or far from heat
source.
Compressor motor overload Compressor out of order. Replace the compreessor.
relay actuated.

NOTE :

1. If alarm does not display, motor still runs but oil is not cool, please record the situation
and ask technical service or local agent right away.

2. Damage from cleaning air filter irregularly is not included quarantee period.

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5-4 PENUMATIC SYSTEM

5-4-1 FRL UNIT :

Filter Regulator Lubricator

NO. NAME NO. NAME

1 Body 1 Body
2 Bonnet 2 Sight Dome
3 Valve Assembly 3 Filter Cup
4 Filter Element 4 Damper Guide
5 Baffle 5 Needle Valve
6 Diaphragm Assembly 6 Bowl
7 Deflector 7 O Ring
8 Bowl 8 Damper
9 Spring
10 O Ring(Case)
11 O Ring(Valve)
12 MY seal
13 O Ring
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5-4-2 TECHNICAL DATA AND OUTLINE DIMENSION :

a. TECHNICAL DATA :

TYPE AC3010 FILTER REGULATOR LUBRICATOR

Max. operating pressure 9.9 kgf/c ㎡

Min. operating pressure 1 kgf/c ㎡

Regulating range 0.5～8.5 kgf/ c ㎡

Ambient and media temperature 5～60℃

Pressure gauge indicated 10 kgf/c ㎡

Filter rating 5 μm

Filter bowl capacity 20 cm3

Max. flow rate 1700 l/min
Lubricator bowl capacity 50 c m3
Recommanded oil ISO VG 32 (20℃)

Range of lubricator function 5 drops/min, PIN=5 kgf/ c ㎡, 40l/min

NOTE : 1. Polycarbonate bowls may be damaged and possibly fail if exposed to synthetic oils,
thinner solvents, trichlorethylene, kerosene or other aromatic hydrocarbons. When
used in above atmosphere, please use a metal bowl.

2. Unsuitable for flow is below 100 normal l/min.

3. The drain line should be 8 mm or more and overall line should be less than 5 M.

b. OUTLINE DIMENSION :

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5-4-3 THE SETTING METHOD OF FRL UNIT :

a. Check pressure supply before adjusting system pressure.

b. The adjustment knob is a locking type. Pull the knob upward from the bodyuntil an orange
band is visible. (Show on the drawing)

c. Adjust as necessary, that with watch of the pressure gauge and clockwise rotaton of the knob
results in a increasing pressure or counterclockwise turn will reduce the pressure.

d. Then push the knob back into locking position after adjusting.

e. Adjust oil droplet by turning a knob of needle valve, clockwise turn will increase oil
capacity and counterclockwise turn(fully open) will stop the oil droplet.

5-4-4 THE ROUTE SKETCH OF PNEUMATIC SYSTEM :

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5-5 HEAT EXCHANGER SYSTEM :

5-5-1 OUTLINE DIMENSION OF HEAT EXCHANGER :

5-5-2 GENERAL CAUTION :

1. For using in an ambient with high moisture or oil mist content, calk it with sealing
material around.
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 2. Keep the air inlet portion of heat exchanger open to fresh air.

3. Every month clean the fan net with clean water and reinstall in after completely
dry.

4. Replace the filter once a year.

5-5-3 SPECIFICATION AND TECHNICAL DATA :

TYPE EA-2AR
Cooling Capacity (w/°C) 10
Voltage AC 220V
Quantity of heat 200 W
exchanging
Environment temperature below 35°C

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6 COORDINATION SYSTEM :
6-1 PROGRAMMING ZERO POINT :
When execute a program, it must be determined a program zero point at first. The
programmer determines the zero point after viewing thr machine drawing. The value of
coordination determines a graphic position with 3 perpendicular lines mutually crossing at a
point as shown as following drawing.

6-2 THE FLOWCHART OF ATC OPERATION :

Power on
↓
Return to the reference point on three axes
↓
Prepare the workpiece
↓
Call a proper program
↓
Locate all tools to tool pocket
↓
Mount tool onto the tool magazine
↓
Measure tool length and set tool compensation data
↓
Set work coordination system and zero point
↓
Prepare for automatic operation
↓
Dry run for testing program
↓
Machine program executing

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7 CLEAN AND MAINTENANCE

CAUTION : 1. Shut off the power before doing any maintenance or cleaning job and obey the
instruction or you might be hurt.

2. Any clean or maintenance concerned with removing must be careful and only
well-trained personnel can do it.

7-1 DAILY MAINTENANCE :

7-1-1 BEFORE POWER ON :

a. Inspect if the power cable and external cable are normally connected and the voltage
capacity is matched as machine required.

b. Check if there is oil or coolant leakage arround the coolant pipes.

c. Check if there are enough lubricant for lubrication unit and coolant unit.

d. Check if the pressure gauges of pneumatic unit were indicated to zero position and normal
performance.

e. Check if the auto tool changer unit is at the normal position.

7-1-2 AFTER POWER ON :

a. Check if there is alarm message after NC power on.

b. NC should be ready to execute the program.

c. All the running components should be run at normal condition without noise.

d. The pressure gauge for pneumatic system should be at 6 kg/cm2.

e. Auto lubricator should be actuated to pump oil with flow setting to 3-6 c.c./cycle.

f. The lubricant should flow out to the slideways.

g. The wipers on the telescopic covers should be cleaned from the chips.

h. Test tool changing unit and make sure the unit can work smoothly.

7-1-3 AFTER FINISHING DAILY WORK :

a. Inspectthe oil level of auto lubricator tank to refill up, if it is necessary and is consumed.

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 b. If there is water or dirt in the tank, relieve and change fresh oil.

c. Check the level of coolant to refill up and flush the coolant pump through with clean water
if there is impurities after use.

d. Clean the chips on the chip tank, conveyor, tool tip and tool magazine.

e. Remove and centralize the chips on the chip bucket out side of the shop.

f. The coolant pump which is not being used during periods frost should be drained (shown
as the following sketch) or it will be harmful for pipe and pump. Take off the primiing
plug P and drain plug V for draining.

g. Turn off working light, power supplier and draw out the connector of power cable
whenever finishing work.

7-2 WEEKLY MAINTENANCE :

a. Clean fan net of heat exchanger on electrical cabinet.

b. Clean fan net of spindle oil cooler.

c. Clean fan net of the heat exchanger.

d. Clean the motor fan of chip conveyor .

e. Clean the filter net inside of coolant tank.

f. Clean ATC motor fan and the brake of surrounding motor.

g. Fill the grease for the warm gear of ATC transmission unit.

7-3 SEMIANNUAL MAINTENANCE :

a. Check and re-adjust the machine level and static accuracy.

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 b. Inspect the home position and reset, if necessary.

c. Ensure there is enough of lubricant on the slideway, gear of reducer and change or refill the
fresh oil, such as lubricant, oil cooler tank, etc.

d. Inspect the backlash of ball screw on three axes.

e. Inspect the repeatitive accuracy and geometric accuracy of machine.

f. Replace the fan net of heat exchanger on electrical cabinet.

g. Replace the element of filter on coolant tank, oil cooler unit or other accessary parts.

h. Clean the electrical motor outside and turn off the power at first.

i. Before cleaning the chip or dirt on the conduction block of sensor and magnetic switch, turn
off the power.

j. Check the smooth function of all limit switches for axes and clean the dirt or re-adjust the
position, if necessary.

7-4 ANNUAL MAINTENANCE :

a. Follow the same procedures as mentioned above semiannual maintenance.

b. Replace the oil accirding to the oil recommandation.

c. Replace the filters for auto lubricator or oil cooler and clean the lubrication tank, coolant
tank.

d. Do not pour out the wasting oil or coolant liquid casually. It‘d better remain in oil bucket
periodically and send to the authorities concerned of shop or recycle shop to do with it.

e. Check and correct the geometric accuracy of machine.

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APPENDIX
 Caution: Spindle Operation
A. SPINDLE AIR PURGE：
1.Set spindle air purge pressure at 1.2kg/cm2～1.5kg/cm2.
Caution At power on for turning, check spindle air purge is functioning correctly.
Caution Do not turn off spindle air purge or adjust pressure, it will lead to spindle
defected or damage of spindle.

B. SPINDLE OIL COOLER：

1. Spindle shaft and quill with temperature difference may lead to spindle bearing
burns. Spindle oil cooler temperature set up have to 2°C higher than room
temperature.
2. Rotary type of spindle oil cooler temperature is 25°C at initial. Pls. adjust according
to machine site.
3. Digital spindle oil cooler will detect spindle room temperature, no more adjustment
is required.
Caution At power on for turning, check spindle oil cooler is functioning correctly.

C. SPINDLE WARM UP：

To ensure spindle smooth rotation in long term and long lifetime, at machine,
installation or daily turn on, follows spindle warm up operation.

D. SPINDLE TEMPERATURE INCREASE：

1. This machine spindle was build up with high accuracy of spindle angular ball
bearing of which add with high temperature endurable grease lubricator effective for
maintain its accuracy with low temperature increasing at rotation.
2. If spindle temperature increased higher than 20°C of room temperature, this
indicates abnormal of the spindle. Contact machine builder immediately for
authorized engineer delicate for maintenance will be required.
Caution None authorized personnel disassembling spindle is prohibited. In case this
accident happened, any failure to the spindle is subject to customer’s obligation.

E. SPINDLE HIGH SPEED ROTATION TIME MANAGEMENT：Ref. table 1

1. Extreme speed of spindle rotation do not exceeds 1/4 of daily working hours.
2. Spindle speed stay less than normal rotation speed（85% of extreme spindle
speed）for machining.
3. Spindle run at normal continuous rotation speed do not exceed 8 hours a day.
Otherwise, lower normal rotation speed to 70% of spindle speed, or reduce
spindle speed to minimum speed for 1 hour will be required.

1 01
 4. Spindle speed less than minimum speed is not allowed.

Table 1
Spindle Extreme speed Normal spindle rotation Minimum
specification of speed at speed
Spindle rotation 85% of Spindle peak
8000rpm 8000rpm 7000rpm -
10000rpm 10000rpm 8500rpm 3000rpm
12000rpm 12000rpm 10000rpm 5000rpm
15000rpm 15000rpm 12000rpm 6000rpm

F. SPINDLE GUARANTEE：
1. Spindle of normal operation, general spare parts will be guaranteed for 1 year.
2. Spindle bearing guaranteed for 2000hrs of rotation.

2 01
MEMO