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Machining Center: Use and Maintenance Instruction Manual
Machining Center: Use and Maintenance Instruction Manual
Machining Center: Use and Maintenance Instruction Manual
Mod.: ARTIST
Document: MAN_ARTIST0915en
Edition: 09/2015
Rev.: … Date: 18/09/2015
ARTIST – Use and maintenance instruction manual
Instruction manual for the machine models and the versions listed below.
.
MACHINE MODELS AND VERSIONS DESCRIBED IN THE MANUAL
MODEL DESCRIPTION
Cap. 0
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GENERAL INDEX
General index 0
Foreword 1
Safety information 2
Installation 4
Maintenance 6
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ARTIST – Use and maintenance instruction manual
Cap. 0
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CHAPTER 1 – Foreword
CHAPTER
1 Foreword
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ARTIST – Use and maintenance instruction manual
INDEX
1 Foreword ...................................................................................................................... 1
1.1 Objective of the manual ..................................................................................................................... 4
1.2 Manual addressees............................................................................................................................. 5
1.2.1 Description of symbols, deadlines and abbreviations adopted................................................................ 7
1.2.2 Symbols adopted, glossary of terms and illustrations............................................................................. 7
1.3 Glossary of safety terms .................................................................................................................... 9
1.4 Use and conservation of documentation ........................................................................................ 10
1.5 Update of the manual ....................................................................................................................... 10
1.6 How to request additional copies .................................................................................................... 11
1.7 Manufacturer’s Identification and Contact Details.......................................................................... 11
1.8 Customer service ............................................................................................................................. 12
1.8.1 How to request spare parts................................................................................................................. 13
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CHAPTER 1 – Foreword
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ARTIST – Use and maintenance instruction manual
As foreseen in the Machinery Directive 2006/42/EC, this manual provides information on safety and the
life phases of the machine (transport, installation, use, maintenance, dismantling).
Read carefully and understand this technical publication before intervening at operational level on the
machine or performing adjustment and/or maintenance interventions.
Exclusively abide by the instructions provided and in case of doubt always contact the manufacturer.
This manual provides basic information that the user must know before using the machine. Furthermore,
it contains information on machine maintenance needed to keep it efficient and safe over time.
For proper machine use, please also consult the Software User Manual and any attachments.
The configuration of certain parts or devices described or illustrated in the manual may differ from the
ones supplied with machine without, however, jeopardising its understanding.
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CHAPTER 1 – Foreword
All operations described will be accompanied by a symbol (pictograph) corresponding to the operator
considered more suitable for the task; the symbols at the head of each paragraph correspond to the
addresses of the information provided. Please find below the instructions necessary for the identification
of the different professional figures.
A - Operators
Personnel with no specific skills capable of performing only simple tasks, such as
operating the machine using the controls located on the pushbutton panel, loading
and unloading the materials used in production with installed and enabled
protection guards and service settings.
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ARTIST – Use and maintenance instruction manual
Certain pieces of information of the manual may address non-professional figures (e.g. cleaning
personnel of the premises where the machine is installed) who are not authorised to operate the
machine, but may be close to the premises for different reasons.
G – Common Individual
Non-qualified individuals who are not suitable for carrying out any tasks intended
for the professionals described under items A, B, C, D, E, F and thus not
authorised to operate the machine.
INFORMATION!
Remember that information, training and supervision of common persons (par. G) is up to the
employer.
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CHAPTER 1 – Foreword
For optimum machine use, we recommend you are familiar with the terms and symbols contained in the
manual.
Information addressees
Refer to paragraph “1.2 Addressees of the manual”
DANGER!
The information marked by the symbol on the left and this style denote dangerous situations
for the exposed individual.
WARNING!
The information marked by the symbol on the left and this style denote situations that may
damage the machine.
INFORMATION!
The information marked by the symbol on the left and this style denote useful suggestions
and recommendations for the user.
ENVIRONMENTAL INFORMATION!
The Information marked by the symbol on the left refer to environment-related information, such
as handling hazardous substances, waste or recycling of the used materials produced by the
machine.
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ARTIST – Use and maintenance instruction manual
INFORMATION!
The colours of the photos shown this manual illustrating the machine's structure or
constituting parts may differ from the ones installed on your machine. Remember that the
content of this manual refers to technically comparable machines that represent the machine
you possess and that different colours do not mean that the information provided is incorrect,
except for the cases in which a colour define aspects concerning the safety of exposed
persons.
If the illustrations of this manual are used to explain certain machine functions, they could differ from
the functions of your machine or they could be incomplete. If necessary, and in addition to the
instructions of this manual, it is advisable to consult the specific design of the component or unit on
which intervention is required. For the specific design (e.g. installation layout, assembly unit etc.)
please address the manufacturer.
INFORMATION!
For the sake of clarity, the machine is illustrated without panels and/or protection devices in
this technical manual. Do not use the machine when protection devices are dismantled,
removed and/or disabled.
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CHAPTER 1 – Foreword
Work cloths and overalls that do not specifically protect workers’ safety and health;
Equipment of aid and rescue services;
Personal protective equipment of armed forces, police forces and service personnel for keeping
public order;
Personal protective equipment of means of road transport;
Sports materials;
Self-defense and determent materials;
Portable devices for the identification and reporting of risks and harmful factors.
WORKER
A person who is hired by an employer to perform labour, except people in charge of domestic and family
services, even with a special subordinate work relationship.
Partners of co-operatives or companies who perform their job on behalf of companies and organisations
and users of school, university and professional guidance and training services that have started working
for employers to facilitate or optimise their professional choices are intended as workers.
Students of educational and university institutes and the participants of professional training courses
where one can use laboratories, machines, devices and work equipment in general; chemical, physical
and biological agents are also considered workers. The forenamed subjects are not included in the
calculation of the number of workers for whom particular obligations arise in accordance with this decree.
EMPLOYER
The person who holds an employment relationship with the worker or, in any case, the subject who,
depending on the company type and organisation, is responsible for the company or the productive unit
and has decision making powers and expenses.
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ARTIST – Use and maintenance instruction manual
The consultation of this manual and the documentation provided with the machine is of paramount
importance in order to train users on how to use the machine correctly for productive purposes, on how
to abide by the safety standards and understand the residual risks in the product. The user is required to
be familiar with the contents of the manual concerning the duties he/she is to perform.
Even if the manual provides information on how to use the machine correctly and residual risks
connected with machine use, it cannot replace the user’s experience; users must necessarily be
“experts” who are familiar with the sector and related operational and safety procedures.
The documentation delivered and its content must be checked upon receipt and upon completion of the
training session.
Keep the manual and all attached publications in a place that can be easily accessed by all users.
The information contained in this manual is property of Paolino Bacci S.r.L.; total or partial reproduction
is forbidden without prior authorisation. If you need additional copies of the documentation intended for
machinery users, please send a request to Paolino Bacci S.r.L.
If doubts arise during consultation of this manual, please contact Paolino Bacci S.r.L. before performing
any operation.
Paolino Bacci S.r.L. reserves the right to modify the characteristics of the product and content of this
manual without prior notice.
Paolino Bacci S.r.L. reserves the right to provide a soft copy of the manual. The publication on file is in
PDF (Portable Document File) format; for consultation you need to set up the Adobe® Acrobat®
Reader™ software beforehand. Instructions on installation and use of the Adobe® Acrobat® Reader™
software are available together with the set up file. Further information can be found on the website of
Adobe Systems Incorporate, from which it is possible to download a free version of the Adobe®
Acrobat® Reader™ software.
Adobe® Acrobat® Reader™
If modifications or updates are performed during the lifecycle of the machine by Paolino Bacci S.r.L., a
reviewed copy of this document will be sent to the customer. All contractual copies of the customer will
be destroyed and replaced upon prior contact with Paolino Bacci S.r.L..
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CHAPTER 1 – Foreword
Further copies of this document apart from the contractual ones are available upon request by sending a
regular purchase order to Paolino Bacci S.r.L..
Company name:
Paolino Bacci S.r.l.
Address:
Viale Palermo, 32
56021 CASCINA (PI) - ITALIA
Tel. :
+39 050 754 91
Fax:
+39 050 754 975
Fax assistance:
+39 050 975
E-mail – assistance::
service@bacci.com
Website:
www.bacci.com
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ARTIST – Use and maintenance instruction manual
To guarantee our customers optimum use of the product purchased, Paolino Bacci S.r.L. provides the
following technical support services:
Customer service:
Office services provided by qualified operators, who are able to diagnose and decide upon the
interventions required to restore damaged and malfunctioning machinery components. These services
are provided mainly over the phone; they provide assistance to maintenance technicians during
troubleshooting and repair works. Technical assistance uses the diagnostic service provided via
MODEM if it is installed on the machinery.
Support services are open during the working hours and days mentioned in the following tables. The
office hours outlined in the tables below are based on the time zone of Rome (GMT+1,00 h).
Customer service
8.00 – 18.00 (GMT + 1.00h)
Spare parts support
INFORMATION!
When you require a support/assistance service, please remember to provide the data
indicated on the identification plate of your machine.
INFORMATION!
Ordinary maintenance interventions are up to the user’s personnel. Support interventions on
the machine's systems (electrical, pneumatic etc.) must be performed by qualified personnel
duly authorised by Paolino Bacci S.r.l.
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CHAPTER 1 – Foreword
Serial number.
Machine type.
Warehouse code* Paolino Bacci S.r.L.
Description*.
Quantity*.
INFORMATION!
The code numbers and description of the parts to order are mentioned in the “list of spare
parts" or in the wiring, pneumatic and hydraulic diagrams provided with the machine. Should
these data not be available, contact Paolino Bacci S.r.L.
DANGER!
You must use original spare parts. The replacement of parts with non-original parts or parts
that have not been previously authorised by Paolino Bacci S.r.L. is at the customer's own
risk and shall result in the immediate expiry of the warranty and of the certification pursuant
to applicable community directives.
Machine performance and safe operation are guaranteed with the use of original parts as
provided in the original project.
Paolino Bacci S.r.L. cannot be held liable for malfunctioning, damages or injuries caused by
the use of non-original spare parts.
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CHAPTER 2 – Safety information
CHAPTER
2 Safety information
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INDEX
2 Safety information ....................................................................................................... 1
2.1 Qualification of personnel .................................................................................................................. 4
2.2 General safety rules ........................................................................................................................... 5
2.3 Use of Personal protective equipment (PPE) .................................................................................... 7
2.3.1 Minimum equipment ............................................................................................................................. 8
2.4 Safety and warning sings................................................................................................................... 9
2.4.1 Description of hazard images ............................................................................................................... 9
2.4.2 Description of prohibition images ........................................................................................................ 13
2.4.3 Description of obligation symbols........................................................................................................ 14
2.4.4 Description of miscellaneous and customised symbols ........................................................................ 14
2.4.5 Location of information and warnings on the machine.......................................................................... 15
2.5 Envisaged use .................................................................................................................................. 16
2.6 Reasonably foreseeable incorrect use ............................................................................................ 17
2.7 Information on the work environment ............................................................................................. 18
2.7.1 Illumination and aeration .................................................................................................................... 18
2.7.2 Dust removal system .......................................................................................................................... 18
2.7.3 Vibrations .......................................................................................................................................... 18
2.7.4 Electromagnetic emissions ................................................................................................................. 18
2.7.5 Noise hazards typical of the wood industry.......................................................................................... 19
2.8 Safety devices .................................................................................................................................. 20
2.8.1 Safety device checks.......................................................................................................................... 24
2.8.1.1 Emergency pushbutton check .......................................................................................... 24
2.8.1.2 Fixed and removable guard checks.................................................................................. 24
2.8.1.3 PADLOCK STATION, clamps, padlock checks ................................................................. 25
2.8.1.4 Warning lights and horn check ......................................................................................... 25
2.8.1.5 Key management check .................................................................................................. 25
2.9 Machine areas and workstations ..................................................................................................... 26
2.9.1 Identification of work areas ................................................................................................................. 27
2.9.2 Responsibilities of the operator in charge of running the machine ........................................................ 27
2.9.3 Responsibilities of the operator in charge of loading/unloading the machine......................................... 27
2.9.4 Warnings regarding conduct inside the all-around enclosure................................................................ 28
2.10 Machine operations/functions ......................................................................................................... 28
2.11 Safety regulations for spindle use and maintenance ..................................................................... 31
2.12 Safety regulations for use and maintenance of mechanical components ..................................... 31
2.13 Safety regulations for programming................................................................................................ 32
2.14 Safety regulations for electrical maintenance................................................................................. 32
2.15 Safety regulations for pneumatic maintenance .............................................................................. 34
2.16 Residual risks ................................................................................................................................... 34
2.16.1 Residual risks present during any stage .............................................................................................. 35
2.16.1.1 Passing through or stationing near dangerous areas – (Risk ID: 00.01) ............................. 35
2.16.2 Residual risks during normal operation ............................................................................................... 36
2.16.2.1 Normal operation – (Risk ID: 04.06) ................................................................................. 36
2.16.2.2 Normal operation – (Risk ID: 04.07) ................................................................................. 37
2.16.3 Residual risks during assembly/disassembly ....................................................................................... 38
2.16.3.1 Assembly/disassembly– (Risk ID: 06.01).......................................................................... 38
2.16.3.2 Assembly/disassembly– (Risk ID: 06.03).......................................................................... 39
2.16.4 Residual risks during handling and transportation................................................................................ 40
2.16.4.1 Handling and transportation– (Risk ID: 07.01) .................................................................. 40
2.16.5 Residual risks during various activities – inspection, cleaning, etc. ....................................................... 41
2.16.5.1 Various activities – inspection, cleaning, etc. – (Risk ID: 08.03)......................................... 41
2.16.6 Residual risks during work on the electrical system ............................................................................. 42
2.16.6.1 Work on the electrical system – (Risk ID: 09.01) ............................................................... 42
2.16.6.2 Work on the electrical system – (Risk ID: 09.02) ............................................................... 43
2.16.7 Residual risks during lubrication/greasing ........................................................................................... 44
2.16.7.1 Lubrication/greasing – (Risk ID: 11.01)............................................................................. 44
2.16.8 Residual risks during SINGLE PIECE loading/unloading (work cycle) .................................................. 45
2.16.8.1 SINGLE PIECE loading/unloading (work cycle) – (Risk ID: 12.01) ..................................... 45
2.16.8.2 SINGLE PIECE loading/unloading (work cycle) – (Risk ID: 12.02) ..................................... 46
2.16.9 Residual risks during the TANDEM work cycle .................................................................................... 47
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CHAPTER 2 – Safety information
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ARTIST – Use and maintenance instruction manual
This manual provides instructions on use and maintenance, lists the hazards and residual risks of the
machine but does not take into account the risks of the work environment and the specific work
modalities of the company using the machine.
As to the choice of the personnel responsible for operating the machine, it is up to the
employer to make sure that the duties assigned to workers are compatible with the
qualification and level of information and training required. It is indispensable that
qualified personnel such as operators, maintenance personnel and technicians, for
definitions see chapter 00, is exclusively made up of Expert Persons (EXP), and
Informed Persons (INFP) and not Common Persons (COMP).
INFORMATION!
Remember that it is up to the employer to inform and train the personnel
who is going to run the machine; this must be done on the basis of
available knowledge, information and instructions, before working activities
are assigned to workers.
The instructions for use and maintenance provided in this manual are not addressed to
Common Persons (COMP), who are not authorised to run the machine. However,
information on the safety of these persons is provided in this manual to facilitate the
employer to fulfil his duty of instruction and supervision.
INFORMATION!
Remember that instruction and supervision of common persons is up to the
employer.
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CHAPTER 2 – Safety information
A series of general rules for correct machine use are provided here following; these rules must be
integrated with the specific operating procedures.
It is up to the purchaser:
The user actively participates in maintaining a high level of machine safety in the
long term. Please consider the following aspects concerning one’s responsibility
for use:
Before starting any operation, read the instruction manual and abide by the safety
operational rules.
Comply with the warnings located next to the dangerous areas.
Use suitable clothing for the tasks to perform; avoid clothing with loose parts and
do not use any hooking accessories to avoid entanglement and dragging.
Always use Personal protective equipment (PPE) such as safety boots, gloves,
googles etc., if necessary, in accordance with the specific instructions of the
manual and company standards.
Before performing any operation, take off watches, bracelets, rings, chains and pull
up long hair or put on a cap.
If there are considerable noise producing sources (over 80 decibel) always use
suitable ear protection devices (earmuffs, earplugs).
Take on ergonomically correct positions to avoid strains or excessive tiredness
while performing these tasks.
Make sure that there are no production residues or superfluous objects in the
working area or on the machine.
Check the efficiency of all machine protections and safety devices every day and
before use; do not operate in case of malfunction; before using the machine restore
effective operation.
Do not run the machine if protections have been removed.
Do not circumvent the guards and safety devices voluntarily.
Keep the characteristics of the machine and avoid making any modifications,
altering the function of the machine or tampering with protections or safety devices.
Do not use the machine if there are operational malfunctions, defects, faults or
damage.
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CHAPTER 2 – Safety information
If the use of Personal protective equipment (PPE) is required according to the manual or signs/warnings
on the machine, remember that the choice of the most suitable type for the level of protection required is
up to the employer.
Personal protective equipment is defined by Directives 89/686/EEC and 89/656/EEC. In Italy, reference
must also be made to Ministerial Decree No. 277/91, which has transposed into national law Council
directives 80/1107/EEC, 82/605/EEC, 73/477/EEC, 86/188/EEC and 88/642/EEC. The use of PPE is
indicated in the manual and on the machine with the symbols listed below:
Symbol Explanation
You are obliged to use protective gloves against heat or fire related
risks.
You are obliged to use protective gloves against acides and corrosive
agents.
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ARTIST – Use and maintenance instruction manual
Symbol Explanation
The minimum workers’ Personal protective equipment (PPE) the employer is required to provide
comprises the following devices:
Symbol Explanation
It is indispensable as a minimum requirement that the operator uses the Personal protective equipment
(PPE) mentioned above during all stages of machining of the machine.
Therefore, reference will be made to specific PPE as operators are considered to be equipped with the
devices mentioned above.
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CHAPTER 2 – Safety information
DANGER IMAGES 1 of 4
SYMBOL DESCRIPTION OF HAZARD INDICATIONS/WARNINGS
If manual equipment is used, take care to
prevent cuts and shears. Follow the safety
Cutting, shearing
provisions and wear the appropriate PPE
(safety gloves against general risks).
Keep a safe distance from the indicated
zones to prevent guillotining or excision
Guillotining, excision hazards due to the movement of machine
parts or to the presence of sharp parts.
Follow the safety provisions.
Keep a safe distance from the indicated
zones to prevent snagging and dragging
Snagging and dragging hazards with the product or moving belts
and consequent dragging. Follow the
safety provisions.
Keep a safe distance from the areas
indicated so as to avoid dangers of
Dragging
dragging between rollers and rotating
components. Follow the safety provisions.
Keep a safe distance from the indicated
zones to prevent snagging and dragging
Snagging and dragging
with moving members or mechanical
components. Follow the safety provisions.
Keep a safe distance from the indicated
zones to prevent limb crushing. Do not
insert your hands into the sliding guides of
the machine units to prevent hazards due
Crushing of upper limbs
to the movement of the devices. Watch out
for all movements of the unit where the
image is located. Follow the safety
provisions.
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ARTIST – Use and maintenance instruction manual
DANGER IMAGES 2 of 4
SYMBOL DESCRIPTION OF HAZARD INDICATIONS/WARNINGS
Keep a safe distance from the indicated
zones to prevent lower limb crushing.
Crushing of lower limbs Watch out for all movements of the unit
where the image is located. Follow the
safety provisions.
Be careful near protruding or sharp
Impact machine parts. Follow the safety
provisions.
Danger of falling due to height Watch out for any differences in the height
differences of different machine zones.
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CHAPTER 2 – Safety information
DANGER IMAGES 3 of 4
SYMBOL DESCRIPTION OF HAZARD INDICATIONS/WARNINGS
Follow the safety provisions and adopt the
Hazards generated by noise for
appropriate PPE (ear safety devices or
values above 80 Db
soundproof headsets).
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ARTIST – Use and maintenance instruction manual
DANGER IMAGES 4 of 4
SYMBOL DESCRIPTION OF HAZARD INDICATIONS/WARNINGS
Be careful near the indicated zones. Keep a safe
distance to prevent the injection of fluids under
Injection of pressurised fluids pressure (pneumatic or hydraulic system). Follow
the safety provisions and wear the appropriate PPE
(safety screen).
Pay attention to the intense magnetic fields near
the pictogram. Persons wearing pacemakers must
Intense magnetic fields
maintain a safety distance from the machine or
parts of it when it is dismantled for maintenance.
Check that there are no potentially falling objects or
cables that could become entangled. Do not stand
Suspended loads or move during the load lifting and handling steps.
Follow the safety provisions and wear the
appropriate PPE (safety helmet).
General hazard
(the image is completed with the Adopt the precautions indicated in the warning text.
hazard description)
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CHAPTER 2 – Safety information
PROHIBITION IMAGES 1 of 1
SYMBOL DESCRIPTION INDICATIONS
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ARTIST – Use and maintenance instruction manual
OBLIGATION IMAGES 1 of 1
SYMBOL DESCRIPTION INDICATIONS
It is mandatory to disconnect and isolate
Obligation of disconnection and the sources of energy before starting
isolation of the sources of energy. maintenance and adjustments on the
machine.
It is mandatory to refer to the instructions
(User’s manual and Maintenance, wiring
Use instructions
diagrams, etc.) provided with the machine,
before operating it.
It is mandatory to use personal locks to
Use of padlocks for the blocking of
block the electrical system, pneumatic
the supply or access to the
supplies etc. or to access the machine and
machine
avoid untimely start-ups during works.
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CHAPTER 2 – Safety information
CLASS 2 LASER
WARNING: DO NOT STAND NEAR
THE LASER BEAM.
Do not enter
AO02 IT IS MANDATORY to use the specified Located near the hoisting
hoisting points. points.
Hoisting point
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ARTIST – Use and maintenance instruction manual
Envisaged use means use of the machine in conformity with the information provided in the user
instructions.
The machine may be used only by professional operators who are trained and informed as to the
contents of this instructions manual.
Operators designated to running the machine are responsible for preparing the machine for operation,
starting up the machine and checking and adjusting the work parameters. All operations must be carried
out in accordance with the commands and work procedures described in the instruction manual.
The machine is designed to machine pieces made of wood or other similar materials, the characteristics
of which are defined in the technical data.
The machine is provided with 2 work stations, one in front of the control panel and another in front of the
loaders, where the operator may stand during the work cycle.
The machine may be used by only one operator at a time; simultaneous use by two or more operators is
forbidden.
Recipe settings and parameters are set using the HMI device installed on the electrical control panel.
Access to hazard areas for any task required for machine operation are limited by safety requirement
conditions; access to these areas must be carried out in conformity with the instructions provided in this
manual and in all annexed documents.
The machine is designed and manufactured to mill, drill and cut woody materials, materials deriving from
wood or other similar materials (1). The machine may not be used to process other kinds of materials;
uses different from that envisaged may damage the machine and constitute a hazard for operators.
To avoid possible, improper use, we recommend taking into consideration the consistency of the
material and rapport it to the spindle motor being used. Furthermore, do not use the machine to process
pieces that do not fit into the maximum work strokes specified in the section “Technical and ambient
data”.
NOTE (1): similar materials: materials with machining parameters for milling, drilling and cutting that are
comparable to the machining parameters for wood materials (for example: ureic resin, PVC).
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CHAPTER 2 – Safety information
Reasonably foreseeable incorrect use means use of the machine in a manner that differs from that
specified in the user instructions but that may derive from easily foreseeable human conduct.
The experience of the manufacturer, PAOLINO BACCI s.r.l. permits signalling out the following
examples of incorrect use machine use:
A) INSTALLATION
The following cases are considered incorrect use:
Installing the machine in environments where, during normal work activities the atmosphere is or
may become explosive for short or long periods of time (classification as per the 1999/92/EC
ATEX Directive).
Installing the machine outdoors or in environments with characteristics that are not conformant to
the ambient technical data specified in the instruction manual.
Installing the machine without abiding by the instructions provided by the manufacturer PAOLINO
BACCI s.r.l.
B) USE
The following cases are considered incorrect uses:
Use on behalf of operators who are not of legal working age in accordance with the laws currently
in force in the country of use.
Use on behalf of operators who have not been trained, formed and informed in advance as
regards all residual risks and trained regarding safety issues.
Using the machine without the proper personal protective equipment (PPE), as required by the
instructions and by the laws in force in the country of use.
By-passing machine safety device even temporarily.
Using the machine even if it shows signs or malfunction or is partially malfunctioning
Failure to respect the technical data regarding machining limits (materials, speed, etc.).
Simultaneous use of the machine by two or more operators who may reciprocally endanger one
another or create hazards for exposed persons.
Machine start-up by the sole operator designated for use, without checking that there are no
exposed persons in the machine danger areas before acting on the machine controls.
Running the machine without having read and comprehended the instructions provided by the
manufacturer PAOLINO BACCI s.r.l
Carryout out operations regarding which the manufacturer PAOLINO BACCI s.r.l. has not
provided instructions or information.
Carrying out operations that are difficult to interpret based on the instructions provided by the
manufacturer PAOLINO BACCI s.r.l.
Carrying out operations in a manner different from that described in the instructions.
Carrying out operations that are expressly prohibited in the instructions.
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D) ALTERATIONS
The following cases are considered incorrect uses:
Altering the machine in any way that alters the envisaged use of the machine.
The machine has been constructed to operate in closed, well ventilated environments that are full of
light. Temperature and humidity rates in the work environment must be within the limits mentioned in the
specific technical data attached to this manual.
Environmental conditions other than the ones indicated in this manual may seriously damage the
machine, particularly electronic devices.
Positioning the machine in unsuitable environments that do not meet the established requirements shall
lead the expiry of the warranty for the parts to replace.
If the machine does not work, it must be stored taking all the necessary precautions as established in
this manual. Temperature and humidity rates in the place where the machine will be stored must be
within the limits mentioned in the specific technical data attached to this manual.
Abide by the current standards on illumination of work environments. Please note that the lack of
adequante lighting could pose risks for the persons exposed.
The machine must run in a properly aerated environment.
2.7.3 Vibrations
Mechanical vibrations, if transmitted to the hand-arm system and/or to the whole body: pose risks for the
health and safety of operators as evaluated on the basis of the European Directive 2002/44/EC.
The emission values are conformant to regulatory requirements thanks to the use of components that
comply with the Electromagnetic Compatibility Standards, appropriate wiring and connections and the
installations of filters as required. Hence, the machine is conformant to European Directive 89/336/EC on
Electromagnetic Compatibility (EMC).
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CHAPTER 2 – Safety information
By way of example, the noise emission values for the machine during a work cycle are provided below:
During machining, especially when the tool enters the materials, noise peaks up to 109.8 dB (A) were
reached.
The above-mentioned noise values are emission values and not necessarily safe working levels.
While there is a correlation between emission levels and exposure levels, it may not be used reliably to
determine whether or not additional precautions are required.
Factors affecting the actual worker exposure level include:
Duration of exposure,
Environment conditions,
Other noise sources, such as for example the number of machines that are performing other
machining work in the vicinity.
Furthermore, permitted exposure levels may vary from one country to another.
The information provided herein is nevertheless sufficient to allow machine users to better assess risks
and hazards.
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This section contains information regarding the safety devices adopted to eliminate or reduce machine
hazards.
When a safety device does not fully eliminate a hazard and a reduced risk remains, this risk is described
in the manual as a residual risk.
The safety devices that have been installed must be checked and kept efficient during the machine’s
entire service life.
M03 SIGNAL COLUMN Every time the machine is started up, the
Signals machine conditions using warning warning lights turn on and the horn sounds,
lights and horns. so as to warn everybody present in the work
area of imminent machine start-up.
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An example application is a single guard that NOTE: In case of guards for machines with
stops all dangerous movements of the Y1-Y2 axes table, the ejection of tool
machine, when it is opened. Only when the fragments is reduced to a minimum, at least
guard is closed, the machine can perform the along the direction of two horizontal axes
operating cycles (for use in single-table (ref. EN 848-3:2007+A2:2009, section
machines with Y axis or X-Y axes). 5.3.7.1.2.3.1).
.
A further example application is a protection
made up of 4 guards named A, B, C, and D
(for use in machines with Y1-Y2 axes table).
The opening/closing pattern is such that the
coordinated opening/closing of the guards
allows access to loading/unloading areas, in
which dangerous movements are safely
blocked, but does not allow access to other
areas where the operating cycle continues to
be performed. An example of such operating
pattern is the following:
LOADING:
(C)… OPEN / (A)…CLOSED
(D)… OPEN / (B)…CLOSED
UNLOADING:
(B)… OPEN / (D)…CLOSED
(A)… OPEN / (C)…CLOSED
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NOTE: The checks described here below refer to the guards described in the preceding sections
of the manual.
NOTE: Both tests must be repeated for each emergency pushbutton on the machine.
Every time the machine is used, carry out the following checks:
Visually check that the guards are in place before using the machine.
For removable guards, check that the interlocking device is functioning properly.
Check that the guards are assembled properly and functional after every maintenance intervention.
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Check that the padlocks and clamps to lock off and tag out energy supplies are always on hand.
NOTE: padlocks and clamps are not supplied by the machine manufacturer Paolino Bacci S.r.l,
and must be provided to operating personnel by the employer.
Regularly check that the lights and horns are working properly.
Always check:
That the keys are used only for the time required by the intervention. Once the intervention is
completed, they must be removed and stored by the designated person.
The keys may be used only by authorised and qualified personnel, identified in a written
procedure.
It is forbidden to duplicate the keys.
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The machine is designed and manufactured considering use by only one operator, whose task it is to
supply the machine for production and remove the machined product, as well as operate the manual
controls, only after having verified that there are no exposed persons in the danger areas.
INFORMATION!
During normal machine operation, operators may station in the areas specified here following.
INFORMATION!
The work area must always be clear, and nothing must hinder the operator’s freedom of movement.
In case of an emergency, immediate access to the machine on behalf of designated personnel must be
ensured.
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The area around the main pushbutton panel and loading/unloading are the main operator
work areas from which the operator may enable commands, program work cycles and
check proper machine operation. For maintenance and to fit tools on the machine, the
operator must also access the safety enclosure.
Before starting the work cycle, the operator in charge of running the machine must be
perfectly aware of the location and function of all the controls and of the machine
characteristics. The machine must be run only by operators who have been specifically
trained and have read the instructions contained in this manual thoroughly. Instructions,
warnings and general accident prevention regulations contained in this manual must be
followed scrupulously.
Before starting the work cycle, the operator in charge of loading/unloading the machine
must be perfectly aware of the location and function of all the controls and of the machine
characteristics. The machine must be run only by operators who have been specifically
trained. Loading and unloading operators must have read the instructions regarding piece
loading and unloading and the general safety instructions contained in this manual.
Instructions, warnings and general accident prevention regulations contained in this
manual must be followed scrupulously.
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Interventions inside the all-around enclosure must be carried out only by qualified
technicians. Before carrying out this type of interventions, place a “MAINTENANCE
UNDERWAY” sign on the machine.
While working inside the all-around enclosure, open the doors and keep them open.
The following machine operations and functions have been assessed for risks. Those operations and
functions that present risks are specified in the “residual risks” section of this manual.
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Check that the tools have been fitted only after the spindle seat has been cleaned.
Check that the tools are clamped tightly.
Make sure that the number of programmed revolutions is less than the maximum number of
revolutions permitted for the tools fitted on the heads.
Make sure that the size and weight of the tools and the number of programmed revolutions is
compatible with the spindle power characteristics.
Make sure that the direction of rotation is the proper direction of the tools fitted on the heads
during machining.
If one spindle must turn in the opposite direction with respect to the standard rotation, check that
the safety ring-nut (or other appropriate safety devices) is present and tight.
If there is an all-around enclosure or cabin, make sure that the doors are closed and that no one
is standing inside the enclosure.
Check the conditions of the tools and make sure that they are not chipped or deformed.
Make sure that the tools, spacers and tool holding shafts meet the specifications contained in the
machine instructions.
Before bringing the spindle to the programmed revolving speed, start the spindle turning slowly and
check (by listening to the noise) that the tools are balanced and do not vibrate excessively.
Before stopping spindle rotation during machining, make sure that the tool is not in contact with the piece
and/or parts of the template.
Do not remove the safety guards (panels and gates) except for ordinary and extraordinary maintenance.
Never start-up the machine when the guards are not in place.
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Before starting any program, including automatic homing, we recommend making sure that the portable
pad is enabled in order to be able to reduce speed and, if necessary, stop machine movements.
When running a program for the first time, disable spindle start-up (following the procedure described in
the relative section of the manual) and proceed at reduced speed using the potentiometer on the
keypad.
Respect the technological parameters for tools and machining, especially as regards machining speed
and the number of spindle revolutions.
Do not use the potentiometer to reduce or control speed during normal production.
Knowledge of first-aid procedures for electrical accidents is required. Before starting maintenance on
electrical circuits, the person in charge of the work must check that all safety regulations have been
respected. Comply with current national laws and regulations regarding work on electrical systems.
All work must be carried out using only suitable and isolated tools.
Respect safety signs! Do not remove the safety signs.
Before starting work, adopt the precautions described below.
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1 1
2
Maintenance may be carried out only by qualified technicians. Before starting any type of
maintenance, place a “MAINTENANCE UNDERWAY” warning sign on the machine, stop the
machine and cut-off all electrical and pneumatic sources. For this purpose, close the main
pneumatic supply valve (1), then turn off the main switch (2) and adopt all the measures required
to avoid start-up.
To carry out maintenance on the pneumatic system, first release the pressure using the
pneumatic EMERGENCY STOP switch (1) and releasing all residual compressed air.
Use appropriate tools and equipment for proper disassembly and re-assembly.
Use only appropriate hoisting equipment. Before hoisting the unit, check the weight, barycenter,
and location of the anchor points. Please consult the specific instructions contained in the
Installation chapter.
Before starting the system, check for defects.
Make sure that the machine safety devices are present and functioning. Do not remove safety
devices or other safety equipment. If safety devices must be dismantled, for example for
maintenance or repair work, they must be replaced immediately upon completion of the work and
tested for proper functioning.
Follow current safety regulations when handling oils, greases and other chemical substances.
The machine is manufactured and protected so as to provide for maximum safety only when used in
compliance with the specifications for use. The machine is equipped with safety devices to safeguard
operating personnel.
Some risks cannot be fully eliminated. Personnel are therefore exposed to some residual risks. Such
risks are specified and described following, along with possible causes and the precautions to be taken
to avoid them.
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2.16.1.1 Passing through or stationing near dangerous areas – (Risk ID: 00.01)
ACCIDENT SCENARIO
Consequences: 1.0 Various mechanical hazards
Situation: Passing through or stationing near the dangerous machine areas during the various
stages of the life cycle (installation, use, maintenance, etc.)
Event: Contact with moving machine parts and the product being machined.
Contact with moving machine parts, suspended loads, eqiupment and/or equipment
used during assembly and maintenance.
Contact with toxic and noxious elements used during machine operation.
Risk of permanent damage to hearing apparatus due to high noise and prolonged
exposure to noise sources.
Body part: Entire body.
RESIDUAL RISK
Common persons who have not been instructed may be exposed to various risks deriving from both the
machine and the work environment. The employer must limit access to dangerous areas on behalf
common persons in specific company procedures.
LIMITATION MEASURES
Mechanical: -
Electrical: -
Informative: - unauthorised personnel may not enter the machine.
- Common persons who, for whatever reason, must pass through or station near
the machine must always be accompanied by personnel who have been trained
and informed regarding the risks, who must keep an eye on common persons.
Symbols: - Access denied to unauthorised personnel signs (WARNING AD01).
- Ground signs limiting and identifying dangerous areas.
- Internal company procedures.
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ACCIDENT SCENARIO
Consequences: 7.6 Fire
Situation: Accumulation of dust and machining residues (chips).
Event: Fire hazard deriving from contact between dust and machining residues with live
flames or parts of the electrical system.
RESIDUAL RISKS
Fire hazard deriving from contact between dust and machining residues with live flames or parts of the
electrical system.
LIMITATION MEASURES
Mechanical: Arrange for connection to a centralized dust removal system.
Electrical: -
Informative: - Connect the machine to a vacuum system with a capacity equal to that specified
in the technical data.
- Periodically remove dust and machining residue from the machine frame, avoiding
accumulation.
- Do not use live flames and periodically check the insulation of all electrical
components near dust accumulations spots.
- The employer is required to include this assessment in the plant risk assessment
procedures procedure in order to implement appropriate ORGANISATIONAL
measures for risk reduction.
Symbols: -
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ACCIDENT SCENARIO
Consequences: 7.1 Respiratory difficulties, suffocation
7.2 Cancer
Situation: Dust emissions into the air
Event: Respiratory difficulties deriving from the presence of dust in the air cause by
material machining.
Body part: Breathing apparatus
RESIDUAL RISK
Respiratory difficulties deriving from the presence of dust in the air cause by material machining.
LIMITATION MEASURES
Mechanical: Arrange for connection to a centralised dust removal system (M13 SAFETY
MEASURES).
Electrical: -
Informative: - Connect the machine to a vacuum system with a capacity equal to that specified
in the technical data.
Symbols: -
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ACCIDENT SCENARIO
Consequences: 1.3 Crushing
1.4 Cutting or shearing
Situation: Working in machine disassembly areas.
Event: Various risks (crushing, shearing) deriving from machine or machine parts
disassembly.
1.3 CRUSHING:
- Under falling parts being handled
- Between machine parts being handled and surrounding structures (plant, other
machines).
- Between machine parts being handled and cables or straps used for hoisting.
1.4 CUTTING OR SHEARING:
- Between machine parts being handled and surrounding structures (plant, other
machines).
Body part: Entire body
Upper limbs
Hands
RESIDUAL RISK
Various risks (crushing, shearing) deriving from machine or machine parts disassembly.
Crushing:
- Under falling parts being handled
- Between machine parts being handled and surrounding structures (plant, other machines).
- Between machine parts being handled and cables or straps used for hoisting.
Cutting or shearing:
- Between machine parts being handled and surrounding structures (plant, other machines).
LIMITATION MEASURES
Mechanical: -
Electrical: -
Informative: - This operation is reserved exclusively to expert personnel (EXP) with significant
know-how and experience such as to allow for proper assessment of the risks and
avoidance of the hazards engendered by the task.
- Mark off the work area and forbid access by unauthorised persons.
- Follow assembly instructions.
The employer is required to use only expert personnel (EXP) for disassembly work.
Symbols: -
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ACCIDENT SCENARIO
Consequences: 1.3 Schiacciamento
1.4 Taglio o sezionamento
Situation: Operare in prossimità di parti di macchina sollevate durante le operazioni di
movimentazione e trasporto.
Event: Various risks (crushing, shearing) deriving from handling of machine or machine.
1.3 CRUSHING:
- Under falling parts being handled
- Between machine parts being handled and surrounding structures (plant, other
machines).
- Between machine parts being handled and cables or straps used for hoisting.
1.4 CUTTING OR SHEARING:
- Between machine parts being handled and surrounding structures (plant, other
machines).
Body part: Entire body
Upper limbs
Hands
RESIDUAL RISK
Various risks (crushing, shearing) deriving from handling of machine or machine parts.
Crushing:
- Under falling parts being handled
- Between machine parts being handled and surrounding structures (plant, other machines).
- Between machine parts being handled and cables or straps used for hoisting.
Cutting or shearing:
- Between machine parts being handled and surrounding structures (plant, other machines).
LIMITATION MEASURES
Mechanical: Anchor and hook-up points for hoisting equipment.
Electrical: -
Informative: - This operation is reserved exclusively to expert personnel (EXP) with significant
know-how and experience such as to allow for proper assessment of the risks and
avoidance of the hazards engendered by the task.
- Mark off the work area and forbid access by unauthorised persons.
- Follow assembly instructions.
The employer is required to use only expert personnel (EXP) for handling.
Symbols: Indication of hoisting points (WARNING AO2)
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ACCIDENT SCENARIO
Consequences: 7.9 poisoning
7.10 Sensitisation
Situation: Use of toxic and/or noxious substances for machine cleaning.
Event: Various risks (7.9 POISONING, 7.10 SENSITISATION) deriving from the type of
substance use to clean the machine, due to both skin contact or inhalation of
dangerous fumes (eg. accidental mixing of detergents).
Body part: Entire body.
RESIDUAL RISK
During machine cleaning, there is a residual risk of POISONING and SENSITISATION deriving from the
type of substances used to clean the machine, through contact with the skin and the inhalation of
dangerous fumes (for example, accidental mixing of detergents).
LIMITATION MEASURES
Mechanical: -
Electrical: -
Informative: Always use Personl protection equipment (PPE) suited to the type of product used
for cleaning.
Symbols: -
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ACCIDENT SCENARIO
Consequences: 2.4 Electrocution
Situation: Maintenance on the electrical system (inspection, adjustment, substitutions).
Event: Risk of electrocution from direct and indirect contact with live parts.
Body part: Entire body.
RESIDUAL RISK
Risk of electrocutiion from direct and indirect contact with live parts.
LIMITATION MEASURES
Mechanical: - Create/install containers and sheaths capable of guarantying adequate insulation
of live parts (SAFETY MEASURE Q03).
- Wiring of electrical instruments in compliance with CEI EN 60204-1 standards
(SAFETY MEASURE Q03).
- Electrical cabinet doors may be opened only with a key entrusted to maintenance
personnel (SAFETY MEASURE Q02).
- The door to the electrical cabinet cannot be opened when the switch is in the ON
position.
Electrical: -
Informative: - Work on the electrical instruments, be they powered or not, may be carried out
only by expert personnel (EXP) and informed persons (INFP), as per the definition
provided for in CEI 11-27. CEI EN 60204-1 standards do not differ between work
carried out on electrical instruments that are not power and those that are live,
therefore not obligatorily requiring that the latter be carried out by Competent
Persons (COP) as per the definition provided for in CEI 11-27.
- Work on live equipment carried out inside the electrical board may be performed
only after having cut off power, having opened the board door, and having newly
powered the equipment by purposely turning the main switch to ON.
Symbols: - Electrocution warning sticker on boards and boxes containing live parts
(WARNING PE01)
- Do not enter prohibition sticker for unauthorised personnel on electrical boards
and boxes that consent access to live parts with the entire mbody (WARNING
AD01)
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ACCIDENT SCENARIO
Consequences: 2.4 Electrocution
Situation: Maintenance on the electrical system (inspection, adjustment, substitutions).
Event: Risk of electrocution due to direct or indirect contact with parts that remain powered
even after the main switch has been sectioned:
- Interface signals
- Circuits upstream of the switch.
RESIDUAL RISK
Risk of electrocution due to direct or indirect contact with parts that remain powered even after the main
switch has been sectioned:
- Interface signals
- Circuits upstream of the switch.
LIMITATION MEASURES
Mechanical: - Wiring of electrical instruments in compliance with CEI EN 60204-1 standards
(SAFETY MEASURE Q03).
- Electrical cabinet doors may be opened only with a key entrusted to maintenance
personnel (SAFETY MEASURE Q02).
- The door to the electrical cabinet cannot be opened when the switch is in the ON
position.
Electrical: -
Informative: - Work on the electrical instruments, be they powered or not, may be carried out
only by expert personnel (EXP) and informed persons (INFP), as per the definition
provided for in CEI 11-27. CEI EN 60204-1 standards do not differ between work
carried out on electrical instruments that are not power and those that are live,
therefore not obligatorily requiring that the latter be carried out by Competent
Persons (COP) as per the definition provided for in CEI 11-27.
- Before intervening on any electrical equipment, identify the relative circuits on the
wiring diagram.
- Always check for residual tension before working on circuits.
Symbols: - Electrocution warning sticker on boards and boxes containing live parts
(WARNING PE01)
- Do not enter prohibition sticker for unauthorised personnel on electrical boards
and boxes that consent access to live parts with the entire mbody (WARNING
AD01)
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ACCIDENT SCENARIO
Consequences: 7.9 Poisoning
7.10 Sensitisation
Situation: Handling of lubricants and greases and/or parts that have come into contact with
lubricants or grease used to lubricate rollers, supports, gear motors, etc.
Event: - Various risks (7.9 poisoning, 7.10 sensitisation) deriving from skin or eyes coming
into contact with lubricants or ingestion of lubricants.
- Risk of environmental pollution deriving from lubricant spills.
Body part: Entire body.
RESIDUAL RISK
Risk of poisoning or sensitisation deriving from skin or eyes coming into contact with lubricants or
ingestion of lubricants.
- Risk of environmental pollution deriving from lubricant spills.
LIMITATION MEASURES
Mechanical: -
Electrical: -
Informative: Lubricants (greases and oils) are toxic and noxious. Follow the producer’s safety
information.
Always use personal protective equipment (PPE) for all tasks where there is a
foreseeable risk of coming into contact with lubricants.
Waste lubricants must be disposed of by orgnisations authorised to collect and
dispose of these types of substances.
Symbols: -
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ACCIDENT SCENARIO
Consequences: 1.3 Crushing
Situation: Loading/unloading pieces from the clamping devices.
Event: Risk of crushing cause by closure of the clamping devices.
Body part: Hands
Fingers.
RESIDUAL RISK
Risk of crushing cause by closure of the clamping devices.
LIMITATION MEASURES
Mechanical: During loading and unloading two risk LIMITATION MEASURES are adopted in an
attempt to overcome by redundancy possible inattentiveness during use. These
measures are:
- Clamping device adjustment carried out by maintenance personnel during
machine equipping.
- Adoption of two pressure stages (SAFETY MEASURE M10) during
loading/unloading and machining.
Electrical: Check clamping device closing pressure.
Informative: The clamping device is closed by pressing the footpedal control located near the
clamping device. Once the piece has been positioned, keep hands away from the
clamping device and then close the clamps using the footpedal; the clamps close at
a pressure that is lower than that exerted during the machining stage.
The clamping devices may be adjusted only by maintenance personnel, using one
of two procedures described in the machine controls and use chapters of the
manual.
Symbols: -
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ACCIDENT SCENARIO
Consequences: 1.3 Crushing
1.8 Impact
Situation: Unloading pieces from the work table.
Event: Risk of crushing and impact casued by pieces falling from the work table.
Body part: Hands
Fingers
Feet
Lower limbs.
RESIDUAL RISK
Risk of crushing and impact caused by pieces falling from the clamping devices.
LIMITATION MEASURES
Mechanical: -
Electrical: -
Informative: The piece/s are loaded and correctly positioned on the clamping device. Once the
stability of the piece has been ensured, block it into place using the footpedal
control near the work table.
The pieces are unloaded by opening the clamping devices using the footpedal
control located near the work table. Grip the piece and then activate the footpedal
control to open the clamps and remove the piece. Rest the piece on the ground or
in collection containers.
Symbols: -
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ACCIDENT SCENARIO
Consequences: 1.1 Being struck
1.12 Perforation or puncture
Situation: Standing near the loading/unloading area.
Note: risk assessed after the machine has been equipped to switch from TANDEM
mode to the SINGLE PIECE loading/unloading work cycle.
Event: Risk of being struck by tool parts or by the tool itself flying off the machine after
breaking.
Body part: The entire body
Face
Eyes
RESIDUAL RISK
After the machine has been equipped to switch from TANDEM machining to the SINGLE PIECE
loading/unloading work cycle, there is a residual risk of being struck by tool parts or by the tool itself
flying off the machine after breaking, if the central safety panel for the Y1-Y2 axes has not been fitted
back into place (SAFETY MEASURE M11).
LIMITATION MEASURES
Mechanical: The all-around safety guards (SAFETY MEASURE M04), the access doors
(SAFETY MEASURE M05), the central safety guard between the piece support
devices (axes Y1 and Y2) (SAFETY MEASRUE M11) and the combination of
movable guards (SAFETY MEASURE M06) are appropriately designed to resist
against and contain breaking tools.
Electrical: -
Informative: Upon completion of TANDEM machining, the maintenance technician responsible
for equipping the machine must put the central safety guard back into place
(SAFETY MEASURE M11) before enabling the SINGLE PIECE loading/unloading
work cycle. Follow the procedure described in the instructions manual.
NOTE: The expulsion of broken tool parts is reduced to a minimum, at least in the
direction of the two horizontal axes (ref. EN 848-3:2007+A2:2009, paragraph
5.3.7.1.2.3.1)
Symbols: -
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ACCIDENT SCENARIO
Consequences: 1.3 Crushing
1.8 Impact
Situation: Use of HOLD-TO-RUN controls on the portable control panel.
Event: Risk of crushing and impact caused by the movement of parts controlled by the
relative controls.
Body part: Entire body
Head
Upper limbs
Hands.
RESIDUAL RISK
During machine operation with HOLD-TO-RUN type movements, there is a residual risk of crushing and
impact caused by movement of the parts through the controls.
LIMITATION MEASURES
Mechanical: - The controls are located on a pushbutton panel that is enabled while the operator
is standing inside the safety guards.
- The internal moving parts are protected by special fixed buards (SAFETY
MEASURE M08).
Electrical: Hold-to-run controls that allows moving one axis at a time (SAFETY MEASURE
M09). The controls are located on a portable panel and must be enabled by
pressing the relative pushbutton on the panel.
Informative: - Machine movements carried out usiing the controls on the portable panel must be
carried out by an Expert Person who has been authorised, trained and informed
regarding the risks present in the area inside the machine enclosure.
- During use of the pushbutton panel, only one Person may be inside the machine,
holding the remote portable pushbutton control and controlling the movements
while standing at a safe distance.
Symbols: -
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ACCIDENT SCENARIO
Consequences: 1.11 Slipping, tripping and falling
Situation: Maintenance work required by the manufacturer for which the maintenance
operator must work at height.
Event: Risk of slipping, tripping and falling off permanent access equipment and/or
machine structures.
Body part: Entire body
Head.
RESIDUAL RISK
There is a risk of slipping, tripping and falling when climbing, descending or standing on ladders,
scaffolding and/or permanent footbards.
LIMITATION MEASURES
Mechanical: There is no permanent access equipment.
Electrical: -
Informative: - It is forbidden to climb onto machine structures from any point that is not equipped
for climbing.
- Always use permanent access equipment on the machine for all height work.
- Where the machine is not fitted with permanent access equipment, use ladders,
scaffolding and/or moving platforms.
- Wear personal protective equipment /PPE) suited for height work.
- Move carefully when climbing or descending ladders or standing at heights.
Symbols: -
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ACCIDENT SCENARIO
Consequences: 6.2 Injury to eyes and skin.
Situation: Standing near the laser adjustment device.
Event: Risk of injury to eyes looking directly into the laser beam.
Body part: Eyes.
RESIDUAL RISK
Risk of injury to eyes looking directly into the laser beam.
LIMITATION MEASURES
Mechanical: The photocells are positioned in such a way as to avoid the laser beam from
pointing directly into the operator’s eyes.
Electrical: -
Informative: Take care never to look directly into the laser beam.
A warning sticker bearing the warning below is located near the lawer:
CLASS 2 LASER
DO NOT STAND NEAR THE LASER BEAM.
Symbols: Placement of a sticker warning of the presence of a class 2 laser (WARNING
AP05)
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ACCIDENT SCENARIO
Consequences: 1.0 Various mechanical hazards
Situation: Being trapped inside the all-around enclosures.
Event: Various risks deriving from the unexpected start-up of machine moving parts.
Body part: Entire body.
RESIDUAL RISK
Various risks deriving from the unexpected start-up of machine moving parts.
LIMITATION MEASURES
Mechanical: The access doors are designed to avoid involuntary closing.
Electrical: The door, once it has been closed, must be reset by pressing the relative reset
pushbutton.
Informative: In case of becoming trapped, move away from the moving machine parts and
towards the closest door. If necessary, press the closest emergency stop
pushbutton. The door may be unlocked using the unlocking key located near the
interlocking device.
Symbols: -
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2.16.14 Residual risks present during telephone help desk and remote assistance work
2.16.14.1 Telephone help desk and remote assistance work – (Risk ID: 19.01)
ACCIDENT SCENARIO
Consequences: 1.0 Various mechanical hazards
Situation: Execution of troubleshooting interventions with telephone support of the
manufacturer’s customer help desk, and machine that could have comand and
control logic connected to remote assistance communication lines, with the
possiblity of remote control.
Event: Various risks deriving from the unexpected start-up of machine moving parts.
Body part: Entire body.
RESIDUAL RISK
During troubleshooting with telephone support from the manufacturer’s customer help desk, and control
logic connected to remote assistance communication lines, with the possiblity of remote control, there
are various residual risks deriving from the unexpected start-up of machine moving parts.
LIMITATION MEASURES
Mechanical: -
Electrical: -
Informative: Troubleshooting must be carried out only by specialised and authorised
maintenance personnel. Troubleshooting activities must be co-ordinated with the
manufacturer’s technical assistance service. Follow the procedures present in the
instructions manual.
Symbols: -
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CHAPTER 3 – Machine description and technical data
CHAPTER
3 Machine description
and technical data
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INDEX
3 Machine description and technical data................................................................................... 1
3.1 Aim of this chapter........................................................................................................ 3
3.2 Description of machine functioning ............................................................................ 3
3.3 Characteristics of machinable materials ..................................................................... 3
3.4 Maximum sizes of pieces to be loaded for machining ............................................... 4
3.5 Possible machining ...................................................................................................... 4
3.6 Manufacturing features ................................................................................................ 6
3.7 Machine layout .............................................................................................................. 7
3.7.1 Machine operating diagram ........................................................................................................ 7
3.8 Description of main units ........................................................................................... 10
3.8.1 Machine body and carriage 2 ................................................................................................... 10
3.8.2 Z axis carriage ......................................................................................................................... 10
3.8.3 Machining heads ..................................................................................................................... 11
3.8.4 Tables ..................................................................................................................................... 17
3.8.5 Piece blocking clamps ............................................................................................................. 18
3.8.6 Tool accessories...................................................................................................................... 21
3.8.7 Automatic tool change ............................................................................................................. 22
3.8.8 Electrical cabinet ..................................................................................................................... 23
3.8.9 Numeric control ....................................................................................................................... 23
3.8.10 Centralised grease lubrication system ...................................................................................... 24
3.8.11 Centralised oil lubrication system ............................................................................................. 25
3.8.12 Safety guards and devices ....................................................................................................... 25
3.9 Technical data ............................................................................................................. 26
3.9.1 Machine technical data ............................................................................................................ 26
3.9.2 Machine electrical wiring data .................................................................................................. 26
3.9.3 Power and consumption........................................................................................................... 26
3.9.4 Pneumatic system data (compressed air) ................................................................................. 26
3.9.5 Static and dynamic loads ......................................................................................................... 27
3.9.6 Overall measurements ............................................................................................................. 27
3.9.7 Spaces for use and maintenance ............................................................................................. 27
3.9.8 Tool technical characteristics ................................................................................................... 27
3.10 Machine identification ................................................................................................ 28
3.11 EU Declaration of Conformity .................................................................................... 29
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For machines with special configurations, please consult chapter 7 and/or any supplements to this
manual provided by PAOLINO BACCI S.r.l.
The over-sized crossbeam permits wide-ranging sideways movements of the operating head (X
axis).
The high dynamics of the ARTIST machining centre derives from the use of precision reducers with
zero backlash and that require no periodic adjustments, as well as from a perfect, automatic “from
the inside out” lubrication system. In addition to traditional programming systems, the ARTIST
machine may be programmed using the exclusive Bacci PITAGORA software, which allows taking
the best possible advantage of the elevated dynamics of the machine, thereby reaching
exceptional performance yields.
Wood (hardwood, plywood, block board, wood strips, engineered woods, laminar woods,
hollow cored woods).
Wood derivatives (hardboard, MDF, OSB) or similar materials*.
Materials defined as plastics or composites, that is to say, polymers (for example, PVC,
ABS, PMMA, Lexan), resins (for example glass fibre reinforced plastics), thermoplastic
materials (meaning materials resulting from treated polymers) and rubber materials.
* similar materials: materials that have machining parameters for milling, boring and cutting that are
comparable to the machining parameters for wood materials (for example: urea resins, PVC, ...)
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Data regarding piece machinability must be calculated each time, case by case, taking into
account the maximum movements that may be carried out by the working unit used for machining,
the position of the piece on the work table, the size of the tools and the space taken up by the
other groups present on the working unit.
Before starting machining, always check that the piece is held firmly and blocked properly.
Minimum sizes are not easy to define in that the gripping intensity of the vacuum suction system
depends on piece porosity, thickness and size.
Moreover, the minimum gripping intensity is different for each type of tool used.
In any event, the manufacturer PAOLINO BACCI S.r.l. is available for further information.
MACHINING FIGURE
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MACHINING FIGURE
Cutting
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Z axis carriage
Machine body
External safety enclosure
Centralised lubricating system
Electrical cabinet
Piece supporting system
The following optional units may be installed on the machine, even subsequent to machine
purchase and installation:
Clamping devices
may require changes to the systems
Boring head
unit to be fit into the electric spindle
Angular heads
unit to be fit into in the electric spindle
“PITAGORA” programming software
intelligent and user-friendly CAM software to program and optimize machining
“ALPHACAM” programming software
Software available on the market to program up to 5 axes
“MICROSCRIBE” system
system to define routes and surfaces from an existing piece
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GANTRY FRAME
Z
C-A HEAD
A
X
TABLE
Y1 (Y2)
Y2* is optional.
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All screws and skids are automatically lubricated through the numeric control system and
lubrication is checked along the line by a control sensor.
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The main units and optional units making up the machine are listed below.
2 3
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The slide guides for the Z axis carriage along the X axis are located on the machine body.
POS. NAME
1 Operating head
2 Balancing cylinder
3 Electrical spindle
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POS. NAME
1 2-armed fork
2 Electric spindle
The operating head is held by a 2-armed fork. The fork allows using tools up to 140 mm long and
circular blades with a diameter up to 200 mm.
4 P TYPE
N. 4 independent spindles.
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3 P TYPE
N. 3 independent spindles
1-45° TYPE
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1M TYPE
1D TYPE
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1E TYPE
3 FOLDING TYPE
N. 3 independent spindles
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4C H TYPE (PATENTED)
N. 4 independent spindles
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3.8.4 Tables
Variable geometry tables (TGV) placed over the machine table for PV vacuum suction.
Variable geometry tables with Schmaltz beams supported by TGV uprights TGV
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SIDE CLAMP
TOP CLAMP
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TGV / VM
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SP
PR
Height-adjustable clamps.
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TCS CN 8
TCS CN 16
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POS. NAME
1 Numeric control with display.
2 Main operator panel
3 Air conditioning
A NC machine simply executes the program that has been set, regardless of what happens around
the machine, and the operator’s task is to prepare the pieces to be machined and intervene if
anything unexpected takes place.
NC machines must always run under the supervision of an operator authorised to use the machine.
Consult the documentation attached to this manual for a description of the numeric control system
installed on the machine.
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1
The centralised, automatic lubrication system is
connected by means of progressive distributors
to all the recirculating ball carriages and all the
axis worm screw nuts.
The system lubricates all the connected points
at the preset greasing intervals, with the grease
in the greasing tank (1).
POS. NAME
1 Grease tank
2 Grease pump
3 Pressure gauge for working pressure
The pump (2) is connected to the lower part of the tank and is controlled by a simple effect piston
driven by compressed air.
Return to starting position is ensured by a spring. A spring with a presser disk is installed inside the
tank. The system includes an electric minimum level sensor and a filling filter.
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POS. NAME
1 Oil tank
2 Oil pump
3 Pressure gauge for working pressure
The safety guards and devices installed on the machine to protect mechanical moving parts (for
example, chains, gears, transmissions and moving organs) are described in the chapter “2 Safety
information”, paragraph “2.8 Safety measures”.
The efficiency of the safety devices must be assessed after the machine has been installed at the
end user’s site, at which point the risks related to interconnection of the machine with the other
machines in the plant may be evaluated, providing for any additional guards and/or safety devices
that may be deemed necessary.
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INFORMATION!
The paragraphs that follow contain the main technical data for the machine, or in any event the
minimum and maximum obtainable performance yields; data may differ based on specific
customer requirements.
TYPE DESCRIPTION
Electrical voltage in Volts See machine plate
Electrical frequency in Hz See machine plate
Electrical absorption in kW See machine plate
Contemporaneity factor 0.7
3 phases + 1 earth
Type of connection Star connection:
TT;TN-C;TN-S
Max. resistance to ground 2 Ohm
Max. power See machine plate
Type B device
Protection Delayed action (0.3 sec.)
0.3A adjustable differential current.
The machine will work efficiently only if all the specifications are met.
TYPE DESCRIPTION
Recommended diameter for the
1/2"
compressed air pipe line
25 mm external
Connection diameter for rubber pipe:
17 mm internal
Air consumption at 6 bar Based on the model
Optimal line pressure 6.5 bar
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HAZARD!
Dust, condensation and oil may damage the spindle.
Use only air that is clean dry, filtered, not lubricated, and condensation-free.
Machine static and dynamic loads are shown in the structural work installation layout drawings.
INFORMATION!
Space requirements for use and maintenance must be verified on the machine’s main installation
layout drawing, which must always be consulted.
The presence of structural elements such as, for example, walls, columns, etc., or work equipment
in the area destined to machine use and maintenance may render proper installation impossible.
The user may therefore be required to carry out structural work to adapt the site to machine
installation before the machine may be installed and started up.
Space requirements for use and maintenance are shown in the main layout drawing (see ANNEX
B TECHNICAL DIAGRAMS AND GENERAL INFORMATION).
Use only tools having the diameters and weights shown in the table below.
COUPLING SIZE MAX TOOL SHAFT ROTATION SPEED MAX TOOL MAX TOOL
DIAMETER (MM) (RPM) DIAMETER (MM) WEIGHT (KG)
6000 / 9000 150 10
9000 / 12000 130 7
ER40 25
12000 / 15000 110 5
15000 / 18000 80 5
6000 / 9000 140 4
9000 / 12000 130 4
ER32 20
12000 / 15000 110 2,5
15000 / 18000 80 2,5
DANGER!
Risk of flying tool parts
The machine and electrical board identification data are shown on the identification plates. The
location of the identification plates is shown in the figure below.
The symbol is present only on the machine identification plate and only for machines
marketed and sold within the European Community, accompanied by the relative EC
declaration of conformity, as per annex II A of the Machinery Directive 98/37/CE.
The symbol is not present on machines marketed and sold in countries that do not
belong to the European Community.
INFORMATION!
Do not remove the machine or electrical board identification plates. If the plates are damaged,
always contact the manufacturer.
The location of the plates is shown in the general layout (see ANNEX B TECHNICAL DIAGRAMS
AND GENERAL INFORMATION).
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If the machine is to be sold on the European market, it will be accompanied by its related EU
declaration of conformity as per Annex II A of Machinery Directive 2006/42/EC. The signed EC
declaration of conformity is provided upon delivery of the machine; please see a facsimile of said
declaration below.
EU DECLARATION OF CONFORMITY
(according to 2006/42/CE)
NAME (FUNCTION)
SERIAL NUMBER
YEAR OF MANUFACTURE
2006/42/EC (MACHINERY)
2004/108/EC (EMC)
DESIGNATES:
as person authorised to prepare the Technical File the company Paolino Bacci S.r.l.,
via Palermo 32 56021 CASCINA (PI) - Italy.
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CHAPTER
4 Installation
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INDEX
4 Installation ................................................................................................................... 1
4.1 Information required on handling of loads and installation ............................................................. 3
4.1.1 Load handling equipment provided by the customer .............................................................................. 4
4.1.2 Installation equipment provided by the customer ................................................................................... 5
4.1.3 Installation preparations made by the customer ..................................................................................... 5
4.2 Packaging, handling, transport.......................................................................................................... 6
4.2.1 General safety recommendations for load handling ............................................................................... 6
4.2.2 Information regarding shipment and delivery ......................................................................................... 8
4.2.3 Packaging and shipment precautions and tactics .................................................................................. 9
4.3 Preparing the machine for shipment ............................................................................................... 11
4.3.1 Disconnecting the electrical cabinet .................................................................................................... 11
4.3.2 Mechanical preparations for transport ................................................................................................. 12
4.4 Component and load group identification and handling ................................................................ 13
4.5 Loading, transportation and unloading ........................................................................................... 16
4.6 Installation site requirements .......................................................................................................... 17
4.6.1 Floor specifications ............................................................................................................................ 17
4.6.2 Ambient data ..................................................................................................................................... 17
4.6.3 Illumination and aeration .................................................................................................................... 18
4.6.4 Dust removal system .......................................................................................................................... 18
4.7 Assembly .......................................................................................................................................... 18
4.7.1 Anchoring the machine....................................................................................................................... 18
4.7.2 Removing safety guards and blocks used for transportation ................................................................ 20
4.8 Connection to power supplies ......................................................................................................... 20
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The following paragraphs provide the minimum information required on how to handle loads correctly
and install the machine.
For installation always refer to this manual and the documents mentioned in the different procedures.
This chapter contains all the necessary information on the installation step of the machine.
This step includes the preparation, loading and unloading of the machine for transport purposes.
Furthermore it describes the positioning of the machine components and its fastening to the floor. Finally,
it illustrates how to assemble the components removed in order to facilitate transport and connect the
machine to the electric and pneumatic system.
All operations described in the Installation chapter must be performed by qualified personnel, authorised
by PAOLINO BACCI S.r.l.
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Unless otherwise agreed upon with the PROJECT MANAGER, all the all the materials and equipment
must be available at the site of installation upon delivery of the machinery.
Crane
Stacker
Rocker arm
INFORMATION!
The choice of the means to use for handling loads must be based on the evaluation of the
mass to hoist and the existence of environmental limitations, such as the height of the
installation site and accesses.
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INSTALLATION EQUIPMENT 1 of 1
EQUIPMENT
Extension leads
Welding machine
220 volt power supply points, close to the machine assembly site, to which the different work
equipment (drills, welding machine etc.) can be connected
A telephone line with Internet access.
Any necessary civil works must be implemented and the foundations and/or installation site must
be prepared.
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The following paragraphs provide the main information on the preparation of the machine for transport or
shifting. Certain machine parts are actually disassembled before transport to facilitate handling or to
reduce the maximum dimensions of the machine. Thus the maximum height of the machine is reduced
less than 2.5 m and the machine can be transported in a standard truck or inside a container.
The following paragraphs also include the main information on how to handle the machinery; they make
reference to the procedures to adopt, the means used and safety measures.
Given the specific nature of operations, it is obligatory to employ informed and trained personnel who will
work using hoisting means and will be aware of the operational and safety procedures to follow when
handling loads.
Before starting the transport of the machine and its components, consult the shipment list for information
on sizes.
During the loads hoisting and handling operation it is OBLIGATORY to abide by the following rules:
IT IS OBLIGATORY that all load hoisting and handling be carried out only by specialised and
authorized personnel.
IT IS OBLIGATORY to use personal protective equipment (PPE), such as safety footwear, work
wear, gloves for protection against crushing, safety helmet and harness for height work.
IT IS OBLIGATORY that only personnel authorised for load handling work in the work area, in
compliance with common safety regulations that require safety areas around suspended loads,
lift-truck and/or moving overhead travelling cranes.
IT IS FORBIDDEN:
Parts weighing more than 25 kg must not be handled manually. The barycenter for these parts is
shown on the part itself and they are fitted for hoisting by means of appropriate accessories
(harness, ropes, eyebolts, anchor bolts, .....).
Use only ropes or chains that allow guiding the load while standing at a safe distance.
Except for during stop and start, handling must take place without speeding up or slowing down
the load movement and avoiding jolts or impulse-type movements.
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Before hoisting the load completely, always check that hoisting is aligned with the barycenter of
the load being hoisted; if necessary, adjust the position of the hoisting equipment or redistribute
the loads.
During horizontal movements, avoid pitching as much as possible, especially during movement
start-up or stop.
Changes in direction must take place after a full stop from load standstill.
As far as possible, the hoisted load must be kept away from obstacles and as closet o the ground
as possible.
If the case bears the symbols shown below, crossed out, that type of hoisting for the load in
question is expressly prohibited.
To rest the machine onto the platform of a truck or on the ground temporarily, the resting surface
must first be equipped with wood strips, all of equal height, positioned so as to provide a stable
resting surface and avoid damage to machine parts (where possible, rest the machine on its
side).
The machine and or the equipment and components must be lowered to the ground slowly and
carefully, to avoid damage.
Inspect the load hoisting equipment (hooks, harness, chains, eyebolts, anchor bolts) thoroughly
before use.
If defects are found, replace the accessories with new ones, making sure that the replaced
hoisting equipment is put out of use definitively. Possible defects include:
o Absence or illegibility of labels bearing the load capacity;
o Presence of cuts, holes or rips on synthetic straps;
o Twisted or crushed points on ropes or metal cables;
o Signs of corrosion on metal parts;
o Abrasions and signs of wear due to excess friction on components.
Cuts are the main cause of breaking of synthetic straps. Cuts are generally produced when the
straps rub against sharp edges on the load being handled.
To ensure the integrity of straps, and therefore hoisting safety, we suggest inserting a soft
material along the edges of the load where it comes into contact with hoisting straps.
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Based on the type and size of the components to be shipped, P. Bacci will use appropriate packing to
ensure the machine does is not damaged during shipment and up to delivery to the customer.
The machine will be shipped directly on the truck platform or inside a container, based on the distance
from the place of delivery, on customer requirements and on how long the machine will remain packed.
If the machine is to remain packed for a long time or if shipping involves crossing the sea, machine parts
subject to oxidising (screws, chains, etc.) will be covered with a protective rust-proof substance.
Anti-humidity salts are placed inside the electrical boards to absorb possible humidity/condensation. All
precautions are taken when placing these salts to avoid contact with metal parts that may become
corroded. Based on the type of shipment, the inside of the electrical cabinet may also be packed with a
barrier bag to keep out humidity.
For load hoisting and handling, it is OBLIGATORY to always consult the respective specifications
contained in this manual.
Upon delivery of the machine, check that the packaging has not been damaged during shipment and that
the supply is conformant to the contract specifications.
If the machine has been damages, immediately notify the carrier and the Bacci technician.
Either wood or metal blocks may be used to ensure machine stability during shipment. These blocks
must all be removed.
For the entire time that the machine remains idle waiting for start-up, we recommend:
Protecting the machine with polyethylene sheets or tarps to keep dust from covering the
mechanisms and collision-proof covers to avoid possible damage.
Always check that storage temperatures are within the maximum and minimum temperature
range specified in the technical data and machine performance data.
All operations must be carried out by qualified personnel authorised by P. BACCI S.r.l.
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The machine can be transported using different types of packaging depending on destination and
transport modalities.
INFORMATION!
In the event of damage or lack of certain parts, contact Paolino Bacci Srl to agree upon the
procedures to adopt.
Depending on the characteristics of the machine or its parts, different devices and materials are used to
protect the machine or its parts during transport.
PACKAGING PRECAUTIONS 1 of 2
TYPE DESCRIPTION COMPONENTS
Nylon protective film is used as a dust-proof cover and
protection against light collisions and scratches of painted
Structure.
Nylon parts.
protective film Control
The film also partly protects the machine from gentle
panels.
atmospheric phenomena and prevents foreign material (dirt)
from depositing on the machine.
The application of grease on surfaces or machine Joints.
components aims to protect the components from Couplings.
Grease
atmospheric agents and prevent accumulation of foreign Guides.
material on the machine. Bearings.
Application of protective rustproof paint on surfaces or
machine components aims to protect components from
atmospheric agents and corrosion phenomena.
Machine parts subject to rust are covered with protective
paint:
o if the period between shipment and installation is
over 3 days.
o if the machine must be shipped by sea. Structure
o in winter and in climatic zones where there is high Screws
Protective
rustproof paint humidity. Uncovered
parts
INFORMATION!
Before the first start-up of the machine it is
necessary to clean the different components that
underwent protective treatment for shipment
purposes. Refer to the rustproof paint supplier’s
card for safety information on using masks/shields
and clothing to avoid contact with paint.
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PACKAGING PRECAUTIONS 2 of 2
TYPE DESCRIPTION COMPONENTS
Bags of anti-humidity salt are placed inside electrical
switchboards and control panels.
When the machine is shipped in a container anti-humidity
salt is placed inside the barrier bag. Electrical
Anti-humidity
boards
salts
INFORMATION! Barrier bag
Before the first start-up of the machine it is
necessary to remove all bags of anti-humidity salt.
ENVIRONMENTAL INFORMATION!
The disposal of packaging material must be performed in accordance with the current waste
disposal standards of the country where the machine will run.
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Disconnecting 1
2
machine wires
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To keep machine parts from moving during transportation, the linear axes
may be blocked into place mechanically.
Wind a part of the ball screw (1) with a copper sheet (4) to protect it.
Screw the block (2) on the part of the screw covered by the sheet (4).
Tighten the screws (5) against the surface of the structure (3).
Mechanical
3
block of axes
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Machine hoisting and handling equipment that must be provided by the end user customer are:
N. 1 crane.
N. 1 lift-truck.
Polyester hoisting straps.
80 mm diameter hoisting pipes. The length must be 500 mm longer than the machine frames.
DANGER!
All hoisting equipment must be chosen based on the weights to be hoisted to keep the loads from falling.
The table below summarised a few types of hoisting methods. The photographs are indicative of the
method to be used to prepare and hook up the hoisting equipment.
Machine hoisting drawings and diagrams may be found in ANNEX B TECHNICAL DIAGRAMS AND
GENERAL INFORMATION.
TYPE OF HANDLING
HOISTING
Certain structures or the machine body may be hoisted by using a crane (1),
hooked up to the polyester straps (2) and pipes (3) inserted in the special
holes on the machine structures.
The polyester straps anchored to the pipes may be positioned closet o the
structures or left at a distance of about 400 mm (4) to be able to balance the
movement deriving from the distribution of the machine weight.
Handling using a
crane, hoisting 2
pipes and straps
3
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TYPE OF HANDLING
HOISTING
Some machine structures or the machine body may be hoisted using a crane,
hooked up to the polyester straps (1) wound around the structures.
Position the straps on the external part of the structures to be hoisted (2),
making sure they will not be crushed or come into contact with edges or
corners that may damage them.
Rest the structures on wood supports (3) that make it possible to slip off the
polyester straps.
Some machine structures may be hoisted using a lift-truck. The forks of the lift-
truck (1) must be positioned under the pipes (2) inserted in the special holes
on the machine structure.
2 1
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TYPE OF HANDLING
HOISTING
The machine’s electrical cabinet (6) has four eyebolts (7) located on the upper
section of the cabinet to allow for hoisting using a specific hoisting device,
such as, for example, a crane (1) and four ropes (2).
If the cabinet has been packed in a barrier bag (3) for shipping, it may be
handled using a lift-truck (5).
Once the protective wood crate has been removed (4) the electrical cabinet
may be handled using a crane (1) and four ropes (2) connected to the four
eyebolts (7).
Handling the
electrical cabinet
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The procedure below describes the main recommendations for loading, transporting and unloading the
machine.
STEPS DESCRIPTION
Loading and unloading must be carried out only by specialised and authorised
Safety checks personnel.
Mark off the loading and unloading area and warn exposed persons of the
operations underway.
The machine is shipped in more than one piece, each of which is anchored
using wood beams, straps or similar means, to store and fasten the load.
Loading The load is always protected against inclement weather conditions using PVC
sheets.
Inspect the load visually and make sure that the PVC sheets are whole and not
cut or torn.
After having removed the PVC sheets, make sure that the load has not moved;
Checks on the straps must be in place and pulled taut and the wood slats must be well
arrival anchored to the load.
If the machine has been damaged, immediately inform the carrier and Paolino
Bacci S.r.l technical personnel.
Always upload the smallest and most easily reached items first.
Unload one load unit at a time.
Find the hook up points of the load units and always fasten the hoisting
Unloading equipment before removing the straps and slats that block the load.
Start hoisting gradually, moving the load without bumping against the transport
vehicle.
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The site where the machine is to be positioned must meet certain requirements. The buyer is
responsible for preparing the machine’s site of installation.
For machine installation, an industrial type floor made of plain concrete (or a similar material), at least 20
cm thick, will suffice.
If the concrete is reinforced with a steel grid, the grid must be deep enough under the surface of the
floor, seeing as the machine is installed using anchoring bolts that reach a depth of 15 cm.
Ditches for the removal of dust and chips must be at a distance of at least 10 cm from the machine’s
resting feet.
TYPE DESCRIPTION
Type of floor Industrial cement
Floor thickness At least 20 cm
Surface planarity 2:1000
Distance from the surface of reinforcement > 15 cm
grid
Distance of ditches from resting feet > 10 cm
CRITERIA SPECIFICATION
Temperature Between +5°C and 47°C
Relative humidity Between 10% and 90%
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The vacuum system is not provided with the machine. For correct and safe machine use, the machine
must be connected to a dust removal system that meets the specifications provided in ANNEX B
TECHNICAL DIAGRAMS AND GENERAL INFORMATION.
4.7 Assembly
The machine is assembled by Bacci technicians, as assembly may present risks for non specialised
personnel and requires specific and unique manufacturer know-how.
The information provided in this manual provides a minimal description of the tasks to be carried out.
During cleaning and installation, designated personnel must use all appropriate personal protective
equipment (overalls, gloves, glasses, etc.) and must be familiar with machine access procedures and
residual risks associated to the tasks being carried out.
Personnel must be informed of the safety procedures and risks present in the customer’s plant.
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STEP ACTION DESCRIPTION
Measure the levelness of the X axis by placing a precision level halfway
Levelness along the length of the X axis ball screw or halfway along the length of one
4
check of the X axis linear guides.
Turn the four adjustment screws (2) at the corners of the machine body.
Turn the screws 1/4 turn at a time.
5 Adjustment
Levelness Measure the levelness of the Y axis by placing a precision level on the
6
check resting plate.
Turn the four adjustment screws (2) at the corners of the machine body.
Turn the screws 1/4 turn at a time.
7 Adjustment
Act on the adjustment screws (2) to rest all the other plates on the ground
Fastening the uniformly. Always turn the pair of screws at the opposite ends by 1/4 of a
8
plates turn at a time.
Tightening the Block the adjustments screws using the lock-nuts (4).
10
screws
Use the anchoring holes (1) as a template to drill the anchoring holes in the
Inserting
11 ground for the anchor screws.
anchor screws
Anchor the machine body to the ground using the anchoring bolts (3).
12 Anchoring
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Once the machine has been anchored to the ground, remove all the safety guards and blocks used
during transportation.
The wires and cables between the machine and the electrical cabinet are removed for ease of
transportation.
Connect the machine cables and wires to the electrical cabinet following the wiring diagram.
The position of the electrical power supply connection points is shown in ANNEX B TECHNICAL
DIAGRAMS AND GENERAL INFORMATION.
For electrical and pneumatic connection information, please consult the technical data.
DANGER!
The customer shall be liable for any damage deriving from the machine being connected to electrical
and/or compressed air power supplies that are not conformant to the specifications provided here
following.
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CHAPTER
5 Controls and use
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INDEX
5 Controls and use ......................................................................................................... 1
5.1 Location of machine control panels .................................................................................................. 3
5.1.1 Main switch.......................................................................................................................................... 5
5.1.2 Main pushbutton panel ......................................................................................................................... 6
5.1.3 Portable pushbutton panel .................................................................................................................... 9
5.1.4 Right and left bench pushbutton panel ................................................................................................ 11
5.1.5 Bench foot pedal control ..................................................................................................................... 12
5.2 Operating procedures ...................................................................................................................... 13
5.3 Machine turn on and start up procedures ....................................................................................... 13
5.3.1 Start-up procedure – preliminary operations ........................................................................................ 14
5.3.2 Start-up procedure – Turning on the machine...................................................................................... 16
5.3.3 Start-up procedure – Zeroing .............................................................................................................. 18
5.3.4 Spindle pre-heating ............................................................................................................................ 20
5.4 Machine turn off procedure.............................................................................................................. 21
5.4.1 Procedure to turn off the machine for more than two hours .................................................................. 22
5.5 Machine stop and re-start ................................................................................................................ 23
5.5.1 Procedure to stop and re-start for EMERGENCY interventions ............................................................ 24
5.5.2 Stop and re-start procedure after working stop - STOP........................................................................ 25
5.5.3 Stop and re-start procedure after working stop - RESET...................................................................... 27
5.5.4 Machine stop during machining .......................................................................................................... 28
5.6 Operating procedures ...................................................................................................................... 28
5.6.1 Operating modes ............................................................................................................................... 28
5.6.2 HOLD-TO-RUN movements (portable control) .................................................................................... 29
5.6.3 SINGLE PIECE loading/unloading (work cycle) ................................................................................... 30
5.6.4 TANDEM work cycle .......................................................................................................................... 32
5.7 Equipping the machine .................................................................................................................... 33
5.7.1 Tools ................................................................................................................................................. 33
5.7.2 Machine tool diameter and weight....................................................................................................... 34
5.7.1 Sharpening machine tools .................................................................................................................. 34
5.7.2 Machine tool assembly information ..................................................................................................... 35
5.7.3 Balancing machine tools..................................................................................................................... 36
5.7.4 Cleaning machine tools ...................................................................................................................... 37
5.7.5 Tool load and presetting ..................................................................................................................... 38
5.8 Equipping the piece holder device .................................................................................................. 40
5.8.1 Equipping sequence........................................................................................................................... 40
5.8.2 Checking proper piece blocking .......................................................................................................... 40
5.8.3 Machining check ................................................................................................................................ 41
5.9 Equipping the TANDEM work cycle ................................................................................................. 42
5.10 Programming .................................................................................................................................... 42
5.11 Overview of the main PITAGORA functions .................................................................................... 43
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CHAPTER 5 – Machine controls and use
The machine must be run and operated by qualified and authorised personnel who have read and fully
understood the instructions provided in this manual and who are familiar with the machine’s safety
devices.
In the event of serious or unidentifiable machine malfunctions, stop the machine and wait for qualified
technicians to intervene.
CONTROL LOCATION
Main switch Located on the door of the
electrical cabinet.
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CONTROL LOCATION
Industrial PC keyboard Located on the electrical board or
on the portable console.
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MAIN SWITCH
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1 2 3 4
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5 6
7 8
Select the “HOLD TO RUN” mode only for tasks that must be
carried out on board the machine, such as, for example,
equipping the machine, machining trial runs and maintenance,
etc.
Select “Automatic” mode to carry out normal piece machining.
Press this button to stop the axes and spindles. It does not turn
off the machine.
7 Stop work pushbutton
Restart the cycle by pressing the automatic Start Cycle button.
“Turn on auxiliaries” Use this control to turn on the auxiliaries. Power supplies
8
control pushbutton (compressed air and electricity) must be present.
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9 10 11 12
9 RESET pushbutton Press the RESET button to reset the machine after a stop.
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4
2
Collision hazard.
3 Life Man Switch For all manual movements: Keep an eye on the orientation of the
axes.
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6
7
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CHAPTER 5 – Machine controls and use
Emergency stop The pushbutton has a mechanical block that keeps it in position;
1
pushbutton turn it to the left to release.
3 "Door" control pushbutton Automatic mode: Closes the sliding loading doors of the all-
around safety enclosure. When the doors are closed, the piece is
high-pressure blocked and the cycle starts.
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Manual mode:
The piece is blocked:
1
“Piece blocking” pedal
control Automatic mode:
The piece is blocked:
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CHAPTER 5 – Machine controls and use
We recommend designated personnel read and fully comprehend the instruction manual, particularly as
regarding operating instructions and safety recommendations.
The first start-up procedure may be carried out first as an empty run, without loading pieces into the
machine, to check the correct functioning of the machine units and, subsequently, loading pieces to be
machined to check that the machine and the piece gripping devices are functioning properly.
Machine production depends on customer choices (with the exception of the limits specified in this
manual); each type of production needs to be prepared based on the characteristics of the final product.
The sections that follow describe the procedures to be carried out to turn on, start-up and run the
machine.
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Opening the
4
cut-off valve
1 1
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CHAPTER 5 – Machine controls and use
Check that the pressure gauge for the doors/piece clamps (5) shows a
working pressure of 6 bar.
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CHAPTER 5 – Machine controls and use
Release
6 emergency
pushbuttons
7 RESET
Turn on
8
auxiliaries
7 8 9 10 11 12
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1
4 2
Activation of 3
the portable 5
4
pushbutton
panel
6
7
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CHAPTER 5 – Machine controls and use
Zero
5
potentiometer
Zero all the axes using the control panel. From the Main Menu, press the
ZEROING Softkey F.
6 Zero axes
Set
7
potentiometer
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During the first daily start-up, and any time the spindles have cooled to room temperature, all the
spindles must first run through a short heating cycle, to allow the bearings to gradually reach a uniform
working temperature.
For this purpose, a program must be created in which all the spindles are used as follows:
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CHAPTER 5 – Machine controls and use
Machine
1 Reset
Emergency
2
Pushbutton
7 8 9 10 11 12
Exit the submenus of the interface panel and return to the main
3 Exit submenus page.
The following message will appear: “You may now turn off the machine.”
Turn the main switch to "0".
Cut-off power
4 to the machine
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5.4.1 Procedure to turn off the machine for more than two hours
For a machine stop that is to last longer than 2 hours, follow the procedure described below.
DANGER!
Safety warning
2 The balancing cylinders remain pressurised even after the main switch has
been tagged out.
Do not tamper with the relative pneumatic pipes to avoid sudden
machine movements.
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CHAPTER 5 – Machine controls and use
In fact, there are three different types of machine stops that the user may execute to stop the machine
running.
The “Emergency” stop is carried out in the event it becomes necessary to immediately block the
machine due to a risk or unforeseen event. To perform an emergency stop, press the nearest
“Emergency” pushbutton; the program being run stops immediately and all movements are slowed
down at the maximum deceleration possible. Electric power is cut-off and the auxiliaries turn off.
The working "Stop" is used to stop the program being run without fully stopping all machine
functions. This kind of stop is executed by pressing the “STOP” button on the main panel; the
program being run stops immediately and all movements are slowed down at the deceleration set in
the software parameters. Electric power is not cut-off. The auxiliaries remain turned on.
The “Reset” stop is used to stop a machining cycle and stop the program by pressing the “Reset”
pushbutton on the main panel or the “Reset” key in the lower right hand corner of the monitor. We
recommend executing this stop only when in cycle standby.
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In the event of a sudden machine stop, be it intentional or accidental, correct function re-start depends
on how the machine has been stopped.
Proceed as described following.
Restart
2
procedure
7 8 9 10 11 12
1 2 3 4 5 6
Turn on
3
auxiliaries
7 8 9 10 11 12
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CHAPTER 5 – Machine controls and use
In the event of a sudden machine stop, be it intentional or accidental, correct function re-start depends
on how the machine has been stopped.
Proceed as described following.
Re-start
2
procedure
7 8 9 10 11 12
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3 Start cycle
7 8 9 10 11 12
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CHAPTER 5 – Machine controls and use
In the event of a sudden machine stop, be it intentional or accidental, correct function re-start depends
on how the machine has been stopped.
Proceed as described following.
Re-start
2
procedure
7 8 9 10 11 12
3 Start cycle
7 8 9 10 11 12
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If the machine has been stopped during a machining cycle, the operator must remove the spindle from
the piece.
NOTE
Safety
warning
DANGER!
Danger of collision between the spindle and the piece.
We recommend the instruction manual be read and fully comprehended before machine use, especially
as regards operating procedures and safety regulations.
.
Clamp closing during the stage in which the operator interacts with the piece holding device is carried
out at reduced pressure. Clamping pressure increases after loading has been confirmed by pressing the
relative pushbutton.
Once machining is completed, the piece is automatically moved outside the machine and the operator
manually removes it from the holding devices and then loads a new piece to be machined and starts a
new work cycle.
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CHAPTER 5 – Machine controls and use
The machine may be used in “HOLD TO RUN” mode only by the operator designated
to run the machine.
The operator must use the “HOLD TO RUN” mode only for operations that must be
supervised closely.
The operator enters the enclosure while the machine is running. All machine
movements are slowed down to a maximum speed of 2 m/min.
To enable any movement, the operator must press the specific command
pushbutton on the portable control and the “Life man” pushbutton, keeping it
pressed until the position required is reached. When the pushbutton is released,
the movement stops.
Manual spindle rotation is not enabled in this mode.
NOTE
DANGER!
Safety warning Crushing hazard.
The machining head moves in every direction.
Hold the portable control in one hand.
Rest the other hand on the STOP pushbutton.
Be careful of moving machine parts.
NOTE
DANGER!
Safety warning Danger of flying dust, chips and machining scraps.
All machining scraps fly off the tool.
The direction in which scraps fly off the tool may change suddenly and quickly.
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Machine equipping
Machine cleaning
Maintenance personnel Machine maintenance
INFORMATION!
All other operations are forbidden in manual mode.
The machine must be used by the operator or maintenance technician for normal
machining of materials.
STEP DESCRIPTION
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CHAPTER 5 – Machine controls and use
STEP DESCRIPTION
The machine automatically closes the door. Once the door is closed, the clamps
block the piece with a high clamping pressure.
The programmed machining work is performed.
Machining is completed and the piece holding devices return to the home position.
The doors open to allow manual unloading of the machined piece. Based on the
settings entered in the control software, the clamps may open automatically, when
the piece holding devices return to the zero position, or the clamps must be
opened by the operator using the pedal control.
The next piece is loaded manually and the work cycle is repeated
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The machine must be used by the operator or maintenance technician for normal
machining of materials.
STEP DESCRIPTION
Equip the machine by following the procedure described in the paragraph “Equipping the
1
machine for TANDEM work cycle”.
To perform the work cycle (CNC program), follow the instruction described in the
2 previous paragraph “5.6.3 SINGLE PIECE loading/unloading (work cycle)”.
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CHAPTER 5 – Machine controls and use
Only the operator in charge of running the machine may carry out the tasks described in this chapter.
This chapter is divided into two parts. The first part deals with the tool, including safety
recommendations, tool choice, maintenance and presetting. The second part deals with how to block the
piece.
5.7.1 Tools
MAINTENANCE NOTE
Machine
maintenance
information INFORMATION!
The tools to be installed on the machine must comply with the EN 847-1:1997
Directive.
STEP DESCRIPTION
Check the following parameters/data on the tool:
Tool marking
Manufacturer name
Max number of revolutions
Measurements: diameter, length...
Tools must be marked.
Work cycles
INFORMATION!
Tools must be marked and must comply with European Community directives. Check
the data on the information plate (1).
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NOTE
DANGER!
Cutting hazard
Tool cutting edges are sharp and may cause:
Safety warning Cutting injuries
Puncture injuries.
Handle tools with extreme care.
Use the following personal protective equipment (PPE): metal mesh gloves , when
replacing and handling tools.
Use only tools that have the diameters and weights shown in the table below.
MAINTENANCE NOTE
Machine
maintenance
information INFORMATION!
Tools must always be sharp to reduce cutting stress and spindle working temperature.
The heat generated by the spindle itself may overheat the bearings and bearing
lubricant. Overheated lubricant is less efficient and reduces spindle bearing service life.
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MAINTENANCE NOTE
INFORMATION!
Use only spacers that correspond to the diagram below:
Machine
maintenance
information
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Tools, tool holders and any spacers used must be dynamically balanced in G1.
MAINTENANCE NOTE
INFORMATION!
Rebalance the tool and tool holder every time the tool is sharpened.
Machine
maintenance
Improper tool balancing may lead to:
information
The tool breaking,
The tool coming off the spindle.
NOTE
DANGER!
Danger of flying tool parts.
Safety warning
Use the following personal protective equipment (PPE): metal mesh gloves , when
replacing and handling tools.
Use the following personal protective equipment (PPE): safety glasses when
sharpening tools.
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CHAPTER 5 – Machine controls and use
Tools, tool holders and any spacers used must be dynamically balanced in G1.
MAINTENANCE NOTE
INFORMATION!
Keep the following components rigorously clean:
Tapers
Shafts
Tool gripping clamps
DANGER!
Machine Danger of the tool holder group breaking.
maintenance
information
The presence of dust deposits on the tool stem may lead to:
Tool misalignment
The tool being blocked poorly.
If the operator tightens the clamp ring nut applying excessive torque, the shaft or tool
holder thread may be damaged.
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Positioning
1
spindle head 1
Select the clamp with the diameter best suited to the tool.
3 Select clamp Insert the clamp in the taper.
Insert the tool in the clamp and, after having positioned the tool in its seat,
4 Insert tool tighten the ring nut.
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1
4 2
Reposition the 3
5
head 5
6
7
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The equipping sequence varies based on the type of piece holding device fitted on the table. As the
machine may be fitted with piece holding devices made by the customer, we request that the customer
provide personnel authorised to run the machine with all the required instructions regarding piece
holding devices used during the work cycles.
NOTE
DANGER!
Safety warning Danger of the piece or tool parts flying off the machine.
Improper or inadequate blocking may cause:
The piece to fly off
The tool to break and fly off the machine.
Check that the piece is properly blocked before starting the work cycle.
After having fitted and adjusted the blocking devices, including counter-profiles if any are being used,
check that the piece has been blocked properly. Check that the piece is blocked in every direction in
which machining pressure may be applied.
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NOTE
DANGER!
Safety warning Danger of the piece or tool parts flying off the machine.
An erroneous piece program or a piece program applied to a piece that is not blocked
properly may cause the tool to break and tool fragments to fly off the machine.
Check the piece program before starting machining.
Once the machine has been equipped, the operator in charge of running the machine must check that
the work cycle is executed as required. Generally, checks carried out in the original conditions are the
best. The only difference with the final cycle is that the operator holds the portable control and reduces
the machining speed using the potentiometer in order to be able to intervene quickly in the event of
programming or equipping errors, etc.
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Tandem machining is carried out with the piece supported by both devices (axes Y1 and Y2), as the two
axes move synchronously.
The maintenance technician must remove the central safety guard located between the Y1 and
Y2 axes and enable tandem machining in the control software, allowing the Y1 and Y2 axes to
move forwards synchronously.
Once the equipping procedure has been completed, the machine may be started by following the
instructions provided in the paragraph “SINGLE PIECE loading/unloading (work cycle)”.
Upon completion of tandem machining, the maintenance technician must re-equip the machine for
SINGLE PIECE loading/unloading. To do so, the technician must replace the central safety guards for
the Y1-Y2 axes and disable tandem machining in the control software
5.10 Programming
The machine is programmed using the PITAGORA software package, used as the only programming
environment and to optimise all Paolino Bacci S.r.l. CNC work centres. Use of this software allows:
Fast and easy acquisition of CN programs with maximum optimising in terms of machine yield,
reducing programming time.
Optimising of programs generated by normal CAD CAM systems in terms of productivity and best
possible use of machine performance potential.
Using the technical features of Paolino Bacci S.r.l. work centres, taking advantage of speed,
accelerations and axis power, through the advanced machining path “jerk limitation” and
“smoothing” functions, without compromising machine reliability and long service life.
PITAGORA is a pure and original WINDOWS® software based on OpenGL® graphics and a calculation
motor developed by Paolino Bacci S.r.l.
The software creates three dimensional, dynamic images for complete collision control and NC programs
which, as they are developed using practical and intelligent tools, may be optimised to obtain maximum
performance in terms of machine yield.
For detailed information regarding the use of the PITAGORA software, please consult the specific
documents provided in ANNEX D OPERATOR INTERFACE SOFTWARE MANUAL.
The following section of the manual illustrates the main features of the PITAGORA software.
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Collision control is fully automatic and the programmer need only follow the instructions provided by
PITAGORA for error-proof results.
POS. DESCRIPTION
1 Dialogue box to enter machining selection
2 Dialogue box to enter machining
3 Geometric and technological machining data
4 3D animation
5 Automatic collision check
6 Machining time
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2 4
7
9
POS. DESCRIPTION
1 Dialogue box to enter quick coupling
2 Dialogue box to enter the path and quick feedrate
3 3D animation
4 Automatic collision check
5 Execution time for quick coupling
6 Dialogue box to enter ISO program
7 File importing
8 NC code entered
9 Machining time
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CHAPTER 5 – Machine controls and use
1
2
POS. DESCRIPTION
1 Windows® interface
2 OpenGL® graphic interface
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CHAPTER 6 – Maintenance
CHAPTER
6 Maintenance
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INDEX
6 Maintenance ................................................................................................................ 1
6.1 Maintenance........................................................................................................................................ 3
6.2 Safety instructions ............................................................................................................................. 4
6.2.1 Other interventions............................................................................................................................... 5
6.3 Maintenance timetable ....................................................................................................................... 6
6.3.1 Ordinary and extraordinary maintenance timetable................................................................................ 6
6.3.2 Maintenance interval for multi-shift use of the machine .......................................................................... 8
6.4 Greasing and lubrication.................................................................................................................... 9
6.4.1 Useable oils and grease ....................................................................................................................... 9
6.4.1.1 Lubricant oil for the pneumatic system (FLR).................................................................... 10
6.4.1.1 Oil for the tool holders ..................................................................................................... 11
6.4.1.1 Oil for the centralised lubrication system .......................................................................... 12
6.4.1.2 Greases for the centralised greasing system .................................................................... 13
6.4.1.3 Greases for mechanical elements/parts (manual lubrication)............................................. 14
6.4.2 Maintenance of the centralised lubrication system ............................................................................... 15
6.4.2.1 Automatic system check and topping-up .......................................................................... 16
6.4.3 Maintenance of the centralised greasing system ................................................................................. 18
6.4.3.1 Automatic system check and topping up .......................................................................... 19
6.5 Daily maintenance ............................................................................................................................ 22
6.5.1 Cleaning the machine at the end of each work shift ............................................................................. 22
6.5.2 Cleaning the FRL group (Filter - regulator – lubricator) ....................................................................... 23
6.5.3 Cleaning tools and tool holders........................................................................................................... 24
6.6 Weekly machine maintenance ......................................................................................................... 25
6.7 Monthly machine maintenance ........................................................................................................ 27
6.7.1 Centralised Lubrication of Linear Axes (OIL LUBRICATION) ............................................................... 27
6.8 Six-monthly checks and tests .......................................................................................................... 28
6.9 Extraordinary maintenance .............................................................................................................. 30
6.10 Decommissioning............................................................................................................................. 30
6.11 Dismantling ....................................................................................................................................... 31
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CHAPTER 6 – Maintenance
6.1 Maintenance
This chapter contains information that is essential to keep the machine in perfect working order. The
machine is designed to reduce maintenance needs to a minimum.
In order to avoid malfunctions or inconveniences, please follow the maintenance instructions provided in
this section.
MAINTENANCE NOTE
INFORMATION!
Machine A machine that is not regularly cleaned may entail risks for the operator's health. Bad
maintenance maintenance causes early wear and increases the probability of failures and
information breakdowns.
All interventions must conform to the safety guidelines and safety rules must be
rigorously complied with for the operator's integrity.
INFORMATION!
The concept of maintenance is closely linked with that of functionality. Maintenance stands for the series
of operations that must be performed for a product to remain effective and functional and meet the aims
for which it has been designed; product stands for a building, a machine, a system or a road. The
maintenance activity comprises a series of operations, such as tests, repairs, replacements of pieces or
parts of a product etc.
INFORMATION!
Lubrication maintenance operations can either be performed independently by operators, who intervene
during the work shift when a malfunction, such as low oil level, squeaking etc. arises (autonomous
maintenance intervention), or maintenance mechanics (planned maintenance intervention).
INFORMATION!
Before carrying out any maintenance operation which is not described in this manual, or in case you
have doubts on the information provided please contact Paolino Bacci S.r.L..
INFORMATION!
All planned mechanical and electrical maintenance operations must be correctly carried out
according to the recommended timetable.
All use and maintenance operations of the main commercial components of the system, which are
not mentioned in this manual, are contained in the suppliers' publications.
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Both the main switch and the cut-off valve are blocked using locks to prevent machine start-up.
NOTE
DANGER!
Electrocution hazard
Safety warning
The machine must be turned off before any maintenance is carried out. Live parts or
pressurised parts may cause very serious injury.
Turn off the machine and cut-off the air supply.
Block the main switch and the cut-off switch with locks.
NOTE
DANGER!
Safety warning Crushing hazard
The balancing cylinders remain pressurised even after the main valve has been cut-off.
Do not tamper with the relative pneumatic tubes to avoid sudden movements of the
machining head.
NOTE
DANGER!
Safety warning Risk of injury and damage to the machine
Never use compressed air to clean the machine. The jet of air may push chips
and dust into the milling unit or under the contacts of the electric components in
the electrical cabinet.
Clean the machine using an industrial vacuum!
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CHAPTER 6 – Maintenance
NOTE
WARNING!
Safety warning Risk of damage to the machine.
Before starting the machine again, make sure that all maintenance interventions have been duly
completed and the start of the machine does not entail any risks for operators and anyone (PES)
present in the area.
Immediately after termination of the maintenance intervention, restore and check the safety
devices that were removed during maintenance and repair.
EXCLUSIVELY use original spare parts. Spare parts that are not original may not be compatible
and damage the machine.
All interventions must be compatible with and rigorously respect the safety rules on the operator’s
integrity.
If the need for maintenance and repair interventions that are not contained in this manual arises while
you use the machine, you are recommended to address the Technical Support department of Paolino
Bacci S.r.L.
For telephone and fax contact details please refer to Chap 1 "Manufacturer’s Identification and Contact
Details". In your requests of technical support, always mention the machine identification data referred to
in Chap 1 "How to request spare parts"
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The table below contains all the machine maintenance requirements and specifies the maintenance
intervals. Maintenance intervals are calculated considering a 5 day work week, each day being made up
of 8 working hours, in normal working conditions. For multi-shift machine use, consult the section
“Maintenance intervals for multi-shift machine use ".
Resting surface 8h
Micro-switches and cams
Blowers
FRL unit:
8h NLGI-0
Level control
1000 h NLGI-1
Visual inspection
1000 h
Pressure check
2nd degree machine cleaning:
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CHAPTER 6 – Maintenance
*1 skids and guides that are not included in the automatic lubrication system.
Electrical wiring:
Electrical, electronic and electro-
mechanical components
Machining head electric
2000 h
manifold check and brush
replacement
Electrical cabinet air conditioner
fan
All indications regarding the maintenance intervals refer to use of the machine for one work shift each
day. If the machine operates for more than one daily shift, the maintenance frequency must be increased
accordingly:
Every 8h of work, that is, at the end of each shift; (every day for a single shift)
Every 40 of work, that is, every 5 shifts;.(every week for a single shift)
Every 160 of work, that is, every 20 shifts; (every month for a single shift)
Every 320 of work, that is, every 40 shifts.(every 2 months for a single shift)
Every 1000 of work, that is, every 125 shifts.(every 6 months for a single shift)
Every 2000 of work, that is, every 250 shifts.(every year for a single shift)
Every 10.000 of work, that is, every 250 shifts.(every 5 years for a single shift)
INFORMATION!
The employer is responsible for providing maintenance personnel with appropriate PPE.
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CHAPTER 6 – Maintenance
MAINTENANCE NOTE
Risk of damage to the machine.
The use of incompatible oils mixed together or one after the other may create
substances that are damaging for machine operation, thereby compromising machine
safety.
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MAINTENANCE NOTE
INFORMATION!
Risk of damage to the machine.
Machine
maintenance
information Use only the oils specified above.
Other products may be incompatible with the product used by the manufacturer for first
lubricant top-up.
The use of incompatible oils mixed together or one after the other may create
substances that are damaging for machine operation, thereby compromising machine
safety.
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CHAPTER 6 – Maintenance
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Use one of the products indicated in the table below or an ISO/UNI F class or ISO/UNI H class hydraulic
oil.
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CHAPTER 6 – Maintenance
TYPE OF GREASE
MAINTENANCE NOTE
Risk of damage to the machine.
Use only grease that is resistant to high pressure, otherwise, if the oil soaps separate
Machine
inside the lubricant grease, they may then solidify and jam up the pneumatic system.
maintenance
information
Use only one of the greases specified above. Other products may be incompatible with
the product used by the manufacturer for initial greasing. Incompatible greases mixed
together or used one after they other may create substances that are damaging for
machine operation, thereby compromising machine safety.
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ARTIST - Use and maintenance instruction manual
TYPE OF GREASE
MAINTENANCE NOTE
Risk of damage to the machine.
Use only grease that is resistant to high pressure, otherwise, if the oil soaps separate
Machine
inside the lubricant grease, they may then solidify and jam up the pneumatic system.
maintenance
information
Use only one of the greases specified above. Other products may be incompatible with
the product used by the manufacturer for initial greasing. Incompatible greases mixed
together or used one after they other may create substances that are damaging for
machine operation, thereby compromising machine safety.
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CHAPTER 6 – Maintenance
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ACTIVITY
STEP ACTION DESCRIPTION
Before working on any circuit or component, it is OBBLIGATORY to
check for residual voltage or pressure in the systems, making sure to
always work in safe conditions.
Risk of bumping into the machine structure and parts. Move cautiously
while carrying out maintenance.
Safety checks
Risk of slipping, tripping and falling on machining scraps.
1 Move cautiously while carrying out maintenance.
Risk of dust and materials being flung or sucked in.
In addition to commonly used PPE, based on the maintenance being
; , .
Check the lubricant oil level in the tank.
Keep the tank full (electrical minimum level signal). If the oil pump works
2 Check with the tank empty, air may get pumped into the lubrication system; this
may make it difficult to keep the pumping pressure up and may keep the
pump from priming.
Inspect the entire system, including rigid and flexible pipes (replace if
damaged), couplings (must be sealed) and all the bearings (a small
3 Visual inspection amount of lubricant should be visible along the edge of each bearing).
Check that the lubricating pump is working properly.
MAINTENANCE NOTE
Machine INFORMATION!
maintenance Risk of damage to the machine.
information
It is essential to bleed all the air from the system. Correct pressure readings depend on
the circuit being full of lubricant. Distributors that have air trapped inside them cannot
signal clogged points. To eliminate all the air from the system, follow the bleeding
procedure described in the attached manual.
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CHAPTER 6 – Maintenance
MAINTENANCE NOTE
Machine INFORMATION!
maintenance Risk of damage to the machine.
information
Use only one of the greases specified above. Other products may be incompatible
with the product used by the manufacturer for initial greasing. Incompatible
greases mixed together or used one after they other may create substances that
are damaging for machine operation, thereby compromising machine safety.
MAINTENANCE NOTE
Machine
maintenance INFORMATION!
information Risk of damage to the machine.
Check system pressure. Follow the procedure described in the attached manual.
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NOTE
DANGER!
Safety Risk of the spring flying off
warning
There is a highly loaded spring (1) inside the tank (see plate 2).
Do not open the lubricant tank.
Top up the tank using the coupling (see procedure).
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CHAPTER 6 – Maintenance
; , .
Check the lubricant grease level in the tank.
Keep the tank full (electrical minimum level signal). If the pump works with
2 Check the tank empty, air may get pumped into the lubrication system; this may
make it difficult to keep the pumping pressure up and may keep the pump
from priming.
Inspect the entire system, including rigid and flexible pipes (replace if
damaged), couplings (must be sealed) and all the bearings (a small
3 Visual inspection amount of lubricant should be visible along the edge of each bearing).
Check that the lubricating pump is working properly.
MAINTENANCE NOTE
Machine INFORMATION!
maintenance Risk of damage to the machine.
information
It is essential to bleed all the air from the system. Correct pressure readings depend on
the circuit being full of lubricant. Distributors that have air trapped inside them cannot
signal clogged points. To eliminate all the air from the system, follow the bleeding
procedure described in the attached manual.
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Topping up the
4
tank
Connect the
5
system
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CHAPTER 6 – Maintenance
MAINTENANCE NOTE
INFORMATION!
Machine Risk of damage to the machine.
maintenance
information Use only grease that is resistant to high pressure, otherwise, if the oil soaps separate
inside the lubricant grease, they may then solidify and jam up the pneumatic system.
Use only one of the greases specified above. Other products may be incompatible with
the product used by the manufacturer for initial greasing. Incompatible greases mixed
together or used one after they other may create substances that are damaging for
machine operation, thereby compromising machine safety.
MAINTENANCE NOTE
Machine
maintenance INFORMATION!
information Risk of damage to the machine.
Check system pressure. Follow the procedure described in the attached manual.
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Remove
1
chips
Do not clean the machine using compressed air as the machining chips
may penetrate between the movement gears compromising machine
operation.
Clean the
2
machine
Clean the Clean the machine components thoroughly, removing all grease and dirt
3 machine deposits.
components
MAINTENANCE NOTE
Machine INFORMATION!
maintenance Risk of damage to the machine.
information
Do not use compressed air to clean the machine. The jet of air may push chips
and dust inside the dust guards.
Use an industrial vacuum to clean the machine.
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CHAPTER 6 – Maintenance
Check the
lubricator
1
and the oil
level
Discharge condensation from the lubricator filter (1) following the instructions
provided by the FRL group manufacturer.
Check
2
condensation
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Clean the tool tang (2) and the tapered surface of the tool holder (1).
Apply a thin layer of lubricant on the tapered seat of the spindle.
Check the wear of the tool’s cutting edges. Replace the tool if the
cutting edge is damaged or dull.
Use only tools/tool holders that have been balanced in G1. Rebalance
the tool every time it is sharpened.
1 Clean
NOTA
DANGER!
Risk of flying tool parts.
Safety
warning
Negligence during tool maintenance represents a major cause of accidents.
Clean and sharpen the tools.
Keep tools clean and sharp.
Balance tools in G1 every time they are sharpened.
MAINTENANCE NOTE
Machine Use only one of the greases specified above. Other products may be incompatible with
maintenance the product used by the manufacturer for initial greasing. Incompatible greases mixed
information together or used one after they other may create substances that are damaging for
machine operation, thereby compromising machine safety.
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CHAPTER 6 – Maintenance
ACTIVITY
STEP ACTION DESCRIPTION
Before working on any circuit or component, it is OBBLIGATORY to
check for residual voltage or pressure in the systems, making sure to
always work in safe conditions.
Risk of bumping into the machine structure and parts. Move cautiously
while carrying out maintenance.
Safety checks
Risk of slipping, tripping and falling on machining scraps.
1 Move cautiously while carrying out maintenance.
Risk of dust and materials being flung or sucked in.
In addition to commonly used PPE, based on the maintenance being
; , .
After 5 work shifts, specifically clean:
The filter of the electrical cabinet conditioner. Remove the grid of the
2 Cleaning electrical cabinet conditioner (1).
Inside the electrical cabinet (2).
Inside the machine and under the dust guards.
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NOTE
DANGER!
Risk of accidents and damage to the machine.
Safety warning
Never use compressed air to clean the machine. The jet of air may push chips and
dust present in the air inside the milling unit or between the contacts of the
electrical components in the electrical cabinet.
Clean the machine and the inside of the electrical cabinet using an industrial
vacuum.
NOTE
DANGER!
Electrocution hazard.
Safety warning
Never use compressed air to clean the machine. The jet of air may push chips and
dust present in the air inside the milling unit or between the contacts of the
electrical components in the electrical cabinet.
Clean the machine and the inside of the electrical cabinet using an industrial
vacuum
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CHAPTER 6 – Maintenance
ACTIVITY
STEP ACTION DESCRIPTION
Before working on any circuit or component, it is OBBLIGATORY to
check for residual voltage or pressure in the systems, making sure to
always work in safe conditions.
Risk of bumping into the machine structure and parts. Move cautiously
while carrying out maintenance.
Safety checks
Risk of slipping, tripping and falling on machining scraps.
1 Move cautiously while carrying out maintenance.
Risk of dust and materials being flung or sucked in.
In addition to commonly used PPE, based on the maintenance being
; , .
Discharge the condensation from the electrical cabinet conditioner
2 Clean (1). See the attached manual.
MAINTENANCE NOTE
Machine
maintenance
information Check proper functioning of the lubrication system and the oil level in the tank.
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ACTIVITY
STEP ACTION DESCRIPTION
Before working on any circuit or component, it is OBBLIGATORY to
check for residual voltage or pressure in the systems, making sure to
always work in safe conditions.
Risk of bumping into the machine structure and parts. Move cautiously
while carrying out maintenance.
Safety checks
Risk of slipping, tripping and falling on machining scraps.
1 Move cautiously while carrying out maintenance.
Risk of dust and materials being flung or sucked in.
In addition to commonly used PPE, based on the maintenance being
; , .
Visually inspect that the electrical cables and cable holding chains are
not damaged and replace damaged components as required.
2 Check Check that the electrical connectors as fastened tightly.
Check electrical, electronic and electro-mechanical components and
the electrical cabinet.
Check that all mechanical safety devices are in place and working:
Enclosure
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CHAPTER 6 – Maintenance
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The maintenance described here following requires know-who and specific tools.
This maintenance may be carried out only by the Paolino Bacci S.r.l. Technical Servicing department or
by technical personnel authorised by Paolino Bacci S.r.l.
Pneumatic system:
Solenoid valve check (heating and binding) and FRL group check, including replacement as required.
Electrical wiring:
Electrical, electronic and electro-mechanical components
Check on the electrical manifold of the machining head and brush replacement
Electrical cabinet conditioner fan
Overhaul of the electrical cabinet conditioner
Mechanical
Check that transmission belts are taut.
Check that mechanical organs are tight (ring nuts, flanges, etc.).
6.10 Decommissioning
Before long idle periods, the machine must undergo the following maintenance:
Thorough cleaning
Lubrication of all moving parts
Surface rust-proofing treatment on all unpainted metal parts (apply oil or MoS2 spray).
Cover the machine with a water-proof sheet to protect it against dust and humidity.
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CHAPTER 6 – Maintenance
6.11 Dismantling
The machine may have to be moved to different premises during its life cycle. In this case proceed as
follows.
STEP OPERATION
Once the machine has reached the end of its technical life, it must be shut down and must not be used
again for the purposes for which it was originally designed and manufactured; however, you must make
sure the parts and raw materials it is made up can be re-used. Said re-use must not be performed
according to modalities and functions that differ from those for which individual machine parts and the
machine as a whole were designed and manufactured.
PAOLINO BACCI S.r.l. declines any responsibility arising from damage incurred by persons or objects
due to the re-use of individual machine parts for functions or assembly different from the original
functions or assembly. PAOLINO BACCI S.r.l. shall not implicitly or explicitly acknowledge the suitability
of machine parts that were reused after the final de-activation of the machine for dismantling purposes.
Electronic parts
Electronic cards, batteries, storage batteries and buffer batteries of the electrical
switchboard are considered to be hazardous and toxic waste. These parts must be
disposed of by special authorised companies according to directive: 2002/96/EC.
Oil
The oil used during the work cycle of the machine and/or its maintenance must be disposed of according
to the EEC European Directive 75/439 of 16 July 1975.
In accordance to this directive all companies that dispose of used oil are obliged to provide the
competent authorities with information pertaining to the elimination and disposal of used oil and oil
residues.
Please note that according to Presidential Decree (DPR) N° 691 of 23 August 1982, it is obligatory to
address the CONSORTIUM OF USED OIL.
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CHAPTER 7 – Attached documentation and diagrams
7 CHAPTER
Attached documents and
diagrams
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INDEX
7 Attached documents and diagrams ..................................................................................... 1
7.1 List of attached documents ............................................................................................................... 3
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CHAPTER 7 – Attached documentation and diagrams
To support and complete the information provided in this manual, PAOLINO BACCI S.r.l. provides a
series of “ANNEXED” documents.
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