Rover A Edge 1643 User Manual English

Translation of the original instructions
Rover A
1425, 1432, 1443, 1459, 1625, 1632, 1643, 1659, 1632 EDGE, 1643 EDGE, 1659 EDGE
Processing centre
User Manual
2.3
5801A0520
Serial number
INGLESE
Information about the publication
Code Issue Code of previous issue

5801A0520 2 5801A0511
Revision Description of updates

0 (05/2014) Nouveau document
1 (04/2016)
2 (01/2017)
3 (11/2017)
This manual has been prepared by the manufacturer to be used by customers only and it contains
information protected by copyright. It must not be photocopied or reproduced in any form, either
fully or in part, without the prior written consent of the manufacturer.
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Table of contents
Table of contents
Introduction ............................................................................................................................... 11
Preliminaries
1 Safety information
1.1 Main safety warnings ....................................................................................................... 17
1.2 Safety devices .................................................................................................................. 19
1.3 Signs ................................................................................................................................ 20
1.4 Residual risks ................................................................................................................... 21
2 Main parts
2.1 General description of the machine ................................................................................. 23
2.2 General overview and main parts .................................................................................... 24
2.3 Work table ........................................................................................................................ 28
2.4 Operating section ............................................................................................................. 32
2.5 Uninterruptible power supply (UPS) ................................................................................. 36
2.6 Bar code reader ............................................................................................................... 37
2.7 Identification of the manufacturer and the machine ......................................................... 38
3 Basic information
3.1 Guideline indications ........................................................................................................ 39
3.2 Cartesian axes and co-ordinates ..................................................................................... 40
3.3 Machine axes ................................................................................................................... 41
3.4 Origins .............................................................................................................................. 44
3.5 Working areas .................................................................................................................. 46
3.6 Stop lines ......................................................................................................................... 47
3.7 Information on the rotation direction of the spindles ........................................................ 48
3.8 Slot, Tp ............................................................................................................................. 49
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Table of contents
4 Intended use
4.1 How to load and unload the piece .................................................................................... 51
4.2 Characteristics and dimensions of workable materials .................................................... 51
4.3 Edgebanding strip features and dimensions .................................................................... 53
4.4 Executable machining operations .................................................................................... 54
4.5 Work area ........................................................................................................................ 58
4.6 Danger area ..................................................................................................................... 58
5 Commands and indicator devices

5.1 Control panel .................................................................................................................... 59
5.2 Indicator lamp .................................................................................................................. 63
5.3 bPad terminal ................................................................................................................... 64
5.4 Hand-held terminal RM850 .............................................................................................. 66
5.5 Working area button pad .................................................................................................. 71
5.6 Chain type tool magazine and banding material container button pad ............................ 72
5.7 Gluing unit commands ..................................................................................................... 73
5.8 Safety fence reset button pad .......................................................................................... 74
Use
6 Using the machine

6.1 Switching the machine on ................................................................................................ 77
6.2 Zero-setting the machine axes ......................................................................................... 78
6.3 Global zero-setting of the carriages ................................................................................. 79
6.4 Moving the machine axes ................................................................................................ 79
6.5 Operating section warm-up cycles ................................................................................... 80
6.6 Checking the electrospindle temperature ........................................................................ 80
6.7 Stopping the machine ...................................................................................................... 81
6.8 Restoring the machine ..................................................................................................... 82
6.9 Interrupting the program .................................................................................................. 82
6.10 Restarting the program after an emergency stop ............................................................ 83
6.11 Switching off the machine ................................................................................................ 84
6.12 Using the RM850 hand-held terminal .............................................................................. 85
6.13 Using the bPad terminal ................................................................................................... 86
6.14 Using the piece alignment laser projector ........................................................................ 87
6.15 Shutdown of piece alignment laser projector ................................................................... 87
6.16 Using the bar code reader ............................................................................................... 87
7 Using the safety devices

7.1 Emergency stop button .................................................................................................... 89
7.2 Main switch ...................................................................................................................... 90
7.3 Contact mat ...................................................................................................................... 91
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Table of contents
7.4 Operating section guards ................................................................................................. 93

7.5 Photocell barrier ............................................................................................................... 94
7.6 Safety fence ..................................................................................................................... 95
7.7 Compressed air cut-out valve .......................................................................................... 96
7.8 Key-activated commands ................................................................................................. 97
8 Carrying out machining operations

8.1 Warnings for correct machining operations ...................................................................... 99
8.2 Changing the machine axis transfer speed .................................................................... 102
8.3 Changing the spindle rotation speed .............................................................................. 103
8.4 Machining operation procedure ...................................................................................... 103
8.5 Program simulation ........................................................................................................ 104
8.6 Activate stop line ............................................................................................................ 104
8.7 Selecting the origin ......................................................................................................... 105
8.8 Manual positioning of both the piece mobile support and the carriages of the ATS assisted
work table 105
8.9 Locking the piece on the work table ............................................................................... 106
8.10 Activation of piece movement devices ........................................................................... 115
8.11 Managing the operating section parking mode .............................................................. 115
8.12 Starting the machining operation ................................................................................... 116
8.13 Piece unlocking and unloading ...................................................................................... 116
8.14 Machining operation with manual loading of the edgebanding strip .............................. 116
8.15 Information on the closed ring edgebanding .................................................................. 116
9 Troubleshooting
9.1 Problems, causes and solutions .................................................................................... 117
Tooling
10 Preparing the operating section

10.1 Installing tools ................................................................................................................ 125
10.2 Installing the chip deflector ............................................................................................. 138
11 Preparing the magazines

11.1 Preparing the Revolver tool magazine ........................................................................... 139
11.2 Preparing the Chain type tool magazine ........................................................................ 140
11.3 Preparing the Flexstore magazine ................................................................................. 141
11.4 Preparing the Rack magazine ........................................................................................ 141
11.5 Tools and aggregates that can be used, and their direction ........................................... 143
11.6 Preparing the banding material container ...................................................................... 144

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Table of contents
12 Preparing the work table

12.1 Installing the shapeable suction cups ............................................................................ 145
12.2 Installing the gasket on the shapeable suction cups ...................................................... 146
12.3 Installing the stops for pieces with protruding finish ....................................................... 146
12.4 Installing the clamp stop plates ...................................................................................... 147
12.5 Installing the waste supports .......................................................................................... 148
12.6 Installing and adjusting the Uniclamp-Hyperclamp devices ........................................... 149
12.7 Installing and adjusting the horizontal clamps ............................................................... 157
12.8 Installing the CFT work table ......................................................................................... 160
12.9 Creating the locking areas on the CFT work table ......................................................... 161
12.10 Installing the tilting side stops ........................................................................................ 162
12.11 Removing the side stop supports ................................................................................... 162
12.12 Changing the bar support stroke .................................................................................... 164
12.13 Positioning the mobile elements of the work table ......................................................... 165
Interventions
13 Adjustments
13.1 Adjustment of the presser roller guide ........................................................................... 171
13.2 Replacement of the presser roller .................................................................................. 172
13.3 Glue replenishment ........................................................................................................ 173
13.4 Glue heating ................................................................................................................... 174
13.5 Adjustment of the amount of glue applied on the piece ................................................. 176
14 Maintenance
14.1 Warnings relating to machine maintenance ................................................................... 177
14.2 Forced lubrication .......................................................................................................... 177
14.3 List of the maintenance operations to be carried out on the machine ........................... 178
14.4 General cleaning of the machine ................................................................................... 181
14.5 Cleaning the machine guides and racks ........................................................................ 181
14.6 Updating the antivirus system ........................................................................................ 181
14.7 Pressure check .............................................................................................................. 182
14.8 Lubricating the X-drive devices (slide blocks and rack) ................................................. 183
14.9 Lubrication of the Y and Z drive devices (slide blocks and lead nuts) ........................... 184
14.10 Lubrication of the machine X-axis gears ........................................................................ 185
14.11 Lubricating the Rack type magazine drive devices ........................................................ 185
14.12 Topping up the grease level ........................................................................................... 186
14.13 Topping up the lubrication pump .................................................................................... 188
14.14 Topping up the boring unit lubrication pump .................................................................. 188
14.15 Cleaning the carriage filters ........................................................................................... 189
14.16 Interventions on the operating section ........................................................................... 193
14.17 Interventions on the electrical cabinet ............................................................................ 207
14.18 Interventions on the FR unit ........................................................................................... 208

Table of contents
14.19 Interventions on the Becker Picchio 2200 vacuum pump .............................................. 210
14.20 Operations on the Becker VTLF2.250 vacuum pump .................................................... 212
14.21 Interventions on the Busch Mink vacuum pump ............................................................ 214
14.22 Interventions on the Becker U 4.250 SA/K vacuum pump ............................................. 216
14.23 Interventions on the Becker U 4.100 SA/K vacuum pump ............................................. 219
14.24 Operations on the magazines ........................................................................................ 221
14.25 Interventions on the refrigerator ..................................................................................... 222
14.26 Comparative lubricant table ........................................................................................... 224
Appendices
A Technical characteristics
A.1 Main machine axes X, Y, and Z ...................................................................................... 227
A.2 Types of electrospindles ................................................................................................. 227
A.3 Collet spindles ................................................................................................................ 228
A.4 Boring unit ...................................................................................................................... 229
A.5 Horizontal milling unit ..................................................................................................... 230
A.6 Motorised rotating milling unit ........................................................................................ 230
A.7 Multifunction unit ............................................................................................................ 231
A.8 C-axis ............................................................................................................................. 231
A.9 5-axis milling unit ............................................................................................................ 231
A.10 Chip deflector ................................................................................................................. 232
A.11 Rack type tool magazine ................................................................................................ 232
A.12 Revolver tool magazine .................................................................................................. 232
A.13 Chain type tool magazine ............................................................................................... 233
A.14 Dimensions of the shapeable suction cups .................................................................... 233
A.15 Dimensions of the CFT table .......................................................................................... 233
A.16 Working field in X-Y ........................................................................................................ 233
A.17 Working field in Z ........................................................................................................... 233
A.18 Noise level ...................................................................................................................... 234
B Transport
B.1 Notices on lifting and unloading the machine ................................................................. 235
C Installation
C.1 Warnings regarding machine installation ....................................................................... 239
C.2 Working dimensions and connection points ................................................................... 240
C.3 Installation area requisites ............................................................................................. 241
D Decommissioning - Demolition

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Table of contents
D.1 Decommissioning ........................................................................................................... 247

D.2 Scrapping ....................................................................................................................... 247
E Guarantee and customer service

E.1 Warranty ........................................................................................................................ 249
E.2 Customer service ........................................................................................................... 249

Introduction
Introduction
This document, together with the interface instruction manual and any attachments, provide the
information required for proper use of the machine. The procedures described must only be
carried out by suitably trained personnel.
To avoid any incorrect manoeuvres that could endanger people, it is important to read and fully
understand all the documents that come with the machine. The manufacturer cannot be held
responsible or legally liable for any damage resulting from incorrect use of the documentation.
The description or illustration /of certain devices may differ slightly from the actual ones without in
any way compromising their comprehension. Some devices indicated and described in this
manual may not be present on your machine.
This document complies with the indications in Machinery Directive 2006/42/EC.
Conventions
The parts of the text requiring special attention are highlighted and preceded by the symbols
illustrated and explained below.
Paragraphs marked with this symbol indicate an imminent danger, and the contents
must therefore be taken into careful account in order to prevent a serious accident.
Paragraphs marked with this symbol indicate procedures to be used and actions to
be taken to avoid any damage to goods and property.
This symbol is used to indicate points of particular importance that must not be overlooked.
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Introduction
Documents supplied with the machine
The documents supplied with the machine must be kept safely throughout the machine's working
life, and must be passed on to third parties on sale. They must be stored in a suitable place within
easy access of and known to the persons using the machine.
Based on the model or configuration of the machine, some of the following might not be present.
The following is a list of the documents supplied with the machine:

User Manual. Contains information about machine use. Given the complexity of the subjects
dealt with, this information may be divided into a number of sections.
User Interface Manual. Contains the information on use of the machine's user interface.
Given the complexity of the subjects dealt with, this information may be divided into a number
of sections. This document could be integrated in the interface.
Pneumatic system diagrams These describe the machine's pneumatic systems and are for
the sole use of the trained technicians authorised by the manufacturer. They are not
necessarily translated into the language of the country to which the machine is being sent.
Electric system diagrams These describe the machine's electrical systems and are for the
sole use of the trained technicians authorised by the manufacturer. They are not necessarily
translated into the language of the country to which the machine is being sent.
EC Declaration of Conformity This certifies that the machine complies with the directives
indicated. It is only issued for machines sold in EEC countries and those where Machinery
Directive 2006/42/EC is applied.
Layout. It contains the overall dimensions, the connection points and technical specifications .
Enclosures These contain additional information that completes and/or replaces the
information in the document with which they are enclosed.
DVD BIESSE-Parts. Contains the spare parts catalogue and the main documents supplied
with the machine.
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Introduction
EC declaration of conformity
Here below a facsimile of the EC Declaration of Conformity delivered with the machine:
B
C D
E
G
H
A - Name of the manufacturer, address.

B - Designation.
C - Model.
D - Serial number.
E - Compliance with directives
F - Person authorised to prepare the technical folder and their address.
G - Name, surname and role of the person authorised to sign.
H - Place and date of issue of the declaration.
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Introduction
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Preliminaries
This chapter contains the main information relating to the safety of the machine user.
1.1 Main safety warnings

The machine has been designed to be used exclusively by one person. To avoid accidents,
the presence of two or more people on a single machine is absolutely forbidden.
Before carrying out any type of operation, carefully check there is nobody near the machine.
It is absolutely forbidden to climb onto any part of the machine.
The machine is only sufficiently safe if:
• all the safety standards governing health and safety at work are respected;
• all the information on machine use contained in the respective manuals and applied directly
to the machine is respected;
• the operators have been suitably trained in the use of the machine;
• the residual risks (see page 21) are taken into due account.
Do not modify the machine's electric system and do not tamper with, elude, eliminate or
bypass the safety devices fitted on the machine. Non-compliance with this warning could
result in serious risks to the health and safety of persons.
The machine must only be used for the purpose for which it was designed.
Wear clothing with an adequate level of protection for the operations to be carried out
(goggles, gloves, safety helmet, shoes, etc.).
Check that all the dust suction hoods are connected to the suction network. Work only with the
suction system on.
Wood machining operations create dust. It is recommended, at the customer’s discretion, that
you wear a mask with a suitable protection level.
Wear headsets or ear plugs to protect hearing.
Before starting the machine, check there is nobody inside the danger areas.
Make sure that nothing will obstruct normal movement of the mobile parts of the machine and
that all the casings, doors and protective covers are in their proper places and securely fixed.
Before starting work, check to make sure that the tools installed in the machine have not been
tampered with in any way.
Always keep the working area clean and tidy.
Before approaching tools, always make sure they are no longer turning, even in the case of
sudden stoppages of the machining operation or to remove chips and sawdust.
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The machine must never be left unattended during operation.

When handling chemical substances such as lubricants, glues etc., comply with the safety
standards for the products in question and refer to the relevant safety data sheets supplied by
the respective manufacturers.
In the case of an accidental interruption in the electricity supply, in order to prevent damage to
the electronic equipment, rotate the main switch of the machine to the “0-off” position
immediately.
Tools
Never use deformed or cracked rotating tools.
Check for perfect balance of rotating tools and make sure they are perfectly sharp and suitable
for the work to be performed.
Grinding wheels cannot be used on the machine.
Never use tools beyond the speed limit, which is stamped on the surface of the tool or
indicated by the manufacturer. If used at rotation speeds higher than those foreseen certain
tools might break, causing pieces to fly out of the machine.
Before installing any tool in its seat make sure that the guide and centring surfaces have no
dents and are perfectly clean.
In each tool apply only the prescribed torque to screws, bolts, nuts and rings.
Always make sure the tool rotation direction is the same as that of the spindle in which it is
mounted.
Tools must always comply with the specifications reported in the instructions for the machine
on which they are to be used.
Don't use aggregates that are different from those referred to in the layout supplied with the
machine. If other aggregates are used without any written authorisation, the manufacturer
shall not be liable in the event of negligence.
Only use tools that comply with EN 847-1 and EN 847-2 and EN 847-3 specifications on the
machine, and always comply with the specifications for use indicated by the manufacturer.
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Tooling, maintenance and repairs

The machine must be set up by one person only. Ensure that nobody else approaches the
machine during the set-up operations.
Never leave tools on the machine when the set-up has been completed.
Never use petrol, solvents or flammable fluids to clean the parts, use commercially available
type-approved detergents that are non-toxic and non-flammable.
When a repair or maintenance needs to be performed in areas not accessible from the
ground, use a ladder or a platform with steps complying with local and national standards.
In the case of repairs, contact the Service Centre.
Comply with all applicable standards when disposing of substances and/or parts of the
machine. Follow the indications supplied by the respective manufacturers on the safety data
sheets.
Do not work under or near any kinematic systems that have not been appropriately supported
and locked in position.
Do not replace or tamper with any laser projectors that may be fitted on the machine.
When replacing tools manually, always check they have stopped before you touch them.
If an inverter error occurs, make sure there are no tools in rotation, before approaching the
machine.
If the remote assistance function is used, operations performed from the remote location must
be authorised by the client.
1.2 Safety devices

The machine is equipped with various devices that increase the level of safety. For information on
the operation and use of these devices, refer to the relevant chapter.
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1.3 Signs
The following describes the danger signs that could be present on the machine.
DANGER - Live components! Before carrying out any operations on the

electrical system, make sure that the power supply has been turned off.
DANGER - Hot surfaces!
DANGER- Chopping!
DANGER - crushing!
Danger area!
Compulsory safety gloves
Refer to the user manual
DANGER - Magnetic fields
PROHIBITION - access with pacemaker
DANGER - Danger area
DANGER - Crushing
The safety signs affixed to the machine must be kept undamaged and clean.
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1.4 Residual risks

This machine is equipped with protection devices in conformity with Directive 2006/42/EC. These
devices are efficient as long as they are properly used and kept in working order. Despite
observance of all the safety regulations and use of the machine according to the rules described in
this manual, there may still be some residual risks:
Accidents caused by incorrect commands given by the operator; always pay great attention
when entering data in the machine interface and when operating the machine.
Injuries or burns caused by tools; handle tools with great care, and always use suitable gloves.
Ejection of cut-offs; to restrict the risk it is recommended that, wherever possible, the cut piece
be suitably fixed.
Detachment of pieces, as the efficiency of the vacuum locking system depends on the
porosity, thickness and size of the piece, as well as the type of tools being used for the
machining operation (see cautionary notice in the section "Intended use").
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2 Main parts
2 Main parts
This chapter provides information on the type of machine, its main and optional parts, and the
configuration of the various models available.
Some devices indicated and described in this manual may be optional features and
therefore not present on your machine.
2.1 General description of the machine

This machine is a numerically controlled processing centre designed to perform a wide range of
boring and milling machining operations as well as for the production of door and window frames.
For further information on the machining operations that are possible, on the loading methods and
on the panel characteristics, please see chapter 4 “Intended use”.
The machine comprises a base, a group of devices that allow the positioning and locking of the
piece/pieces to be machined (work table), and a series of units used to machine the piece
(operating section). The operating section can be configured so as to satisfy the various machining
needs.
More detailed information about the parts that make up the machine is given in paragraph 2.2
“General overview and main parts” on page 24.
The machine is manufactured with safety systems that meet the regulations in force in the various
countries. Machines destined for use in Europe and those countries where Directive
2006/42/EC is applied also bear the EC mark.
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2 Main parts
2.2 General overview and main parts
AA
W
D Q
J
F G
C
H
M K
I
P
X
B
A
Z
O U
Y
R S
N T
A Base; this is the load-bearing structure of the machine.
B Work table; for the description, see page 28.
C Operating section; for the description, see page 32.
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2 Main parts
D Main switch; for the description, see paragraph 7.2, page 90.
E Electrical cabinet; contains the main commands and electronic devices used for managing
machine operations.
• Control panel: for a description of the commands, refer to paragraph 5.1, page 59).
F Revolver tool magazine; contains the tools required for machining, which are picked up and
set down automatically by the operating section.
This magazine can be fitted with a tool/aggregate identification system (Balluff), which enables
the main tool data (length, diameter, rotation speed, etc.) to be read or recorded, using a chip
located inside the collet spindles or in the coupling of the aggregates.
G Chain tool magazine; contains the tools required for machining, which are picked up and set
down automatically by the operating section.
This magazine can be fitted with a tool/aggregate identification system (Balluff), which enables
the main tool data (length, diameter, rotation speed, etc.) to be read or recorded, using a chip
located inside the collet spindles or in the coupling of the aggregates.
H Rack type tool magazine; contains the tools required for the machining operation (maximum
12) and which are automatically picked up and set down by the operating section.
I Pick-up tool magazine: contains the tools required for machining (max. 1), which are picked
up and set down automatically by the operating section.
J Flexstore Magazine ; (optional) contains the tools necessary for the machining operation and
supplies the Chain type tool magazine. This magazine is equipped with a tool/aggregates
identification system (Balluff), which can read or record their related main data (length,
diameter, rotation speed ...). This chip is positioned in the collet spindles or in the connection
device of the aggregates.
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2 Main parts
K Banding material container; the banding material containers A and B house the
edgebanding strip reels to feed the gluing unit. The banding material container C houses the
edgebanding strip reels and the pre-cut edgebanding strips to feed the gluing unit.
L Vacuum pump; supplies the level of vacuum required to lock the piece to be machined on the
work table. The machine may be fitted with a number of pumps of various types, according to
the piece locking needs.
• 90m³/h Becker Picchio 2200 vacuum pump
• 250m³/h Becker VTLF2250 vacuum pump
• 300m³/h Busch type Mink MM 1322 AVM vacuum pump
• 250m³/h Becker Picchio U 4.250 SA/K vacuum pump
• 100m³/h Becker U 4.100 SA/K vacuum pump
M FR unit (filter, regulator); filters the compressed air used by the machine, and keeps its
pressure constant. It is fitted with a cut-out valve A (see section 7.7, page 96), a pressure
gauge B to check the pressures and two filters: the air filter C and the oil separator filter D.
B A
C D
D
N Lubrication pump ; automatically lubricates some devices (slide blocks, lead nuts, racks,
etc.) used to drive the main machine axis carriages. The frequency with which lubrication is
performed is set on the numerical control.
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2 Main parts
O Pressure gauges; allow the pressure in the compressed air system and vacuum system to be
checked. For further information, please consult the 14.7 “Pressure check” section on page
182.
P Chip removal conveyor; removes chip waste. The device also comprises a waste material
collection box to be positioned at the unloading point.
Q Laser alignment projector; projects a line on the work table which is used as a reference
when positioning the front side of the piece. For further information, please consult the
paragraph 6.14 on page 87.
R Cooler; used for cooling down the fluid in the electrospindle cooling circuit.
S Heat exchanger; used for cooling down the fluid in the electrospindle cooling circuit.
T Hand-held terminal RM850: for the description, see paragraph 5.4, page 66.
U bPad terminal: for the description, see page 66.
V Bar code reader; for the description, see page 37.
W Safety fence: for the description, see paragraph 7.6, page 95.
X Contact mat: for the description, see paragraph 7.3, page 91.
Y Working area button pad: for the description, see paragraph 5.5, page 71.
Z Piece locking pedal: commands the locking of the piece on the work table. Each working
area is equipped with one pedal.
AA Synchro; it loads and unloads the machine.
Information about the Synchro is given in the specific User Manual.
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2 Main parts
2.3 Work table

The work table is the group of parts that are used to position and fix the piece to be machined.
There are different work table types:
ATS work table
EPS work table
HTS - ATS work table
HTS - EPS work table
Description of the work table elements
F
E H
D
G
J
I
B
M N
K
A
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2 Main parts
A Mobile piece support; supports the pieces to be machined and their positioning and locking
devices. It is positioned manually along the Cartesian X-axis. The support may be fitted with
an assisted work table to position the mobile support in the right position. The support can be
fitted with a system (EPS) that allows it to be positioned automatically along the Cartesian X-
axis.
B Side stops support; supports the side stops and, if necessary, can be easily removed.
C Front stop; used as a reference when positioning the front or rear side of the piece (according
to the stop line used).
D Side stop; used as a reference when positioning the right or left side of the piece (according
to the working area used).
E Stop for pieces with protruding coating; a type of stop that is installed on the standard
stops (front or side) to provide a correct reference when machining pieces with a protruding
coating.
F Tilting side stop; (positioning device) a type of tilting stop installed on the rods of the
standard side stops, to provide a positioning reference for special pieces (e.g. the parts of door
and window frames).
G Stop for carriage; (positioning device) used as a reference for positioning the carriage. Used
to align clamps, for example.
H Clamp stop plate; installed when required on the stop rods, to allow the locking of the piece.
It is normally used when locking small pieces or when it is not possible to use the suction cups.
I Bar support; lifts up automatically during loading and unloading operations, so as to separate
the piece from the suction cups and facilitate its movement.
When machining pre-assembled doors and windows, it is possible to use specific supports
(two step supports).
J Carriage; houses the panel locking devices (suction cups, clamps, etc.), allowing them to be
changed quickly, to be positioned along the Cartesian Y-axis, and to be turned to 24 different
positions. The carriage may be fitted with an assisted work table to position it in the right
position. The carriage can be fitted with a system (EPS) that allows it to be positioned
automatically along the Cartesian Y-axis.
K Shapeable suction cup; (piece locking device) used to hold the piece by means of a vacuum
pump. Locking takes place by means of channels formed on the surface of the suction cup,
allowing the definition of the area to be de-pressurised via a special rubber seal, so that the
piece will adhere to the suction cups. Various types of shapeable suction cup are available to
permit better piece holding, depending on the working conditions (see paragraph A.14, page
233).
L Waste support; if necessary, must be fitted into the mobile support to block the machined
piece waste.
M Uniclamp device; (piece locking device) blocks the pieces to be machined (see “Types of
Uniclamp devices”, page 30). This type of clamp can be fitted with a magnetic spacer A, to be
applied to the rod to increase its diameter (see “Changing the diameter of the Uniclamp and
Hyperclamp device rods”).
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2 Main parts
N Horizontal clamp; (piece locking device) blocks the piece to be machined.
O Uniclamp device; (piece locking device) blocks the pieces to be machined (see the
paragraph “Types of Hyperclamp devices”, page 31). This type of clamp can be fitted with a
magnetic spacer A, to be applied to the rod to increase its diameter.
P Auxiliary connector: allows auxiliary clamping devices to be used. For further information,
please consult the paragraph “Locking with the aid of auxiliary locking devices” on page 112.
Q CFT table; (piece locking device) supports and holds the piece by means of a supplementary
vacuum system and can be positioned on four carriages. Installation of this table on the
machine allows it to be transformed from an ATS work table into an FT work table.
Types of Uniclamp devices

Various types of clamps are available, to lock the piece in various ways.
A B C
B C
A Clamp with a bottom plate that moves along the Cartesian Z-axis, which can easily be inserted
in pieces that are already locked.
B Clamp with references, to allow alignment of short pieces.
C Clamp with references, to allow alignment of short pieces.

To be able to use these types of clamps, the length in X of the piece to be machined must be
over 210mm.
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Types of Hyperclamp devices

Various types of clamps are available, to lock the piece in various ways.
A B
A Clamp with the lower plate mobile along The Cartesian Z-axis.
B Clamp with references, to allow alignment of short pieces.
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2.4 Operating section

The operating section is the totality of the working units and the supplementary devices (ref.A).
Each working unit is fixed in a pre-set position on the machine Z-axis carriage.
A “Working units” (see page 33); “Additional devices for working units” (see page 35).
B “Operating section guards” (see page 93).
Collet spindles
The collet spindles are used in determined working units to quickly
change the tool during the machining operation cycle (see the
technical data of the collet spindles, appendix A “Technical
characteristics”). The machine is equipped with collet spindles with
ISO 30, HSK F63 or HSK E63 coupling (ref.A), to be used with A
ERC 32 or ERC 40 (ref.B) collets.
There are collet spindles designed for left or right-hand rotation
(see paragraph 3.7 “Information on the rotation direction of the
spindles”, page 48).
B
ISO 30 HSK F63

ERC 32, 40 HSK E63
ERC 40
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Working units
A B C D
E
G
F
I
H
A Boring unit; used mainly to perform series and/or single boring operations. The boring unit is
fitted with vertical spindles and chucks with horizontal spindles, and can be fitted with a
circular blade chuck to make grooves or sectioning.
B Milling unit; allows every type of machining operation to be carried out with the aid of milling
tools and aggregates (see ref. A on page 35). It is fitted with an electrospindle for quick tool
change during the machining operation cycle, using special collet spindles (see page 32). For
the list of the electrospindles available, consult appendix A “Technical characteristics” (page
227).
C 5-axis milling unit ; allows the execution of particular milling operations, as it is equipped with
a system that allows to direct the tool in different directions. It is fitted with an electrospindle for
rapid tool change during the machining operation cycle, using special collet spindles. This unit
is not set up to use aggregates.
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2 Main parts
D Multifunction unit; allows every type of machining operation to be carried out with the aid of
aggregates (see ref. A on page 35) that have a special coupling for multifunction units.
Depending on the aggregate used, the unit can be of two types:
with a fixed aggregate;
with an aggregate that can be orientated on the X-Y plane (from 0° to 360°).
fixed
E Horizontal milling unit; used for carrying out particularly deep horizontal milling operations
(door lock holes).
F Motorised horizontal milling unit; used for carrying out particularly deep milling operations
(e.g. door lock holes). It is fitted with 2 opposing horizontal spindles for cylindrical shank tools,
that can be orientated on the X-Y plane (from 0° to 360°).
G Gluing unit ; applies the edgebanding strip to the piece.

Glue bowl ; heats the glue.
The glue bowl, suitable for operations using PUR glue, is labelled “160°C max”.
Presser roller (ref. A); presses the applied edgebanding strip so that perfectly adheres to the
piece.
Glue roller (ref. B); spreads the glue on the piece.
Inclined roller (ref.C): pushes the edgebanding strip downwards.
A
B
C
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Glue distributor ; supplies the glue bowl. The granule holder C contains the glue granules to
be deposited in the bowl, while the granule doser D allows to dose the correct amount of
granules to convey.
Infrared lamp ; located near the presser roller, heats the edgebanding strip to be applied to
the piece to make it softer and more flexible.
H Refreshing unit ; heats the worked area to restore the original colour of the edge. Used with
some types of material (such as black ABS) which, due to the curvature during application on
the piece, tend to become clearer.
I Blower; cleans the worked piece before being edged.
Additional devices for working units
A B C D E
A Aggregates; additional devices equipped with tools (boring, milling, etc.) to be installed in the
electrospindles and/or the multifunction units, to carry out various types of machining
operation. For further details see the relevant user manuals.
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2 Main parts
B Chip deflector; device that can be installed on the electrospindle and which deflects the flow
of chips produced during the milling operation towards the suction hood.
C C-axis; device that can be installed on the electrospindle, allowing the aggregate spindle axis
to be rotated.
D Presser; device that can be installed on the electrospindle to allow a pressure to be applied to
the piece being machined. This is used in particular when machining stacked pieces to
prevent them from moving.
For information on how to use this device, see the interface User Manual.
E Thickness tracer; device to obtain the co-ordinates of a reference point to be used during the
machining operation programming.
2.5 Uninterruptible power supply (UPS)

The UPS is a device designed to protect the computer. It allows data to be saved in the event of a
power failure (see page 82)
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2.6 Bar code reader

The bar code reader permits rapid transmission to the numerical control of data relating to the
program to be carried out.
D
E
A Reader
B Base
C Yellow LED: indicates that the reader is ready for use (on) and that data is being transmitted
(flashing).
D Red LED: indicates that the batteries are recharging.
E Green LED: indicates that the batteries have finished recharging.
F Restore batteries key: used to restore the battery duration.
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2 Main parts
2.7 Identification of the manufacturer and the

machine
The name and address of the manufacturer are:
BIESSE S.p.A., Via Della Meccanica 16 - 61122 Pesaro ITALY
The manufacturer and the machine are identified by means of the plates provided. The labels
show the data listed below and, where applicable, the conformity marking.
A logo
A B
B compliance mark
C
C company name and address
Tipo
Type D
Modello
Model E
Matricola
D type Serial number F
Anno di costruzione
Year of construction G
Alimentazione pneumatica
E model Air supply
Velocita' aria di aspirazione
H
Suction flow rate
Massa
I
F serial number Weight J
G year of construction
H pneumatic supply
I suction air speed
J machine weight
K electrical diagram number
L electrical cabinet weight
M supply voltage
N current at full load
O number of supply phases
P power A B
C
Q frequency D
E
R short-circuit cut-out power at the supply
F
voltage.
K
J
M
N
O
P
Q
R
electric system rating plate
The electrical data plate is found on the external transformer too, if available.
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3 Basic information
3 Basic information
This chapter deals with various subjects, that give a clearer understanding of how the machine
works.
3.1 Guideline indications

The following figure contains useful guideline indications
+Y +X
D
+Z
B
E G A
A Front side or front of the machine, on which the pieces are loaded and unloaded.
B Rear side of the machine.
C Right-hand side or right of the machine.
D Left hand side or left of the machine.
E Front side or front of the piece.
F Rear side of the piece.
G Right hand side of the piece.
H Left hand side of the piece.
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3 Basic information
3.2 Cartesian axes and co-ordinates

The position and movement of certain parts of the machine are indicated using the Cartesian axes
and co-ordinates system. This system is used in geometry to describe the position of a point on a
plane or in space using the X, Y and Z axes.
The positions of the Cartesian axes with respect to the machine are illustrated below.
+Y +X
+Z
Planes of the Cartesian axes

In some cases, a pair of axes in the Cartesian system is used to refer to a particular plane. An
example of each plane is shown in the figure below.
Y-Z plane X-Y plane X-Z plane
+X
+Y
+X +Y
+Y +X +Z
+Z
+Z
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3.3 Machine axes

The machine axes are electronically controlled elements that allow movement of parts or groups of
the machine.
The position of the machine axes can be displayed at any time on the numerical control, on the
page that normally opens when the software is launched.
The machine axes can be divided into “co-ordinated machine axes” and “auxiliary machine axes”.
Machine co-ordinate axes

The co-ordinated machine axes drive the machine units that are directly involved in machining the
piece (e.g. the operating section), and they can be interpolated.
X; group of parts that move the operating section in the direction of the Cartesian X-axis.
Y; group of parts that move the operating section in the direction of the Cartesian Y-axis.
Y1: group of parts that drives the supplementary operating section working units in the
direction of the Cartesian Y-axis.
Z; group of parts that moves the operating section in the direction of the Cartesian Z-axis.
-
Y1 -
X Y X
+
- + Z
Y
+
-
Ab/Eb; assembly of parts that manage the delivery of the edgebanding strip from the gluing
unit.
Am/Em; assembly of parts that manage the delivery of the edgebanding strip from the
container.
B#; assembly of parts that tilt the electrospindle of the 5-axis milling unit.
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C#; assembly of parts that direct the electrospindle of the 5-axis milling unit, or the assembly
of parts that direct on the X-Y bench the axis of the spindles of the aggregates on the milling
unit.
-
+
-
+ C#
- C#
+
B#
Cb; assembly of parts that rotate (on the X-Y bench) the gluing unit.
Rc; assembly of parts that drive the glue roller.
-
Rc
+ Cb
Z#: group of parts that move the milling unit electrospindle vertically. Refer to the machine Z-
axis for the positive and negative directions of movement.
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3 Basic information
Auxiliary machine axes

The auxiliary machine axes drive the machine units that are not directly involved in machining the
piece (e.g. the tool magazines), and they cannot be interpolated.
CR#; group of parts that rotate (on the X-Y plane) the Revolver type tool magazine or the
Chain type tool magazine tool holder plate.
CR# +
- -
CR#
+
RA#; assembly of parts that move the edgebanding strip on the container.
CF1; assembly of parts that turn the upper tool holder chain of the Flexstore magazine.
CF2; group of parts that drive the lower tool holder chain of the Flexstore magazine.
CNF; assembly of parts that turn the tool change device on the Flexstore magazine.
CF1 +
CF2 +
-
CNF
+
WX#: group of parts that move the mobile supports along the Cartesian X-axis.
WY#: group of parts that move the work table carriages along the Cartesian Y-axis.
-
WY# X
WXB, WYB
WXC, WYC
WXA, WYA
WX1, WY1
WX2, WY2
WX3, WY3
WX4, WY4
WX5, WY5
WX6, WY6
WX7, WY7
WX8, WY8
WX9, WY9
+
Y
WX#
-
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3 Basic information
3.4 Origins
The origin is a pre-set point used as a reference when establishing the position of an element on
the machine. The machine has a number of origins: the absolute origin (or machine origin) and the
work table origins.
Absolute origin
The absolute origin (or machine origin) is an imaginary point located on the milling unit axis (TP1)
when this is reset. It corresponds to the 0 (zero) point in the system of Cartesian axes and co-
ordinates and the main machine axes, and represents the point from which to start when
establishing the position of the other origins. It is set by the manufacturer when the machine is first
tested, using suitably arranged cams and limit switches.
Work table origins

The work table origins are reference points (ref. A) for the program positions.
In the direction of the Cartesian axes X and Y these are the intersection point between two
imaginary lines, a tangent to the front stop B (called “stop line”) and the other tangent to the side
stop C, while in the direction of the Cartesian Z-axis they represent the supporting surface of the
piece on the work table.
X B
A
Y
The work table may have different origins for the clamps.
The work table origins may be of various types:

X
A B C D
0 0 0 0
Y
LPY
LPY
A Straight origins: these use the top left hand corner of the piece as a reference point when the
rear side of the piece is pushed up against the front stops.
B Mirror (or symmetrical) origins: these use the top right hand corner of the piece as a
reference point when the rear side of the piece is pushed up against the front stops.
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C Translated straight origins: these use the top left hand corner of the piece as a reference
point, when the front side of the piece is pressed up against the front stops. In this case, to
make the necessary calculations, the machine uses the dimensions of the piece along the
Cartesian Y-axis (LPY), as entered in the program.
D Translated mirror origins: these use the top right hand corner of the piece as a reference
point, when the front side of the piece is pressed up against the front stops. In this case, to
make the necessary calculations, the machine uses the dimensions of the piece along the
Cartesian Y-axis (LPY), as entered in the program.
The following example illustrates a program containing the instructions required to carry out a
vertical bore at X = +100 and Y = +70 and the result obtained on the various origins.
X
A B C D
70
70
70
70
100 100 100 100
The straight and mirror origins are normally used to create the left and right hand parts of a
furniture unit (sides, doors, etc.) with a single program.
To carry out a machining operation it is necessary to select at least one work table origin, as
described on page 105.
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3 Basic information
3.5 Working areas

The working areas are divisions in the table of the work table. It is possible to position and lock a
piece to be machined in each of the working areas. The work table is divided into various working
areas (see the figure). Each working area is equipped with a locking pedal (see ref.Z on page 27)
and piece positioning references (see “Work table origins” on page 44).
Areas of the work table

X
2 working areas 4 working areas
Y
Each working area can be subdivided into two independent locking zones (example A), to lock two
pieces at the same time, or in more independent and customisable locking zones (multi-area)
(example B), to lock more pieces at a time.
A B
sx1 dx1
sx2 dx2
SX1 DX1 SX1 DX1
sx1 sx2 dx2 dx1
SX1 DX1
A = two working areas (SX1 and DX1) and four locking zones (sx1, sx2, dx1, dx2).
B = two working areas (SX1 and DX1) with multi-area, for example with four locking zones in the SX1 area
and with two locking zones in the DX1 area.
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3 Basic information
3.6 Stop lines

The “stop lines” are imaginary lines tangent to the front stops or to the clamps. The intersection
between a stop line and an imaginary line tangent to the side stops allows an origin of the work
table to be defined (see page 44).
Work table
The machine is able to manage up to 3 stop lines.
X
1
Y
2
1 = first stop line

2 = second stop line
3 = third stop line
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3 Basic information
3.7 Information on the rotation direction of the

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

The definition of “right” spindle (DX) is given to a spindle that rotates clockwise, while “left” (SX) is
used for a spindle that rotates anticlockwise.
To define the rotation direction of a spindle, you must look at it from direction A, as indicated in the
figure below.
boring spindle spindle for circular

collet spindle aggregate spindle
blade
A DX A
A
A DX
SX
SX
DX DX
SX
SX
Determining the spindle rotation direction

Information on the rotation direction of the various spindles is given in appendix A “Technical
characteristics”.
There are, however, conventions that enable the quick determination of spindle rotation direction:
A groove on the outside of the spindle (see examples in figure ref. A) indicates that it is a left
spindle.
SX SX
A
A
The screwing direction of the ring nut or flange that locks the tool is always the opposite of the
spindle rotation direction.
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3 Basic information
3.8 Slot, Tp
The term “slot” defines the areas where the various working units are installed.
In the numerical control software, the slots are identified by the abbreviation “Tp”, followed by the
number of the corresponding slot (e.g. for a milling unit located in slot 1 the abbreviation Tp1 will
be used). The same abbreviation - TP - is also used to identify the circular blade tool chuck,
located on the boring unit. The number used for this chuck varies according to the configuration of
the operating section.
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4 Intended use
4 Intended use
This chapter contains information defining the safe and proper uses for which the machine has
been built.
4.1 How to load and unload the piece

The machine is not designed to be used in line with other machines. The material to be machined
must be loaded and unloaded manually or using suitable devices.
In order to reduce machining times, loading and unloading of the piece can be carried out in one
part of the work table while the operating section is machining in the opposite part (pendular
machining), as long as the dimensions of the piece in the X-axis permit it (see paragraph 4.2).
4.2 Characteristics and dimensions of workable

materials
The following materials can be worked:
Wood (solid wood, plywood, fibre panels, stripboard, multiply plywood, veneered sheets).
Wood derivatives (chipboard, MDF).
The materials listed above, coated with plastic laminates or banding materials.
Under no circumstances must the machine be used to work plasterboard, ferrous

materials or materials not mentioned above.
The table shows the max. dimensions of the pieces to be machined, along both axes X and Y.
Value Xb corresponds to the surface available, along the Cartesian X, when loading in pendular
mode . The Z value corresponds to the maximum workable thickness of the piece.
Maximum dimensions of machinable materials.
Machine model Xb (mm)
X (mm) Y (mm) Z (mm)
EC non-EC
Rover A 1425 2500 1320 - - 200* - 245**
Rover A 1432 3290 1320 1100 1525 200* - 245**
Rover A 1443 4320 1320 1620 2045 200* - 245**
Rover A 1459 5920 1320 2420 2845 200* - 245**
Rover A 1625 2500 1620 - - 200* - 245**
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4 Intended use
Machine model Xb (mm)

X (mm) Y (mm) Z (mm)
EC non-EC
Rover A 1632 3290 1620 1100 1525 200* - 245**
Rover A 1643 4320 1620 1620 2045 200* - 245**
Rover A 1659 5920 1620 2420 2845 200* - 245**
Rover A 1632 Edge 2025 1620 - - 180
Rover A 1643 Edge 3300 1620 600 - 180
Rover A 1659 Edge 4900 1620 1400 - 180
Y X
Z
*
Using the shapeable suction cups H=74 mm
** Using
the shapeable suction cups H=29 mm
The minimum dimensions of the pieces to allow proper locking using the vacuum
locking system are not easy to define, as the efficiency of the locking depends on the
porosity, thickness and dimensions of the piece, as well as on the type of tool used
for the machining operation. Should there be any doubts regarding the efficiency of
the standard locking system, it is recommended that auxiliary locking systems
(clamp stops, front pushers, etc.) be used. In any event, the manufacturer is available
for any clarification that may be required.
Piece workability data vary according to the working field of the working unit involved in the
machining operation (see layout), as well as the piece's position on the work table, the tool and
piece size, and the size of the other working units.
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4 Intended use
Features of the profile to edgeband

The convex Rv or concave Rc angles, obtained by the intersection of two perpendicular lines,
must comply with a minimum radius that depends on the thickness of the piece and the type of
aggregate used; in which case, consult the instructions for the use of aggregates.
Rc
Rv
90°
The edgebanding of pieces with particular profiles must always be checked.
4.3 Edgebanding strip features and dimensions

The machine applies rectangular section ABS, PVC, wood, melamine or similar edges with
dimensions as specified below:
edge height (H) = min 14mm; max 66
edge thickness (T) = min 0.4 mm; max 3.
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4 Intended use
4.4 Executable machining operations

All the machining operations that can be carried out by the machine are described and illustrated
below. Some of them can only be carried out using optional units.
For information on the features of the tools needed for the machining operations foreseen, see
page 127.
Grinding operations are not allowed on the machine.
Boring operations
Vertical and horizontal series boring (system boring).
Vertical A, horizontal B and tilting tool boring operations C, for example to make housings for
dowels or hardware materials.
A B C
Milling operations
Creating any type of profile on the edge of the pieces, using special shaped mills (profiling or
rebating in the case of pre-assembled doors).
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4 Intended use
Creating joints for door and window frame elements (tenoning).
Vertical A, horizontal B, and tilting engraving C.

B C C
A
Cuts
Vertical A, horizontal B, and tilting cuts C.
A B C
Smoothing operations
Smoothing the edges of pieces with squared or curved profiles.
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4 Intended use
Edgebanding operations
The machine can perform the edgebanding, i.e. cover the perimeter surfaces of the materials to be
machined with the appropriate material (edgebanding strip).
The edgebanding includes different machining phases of different types.
Edgebanding steps
Blowing: cleaning of the surface to be edgebanded with compressed air.
Gluing: application of the edgebanding strip (the edgebanding strip is applied in excess in
relation to the surface to be edgebanded).
Edge trimming : elimination of the excess edge on the side edged ends.
Trimming: elimination of the excess edge at the bottom and top.
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Scraping: removal of a thin layer of edge to remove the roughness left by the trimming cutters
and any excess glue.
Corner trimming : rounding of edged corners.
Types of edgebanding
Open ring edgebanding : edgebanding that starts at one point and ends at a point not
coinciding with the first.
edgebanding start point
edgebanding end point
Butt-joined edgebanding : edgebanding that starts and finishes at the same point.
edgebanding start and end point
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4.5 Work area

"Work area" means the area where it is possible to stand while the machine is working, in order to
activate and control the command devices.
Area A: in front of the control panel to use the NC, to activate commands and to oversee the
correct functioning of the machine.
Area B; in front of the work table, for the manual blocking of the pieces and the lifting of the
pieces at the end of the machining operation.
4.6 Danger area

The danger area is the whole of the area occupied by moving parts during the machining
operation. This area is suitably marked off by the safety fence and the contact mat (see pages. 95
and 91).
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This chapter contains the description of the commands and indicator devices on the various button
pads and/or on the machine's control panel:
5.1 “Control panel” (page 59)
5.2 “Indicator lamp” (page 63)
5.3 “bPad terminal” (page 64)
5.4 “Hand-held terminal RM850” (page 66)
5.5 “Working area button pad” (page 71)
5.6 “Chain type tool magazine and banding material container button pad” (page 72)
5.1 Control panel

The control panel is used to control the main functions of the machine .
Emergency stop button
STOP: (black button)

used for stopping the machine.
Machine power; (luminous white button)

used to prepare the moving parts to receive the electric power supply.
• ON = function enabled
Start: allows you to run an operation.
Stop: allows you to interrupt an operation.
Reset: restores the numerical control after an emergency.
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Tooling; (key selector)

activates the tooling mode for machine set-up. When this function is enabled, only the
0 1
voltage (24V) required to operate the solenoid valves is available, so that operations
can be carried out in safety. When the key is removed, the selector will not turn.
• Right = function enabled
; USB pen drive.
1
Soft Console
The commands of the Soft console (A) allow you to manage the machine’s secondary functions
and those relating to certain optional devices.
Activation of stop linesUsed to select the stop line to be employed for the machining
1st operation. Each icon is associated with two stop lines:
• 1st: activates the first (LED lit) or fourth (LED flashing) stop line.
2nd • 2nd: activates the second (LED lit) or fifth (LED flashing) stop line.
• 3rd: activates the third (LED lit) or sixth (LED flashing) stop line.
To activate the fourth, fifth or sixth stop line, click on the respective icon
3rd twice.Pressing and holding the third icon for a few seconds starts one of the two
cycles (load compressed air/unload compressed air) according to the state of the
machine.
Prevent piece unlocking; (pump always active);
prevents the piece from becoming unlocked (vacuum locking only) in the event of an
emergency stop. This function is normally activated when performing milling
operations, so that there is no risk that the piece will have to be discarded in the event
of a sudden emergency.
Deactivation of tool rotation;
disables the rotation of the spindle of each unit of the operating section. This function is
especially useful during program tests to check machine movements, as the curtain
guards are not lowered.
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Enable clamps;
0 1
permits the activation of the clamps.
Enabling clamp stops: enables the clamp stops locking function when running the
program. This control also makes it possible to select whether or not this function is to
be enabled alongside the suction cup locking function.
• On = function activated together with suction cup locking.
• Flashing = function activated without suction cup locking.
Starting up of chip removal conveyor: used to start waste removal conveyor.
Laser projector; used to turn the laser alignment projector on or off.
Activation of piece movement devicesused to activate any devices that facilitate the
movement of the piece during loading/unloading phases (bar supports, electric fan,
etc.).
• ON = function enabled
Open tool magazine: allows you to open any covers of the tool magazines.
Reset electrospindleused to lift the electrospindle that has remained down due to a
sudden machine stoppage.
• Flashing = indicates that the electrospindle has to be reset.
TEST TEST: used to start a test cycle from the position of the tools in the magazine.
Support panel; used to start a procedure on the numerical control software, allows the
martyr panel thickness to be modified (piece used for some machining operations as a
support for the final piece).
Lubrication cycleused to perform a lubrication cycle on certain devices that allow
movement of the main machine axes carriages (slide blocks, lead nuts, racks...).
Reset carriages: used to reset the work table carriages.
Parking modeused to manage the operating section parking mode.

For the description of the status of the red LED, see paragraph 8.11 “Managing the
operating section parking mode” on page 115.
Tooling of the Flexstore tool magazine; activates the operating mode that allows the
preparation of the Flexstore tool magazine while the machine is working.
Boring units heating; used to bring both the boring and milling units up to
temperature.
Disabling the gluing unit; disables the gluing unit. This function is particularly useful
when testing a program, to control the movements performed by the gluing unit.
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Edgeband path opening; used to control the opening of the edgeband passage. This
command also allows to choose whether to activate this function at the beginning or the
end of edgebanding.
• On = opening at the beginning of edgebanding.
• Flashing = opening at the end of edgebanding.
Inclined roller closure; used to command the closing of the inclined roller.
• On = the inclined roller closes when the edgebanding strip has stopped at the blade
of the gluing unit.
• Flashing = the inclined roller closes when the edgebanding strip arrives.
• Quick flashing = the inclined roller is not used.
Edgebanding strip advance ; used to activate the advance mode of the edgebanding
strip.
• On = the edgebanding strip remains in the banding material container until the
edgebanding starts.
• Flashing = the edgebanding strip is ready in the gluing unit (mode not suitable for
edges that are sensitive to high temperatures).
Closed ring instantly ready; used to have 250mm extra of edgebanding strip to
facilitate the set-up of the first closed ring edged piece.
Jog+: commands the movement of the machine axes in the positive direction.
Jog Fast; allows you to increase the speed of the axes during the movement in manual
mode.
Jog- ;commands the movement of the machine axes in the negative direction.
Stop: allows you to interrupt an operation.
Start: allows you to run an operation.
Clear: updates the error log visualised in the numerical control software window.
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5.2 Indicator lamp

Visual signalling device that indicates the machine status.
1. Red light; machine in emergency.
2. Yellow light; indicates faults or errors.
3. Blue light; indicates operator intervention.
4. White lamp (fixed light); indicates that the machine is in program start mode.
(flashing light); indicates that the machine is in program start mode at reduced speed.
5. Green lamp (fixed light); machine powered.

(flashing light); machine ON.
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5.3 bPad terminal

Used to manage various functions from any part of the machine.
The command and signalling elements of the terminal (buttons, knobs, LEDs, etc.) are listed
below.
P1: STOP button
P2: RESET button
P3: quick selection button for accessing one of the menu functions or one of the SoftConsole
functions
P4: BACK button
P5: snapshot button

If the camera is active, a photo is taken when the button is pressed.
If the bar code reader is active, the bar code is acquired when the button is pressed.
P6: ON/OFF button

With the terminal OFF, press for about 1 second to switch it ON; with the terminal OFF, press for
about 5 seconds to switch it OFF.
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J1: used to move the selection in the four directions of the screen, and to confirm the selected item
(by pressing the button on the joystick)
K1: axis override knob
K2: spindle override knob
L1: indicator LED showing that the terminal is powered
L2: indicator LED showing correct operation between terminal and machine
If this LED is disabled, the machine cannot be powered because the emergency
circuit is interrupted.
L3: flashing LED
S1: START button

On the lower part of the terminal grip there is an emergency button. The enabling button is on the
back.
Enabling button
For the description of the command menu of the bPad terminal, see the Command menu
paragraph.
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5.4 Hand-held terminal RM850

Used to manage various functions from any part of the machine.
A Keyboard; (see page 66)
B Display: visualises certain terminal functions (see page 67).

C Emergency button; (see page 89).
D Remote override (axes); changes the speed at which the machine axes move.
E Remote override (spindles): changes the speed at which the working unit spindles rotate.
Keyboard of the hand-held terminal

Table tooling; displays the menu “Table tooling” (see page 68). The LED on the key
indicates the state of the left working area:
Off = area free; if the contact mats in the left area are triggered, the machining operation
will continue in a normal manner.
Flashing = area occupied; if the contact mats in the left area are triggered, the machining
operation will be suspended.
On = area busy: if the contact mats in the left area are triggered, an emergency stop will be
triggered in the machine.
Gen functions; displays the menu “Gen functions” (see page 68). The LED on the key
indicates the state of the right working area:
Off = area free; if the contact mats in the right area are triggered, the machining operation
will continue in a normal manner.
Flashing = area occupied; if the contact mats in the right area are triggered, the machining
operation will be suspended.
On = area busy: if the contact mats in the right area are triggered, an emergency stop will
be triggered in the machine.
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Restore units: moves the working units to the parked position.
Stop: stops an operation.
Up arrow: selects the previous row.
Left arrow: decreases a value and commands movement of the machine axes in the
negative direction.
Enter: visualises the list of commands in the menu and activates a function.
Right arrow: increases a value and commands movement of the machine axes in the
positive direction.
Esc/Clear: press and release the button quickly to go back one level in the command
menu; hold the button down to update the list of errors displayed in the special numerical
control software window. A flashing LED indicates that a new error has occurred.
Down arrow: selects the next row.
Start: used to start the machining program and indicates that the machine is working (LED
on) or that it is awaiting the start machining command (flashing LED).
Command menu
Environment: used to activate different machine operating modes.
Reset: enables automatic resetting of the machine axes.
Manual Mov.: enables manual movement mode of the machine axes.
Pos. Mov.: enables positioned movement mode (movement to the position indicated) of the
machine axes.
Automatic: enables running of machining programs.
Axes: used to select the machine axis to be moved.
T/TH spindles: used to raise or lower the boring unit spindles. This function can only be used if
machine axis manual movement mode is activated (see the “Environment” menu).
Select T: displays the vertical spindles, allowing them to be selected using the “Arrow” keys
and raised or lowered using “Enter”.
Select TH: displays the horizontal spindles, allowing them to be selected using the “Arrow”
keys and raised or lowered using “Enter”.
TP spindles: used to send commands relating to the selected working unit:
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Down: lower working unit.

Only works if machine axis manual movement mode (see menu “Environment”) and machine
tooling mode (see selector “Tooling”) are activated.
Resting: lift working unit.
Only works if machine axis manual movement mode (see the “Environment” menu) and
machine tooling mode (see the “Tooling” selector) are activated.
Unlock Tool: unlocks the tool from the working unit.
Lock Tool: locks the tool on the working unit.
Hood step: movement of the suction hood to the set position (Step).
The position is set using the “Up arrow” and “Down arrow” keys after selecting the command.
Only works if the machine is turned on (“Machine power” button, page 59, on) and if machine
tooling mode is activated (see the “Tooling” selector, page 60).
During the machining operation, the position (Step) of the suction casing cannot be lower than
that set automatically by the machine.
Unload tool: starts a tool unloading cycle.
Load tool: starts a cycle loading the tool from the magazine.. The tool to be loaded (Pocket) is
set using the keys “Up arrow” and “Down arrow” after selecting the command.
If the machine has more than one magazine, it is first necessary to select the magazine
required.
Only works if the machine is turned on (“Machine power” button, page 59, on).
Table tooling: used to visualise information on positioning and characteristics of the various
mobile elements on the work table:
TABLE: used to select a mobile piece support and visualise the following information
regarding the selected element:
• X: position in the X direction.
JIG: used to select a carriage and display the following information regarding the selected
element:
• Y: position in the Y direction.
• ANG: angle of the shapeable suction cup;
• N: type of shapeable suction cup.
STOP: used to select a line of stops and display the following information regarding the
selected element:
• Y: position in the Y direction.
Debug I/O; used to control the state of the machine inputs/outputs, so as to solve any problems.
Movements mode; used to enable certain functions available in the Positions application software
options (see the interface user manual).
Gen functions: contains various functions:

Stops row 1: enables the first line of stops.
Stops row 2: enables the second line of stops.
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Stops row 3: enables the third line of stops.

Clamps: enables the clamp stops locking function when running the program.
Chip contact mat: starts or stops the chip removal conveyor.
Unloaders: activates or deactivates any devices that facilitate movement of the piece during
loading/unloading phases (bar supports, electric fan, etc.).
Mag. Covers: opens or closes the tool magazine cover.
Lubrication: starts a lubrication cycle on certain devices that allow movement of the main
machine axes carriages (slide blocks, lead nuts, racks, etc.).
Ref. Laser: turns the alignment laser projector on or off.
Rem. extrus.: command deactivated.
Flexstore; manages particular movements of the Flexstore magazine.

Restart; parks the tool change device.
Tools release; releases the tool in the tool change device. This function can be activated only
after the magazine has been reset (see previous function). Only works if machine axis manual
movement mode (see the “Environment” menu) and machine tooling mode (see the “Tooling”
selector) are activated.
Tools lock; closes the tool lock collet. This function can be activated only after the tool has
been released (see previous function). Only works if machine axis manual movement mode
(see the “Environment” menu) and machine tooling mode (see the “Tooling” selector) are
activated.
StepCF1+; positively rotates the upper chain of the magazine advancing it by one position.
StepCF1-; negatively rotates the upper chain of the magazine advancing it by one position.
StepCF2+; positively rotates the lower chain of the magazine advancing it by one position.
StepCF2-; negatively rotates the lower chain of the magazine advancing it by one position.
Locking: used to manage certain elements of the work table to obtain various locking
configurations:
Associate stops: used to create associations, so that certain groups of stops lift up when an
origin is selected:
• Left side: associates all the side stops in the left working area (origins 1-2)
• Right side: associates all the side stops in the right working area (origins 3-4)
• Ext. side: associates all the side stops to the left and right of the machine (origins 1-4)
• Front; associates certain front stops with the first row of front stops (first stop line),
identifiable basically from the following drawing.
SX1 SX2 DX2 DX1 working area
[0] [0] [0] [0] 1-2 stops relating to the second line of stops
[0] [0] [0] [0] 1-3 stops relating to the third line of stops
Symbols [0] and [1] indicate the status of the stops (0 = excluded, 1 = associated). To
change the status of the stop, use “Enter”.
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Select zones: used to enable or disable independent piece locking zones on the work table,
which can be identified using a customised diagram.
Symbols [0] and [1] indicate the state of the locking zones (0 = disabled, 1 = enabled). To
change the state of the locking zone, use “Enter”.
Sel. conf. zone: used to enable a certain locking zone configuration. Enable using “Enter”,
after first using “Up arrow” and “Down arrow” to select the configuration required.
EPS: command deactivated.
Edgebanding; used to manage the movement of some parts of the banding material container
and of the gluing unit.
Edgebanding unit :
• Descent; controls the descent of the gluing unit.
• Ascent - controls the ascent of the gluing unit.
• Opening - controls the opening of the banding material drive rollers in the gluing unit.
• Closing - controls the closing of the banding material drive rollers in the gluing unit.
• Cb axis release - releases the axis of the CB machine.
• Cb axis lock - locks the axis of the CB machine.
• Analogue Debug - allows the control of the presser roller and the glue roller valves
operation, and the infrared lamp voltage.
1 = controls the voltage of the infrared lamp
2 = controls the valve of the presser roller
3 = controls the valve of the glue roller
Banding material container:

• Opening; controls the opening of the banding material drive rollers in the banding material
container.
• Closing; controls the closing of the banding material drive rollers in the banding material
container.
• Edgebanding strip selection; selects the edgebanding strip to be extracted.
• Descent; controls the descent of the banding material container.
• Ascent; controls the ascent of the banding material container.
• Edgebanding strip cut; controls the cutting of the edgebanding strip.
Glue distrib. :
• Descent; controls the descent of the glue distributor.
• Ascent - controls the ascent of the glue distributor
• Batcher adv - allows to empty the glue batcher and convey the glue in the bowl
• Batcher return - allows the filling of the glue batcher
• Glue fill start - starts the glue filling cycle
Collision cont.; used to manage a special collision control system when carrying out machining
operations with the 5-axis milling unit.
Continue; used to continue machining when the collision control system detects a possible
collision.
Disable; used to disable the collision control system.
Enable; used to enable the collision control system.
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5.5 Working area button pad

This button pad is used to manage some functions relating to the working area.
START (1, 2, 3, 4); (luminous green button) used to select the origin and start the machining
operation. The various states of the button indicate the following conditions:
Off = origin cannot be selected for the machining operation;
On = origin can be selected for the machining operation;
Flashing (slowly) = the origin contains a locked piece; press the button to confirm the machining
operation.
Flashing (quickly) = the origin contains a locked piece that has been partially machined; press the
button once to move the operating section to the parked position, press it again to start the
machining operation.
STD - AUX (SX1, SX2, DX2, DX1); (key selector) used to lock the jig in the corresponding working
area and to enable the auxiliary vacuum system. If clamp locking mode is enabled (see the
“Enable clamps” selector on page 61) it is used to force closing of the clamps in the corresponding
working area, for example to prevent the piece from unlocking at the end of the machining
operation. When the key is removed the selector will not turn.
Right (AUX) = function activated.
LOCK - UNL; (key selector) used to release the carriages from the corresponding working area.
When the key is removed the selector will not turn.
Right (UNL) = function activated.
RESET; (blue indicator light button) used to reset the EC-photocell barrier. The different status of
the button indicate the following conditions
Off = EC-photocell barrier not engaged;
On = it is possible to enter the EC-photocell barrier ;
Flashing (slowly) = the EC-photocell barrier has tripped, reset it by pressing the button;
Flashing (quickly) = the pressure sensors have tripped, reset them by pressing the button.
If it get pressed during pendular machining, it allows to cross the EC-photocell barrier to enter the
area in front of the work table and it makes the machine axes to slow down.
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5.6 Chain type tool magazine and banding material

container button pad
This button pad allows to manage the movements of the Chain type tool magazine and the
banding material container, required during the preparation of both. The commands work only if
the numerical control is in "manual setting" (see the interface user manual) and if the machine
tooling mode is active (see page 60).
C A B C
Edgebanding strip selection; (black selector)

allows to choose which edgebanding strip to extract from the container (1, 2, 3 or 4).
A Edgeband opening/closing; (black selector)

allows you to enable the opening or closing of the banding material drive rollers in the
banding material container.
= banding material drive rollers closed
= banding material drive rollers open

B Edgebanding strip movement; (white selector with lamp)
enables the movement of the edgebanding strip selected with the “Edgebanding strip
selection” selector. After turning the selector, press the two “Start functions” buttons
(ref.C) at the same time to activate the function.
= edgebanding strip forward movement
= edgebanding strip backward movement

Enabling the banding material cutter blade; (key selector)
enables the use of the banding material cutter blade. Remove the key to block the
use of the selector.
• Left = function deactivated. In this case the rotation of the magazine can be
activated.
• Right = function active. In this case, press the two buttons “Start functions” (ref. C)
at the same time.
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Magazine rotation direction; (key selector)

selects the rotation direction of the magazine. Remove the key to block the use of the
selector.
After having turned the selector, press the two buttons “Start functions” (ref. C) at the
same time to activate the function.
• Left = the magazine turns anticlockwise, e.g. from position 7 to 6
• Right = the magazine turns clockwise, e.g. from position 7 to 8
• Central = function disabled
C Start functions; (green buttons) start the previously enabled functions through the
rotation of one or more selectors, and are located at the ends of the keypad.
The function is activated by pressing both buttons simultaneously and stops when
they are released.
For the Chain magazine: when the magazine is closed, by pressing button once the
cover opens. The buttons must be held down until the completion of foreseen
movements.
5.7 Gluing unit commands

This group of commands allows to manage some functions of the gluing unit.
Granule distribution; enables or disables the automatic release of the glue granules
into the bowl.
• Left = glue distribution activated
• Right = (flashing selector) glue distribution deactivated
Enabling of glue roller rotation; enables or disables the rotation of the glue roller.
• Right = rotation enabled. The selector on indicates that the glue roller has reached
the set temperature.
• Left = rotation disabled. The selector flashing indicates that the glue roller has
reached the set temperature.
Glue heating; activates the heating of the glue bowl and the glue roller.
• Right = function active (selector on)
• Left = function deactivated
Temperature selection; selects the temperature threshold of the glue.
• Off = low temperature threshold
• On = high temperature threshold
Contact mat tripped; indicates that the contact mat has been stepped on and that its
functions must be reset (see page 82).
Edgebanding strip manual loading; (key selector) allows to load pre-cut

edgebanding strips in the edgebanding unit.
Edgebanding strip pre-cutting; to pre-cut the strips.
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5.8 Safety fence reset button pad

This button allows to reset the safety fence if the machine power is enabled within a few seconds
after it has been pressed.
The different status of the button indicate the following conditions:
Off = safety fence has been reset;

On = safety fence to be reset.
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Use
6 Using the machine
6 Using the machine
This chapter explains the procedures for using the machine: starting up, stopping, switching off,
etc.
Do not install any software on the machine PC without the manufacturer's

permission.
6.1 Switching the machine on

1. Check that the doors in the safety fence are closed.
2. Rotate the main switch of the machine to the 1-ON position (see paragraph 7.2).
3. Disconnect the cut-out valve (see paragraph 7.7).
4. Start the chip suction system to which the machine is connected, making sure that the
connection pipe knife valve is open.
5. Check the software interface of the numerical control for possible error messages. To remedy
the errors, refer to the interface User Manual and the relevant annexes for the error code, read
the description of the fault, and carry out the corrective action indicated.
6. Check that the following safety devices are working correctly (see page 89)
7. Press button “Machine power” (“Control panel”). The button must light up.
8. Activate the “Reset” icon (see page 62).

9. Activate the “Clear” icon (see page 62).
10. Perform a global zero-setting of the machine axes (see page 78).
11. Carry out the warm-up cycles for the units on the operating section (see page 80). Once the
warm-up cycles have been completed, the machine is ready for use.
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6 Using the machine
6.2 Zero-setting the machine axes

Zero-setting is a procedure via which the machine axes move to a pre-set position known to the
NC. Axes reset may be “global”, when all the axes are zero set together, or “single” when the axes
are zero set one at a time on different occasions.
Global zero-setting
To carry out a zero-setting of all the machine axes, follow the instructions given below:
1. On the software interface of the NC, activate the global zero-setting mode for the machine
axes.
2. Activate the “Start” icon (page 62) to start the zeroing procedure.
If the machine is fitted with 5-axis milling unit or setting axis, the zero-setting procedure will not
start immediately, but a message will appear on the numerical control requesting you to check
the state of the axes. In this case, make sure that nothing is likely to obstruct normal
movement of the axes, and start the reset operation by pressing “Start” again.
The first axes to be zero-set are the Z-axes of the working units, followed by the remaining
axes.
When using the shapeable suction cups of 315 x 315 (see paragraph A.14), in order to
carry out the global zero-setting of the WX# machine axes (mobile piece supports)
correctly, remove these suction cups from the carriages.
Single zero-setting
To carry out the zero-setting of a single machine axis, follow the instructions given below:
1. On the interface software, enable single machine axes zero-set mode and select the axis you
wish to zero-set.
2. Check that nothing can impede the regular movement of the axes, then command the start of
the zero-setting by activating the “Start” icon (page 62).
The single reset must follow the order given above for the global reset.
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6 Using the machine
6.3 Global zero-setting of the carriages

By moving a sensor (ref. A) in the Y direction, the global zero-setting of the carriages allows the
position of the carriages themselves to be established and is distinguished from the zero-setting of
the machine axes.
When the machine axes are reset, the transmission belt B of the WY-axis # moves the sensor
group C up against the stop D positioned at the rear end of the mobile support.
This zeroing procedure, however, does not involve the carriages, which must be zeroed using the
“Reset carriages” icon (see page 61).
If the sensor A on the sensor unit breaks (the malfunctioning is indicated by an error message in
the software interface), the zero-setting of the carriages will not be carried out (see the interface
user manual).
6.4 Moving the machine axes

On certain occasions (for example during tooling) it may be necessary to move the machine axes
manually. To move the machine axes manually, use the numerical control (see the interface user
manual) or the hand-held terminal.
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79
6 Using the machine
6.5 Operating section warm-up cycles

When starting up the machine for the first time each day, it is necessary for the units in the
operating section to perform a short warm-up cycle, proceeding as indicated below.
Milling unit warm-up

Each electrospindle must be made to perform a short warm-up cycle to allow the bearings to reach
an even working temperature gradually.
For this purpose, it is necessary to create a program in which each electrospindle is used as
follows:
- 50% of max. rated speed for 2 minutes
- 75% of max. rated speed for 2 minutes
- 100% of max. rated speed for 1 minute
To avoid damaging the locking collet, do not run electrospindles with HSK F63 and
HSK E63 couplings without first installing a collet spindle.
It is recommended that this cycle be repeated every time the machine remains unused for a
period of time sufficient to allow the electrospindle to return to room temperature.
Warming up the boring unit

To obtain precise machining operations, it is very important to make the boring unit carry out a
warm-up cycle for about 15 minutes. Since there is no switch-on command as such, follow the
instructions given below.
Create a simple program in which the boring and milling units are used, and run it.
When the boring and milling unit motors start up, turn the remote override to the left (until it
reaches zero) and wait for the length of time indicated above.
6.6 Checking the electrospindle temperature

The electrospindle is fitted with sensors that check its temperature in certain parts (stator and
bearings) while it is being used.
Pre-alarm and alarm temperature thresholds are envisaged, and must therefore be taken into
consideration.
The pre-alarm threshold signals excessive heating of the electrospindle, and thus a malfunction
that must be kept under control and dealt with as quickly as possible. Once the pre-alarm
threshold has been exceeded, an error message appears on the PC.
The alarm threshold signals serious electrospindle malfunctioning. Once the alarm threshold has
been exceeded, the machining operation stops immediately.
part checked pre-alarm °C alarm °C
stator 100 125
bearings 60 65
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6 Using the machine
6.7 Stopping the machine

The machine stops (it stops working) if the electrical power supply is interrupted (see paragraph
“Stop due to interruption of the electricity supply”), or following the deliberate or accidental use of
one of the safety devices: emergency button (see paragraph “Emergency stop”).
If the machine stops, or the machining operation suddenly stops, always check the
tools are not moving before going near the operating section.
If the machine or the machining operation suddenly stop, always activate the cut-out
valve of the compressed air before going near the operating section (see page 96).
Emergency stop
The “emergency” stop is used when it is necessary to stop operation of the machine immediately
due to a dangerous situation or unforeseen circumstances.
To perform this type of stop, press the closest emergency button (see paragraph 7.1, page 89); the
program being run will stop immediately and the machine will be blocked.
To restart the machine, proceed as described on page 82.
When the function that prevents tool rotation is deactivated (see the “Deactivation of
tool rotation” selector on page 60), the working units lift up, even in the event of an
emergency stop. Before disabling this function, perform a machine reset if necessary
(see page 82).
Stop due to interruption of the electricity supply

If there is an electricity failure, the machine will switch off.
Machine without UPS
Turn the main switch to 0-OFF, and padlock it.
Machine with UPS
Do not switch the computer off manually; wait for it to switch off automatically.
The UPS signals the power failure and begins the countdown.
Wait 4 minutes, until the UPS switches off.
Turn the main switch to 0-OFF and padlock it.
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81
6 Using the machine
6.8 Restoring the machine

If the machine functions stop suddenly (see paragraph 6.7), proceed as indicated below in order to
reset them.
Before moving the machine axes, the tool magazines and the electrospindles,
remove any obstructions to ensure there is no risk of danger.
Resetting in the event of an emergency stop

1. Eliminate the cause of the sudden machine stoppage, resetting any commands or safety
devices activated (see chapter 7).
2. Press button “Machine power” (“Control panel”).

3. Activate the “Stop” icon (page 62).
4. Activate the “Reset” icon (page 62). In certain cases, if stoppage has occurred during
automatic tool change operations, it may be necessary to run a reset cycle for the operating
section and magazine involved.
5. Check the status of the red LED linked to the “Reset electrospindle” command (“Control
panel”). If the LED is flashing, this means the electrospindle must be reset; in this case, check
there are no obstacles to its movement then activate the “Reset electrospindle” icon.
6. Resume the machining operation (see paragraph 6.10).
Resetting after an interruption of the electricity supply

1. Rotate the main switch of the machine to the “0 off” position and, when the electricity supply
has been restored, repeat the machine switch-on procedure (see page 77).
2. Lift the piece from the work table if the electricity supply interruption happened when the
program was running.
3. Carry out the machining operation procedure again (see chapter 8).
6.9 Interrupting the program

This type of stop is used when it is necessary to stop the program being run without stopping the
machine altogether (the spindles continue to turn).
To temporarily stop the machining operation, activate the “Stop” icon (see page 62). By
activating the “Start” icon once again, you can continue the machining operation from the point
at which it was interrupted.
To permanently stop the machining operation, activate the “Stop” icon and “Reset” icon (see
page 62). In this case it is not possible to continue the machining operation from the point at
which it was interrupted.
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6.10 Restarting the program after an emergency stop

If the piece unlocks after the emergency stop, it is necessary to reset the machine functions (see
paragraph 6.8) and restart the machining program (paragraph 8.4).
If the piece release prevention function has been activated (see the “Prevent piece unlocking”
selector ), or if the clamps have been used, the piece being worked remains blocked; in this case,
observe the procedures indicated in the paragraphs below.
Resuming the machining operation from the start

This operation is carried out when the piece release prevention function (“Prevent piece unlocking”
selector enabled) has been activated.
1. Restore the working of the machine, as indicated in paragraph 6.8 “Restoring the machine”
(see page 82).
2. Activate the “Start” icon (see page 62) to start the machining program.
3. Press the flashing button “START (1, 2, 3, 4)” (“Working area button pad”); the operating
section moves to its rest position.
4. Press the “START (1, 2, 3, 4)” button again; the machining operation will restart from the
beginning.
Resuming the machining operation from the point at which it was

interrupted
This operation is carried out when the piece release prevention function (“Prevent piece unlocking”
selector enabled) has been activated, or in the case of locking with clamps (“Enable clamps”
selector enabled).
1. Press button “Machine power” (“Control panel”).

2. Press the flashing button “START (1, 2, 3, 4)” (“Working area button pad”); the machining
operation resumes from the point at which it was interrupted.
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6 Using the machine
6.11 Switching off the machine

To switch off the machine, proceed as follows:
Move the operating section into the park area, on the left-hand side, to prevent any tools that
may be fitted on the units from jolting the elements on the work table.
Remove the tools from the electrospindles and protect the coupling area from dust and/or
impurities by applying a plug or a clean collet spindle.
Deactivate the glue heating by turning the “Glue heating” selector to its central position.
Wait for the glue to cool; this is indicated by the “Enabling of glue roller rotation” selector
switching off.
Stop the glue roller by turning the “Enabling of glue roller rotation” command to the left.
Do not stop the roller when the glue is still hot. At high temperatures, if the roller
does not turn, the glue will burn.
Stop the machine at the end of its working cycle by pressing the black button “STOP”.
Machine with UPS

• The PC must not be switched off manually; the operation is automatically commanded by
the UPS.
• Turn the main machine switch to 0 (OFF) and padlock it if necessary.
• Wait for the PC to switch off completely.
• Wait another 4 minutes, until the UPS switches off.
Machine without UPS

• Carry out the switch-off sequence of the PC clicking on Start - Close session - Stop the
system.
• Wait for the PC to switch off.
• Turn the main machine switch to 0 (OFF) and padlock it if necessary.
Shut off the compressed air system by enabling the cut-out valve (see page 96).
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6.12 Using the RM850 hand-held terminal

The hand-held terminal RM850 (see page 66) can be used to manage various functions from any
point in the machine.
These functions can be used especially during tooling or to perform operations reserved to
qualified personnel authorised by the manufacturer.
To activate a function on the hand-held terminal, use the command menu and/or the
corresponding key on the keyboard (see paragraph “Keyboard of the hand-held terminal”).
An area has been provided on the mobile piece support in which it is possible to fix the hand-held
terminal using the magnet provide, to facilitate use of the hand-held terminal during tooling of the
work table.
Before activating a function using the hand-held terminal, move a safe distance away
from any parts to be moved.
Activating a function using the command menu

1. Use the “Up arrow”, “Down arrow” and “Enter” keys to visualise and select the commands. A
full list of commands is given on page 67. The symbol “>” indicates the current selection. To
return to the main menu, press “Esc/Clear”.
2. Press “Enter” to activate the function associated with the chosen command.
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6 Using the machine
6.13 Using the bPad terminal

The bPad terminal is used to manage a variety of functions from any point on the machine. These
functions can be used during the tooling phases or to carry out interventions reserved for
specialised technicians authorised by the manufacturer.
When the electrical cabinet is powered, the terminal switches on automatically (but only if it is
inserted in the recharging station). To switch on the terminal, insert it in the recharging station or
press the ON button on the terminal itself.
Before activating a function via the terminal, move a safe distance away from any
parts to be moved.
When the electrical cabinet is deactivated, the terminal switches off automatically after a few
minutes.
If the terminal is taken far from the electrical cabinet, it will be out of range and will trigger a
machine emergency situation. In this situation, the homepage will appear on the screen and the
green “L2” LED will switch off.
Switching the terminal off via the relative button triggers a machine emergency.
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6.14 Using the piece alignment laser projector

The laser projector is used to align pieces with particular dimensions and shapes when it is
necessary to lock the piece in a point on the work table that does not have any front stops. The
laser positioning value is set when the machine is first installed.
To activate the laser, it is possible to use the command on the hand-held terminal, or activate the
special “Laser projector” icon.
The beam emitted by the laser is diffused and the radiation level is not dangerous;
however, it is recommended that you avoid pointing the beam directly into the eyes,
as its intensity normally induces the eyelids to take defensive action, just as they
would in bright sunlight.
The lasers used comply with standard 60825.
Do not use optical instruments (binoculars, telescopes, etc.) that might concentrate
the radiation.
6.15 Shutdown of piece alignment laser projector

If necessary it is possible to turn the alignment laser projector off using the hand-held terminal (see
page 85), or by deactivating the “Laser projector” icon.
6.16 Using the bar code reader

Read the bar code with the reader supplied, as shown in the figure below. If the reading is
successful, the reader will make a short beep and the green LED on the reader will come on.
OK
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6 Using the machine
Recharging the batteries

When the reader is placed on its base unit the batteries are recharged, and this is signalled by a
red LED. When the batteries are fully recharged, the green LED will light up.
After a number of recharge cycles, the duration of the batteries may decrease. To restore a good
level of battery duration, position the reader on its base and press the restore batteries key (see
page 37).
Replacing the batteries
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This chapter provides important information for the correct use of the safety devices present on the
machine.
Should these devices fail to operate correctly, inform the maintenance technician or
the Service Centre. Under no circumstances must the machine be used if the safety
devices are not working.
7.1 Emergency stop button

The emergency button (red mushroom-head) is used to stop the machine in the event of a
potential danger or unexpected event, and it is located in various points on the machine:
• Control panel
• Hand-held terminal RM850
• Work table
• Safety fence
Activating the button does not electrically isolate all the parts of the machine.
To avoid wear in the button mechanisms, only use it for emergency stops (see
paragraph 6.7, page 81).
Checking proper operation

1. With the machine switched on, press any one of the available emergency buttons and check
the machine power button is switched off.
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2. To disable the device and restore the normal machine functions, rotate the button in the
direction indicated by the arrows on the button itself.
7.2 Main switch

The main switch isolates the machine from the electricity supply in order to enable maintenance or
repair work to be carried out in safety.
Rotating the switch to the “0-off” position interrupts the flow of electricity from the power supply
network.
When the switch is in the 0-off position, the terminals to which the power supply
cables are attached are still live.
After the switch has been rotated to the 0-off position, the condensers will remain
charged and live for a few minutes.
To prevent the machine from being accidentally switched on during maintenance or

repair work, padlock the switch in the off position.
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7.3 Contact mat

The contact mat detects the presence of those who stand on it, and stops the machine
immediately in the event of danger.
It is made up of individual parts that are joined together to form one or more areas for detection of
persons, separated by special yellow stripes (ref. A).
A A
SX CX DX
A = yellow separator lines;
SX = left-hand area;
DX = right-hand area;
CX = central area, only if the contact mats are divided into three areas.
The contact mat will not detect the presence of persons weighing less than 35 kg (e.g.
children). The minimum pressure required to operate it is 300 N with a disk 80 mm in
diameter, and between 300 and 600 N with a disk 200 mm in diameter (see UNI EN
1760-1).
When the contact mat is triggered, if the machine goes into emergency mode it is necessary to
reset the machine functions (see paragraph 6.8, page 82), otherwise it is only necessary to reset
the mat function by pressing the “START (1, 2, 3, 4)” button “Working area button pad”, page 71) or
the “Machine power” button (“Control panel”, page 59).
You are only allowed to pass across the contact mat in the following cases:
• at the end of the machining operation, when the operating section is in the resting position.
• during the pendular machining operation, to load or unload the piece, when the “START (1,
2, 3, 4)” buttons (see page 71) are lit up or slowly flashing. In this case it is only possible to
pass across the right or left area, but not the central area (if present).
In all other cases, walking across the mat will cause the machine to stop.
When the button “START (1, 2, 3, 4)” flashes quickly, this means that a particular reset
procedure is under way, during which the machine may stop if the mats are trodden on.
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1. Along the Cartesian Y-axis, position the operating section towards the rear part of the
machine.
2. Move the X-carriage to about halfway along the right-hand area of the contact mat.
3. Tread on the right or central area, in the case of mats with three areas; the “Machine power”
button (see page 59) must switch off.
4. Reset the working of the machine (see paragraph 6.8, page 82).
5. In the direction of the Cartesian X-axis, position the operating section about halfway along the
left-hand area.
6. Tread on the left or central area; the “Machine power” button (see page 59) must switch off.
7. Reset the working of the machine (see paragraph 6.8, page 82).
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7.4 Operating section guards

The operating section is fitted with a guard that isolates the working units when they are moving,
hence avoiding any contact with the external areas, limiting the noise emission and the risk of
flying chips or tool parts.
It is fitted with reinforced, transparent panels and curtain guards made of flexible material (ref.A).
The operating section guard may be fitted with pressure sensors (B).
Before starting machining operations, check that the curtain guards are not
damaged.
The front part of the protection has a sliding panel to access the operating section during tooling
and in case of maintenance or repair. The sliding panel is released by pulling the handle at the
bottom. The release of the sliding panel can only occur after having enabled the tooling mode by
means of the appropriate command (see selector“Tooling”).
Never put your hands or other objects into the upper part of the operating section
guard panels.
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7.5 Photocell barrier

The horizontal photocell barrier offers protection against the risk of interference with the moving
parts of the machine.
Crossing the horizontal photocell barrier is allowed in the following cases only:
• at the end of the machining operation, when the operating section is in the resting position.
• during pendular machining, to load or unload the piece, after having pressed button
“RESET” of the work area button pad.
In all other cases, crossing the horizontal photocell barrier will cause the machining operation to
stop.

1. Using the hand-held terminal, move the working unit while crossing the horizontal photocell
barrier.
2. The machine must stop.

3. Restore the horizontal photocell barrier.
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7.6 Safety fence

The safety fence prevents access to the danger zones while the machine is in operation.
Never put your hands or other objects into the upper part of the safety fence guard
panels.
The safety fence is also equipped with doors to allow access for interventions on the machine.
When the doors are opened, the machine stops immediately.
To prevent anyone from accidentally restarting the machine, remove the key from the
limit switch lock before entering the area protected by the safety fence, and keep the
key with you.

1. Turn the “Tooling” selector to unlock the doors.
2. Open the safety fence door.
3. Turn the “Tooling” selector to enable the machine power.
4. Press the machine power button and check that is OFF.
5. To allow the machine to be restarted, press the button on the Safety fence reset button pad,
close the door and power the machine on.
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7.7 Compressed air cut-out valve

The cut-out valve in the FR unit allows the compressed air system of the machine to be isolated in
order to enable maintenance and/or repair work to be carried out safely. When the cut-out valve is
activated, the air present in the machine system is discharged and the flow of air from the external
supply network is shut off.
When the cut-out valve is activated, some of the units might drop down due to
gravity. You should therefore stand well away from the moving parts of the machine.
Some parts of the machine may still be under pressure even after the cut-out valve
has been activated. If necessary, fix all parts that may be subject to the force of
gravity.
To prevent the compressed air from being accidentally turned on during maintenance
or repair work, padlock the cut-out valve.

1. Press the Machine Power button.
2. Press the emergency button.
3. Raise the cut-out valve B.
4. Check that the pressure gauge indicates a pressure of 0 (zero) bar.

5. Press the Machine Power button and check that:
• the machine remains in a state of emergency stop
• the corresponding error message is displayed on the monitor.
6. To disconnect the device, and to allow the machine functions reset, low the cut-out valve B.
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Check the pressure in the vacuum system

1. Press the machine power button.
2. Bring the machine to the emergency stop condition.
3. Make sure that there is no residual vacuum in the shapeable suction cups (press the vacuum
valve on the shapeable suction cup and check that no air comes out)
4. Unfasten the connector that connects the electrical cabinet to the vacuum pump.
5. Quit emergency stop mode by powering up the machine and pressing the Reset button on the
NC keyboard.
6. Select a program and press Start.
7. Carry out the locking procedure:

• select the origin
• press the Piece locking pedal
• press START on the working area button pad
8. Check that:
• the machine does not move from the parked position reached when the locking origin was
selected
• the NC is set to STOP
• the red indicator light signalling the absence of vacuum is turned on
• the LED on the NC keyboard START button is flashing, indicating that the machine is in
suspended mode
• the PC monitor shows the "insufficient vacuum" message
7.8 Key-activated commands

Some machine commands can only be activated by inserting a key in the respective lock, to
prevent someone from accidentally activating the devices when operations are being carried out
inside the danger zones of the machine.
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The information concerning the methods and procedures for performing machining operations
given below presuppose the preparation and start-up of the machine as well as a thorough
knowledge of the software (see the interface User Manual).
8.1 Warnings for correct machining operations

Below there is a list of the warnings to be observed before, during and after the machining
operation.
Failure to observe the following indications could cause injury to people or damage to things.
Before the machining operation

Check the conical coupling of the collet spindles (ISO 30 - HSK) and the conical surfaces and
stop surfaces of the electrospindle are thoroughly clean, to allow safe blocking (see chapter
14 “Maintenance”, paragraph 14.16).
Protect the coupling area of the unused electrospindles from dust by applying a plug or a collet
spindle.
Carry out warm-up cycles on the milling and boring units (see page 80).
Protect unused carriages with the special cover, to prevent them from filling with dust, as this
would result in excessive blockage of the filter and might cause the piece to fall off.
Never use tools beyond the speed limit, which is stamped on the surface of the tool or
indicated by the manufacturer. Certain tools, if rotated at speeds greater than those intended,
could break, projecting splinters.
The values given in the table refer to the maximum rotation speed to be set for the
electrospindle, in relation to the weight and diameter of the tool used.
Tool diameter (mm) Tool weight (kg) Max. speed (rpm)*

ISO 30 HSK F63 ISO 30 HSK F63 ISO 30 HSK F63
HSK E63 HSK E63 HSK E63
150 160 4 6 5000 ÷ 9000 5000 ÷ 9000
130 150 4 6 9000 ÷ 12000 9000 ÷ 12000
100 110 2.5 5 12000 ÷ 14000 12000 ÷ 14000
80 80 2.5 4 14000 ÷ 18000 14000 ÷ 18000
50 50 2 3 18000 ÷ 24000 18000 ÷ 24000
* The
values refer to tools with balance quality G. 2.5, according to ISO 1940 standards.
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Set the correct acceleration and deceleration ramp times according to the diameter and mass
of the tools to be used on the electrospindles. These values are expressed in seconds and
refer to a speed of 24000 rpm, even if the tool is unable to reach this speed.
The values for the same tool must be the same.
If incorrect values are entered, the tool may continue to rotate under inertia for several
minutes, even after an emergency stop or when the machine is switched off, creating a
hazardous situation for anyone coming near the operating section. To check that the data
entered are correct, perform a few start and stop cycles of the electrospindle, checking that
the tool stops correctly and that the NC has not produced any error messages.
A few reference values that must always be checked on the machine are shown below:
Tool diameter Tool weight Maximum speed Ramp time

(mm) (kg) (rpm) (s)
20 0.4 24,000 2
140 3 12,000 4
230 6 5000 9
When the aggregate with copier is used, the aggregate in-and-out speed should not be too
high so as to prevent it from hitting the piece. The speed to be set should not exceed 6/8m/
min.
When using an aggregate with copier, bear in mind the maximum and minimum depth it can
reach. See the following table:
Device type Minimum depth (mm) Maximum depth (mm)

Pneumatic device 16 25
Failure to comply with the above-mentioned indications may cause irreversible

damage to both the electrospindle and the aggregate.
Before running a machining program, perform a simulation to check that there is no

risk of interference during machine movements.
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In order to avoid the piece colliding with parts of the machine (magazine, beams, etc.), during
the locking phase if the front edge of the piece rests against the front stops, ensure that the
length in the Y-axis of the piece does not allow it to pass the first stop line A
NO YES
X
A
Y
When positioning the carriages of the work tables, you must consider that, in the case of the
mobile piece supports, the Y stroke of the first two carriages is subject to limitations (A and
B).
A A
In the case of EPS or HTS-EPS work tables, it is forbidden to command and/or

program the carriages beyond the limits shown above (ref. D and E) as they are not
automatically managed by the NC.
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During the machining operation

Avoid, at all costs, any contact between the rotating, non-cutting parts and the piece being
machined.
During the loading and unloading of the piece, the operator must never lean on the work table
and/or climb onto the machine, as the contact mat might not detect his presence.
When the machine is used in pendular mode (see page 51), take into account the safety limits
set in the numerical control to avoid damaging the piece. If the operating section reaches this
limit while a piece is being loaded or unloaded in the working area opposite the one in which
machining operations are being carried out, the machining operations will be paused. To find
this limit, consult the machine working field layout supplied, or the interface User Manual.
To avoid damaging the locking collet, do not run electrospindles with HSK F63 or HSK E63
type couplings without first installing a collet spindle.
If the axis speed slows down (this is visible in the software interface from the reduction of the
axis speed - axis override bar), this means the electrospindle is absorbing too much current. In
this case, it is necessary to check that the parameters of the machining operation are correct
(speed, etc.) and/or that the tool is not worn; if necessary, change it.
During the scraping of the edgebanding strip, use the suction hood in the high position.
If the machine stops (see paragraph 6.7) or the machining operation suddenly stops,
always check the tools are not moving before going near the operating section.
After the machining operation

If the machine remains unused for a long time (e.g. during the night or on non-working days),
remove the tools from the electrospindles and replace them with a plug or a clean collet
spindle.
At the end of the machining operation, to avoid problems of sticking, always remove the collet
spindle from the electrospindle and replace it with a clean one at room temperature. Caution!
Wear gloves to avoid burns.
8.2 Changing the machine axis transfer speed

The machine axes transfer speed is usually changed when testing a program, in order to select the
speed best suited to the material to be machined, or to allow closer observation of movements in
particularly critical points of the program.
The speed is changed manually by turning the remote override knob (see page 66), located on the
hand-held terminal. The percentage variation is visualised in a special data field on the NC
software interface.
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8.3 Changing the spindle rotation speed

The variation of the rotation speed for the working unit spindles is normally carried out when
testing a program, in order to select the most suitable speed for the material being processed.
The speed is changed manually by turning the remote override knob (see page 66), located on the
hand-held terminal. The spindle rotation speed can be reduced to a minimum of 50% of the
programmed speed. When the spindle rotation speed is reduced, the numerical control software
displays a warning message. The percentage variation is visualised in a special data field on the
NC software interface.
8.4 Machining operation procedure

To carry out a working cycle, observe the following procedure:
1. Create a machining program (see the interface User Manual).
2. Equip the machine, if necessary (for information see “Tooling”).

3. Start the chip removal conveyor enabling the icon “Starting up of chip removal conveyor” or
using the hand-held terminal .
4. Enable the stop line that you wish to use for the machining operation (see paragraph 8.6
“Activate stop line”).
5. From the software interface, run the machining program previously created (see the interface
user manual), then activate the “Start” icon. The machining program could contain instructions
that allow you to suspend the machining operation (see the interface user manual).
6. Select the work table origin (see paragraph 8.7 “Selecting the origin”).
7. Load and lock the piece on the work table (see paragraphs 8.9 “Locking the piece on the work
table”).
8. Start the machining operation (see paragraph 8.12 “Starting the machining operation”).
9. Unload the piece (see paragraph 8.13 “Piece unlocking and unloading”).
To execute another working cycle using the same program, repeat the above procedure from step
4 to step 9.
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8.5 Program simulation

Before running the machining program, it is possible to simulate it in order to check the
correctness of the operations that the machine will carry out.
These operations can be simulated via video (i.e. visualised in the PC software interface) with the
machine not running, or they can be simulated directly on the machine.
Simulation on video
To simulate the machining program in the PC interface software, proceed as described in the
interface User Manual.
Simulation on the machine

To simulate the program directly on the machine, turn the “Deactivation of tool rotation” selector
(see page 60 ) on the control panel to the right, and proceed as if you were carrying out a normal
machining operation, but without locking the piece on the work table.
When the machining operation is started with this function activated, the spindles do not turn and
the curtain guards protecting the operating section are not lowered (when the machine is fitted with
moving curtain guards), thus allowing better observation of the movements of working units.
If present, the fixed curtain guards are always in the down position, even during simulation.
When the function that prevents tool rotation is deactivated (see the “Deactivation of
tool rotation” selector on page 60), the working units lift up, even if an emergency
stop has been triggered. If necessary, perform a machine reset (see page 82) before
disabling this function.
8.6 Activate stop line

To carry out a machining operation it is first necessary to activate a stop line (see page 47).
Before activating it, consider the work table origin you intend to select (see page 105), as each
origin is located on a specific stop line.
The stop line can be activated in different ways:

• using the icon “Activation of stop lines”;
• via the hand-held terminal (see page 85)
• via the insertion of a special instruction in the program (see the interface user manual).
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8.7 Selecting the origin

To carry out a machining operation it is necessary to select any one of the work table origins (see
page 44).
The work table origin is selected by pressing the corresponding “START (1, 2, 3, 4)” button (see
page 71) located on the working area button pads.
According to the dimensions of the piece along the Cartesian X-axis, as defined in the program
being run, the machine will automatically enable the origins on which it is possible to carry out the
machining operation, lighting up the relative “START (1, 2, 3, 4)” button.
The origin to be selected may also be specified in the program, by entering a specific instruction
(see the interface user manuall). In this case the machine will only light up the “START (1, 2, 3, 4)”
button that corresponds to the origin specified in the program.
If locking with clamp stop plates is not enabled, the stops are raised after the origin has been
selected . Using a special function on the hand-held terminal, it is possible to create associations,
so that when an origin is selected certain groups of stops lift up.
If the operating section is close to the selected origin, before approaching the work table wait until
it has moved and then stopped.
8.8 Manual positioning of both the piece mobile

support and the carriages of the ATS assisted
work table
If the machine is equipped with the ATS assisted work table, the following lights are available:
yellow, yellow flashing, green. These lights allow to position the piece mobile supports along X and
the carriages along Y, as set in the working program.
The yellow light indicates that the piece mobile supports/carriages are not correctly positioned.
The yellow flashing light indicates that the piece mobile supports/carriages don't allow the
machining operations to be carried out.
The green light indicates that the piece mobile supports/carriages are correctly positioned.
The correct position is signalled by a beep.
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8.9 Locking the piece on the work table

According to the characteristics of the piece, it is possible to select various locking methods:
Standard locking.
Locking with clamp stop plates.
Locking with Uniclamp or Hyperclamp devices.
Locking with horizontal clamps.
Locking with the aid of auxiliary locking devices.
Locking on the CFT table .
The manufacture of the auxiliary locking devices to be connected to the auxiliary

connector must comply with point 5.2.8 of UNI EN-848/3. The manufacturer cannot be
held responsible for any damage caused by the use of these devices.
If the machine is set up to do so, it is possible to lock a number of pieces to be machined

simultaneously with a single program (see “Locking a number of pieces at a time”, page 114).
Standard locking
Standard locking is carried out using the shapeable suction cups alone. It is suitable for sufficiently
large, flat pieces, that can easily be locked using the vacuum system. If necessary, clean the
surfaces of the suction cups involved before locking.
If the row of front stops closest to the operator is used, the row will lift up when the “START
(1, 2, 3, 4)” button is pressed a second time.
1. Set the piece on the work table up against the stops.
2. Press on the piece to make it adhere well to the work table, then lock by pushing the pedal.
3. To correct the position of the piece after locking, press and hold the pedal to unlock
temporarily.
At the end of the locking operations, always check that the piece has been properly
fixed.
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Locking with clamp stop plates

This type of locking is normally used for small pieces that cannot be adequately locked using the
suction cups alone.
Never put your hands anywhere near the plates on the stops during locking
operations.
1. Install the plates for the clamp stops (see paragraph 12.4 “Installing the clamp stop plates”)
and activate them using one of the following commands:
• icon “Enabling clamp stops”;
• the special function of the hand-held terminal (see menu “Gen functions”);
• the special data command of the software interface of the numerical control (see the
interface user manual).
2. Raise the stops by pressing and holding the fixing pedal for the selected origin.
3. Position the piece against the raised stops.
4. Release the pedal; the stops will drop down, locking the piece.
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Locking with Uniclamp or Hyperclamp devices

This type of locking is normally used for narrow, thick pieces of solid wood (for example elements
for door and window frames), which may not be sufficiently locked in position by the suction cups.
Never put your hands anywhere near the clamps on the stops during locking
operations.
1. Install the clamps as described in chapter 12 “Preparing the work table”.
2. Position the piece on the various references available (stops, stop rods, laser) as illustrated in
the examples given below:
• Positioning a straight piece.
• Positioning a pre-assembled door or window frame.
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• Positioning a curved piece.
laser
3. Press the piece locking pedal provided.
fixed.
Locking system for complete machining operation without movement of the piece
If the piece is locked with specific Uniclamp devices (see page 29), it is possible to carry out a
machining operation on the whole perimeter of the piece without moving it.
1. Lock the piece, using the selector “STD - AUX (SX1, SX2, DX2, DX1)” (see page 71), to
prevent it from being unlocked at the end of the machining operation.
2. Lock the piece and machine its free sides.
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109
3. At the end of the first machining phase, bring up the clamps and lock the piece on the
machined side, remove the clamps from the side that has yet to be machined. Use the
carriage positioning button for these operations.
4. Completing the machining of the piece.
Locking with horizontal clamps

This type of locking is normally used for narrow, thick pieces of solid wood (for example elements
for door and window frames), which may not be sufficiently locked in position by the suction cups.
Never put your hands anywhere near the clamps on the stops during locking
operations.
1. Install the clamps as described on page 157.
2. Position the piece on the various references available (stops, stop rods, laser) as illustrated in
the examples given below:
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• Positioning a straight piece.
• Positioning a curved piece.
laser
3. Press the piece locking pedal provided.
fixed.
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Locking with the aid of auxiliary locking devices

This type of locking is normally suitable when machining special profiles or carrying out machining
operations on particular shaped pieces that require the use of auxiliary locking devices.
For example, a typical auxiliary locking device is the jig (ref. A) to be positioned on the shapeable
suction cups. The jig is formed by machining a raw piece, and it must have a relief of the profile to
be machined and bores for insertion of the pipe (ref. B) connecting to the auxiliary connectors.
To lock using the jig, proceed as follows:
1. Rest the jig A on the work table in the area involved, and connect it with a pipe (ref. B) to the
supplementary vacuum system located on the base under the work table.
2. Bring the jig up to the stops.

3. Lock the jig by turning the key selectors “STD - AUX (SX1, SX2, DX2, DX1)” (see page 71) on
the working area button pads to the right, and remove the key to prevent tampering.
4. Position the piece to be machined (ref.C) on the jig at the pre-established locking point.
5. Press the pedal; the piece will be locked.
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Locking on the CFT table

The locking operation on the CFT work table uses a supplementary vacuum system (to connect
the table to this system, see paragraph 12.8), positioning the pieces directly on the work table in
question. The area in which the pieces are positioned must be limited by sealing gaskets. If
necessary, clean the surface of the table before locking.
To lock the piece, proceed as follows:
1. Set the piece on the work table and position

it, if necessary, against the stops.
2. Press on the piece for it to attach properly

to the work table and lock by pushing the
pedal. After locking, make sure that the
piece is perfectly sealed.
To release the piece briefly in order to correct its

position, keep the respective pedal pressed.
Locking using waste supports

This kind of locking is used for those pieces with maximum dimensions (see enclosed layout).
The piece must be firstly milled to be machined. Remove both the waste and the waste supports
before carrying out the next machining operation.
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Locking a number of pieces at a time

If the working area has independent locking areas (see page 46), it is possible to lock a number of
pieces at a time so that they can be machined with a single program.
1. Enable the area in which the first piece is to be locked, using the Select areas option of the
Locking menu on the hand-held terminal (see page 85). For example, in field A set a value of
[1].
[1] [0]
[0] [0]
2. Position the first piece in the chosen locking area and lock it by pressing the pedal. Consult the
preceding sections for details of how to position the piece.
3. Disable the area in which the first piece has been positioned, to avoid unlocking it, and enable
the area to be used for locking of the second piece, using the option Select areas in the
Locking menu. For example, in field A set a value of [0] and in field B set a value of [1].
[0] [0]
[1] [0]
A B
4. Position the second piece in the chosen locking area and lock it by pressing the pedal.
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8.10 Activation of piece movement devices

The machine is fitted with certain devices (bar supports, electric fan, etc.) that serve to facilitate
movement of the piece during the loading/unloading phases. These devices can be activated in
different ways: using the special “Activation of piece movement devices” icon, using the hand-held
terminal (see page 85), or inserting a specific instruction in the program (see the interface user
manual).
8.11 Managing the operating section parking mode

Before or at the end of the machining operation, the operating section automatically positions itself
in one of the pre-set parking areas. The machine can be fitted with more than one parking area,
depending on the quantity of working areas it has:
• two parking areas in the case of one working area;
• three areas in the case of at least two working areas.
The machine chooses the parking area according to a specific procedure that can be selected by
the “Parking mode” icon.
If the LED of the icon is switched off and the piece being worked is of short or medium length*,
and the machine has more than one working area, the operating section is parked in the
following way:
• in the central area, if the origins selected are the lateral ones;
• in the right hand lateral area, if the origins selected are the central left ones;
• in the left hand lateral area, if the origins selected are the central right ones.
If the LED of the icon is switched off and the piece being worked is of short or medium length*,
and the machine has only one working area, the operating section is parked on the side
opposite the selected origin.
If the LED of the icon is off and the piece being machined is long*, parking is performed on the
side opposite that of the selected origin.
If the LED of the icon is on, the operating section is always parked in the side area opposite
the loading area.
If the LED of the icon is flashing, the operating section is always parked in the central area
(function active only on machines with more than one working area).
* For
clarification on the definition of short, medium or long piece, please consult the interface User Manual.
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8.12 Starting the machining operation

Press the flashing button “START (1, 2, 3, 4)” (page 71) to run the machining operation. In the
case of pendular machining, the machine will only start the next machining operation after it has
completed the current one.
Once the machining operation is under way, if you tread on the contact mat it will be necessary to
reset the functions (see paragraph 7.3 “Contact mat”).
8.13 Piece unlocking and unloading

The piece is generally released automatically at the end of the machining operation. If it does not
release, press the locking pedal for the relative working area or enable the areas involved in the
locking via the Locking menu and the Area Selection option on the hand-held terminal (see page
85).
8.14 Machining operation with manual loading of the

edgebanding strip
1. Launch the machining program from the software interface.
2. Turn the “Edgebanding strip manual loading” selector when the machine is waiting for the
strip.
3. Insert the edgebanding strip in the edgebanding unit and block the strip with the piece locking
pedal.
4. Reset the contact mat function (see page 82).
5. Turn the “Edgebanding strip manual loading” selector.
8.15 Information on the closed ring edgebanding

To accurately perform closed ring edgebanding:
always try to use edgebanding strips with a high degree of flexibility (during testing, good
results were given by edges with Prymer internal lining);
only use the recommended glue;
consult the interface user manual.
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9 Troubleshooting
9 Troubleshooting
This chapter describes how to solve any problems that may arise during use of the machine.
9.1 Problems, causes and solutions

Should a problem occur, first check for any messages on the numerical control screen; if there is
no message, deal with the problem by consulting the table provided in this chapter or, should no
indications be provided, contact the Service Centre.
Problem Cause Solution

The numerical control does Lack of power supply. Check the machine’s main
not switch on. power switch is turned to 1
(ON).
A thermal switch of the Reset the switch.
electric panel has blown.
The start button on the main There are emergency devices Check the emergency button.
control panel does not light activated. Check the emergency cords.
up.
Check the doors of the safety
fence.
Check the position of the cut-
out valve located in the FR
unit.
The bulb is broken. Substitute the bulb.
The piece does not remain The filters on the vacuum Clean the filters.
blocked. system or the vacuum pump
are dirty.
The electric valves are faulty. Check the electric valves.
The tubes connected to the If bent, straighten them
vacuum system are damaged. manually and check sealing
capacity. If broken, replace
with new tubes.
Do not repair them with
adhesive tape or glue.
Uniclamps are full of dust. Clean the clamps.
The vacuum pump motor Do not use the machine, and
rotates in the wrong direction. report the problem at once to
the Service Centre.
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9 Troubleshooting

The machine axes do not The remote override knob is Turn the knob slowly until it is
move and no errors are set to minimum. in the correct position.
visualised.
The machining operation does The functions of the contact Reset the functions of the mat
not start. mat have not been reset. (see the chapter regarding the
use of the safety devices).
During a work cycle, some of The spindle shaft is dirty or Clean the spindle shaft.
the spindles in the boring unit oxidised. This can happen
do not descend when invoked when the spindles are not
by the program. often used.
There may be problems in the Consult the circuit layouts or
electric or pneumatic system. contact the Service Centre.
During the work cycle the There are deposits on the Remove the deposits with a
stops do not move into rods. clean dry cloth or a bronze
position or do not descend. wire brush.
The piece has been pressed Unlock the piece and repeat
too hard against the stops. the positioning operation.
There may be problems in the Refer to the circuit layouts.
electric or pneumatic system.
The spindles on the boring The live wires in the power Switch off the machine and
unit rotate in the wrong supply terminals, inside the contact the Service Centre.
direction. electrical cabinet, are inserted
in the wrong order.
The machining operation The tool is not suitable for the Replace the tool.
quality is poor. type of machining operation
being carried out, or the tool is
worn.
The speed of the tool Adjust the parameters of the
movement and/or rotation is tool movement and/or tool
not suitable for the type of rotation speed.
material being machined.
The axis has reached the end Wrong manoeuvres have Reset the machine.
of its stroke and has come into been carried out.
contact with the mechanical Axis drive system malfunction. Contact the Service Centre.
stop.
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9 Troubleshooting

The electrospindle vibrates. The collet spindle is not Choose a collet spindle on the
balanced. basis of the indications given
in the appendix, in the chapter
relating to the technical
characteristics of the collet
spindles.
The tool is not balanced. Choose a tool on the basis of
the indications given in the
chapter relating to the
preparation of the operating
section.
Dirt in the spindle coupling Remove any impurities as
area and/or on the conical described in the chapter
couplings of the collet relating to the maintenance of
spindles. the electrospindles and the
collet spindles.
The bearings are damaged. Do not use the machine, and
report the problem at once to
the Service Centre.
The bearings of the The bearings are damaged. Do not use the machine, and
electrospindle are noisy. report the problem at once to
the Service Centre.
The Revolver magazine The photocell of the Revolver Clean the photocell (see page
doesn't detect the tools. tool magazine is dirty. 120).
The quality of the The gluing unit blade is worn. Change the blade (see page
edgebanding strip edge 120).
trimming is poor.
The edgebanding strip, in the The edgebanding strip cutting Change the shears
banding material container, is shears is worn. (see page 121).
not cut
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119
9 Troubleshooting
Cleaning the Revolver tool magazine photocell

To remove dust, clean the photocell that detects the position of the magazine tools (ref. A) with a
soft, dry cloth so as to prevent malfunctioning; do not use solvents.
Replacement of the gluing unit blade

When replacing tools manually, always check they have stopped before you touch
them.
An excessively worn blade reduces quality of the closed ring edgebanding.
1. Lower the banding material cutting blade unit using the appropriate functions in the software of
the numerical control (generally this group is identified as TP5).
2. Stop the machine.
3. Remove the casing A.
4. Remove the screws B.
5. Replace the blade C paying attention to the orientation of the teeth.

6. Follow the procedure in reverse to fix the tool and assemble the unit again.
7. Replace the casing A.
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9 Troubleshooting
Replacement of the edgebanding strip cutting shears

1. Remove the washer A.
2. Remove the pin B.
3. Replace the punch C and/or the flange D and complete the operation in reverse. To remove
the punch C, loosen the screws E. To remove the flange D unscrew the screws F.
B
E
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121
9 Troubleshooting
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Tooling
This chapter contains all the information required to prepare the operating section to carry out
machining operations.
10.1 Installing tools

To install the tools in the operating section, position the section at a point allowing the best
possible access to the spindle in question and, if necessary, lower the unit or the spindle.
On page 127 you can see the main characteristics that the tools must possess in order to be
installed in the working units.
The appendix (see “Technical characteristics”) contains some tool information that may be
useful when tooling the units, such as the spindle rotation direction, the wrench size to use
and, if foreseen, the type of collet used.
To install the tools in the boring unit, see the paragraph “Installing
the tools in the boring unit” on page 133.
To install the tools in the electrospindle, consult the following

paragraphs:
“Installing the tools and the aggregates in the electrospindle” on
page 134.
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125
To install the tools in the 5-axis milling unit, see the

paragraph“Installing the tools in the 5-axis milling unit” on page
134.
To install the tools in the horizontal milling unit, see the paragraph
“Installing the tools in the horizontal milling unit” on page 135.
To fit the tools in the motorised rotating milling unit, see the
paragraph “Installing the tools in the motorised rotating milling unit”
on page 135.
To fit the tools in the multifunction unit, see the Aggregate User Manual.
To install the tools in the collet spindles, see the paragraph “Installing the
tools in the collet spindle” on page 136.
When tooling has been completed, the data must be entered in the numerical control software (see
the interface user manual).
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Characteristics of the installable tools

A vast range of tools with special characteristics can be used on the working units:
Boring tools: bits of various types for making boring operations (see page 128).
Milling tools: milling cutters with cylindrical shanks (see page 129) or with ISO 30, HSK F63 or
HSK E63 coupling (see page 130) for performing milling operations.
Cutting tools: circular blade tools (see page 134) for making grooves or sectioning.
For information on the tools to be used with the aggregates, refer to this paragraph. The missing
data is provided in the Aggregate User Manual.
For the speed of advance, use the data provided by the supplier taking into account
the piece locking system.
Do not install several tools with different max. rotation speeds on the same aggregate.
Never use tools beyond the speed limit, which is stamped on the surface of the tool
or indicated by the manufacturer. If used at rotation speeds higher than those
foreseen certain tools might break, causing pieces to fly out of the machine.
The maximum tool diameter entered by the operator must be consistent with its real
diameter.
It is necessary to record the tools that can be installed, in the machine software. To record the tool,
some parameters must be entered (maximum diameter, rotation speed, etc.).
These values are entered according to the rotation speed values stamped or indicated by the tool
manufacturer. These values must be entered to record the tool.
The entered values (maximum diameter and maximum rotation speed) will have to be confirmed.
For a more detailed description of how to enter the data in the machine software, see the user
interface Manual.
Checking the electrospindle tool locking

To carry out this check, fit a tool on each of the electrospindles present and, after stopping the
machine, check manually to ensure they are perfectly locked. Also check that air is coming out of
the electrospindle connection device area.
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127
Bits
D1
D1 D1 D1
L1
L1
L1
L1
L2
L2
L2
L2
D2 D2 D2
D2
A B
Bit dimensions (mm) according to the type of spindle used.

Tool data (mm)
Spindles
D1 max D2 max L1 min L2 max
boring unit vertical spindles 10 20* 20 57
boring unit horizontal spindles 10 20 20 57**
aggregate spindle (see the Aggregate User Manual)
BH 30 2L BH 24 BH 17 BH 9
A = spindles in which it is possible to install bits with a diameter (D2) greater than 30mm.
* Tools
of type B can have a maximum diameter of 35mm.
**
For some machine configurations, this data item may not be correct, so you are advised to always check the
layouts of the working fields.
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Milling cutters with cylindrical shanks

D1
L1
L2
D2
Dimensions of milling cutters with cylindrical shank (mm) according to the type of spindle used.
D1 D2 L1 L2
Spindles (max. (max. (min. mm) (max.
mm) mm) mm)
- electrospindle with ISO 30 coupling and 20 120 40 110
ERC 32 collet
- electrospindle with ISO 30 coupling and 25 160 46 130
ERC 40 collet
- electrospindle with HSK F63 coupling and 25 160 46 130
ERC 40 collet
electrospindle with HSK E63 coupling and 25 160 46 130
ERC 40 collet
spindle of the horizontal milling unit see page 230
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129
Mills with ISO 30, HSK F63, HSK E63 coupling

ISO 30*
min. 45mm
min. 45mm
HSK F63* HSK E63*
min. 52
max. 275
max. 275
max. 282
max. 250mm max. 250mm
* These data concern the maximum dimensions of the tools that can be installed in the electrospindles. For the
maximum dimensions of the tools that can be installed in the magazines, refer to the technical data given in the
magazine layouts.
Milling cutters with HSK F63 coupling for the 5-axis milling unit
A B C E
L1
L1
L1
L1
L2
L2
L2
L2
D1 D1
D D1
D1
L1
L2
D1
Maximum dimensions in millimetres of the milling cutters.

Type of milling cutter L1 (mm) L2 (mm) D1 (mm) kg rpm Max
A Milling cutter for shaping 60 100 170 4 9000
B Milling cutter for roughing operations 45 100 100 3 12,000
C Milling cutter for boring operations 72 145 20 2 20,000
D Milling cutter for cutting 95 2.5 350 1,9 5000
E Milling cutter for tenoning 84 100 250 8 5000
For the maximum dimensions, always refer to the layout supplied with the machine.
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Weight-Barycentre curves of the HS353S 5-axis milling unit
Weight-Barycentre curves of the HS353H 5-axis milling unit
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131
Weight-Barycentre curves of the HS570 5-axis milling unit
Circular blade tools

boring unit blade
Sd
1.05
Sb
De
Sc
Di
Ø 5.5
Ø9
90°
PRF
PANEL
Sb
De
Di
Dimensions of the blades (mm) according to the type of spindle used; Sd = maximum thickness of
the cutting edges; PRF = maximum depth.
Spindles De Di Sb Sc Sd *PRF
boring unit spindle 120 35 50 2÷3 4 25
*
These values can be applied to a machining operation carried out in a number of stages, to avoid damaging the
chuck or aggregate.
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Installing the tools in the boring unit

2. Pick up the tools and approach the unit required.
3. Install the tools as described below.
Boring tools
The boring tools can be fixed in various ways.
Fixing with lockscrew:
1. Insert the tool in the spindle, turning the fixing surface A towards the bore B.
2. Fix the tool using the lockscrew C provided.
B
C
Fixing with bush for snap-on coupling:
1. Insert the tool in the bush opening, turning the fixing surface A turned towards the bore B.
2. Fix the tool using the lockscrew C provided.
3. Slide the cylinder D upwards, insert the bush with the tool and release the cylinder D.
B D
C
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133
Cutting tools
Insert the blade A in the spindle and lock it with the appropriate screws B.
A C
D
E
Installing the tools and the aggregates in the electrospindle

The installation of tools and aggregates in the electrospindle is managed automatically during
machining operations, using the tool magazine.
The electrospindle can only house tools fitted with the appropriate collet spindle (see
“Installing the tools in the collet spindle” on page 136).
The electrospindle can only house aggregates with an ISO 30, HSK F 63 or HSK E63
coupling.
Installing the tools in the 5-axis milling unit

For the installation procedure, see “Installing the tools and the aggregates in the electrospindle”.
The aggregate can only be used in the vertical position in this unit. Therefore axis B# cannot be
oriented differently than 0°.
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Installing the tools in the horizontal milling unit

1. Turn the selector “Tooling” (see page 60) on the main control panel to the right, and remove
the key to prevent anyone from restoring the machine to normal operation.
2. Pick up the tools and approach the unit required.
3. Remove the ring nut A turning it clockwise if the spindle is a left hand one or in the opposite
direction in the case of a right hand spindle; to lock the shaft, use the slot B provided for the
wrench.
4. Insert the collet C in the housing on the ring nut A.

5. Insert the tool shank in the collet and replace the ring nut A.
C
A
Installing the tools in the motorised rotating milling unit

2. Remove ring nut B turning it clockwise if the spindle is a left hand one or in the opposite
direction in the case of a right hand spindle; to lock the shaft, use the slot C provided for the
wrench.
3. Insert collet D in the housing provided on ring nut B.
4. Insert the tool shank in the collet and replace the ring nut B.
C
C
D D
B
B
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135
Installing the tools in the collet spindle

For safety reasons, the collet spindles used on the machine must only be supplied by
the manufacturer.
Follow the instructions provided below, according to the type of collet spindle.
ISO 30 collet spindle

1. To facilitate assembly operations, a special piece of equipment is provided (ref. A) which must
be anchored to a fixed support (e.g. a tool bench) using the relative bores.
2. Position the spindle connection device B in the equipment. Rotate the bracket C until it is
positioned on the spindle, then adjust the screws D and E to lock it in place.
C D
E
3. Remove the ring nut F, turning it clockwise if the spindle is a left-hand one or in the opposite
direction in the case of a right-hand spindle.
4. Insert the collet G in the housing provided on the ring nut F.
5. Insert the tool shank in the collet and replace the ring nut F.
F
G
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Collet spindles HSK F63, HSK E63
The HSK F63 and HSK E63 collet spindles used in the Air Tool electrospindles must
only be purchased from BIESSE.
On the F63 and HSK E63 collet spindles used in the electrospindles, compartment A
and compartment B must non-communicating.
1. To facilitate assembly operations, a special piece of equipment is provided (ref. A) which must
be anchored to a fixed support (e.g. a tool bench) using the relative bores.
2. Position the spindle coupling B in the equipment and tighten the lockscrew C to lock the
spindle in place.
3. Remove the ring nut E, turning it clockwise if the spindle is a left hand one or in the opposite
direction in the case of a right hand spindle.
4. Insert the collet F in the housing provided on the ring nut E.
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137
5. Insert the tool shank in the collet and replace the ring nut E.
E
F
10.2 Installing the chip deflector

In order for it to be picked up by the electrospindle, the chip deflector must be housed in the
special tool holder in the magazine.
To avoid interference while using the chip deflector, the tools must possess the
characteristics indicated in the appendix (see paragraph A.10 “Chip deflector”, page
232).
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This chapter explains the procedures to prepare the tool magazine.
The following tool magazines house tools fitted with a collet spindle (see page 32) and/or
aggregates with the appropriate coupling (see the aggregate User Manual). The chain tool
magazine is designed to house the chip deflector (see page 142).
When tooling an empty tool holder with a tool/aggregate, the following machine data
must be modified (see the tool magazine layouts):
- release offset in the case of a tool;
- release and orientation offset of C axis in the case of an aggregate.
An incorrect C axis release or orientation value could cause a collision.
11.1 Preparing the Revolver tool magazine

The Revolver tool magazine houses the tools fitted with the appropriate collet spindle (see page
32) and/or the aggregates fitted with the appropriate coupling (see the Aggregate User Manual).
For a list of the tools/aggregates that can be used on this type of magazine, see paragraph 11.5.
For the housing procedures, observe the following indications:
1. Turn the “Tooling” selector (see page 60) on the control panel to the right, and remove the key
to prevent anyone from restoring the machine to normal operation.
2. Pick up the tools/aggregates and approach the magazine required.
3. Position the tools/aggregates in the tool-holder, as shown below. To orientate the aggregates
accurately, use the relative dowel seats (ref. A) .
A A
A A
In the case of aggregates, check the lockpin has already been adjusted as explained in the
User Manual.
4. Enter the data in the numerical control software (see the interface user manual).
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11.2 Preparing the Chain type tool magazine

For the housing procedures, follow the instructions in the following paragraphs.
To house the chip deflector in the magazine, follow the instructions on page 142.
Preparing the horizontal magazine

1. Move the operating section on the right of the machine and move the working units away from
the magazine.
2. Open the magazine cover. The operation can be carried out in various ways: using the special
icon “Open tool magazine” (see page 61), using the buttons on the magazine button pad or
using the hand-held terminal (see page 66).
3. Activate the MANUAL MOVEMENTS environment using the command of the hand-held
terminal (see the interface user manual).
5. Pick up the tools/aggregates and approach the magazine required.

6. Rotate the tool magazine using the appropriate command on the hand-held terminal.
7. Position the tools/aggregates in the tool-holder, as shown below. To orientate the aggregates
accurately use the correct lockpin housings (ref. A) .
To move the magazine, use the controls placed on the appropriate button panel (see par.
“Chain type tool magazine and banding material container button pad” , page 72).
A A
A A
In the case of aggregates, check the lockpin has already been adjusted as explained in the
User Manual.
Before commanding magazine movement, make sure you are at a safe distance from
the magazine so that moving tools cannot cause injury.
8. Enter the data in the numerical control software (see the interface user manual).
For a list of the tools/aggregates that can be used on this type of magazine, see paragraph 11.5 on
page 143.
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11.3 Preparing the Flexstore magazine

For the housing procedures, comply with the following:
1. Press the “Flexstore magazine tooling” key (see page 60).

2. Rotate the magazine chains by means of the hand-held terminal (see page 63).
3. Open the door in the safety fence so you can carry out the tooling.
4. Place the tools on their tool holders, as shown.

To orientate the aggregates accurately, use the dowel seats (ref. A) in each housing.
A A
A A
5. Enter the data in the numerical control software (see the user interface Manual).
11.4 Preparing the Rack magazine

For the housing procedures, observe the following indications:
1. Place the tools on their tool holders, as shown.

To orientate the aggregates accurately, use the appropriate seats (ref. A) for the pins in each
housing.
A A
A A
2. Enter the data in the numerical control software (see the user interface Manual).
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Information concerning the use of the chip deflector in the magazine

In order for it to be picked up by the electrospindle, the chip deflector must be housed in the
special tool-holder in the magazine. While it is housed in the magazine, the two pins A must fit
perfectly in their relative seats B on the tool holder.
The magazine can house two chip deflectors, but they can not be in adjacent positions.
When the chip deflectors are placed in the magazine, the following rules must be observed:
tools located in positions adjacent to a chip deflector must respect the following maximum
dimensions:
magazine with distance between centres of magazine with distance between centres of
120mm 180mm
left chip deflector left chip deflector
right chip deflector right chip deflector
the dashed line indicates the maximum diameter that the tool must have in order not to hit chip deflector
when picked up
the tools located at positions adjacent to a chip deflector cannot be taken in the 120mm
centres magazine
When performing a tool change with the use of the chip deflector, follow these guidelines:
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tools adjacent to the housing involved in this tool change must respect the following maximum
dimensions:
magazine with distance between centres of magazine with distance between centres of
120mm 180mm
left chip deflector left chip deflector
right chip deflector right chip deflector
tools adjacent to a chip deflector cannot be taken.
11.5 Tools and aggregates that can be used, and their

direction
The tools and aggregates that can be housed in the magazines are listed in the layouts.
To house the tools/aggregates, you must observe the following rules:

Respect the orientation shown in the layouts, which refers to the aggregate in the pick-up
position.
The tools/aggregates must not exceed the maximum dimensions position shown in the various
layouts, to avoid any collisions with the machine parts when the magazine is rotating.
Respect the positions indicated in the layouts because, during the installation of large
aggregates or tools, it may be impossible to house other tools or aggregates in the adjacent,
previous or subsequent positions.
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11.6 Preparing the banding material container

The edgebands used can be the same or of different types. They should be the same height if
used in the same machining operation. For more information about the characteristics of the
edgebanding strips, refer to page 53.
Proceed as follows for the installation or replacement of the edgebanding strip:
1. Move the operating section in a position so that access to the magazine is easy.
2. Turn the “Tooling” selector on the control panel to the right and remove the key to prevent
anyone from restoring the machine to normal operation.
3. Open the banding material drive rollers A by means of the relative function on the hand-held
terminal (see page 66).
4. In case of replacement, remove the old reel.
5. take the edgebanding strip reel B and position it in a housing of the magazine.
6. Take the end C of the strip and pull it through the related guides to the zone between the
banding material drive rollers A and the common banding material path D.
7. Adjust the guides E according to the height of the strip (leave approx. 0.5mm of play).
E
B
E
8. Repeat points 5, 6 and 7, for each strip to be installed.
9. Close the banding material drive rollers A by means of the relative function on the hand-held
terminal (see page 66).
10. Enter the data of the installed edgebanding strip in the numerical control (see the Software
User Manual).
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This chapter explains the procedures for tooling the work table.
12.1 Installing the shapeable suction cups

To install a shapeable suction cup, simply rest it on any of the free carriages, as illustrated in the
figure, turning it to one of the 24 possible positions (each position corresponds to an angle of 15°).
To orientate the suction cup, see “Angle of the shapeable suction cups”, page 168.
Before positioning the suction cup on the carriage, make sure the latter is clean.
Protect unused carriages with the special cover, to prevent them from filling with
dust, as this would result in excessive blockage of the filter and might cause the
piece to fall off.
Finally, always make sure there are a sufficient number of shapeable suction cups and that they
are adequately positioned with respect to the piece and the tool trajectory.
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12.2 Installing the gasket on the shapeable suction

cups
Install the gasket into the channels on the suction cups, so as to create an area around the
vacuum valve. Various examples are given in the figure below.
vacuum valve
OK
The gasket must seal perfectly at the joint, to ensure the piece does not get detached
from the table during the machining operation.
12.3 Installing the stops for pieces with protruding

finish
Should you wish to machine pieces with a protruding coating
(see figure), it is essential to use this type of stop in order to
position them properly.
After installing these devices, it will be necessary to modify the
origin data using the numerical control software (see the
20mm
Software User Manual).
To carry out installation in comfort and safety, make sure that

the standard stops are up and that the machine is in
emergency mode. To do this, proceed as if you were carrying
out a machining operation and then, when the stops are up
(after selecting the origin), press an emergency button.
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To fit the stops, proceed as follows:

D
1. On the standard stop to which this type of stop is to be A
installed, remove the screw A which acts as a plug.
2. Insert the body of the stop B into the rod C, turning it in the
direction required. After this, fix it in place using the screw B
D.
C
Make sure the suction cups (or other elements) do
not interfere with the upward and downward
movements of the stop.
Screw D must be tightened to a locking torque of 15

Nm.
12.4 Installing the clamp stop plates

Fitting the plates allows the stops to be used as a piece locking device (see chapter 6 on page 77).
They are normally installed when it is necessary to lock small pieces or pieces that it would not be
possible to lock safely using the suction cups alone.
To install them, proceed as follows:

1. Remove the plug from the stop A.
2. Assemble the clamp, inserting the screw B into the plate C and into the spacer D.
3. Insert the assembled clamp into the stop A and fasten the screw B.
A
D
Do not install the clamp stop plates on the first line of stops.
Screw B must be tightened to a locking torque of 15 Nm.
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12.5 Installing the waste supports

The waste supports block the machined piece waste.
1. Put the waste support in its seat.
2. Turn the knob to secure the waste support.
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12.6 Installing and adjusting the Uniclamp-

Hyperclamp devices
Uniclamp-Hyperclamp devices can be installed on any free carriage.
The installation procedure varies according to the type of clamp coupling, which can be screw-on
or snap-on.
After installation, adjust the distance between the plates according to the thickness of the piece
(see page 155). If necessary, you can modify the diameter of the rod (see page 156).
Installing clamps with screw couplings

1. Ensure that the gasket A is not soiled and clean the clamp. If necessary, also clean the
carriage, preferably using a vacuum cleaner or, alternatively, a jet of compressed air.
2. Rest the clamp on the chosen carriage, so that the gasket A coincides with the bore B on the
carriage.
3. Lock the clamp by tightening the screws C.
4. Enable the clamp by opening the valve D and turning the “Enable clamps” selector (see page
61) on the main control panel to the right.
5. To align the clamp, so that the rod can be used as a reference when positioning the piece,
bring the respective carriage up against the relevant stop E. To position the carriage, see page
165.
piece to fall off.
C C
B A
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6. When locking short pieces, use the plate F to increase the stability of the clamp.
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Installing clamps with snap-on couplings

1. Connect the spray gun provided to a compressed air supply system. The machine is fitted with
a connector close to the FR unit.
2. Clean the chosen clamp and carriage, particularly the bores A.
A
A
3. Rest the clamp on the carriage, turning the base as shown in the example below and making
sure that the number of notches at the front of the clamp (ref.B) is the same as the number of
notches at the front of the carriage (ref.C). There may be one or two notches.
B
C
4. Remove the plug D from the clamp unlocking bore and place it on the pin alongside.
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5. Insert the nozzle of the gun supplied with the equipment into the clamp unlocking bore, blow in
compressed air and turn the clamp to the correct position.
6. Stop blowing in air; the clamp will lock.
7. Remove the nozzle of the gun supplied with the equipment from the clamp unlocking bore and
close the bore with plug D.
8. Enable the clamp by opening the valve E and turning the “Enable clamps” selector (see page
61) on the main control panel to the right.
piece to fall off.
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Positioning the carriage

In the case of the ATS or HTS work table, to align the clamp, so that the rod can be used as a
reference when positioning the piece, bring the respective carriage up against the relevant stop F.
To move the carriage, see page 167.
In the case of the EPS or HTS-EPS work table, to align the clamp so that the rod can be used as a
reference when positioning the piece, bring the respective carriage to the pre-established position.
To move the carriage, see page 165.
The pre-established positions set by the manufacturer are shown in the following table.
L1
L1 L2 L3
L= 1422 - 1503 mm 530 1030 1340 1
L2
2
L3
L
Unlocking clamps with snap-on couplings

1. Close the valve E.
2. Remove the plug D from the clamp unlocking bore and place it on the pin alongside.
3. Insert the nozzle of the gun into the clamp unlocking bore, release the clamp by removing the
pins A from their housing B, blow in compressed air and turn the clamp (either to the left or to
the right).
A
B
B
A
4. Stop blowing in air.
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Adjusting the Uniclamp/hyperclamp devices

Observe the corresponding procedure to adjust the various clamps:
Before adjusting or replacing the upper plate of the clamps, make sure all the air has
been discharged from the compressed air system; to do this, use the cut-out valve
(see page 96).
1. Remove the plug.
2. Turn the upper plate of the clamp (with the wrench connection).
3. Fit the plug again.
1. Remove the plug.
2. Loosen the anti-rotation pin.

3. Turn the upper plate (with the wrench connection).
4. Tighten the anti-rotation pin.
1. Remove the plug.
2. Loosen the anti-rotation pin.
3. Turn the upper plate (manually).
4. Tighten the anti-rotation pin.
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Adjusting the Uniclamp devices according to piece thickness

The clamp support plate (ref. A) must be adjusted according to the thickness of the piece.
The distance between the top plate A and the bottom plate B decreases if the top plate is turned
clockwise, and increases if the plate is turned anticlockwise.
The minimum and maximum distances between the top plate A and the bottom plate B vary
according to the type of clamp: 15÷55mm, 40÷98mm, 83÷140mm.
The maximum setting is indicated by a (red) groove C on the clamp.
To avoid crushing your fingers, the top clamp plate must be positioned 3 - 5mm away
from the piece.
Never exceed the (red) groove C, to prevent the clamp from breaking during use.
A
min. (mm) max. (mm)
15 - 40 - 83mm 55 - 98 - 140
B
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Adjusting the Hyperclamp devices according to piece thickness

The top clamp support plate (ref. A) must be selected according to the thickness of the piece.
The distance between the top plate A and the bottom plate B depends on the thickness of the top
plate inserted.
The minimum and maximum distances between the top plate A and the bottom plate B vary
according to the type of clamp: 40÷100 mm, 68÷ 140 mm.
The clamp closing speed is reduced in order to prevent fingers from being crushed
while loading the pieces manually (contact mat activated).
A A
min. (mm) max. (mm)
40 - 68 mm 100 - 140
B B
Changing the diameter of the Uniclamp and Hyperclamp device rods

If necessary, the clamp rod diameter can be changed by installing or removing the magnetic
spacers A.
The possible diameters are 42; 62 or 72mm.
Uniclamp devices Hyperclamp devices
A A
Ø 72 Ø 72
Ø 62 Ø 62
Ø 42 Ø 42
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12.7 Installing and adjusting the horizontal clamps

The clamp can be fitted on any free carriage. To install the horizontal clamp, refer to the installation
procedure for Uniclamp devices with screw couplings (see page 149). After installation, adjust the
clamp according to the characteristics of the piece to be locked.
Adjusting the horizontal clamps according to the width of the piece

Observe the following procedure for adjusting the clamp:
1. Unlock the piston A by turning the lever B anticlockwise.
2. Position the piston A according to the width of the piece to be locked; the minimum
dimensions of the piece to be locked are 30mm, whereas the maximum dimensions are
160mm.
min. 30mm
max. 160mm
3 - 5mm
B
A
To avoid crushing your fingers, the clamp plate must be positioned 3 - 5mm away
from the piece.
To adjust the clamp correctly, use the metric rulers C and D. The metric ruler C is used to
adjust the clamp according to the piece width, while the metric ruler D is applied to the piece
thickness (see “Metric ruler reading”).
C
3. Lock the piston A by turning the lever B anticlockwise.
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Metric ruler reading

In order to see all the units of measurements of the metric ruler C, close the piston E completely.
Take its side F as a reference and position it near the desired unit (e.g. 13, which indicates
130mm; ref. G).
The metric ruler reading point D is the upper side H of the block J; in that case, actuate on the stop
on which the metric ruler is positioned and make it slide (see the section “Adjusting the stop” on
page 159).
E G H
F
J
D
Turning the horizontal clamps

1. Loosen the screw A.
2. Turn the clamp; for precise positioning use the notches on the base.
3. To lock the clamp, tighten the screw A.
Installing the thickness spacers

The horizontal clamps are equipped with various thickness spacers, which can be positioned, if
necessary, on the piece support base.
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Installing the piece positioning reference pins

The horizontal clamps are equipped with a number of pins, to be positioned on the piece support
base to provide an additional reference when positioning the pieces (for example when positioning
curved pieces).
Adjusting the stop

1. Loosen the screws A.
2. Adjust the height of the stop B.
3. To lock the stop, tighten the screws A.
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12.8 Installing the CFT work table

Proceed as following to install the CFT work table and to connect it to the supplementary vacuum
system:
1. Place the table on 4 carriages.
2. Insert the connector A on the work table into the connector B on the distributor C of the work
area in question.
B
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12.9 Creating the locking areas on the CFT work table

In order to be able to lock the pieces on the CFT work table, areas have to be created that
correspond to the form and size of the piece to be locked. These areas are created by positioning
the gasket A supplied in the channels of the work table and removing each plug B inside the area.
B A
OK
NO
The gasket must seal perfectly at the joint, to ensure the piece does not get detached
from the table during the machining operation.
Removing the plugs B

Proceed as follows to remove the plugs B:
1. Insert the screwdriver provided into the plug.
2. Tighten with screwdriver.
1 2
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12.10 Installing the tilting side stops

The tilting side stop (ref. A) is fixed to the rods B of the standard side stops.
To carry out the installation in comfort and safety, make sure that the standard stops are up and
that the machine is in emergency mode. To do this, proceed as if you were carrying out a
machining operation and then, when the stops are up (after selecting the origin), press the
emergency button.
1. Remove the screws D from the standard stops on which you wish to fit this type of stop.
2. Rest stop A on spacer C, and fix it in place using the specific screws E.
A
C
D
B
Screw E must be tightened to a locking torque of 15 Nm.
12.11 Removing the side stop supports

If necessary, both the side stop supports in the central area of the work table can be removed with
ease.
1. Unlock the side stop support by pressing and holding the button A.
2. Pull the side stop support towards you until the slide plates B are on the respective guides.
3. Release the button A.
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4. Remove the side stops support, after disconnecting the relevant pipes/cables from the
connection points on the machine base.
5. Disable the safety sensors for the stops that have been removed, using the function provided
on the hand-held terminal (see page 85).
To return the side stop support to its original position, proceed as follows:
1. Connect the relevant pipes/cables to the connection points on the base of the machine, and
position the side stop support in the locking point foreseen.
2. Press and hold the button A to open the locking system.
3. Push the side stop support forward until the locking device C slots into its housing.
4. Release the button A to lock the side stop support.
5. Enable the safety sensors for the stops that have been installed, using the function provided
on the hand-held terminal (see page 85).
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12.12 Changing the bar support stroke

The stroke that the bar supports make during loading and unloading of the piece is related to the
position of the plunger A that must be set manually, depending on the type of locking device
employed. If the locking system is employed with shapeable suction cups, the plunger A must be
positioned in line with the bore E, if the locking system is employed with Uniclamp or Hyperclamp
devices, the plunger A must be positioned in line with the bore D.
E A
Observe the following procedure for positioning of the plunger.
1. Unlock and remove the pin B.
2. Position the bore on the fork C to correspond with one of the two bores (D or E) on the bar.
3. Replace and lock the pin B.
C
D
B E
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12.13 Positioning the mobile elements of the work

table
Normally, the work table mobile elements are positioned virtually in the numerical control software,
based on the machining program characteristics, before they are positioned physically on the
machine. At the end of this phase a configuration may be generated, to be associated with the
machining program. In this way, when a machining program is run, the values for positioning of the
various elements can be seen on the hand-held terminal or on the interface software.
The work table is fitted with millimetre rules, for reference when positioning an element exactly.
Positioning the side stops

Slightly loosen all the screws A before positioning the stop. Push the stop to the desired position
and lock it by tightening the same screws.
Automatic positioning of the mobile supports and carriages

In the case of the EPS or HTS-EPS work table, positioning of the mobile piece supports and the
carriages takes place automatically immediately when the machining program starts running.
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Manual positioning of the mobile piece support

1. Grasp the handle and unlock the support by pressing the button A.
2. Position the mobile support in the desired point . The base has references that can be used to
position certain mobile piece supports, when the Uniclamp device rods are used as origins for
the machining operation. The positioning values are displayed on the hand-held terminal, the
monitor of the interface software or the mobile support indicator lights .
3. Lock the support by releasing button A.
Visualising the positioning value on the hand-held terminal

1. Run the machining program (see the interface user manual).
2. On the hand-held terminal, select the Table tooling menu and the option TABLE.
3. Select the support required using “Left arrow” and “Right arrow” on the hand-held terminal
keyboard; the supports are numbered in sequence starting from the left.
The positioning value for the support selected is displayed alongside X. The reference on the
millimetre rule is a red nonius arranged in a suitable position.
>TABLE 1 X=312
JIG 1 Y=243
ANG=0 N=132x54
Stop 1 Y=776
A
4. To lock the support again, simply release the button A.
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Manual positioning of the carriage

In case of EPS or HTS-EPS work tables, after manual positioning the machine will no
longer be able to identify the position of the carriages if they are not reset.
1. Release the carriage by pressing button A. In the
case of an assisted work table, it is possible to ATS/HTS/EPS/HTS-EPS
release all the carriages by turning the “LOCK -
UNL” selector.
2. Position the carriage as required. The positioning

values are displayed on the hand-held terminal, the
monitor of the interface software or the mobile
support indicator lights .
A B
3. Lock the carriage by releasing the button A or
turning the lever B clockwise.
Incorrect positioning of the carriage may cause the piece to detach.
Visualising the positioning value on the hand-held terminal

2. On the hand-held terminal, select the Table tooling menu and the option JIG.
3. Select the carriage required using “Left arrow” and “Right arrow” on the hand-held terminal
keyboard; the carriages are numbered in sequence starting from the rear side of the machine.
The positioning value for the carriage selected is displayed alongside Y.
The reference on the millimetre rules is the front surface of the carriage (ref. B).
TABLE 1 X=312
>JIG 1 Y=243
ANG=0 N=132x54
B Stop 1 Y=776
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Angle of the shapeable suction cups

Proceed as follows to move the shapeable suction cup to the desired position:
To position the suction cup at a 0° angle, turn it so that it protrudes on the left side of the
carriage (see the figure).
To position the suction cup, turn it so that the right angle is obtained, making reference to the
following figure and to the notches on the carriage.
Visualising the suction cup angle on the hand-held terminal

2. On the hand-held terminal, select the Table tooling menu and the option JIG.
3. Select the carriage on which the suction cup is installed, using “Left arrow” and “Right arrow”
on the hand-held terminal keyboard; the carriages are numbered in sequence starting from the
rear side of the machine.
The angle of the suction cup is displayed alongside ANG.
TABLE 1 X=312
>JIG 1 Y=243
ANG=0 N=132x54
Stop 1 Y=776
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Interventions
13 Adjustments
13 Adjustments
This chapter describes the procedures for adjusting certain parts of the machine.
13.1 Adjustment of the presser roller guide

A guide is present on the gluing unit presser roller and must be adjusted manually according to the
height of the edgebanding strip to be used in the machining operation.

2. Loosen the knob A.
3. Adjust the position of the guide B based on the height of the strip (leave about 0.2mm of play).
4. Block the guide B in the desired position by tightening the knob A.
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13 Adjustments
13.2 Replacement of the presser roller

The gluing unit presser roller must be replaced manually depending on the geometry of the piece
being edgebanded. Follow the procedure below:
2. Unscrew the screws A.
3. Replace the presser roller with the relative strip guide B.
presser roller 60
presser roller 32
A
4. Insert the correct strip guide.
5. To secure the presser roller, carry out the procedure in reverse.
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13 Adjustments
13.3 Glue replenishment

Observe the following procedure for the replenishment of the glue:
2. Withdraw the container A turning it through 90° (either to the right or left).
3. Introduce the glue into the container.
Any type of pallet hot melt glue can be used, provided that is suitable for use with this type of
machine.
Do not use EVA glue in the PUR glue container, and vice versa.
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13 Adjustments
4. Fit the container A in place and turn it by 90° (either to the right or left).
13.4 Glue heating

Through heating procedure, the glue in the bowl reaches a temperature that will allow it to be used
for edgebanding. A certain period of time is required to heat the glue. For this reason, the heating
activation time can be programmed, or a function selected that allows to keep the hot glue at an
appropriate temperature in order to reach the use temperature quicker.
Glue heating activation

1. Turn the command “Glue heating” to the right (see page 73).
2. Turn the command “Enabling of glue roller rotation” to the right (see page 73), so that the glue
roller starts to roll automatically when the glue reaches a set temperature.
At high temperatures, if the roller does not turn, the glue will burn.
3. Select the high temperature threshold with command “Temperature selection” (see page 73).
For information about the temperature thresholds, see page 175.
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13 Adjustments
Temperature thresholds
The machine has 2 glue temperature thresholds, one low and one high that can be selected with
the command “Temperature selection” (see page 73).
The lower threshold prevents the glue from deteriorating or burning, in the event of prolonged
pauses for example, and allows the operating temperature to be reached quickly.
The higher threshold is used during edgebanding.
After the machine is switched on, the high temperature threshold is automatically sets; whereas if
the activation of the heating is programmed, the low temperature threshold is automatically set
and the high temperature threshold cannot be set.
Modification of the glue temperature

The different temperature thresholds are shown on the displays of the thermoregulators and are
set at the optimum values.
To modify these values, proceed as follows:

1. Press the CHANGE key.
2. The abbreviation “setPt1” will appear on the next screen, (to modify the low temperature
threshold), or the abbreviation “setPt2” (to modify the high temperature threshold).
3. Change the temperature and confirm by pressing OK.
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13 Adjustments
13.5 Adjustment of the amount of glue applied on the

piece
The amount of glue applied to the piece can be adjusted manually by means of a dedicated
regulator. The adjustment is made with the hot glue and with the glue roller rolling.
The glue treatment area is at high temperature. Wear clothing with adequate
protection (goggles, gloves, etc..), and avoid inhaling chemicals by using a mask.
The glue roller keeps rolling.
1. Turn the selector “Tooling” (see page 60) on the control panel to the right, and remove the key
to prevent anyone from restoring the machine to normal operation.
2. Slightly unscrew the screws A near the glue roller.
3. Slightly turn the screw B anticlockwise to diminish the amount of glue applied on the piece, or
clockwise to increase the amount of glue. Use a thickness gauge C for accurate adjustment.
4. Having obtained the desired adjustment, tighten the screws A.
C
A
B
A
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14 Maintenance
This chapter contains information that is essential to maintain the machine in perfect working
order.
14.1 Warnings relating to machine maintenance

Unless otherwise indicated, all maintenance operations must be carried out with the machine
turned off.
In particular, make sure the main switch is in the “0 off” position and that all the air has been
drained out of the compressed air system by opening the cut-out valve (see paragraph 7.7, page
96).
Both the main switch and the cut-out valve must be blocked with a padlock to prevent the machine
from being turned on again.
14.2 Forced lubrication

It is possible at any time to run a lubrication cycle for the parts connected to the lubrication pump
(see ref. N on page 26); to do this, activate the “Lubrication cycle” icon (see page 61) or use the
hand-held terminal (see page 85). When the lubrication cycle starts up, the timer indicating the
time passed since the last lubrication cycle is set at zero.
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14.3 List of the maintenance operations to be carried

out on the machine
The following table lists the foreseen maintenance operations (Intervention column), indicating the
frequency with which each intervention is to be carried out (Frequency column) and, for the
interventions that require it, the page on which the operations to be carried out are quoted.
Frequency Part involved Intervention

General machine • General cleaning of the machine
Work table • Inspection of the condition of the table gaskets, the
suction cups and the jigs. If necessary, replace
them.
Safety devices • Inspection of the condition of the cams and their
safety switches. If necessary, replace them.
Daily Operating section • Inspection of the condition of the curtain guards
(every 8 located on the operating section. If necessary,
working replace them.
hours) • Checking the electrospindle tool locking
• Checking and cleaning the collet spindles
• Checking and cleaning the electrospindle
Becker VTLF2.250 • Cleaning the cooling ducts
vacuum pump
Banding material • Cleaning and control of the banding material
container container
General machine • Cleaning the machine guides and racks
• Pressure check
Work table • Cleaning the carriage filters
Operating section • Cleaning the C-axis
• Cleaning and partial lubrication of the chip
deflector
• Cleaning the PUR glue bowl
Weekly • Cleaning the EVA glue bowl
(every 40 FR unit • Cleaning/replacing the filter
working Refrigerator • Checking and topping up the coolant
hours)ng
Becker Picchio vacuum • Cleaning
pump
Becker VTLF2.250 • Cleaning the filters
vacuum pump
Busch Mink vacuum • Cleaning and replacing the air filters
pump
Becker U 4.250 SA/K • Cleaning the air filter
vacuum pump
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Operating section • Lubricating the multifunction unit (ball blocks)
Fortnightly • Lubricating the horizontal milling unit (ball blocks)
(every 80 General machine • Lubricating the X-drive devices (slide blocks and
working rack)
hours) • Lubrication of the Y and Z drive devices (slide
blocks and lead nuts)
Machine's PC operating • Updating the antivirus system.
system
Operating section • Checking the connections of the electrospindles
• Lubricating the HSK F63 - HSK E63 electrospindle
Monthly release device
(every 160 Flexstore • Lubricating the Flexstore magazine ball blocks
working Work table • Lubrication of WX# machine axes ball blocks
hours)
Becker U 4.250 SA/K • Checking and cleaning the fan
vacuum pump
Refrigerator • Cleaning the cooler
Electrical cabinet • Interventions on the electrical cabinet
Every 2 General machine • Lubrication of the machine X-axis gears
months Operating section • Complete cleaning and lubrication of the chip
(every 320 deflector
working
hours)
Every 3 Busch Mink vacuum • Check there is no dirt or dust in the pump; if
months pump necessary, clean it
(every 480 • Checking the oil level

working Work table • Cleaning the cams to detect the carriage position
hours)
After 1000 Becker U 4.250 SA/K • Changing the oil

working vacuum pump
hours
Becker Picchio vacuum • Lubrication
Every 2000 pump
hours Becker U 4.250 SA/K • Replacement of the oil separator filter
vacuum pump
Every 2000 Busch Mink vacuum • Cleaning the fans and the cooling tubes
hours or at pump
least every 6 Operating section • Cleaning of the gluing unit electrical manifold
months
Every 3000 Becker VTLF2.250 • Lubricating the bearings
hours vacuum pump
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Becker Picchio vacuum • Blade wear check
pump
Every 3000 Becker VTLF2.250 • Blade wear check
hours or vacuum pump
every year Refrigerator • Changing the coolant
Busch Mink vacuum • Cleaning the net filter
pump
Busch Mink vacuum • Replacement of the oil in the gear box. To replace
Every 20,000
pump the oil, consult the appropriate instructions
hours
supplied with the vacuum pump
* FR unit • Replacing the oil separator filter cartridge
** Lubrication pump • Topping up the lubrication pump
boring unit lubrication • Topping up the boring unit lubrication pump
**
pump
Operating section • Lubrication and cleaning of the boring spindle
**
gears
** Operating section • Lubrication of the glue roller
*
See the specific paragraph.
**
When requested by the numerical control.
The shapeable suction cups must be replaced with some new original ones, supplied
by the manufacturer.
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14.4 General cleaning of the machine

Proper cleaning of the machine and the surrounding area will make the working environment
healthier and safer, allowing commands and indicators to be identified with ease and without
mistakes.
Use a vacuum cleaner to remove any wood chips, and if necessary use a compressor to remove
fine dust, making sure you stand at a sufficient distance. To prevent the floor from becoming
slippery, waste chips must be removed using a vacuum cleaner or brush.
Never use compressed air to clean the electrical cabinet; use a vacuum cleaner or
soft cloth, as the dust removed might deposit on the electrical contacts and cause
damage.
To avoid damaging the various operating section covers and the presser sensors,
clean them using soap and water only. Do not use thinners, degreasing agents,
alcohol, benzene or any other chemical products .
14.5 Cleaning the machine guides and racks

Clean any deposits on the guides and racks using a cloth or a bronze wire brush.
Using a brush, spread a thin layer of CENTOPLEX H 0 lubricant on each rack.
14.6 Updating the antivirus system

The updating of the anti-virus system does not take place automatically; it must be done manually
for the entire period of the duration of the licence.
Proceed as follows:
1. From the machine's PC, go to the site http://www2.biesse.it/home/antivirus.asp.
2. Click on “Download antivir update” and download the file.
3. Run the Avira Antivir Professional application software, click on “Update” and “Manual
update”.
4. Open the previously downloaded file. The update will start automatically.
The anti-virus system properly installed and maintained as described does not guarantee
total protection. The manufacturer assumes no responsibility for any inefficiencies in the
system.
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14.7 Pressure check

The following illustrates and describes the pressure gauges on which the pressure must be
checked at regular intervals.
If the pressure value is found to be incorrect, do not make any adjustments, but
contact the Service Centre.
A Pressure gauge indicating the supply pressure = 6.5 - 7.5 bar.

The supply pressure must be checked with the machine in emergency stop mode, without
having activated the cut-out valve.
B Pressure gauges that show the vacuum system pressure = about - 0.85 bar (- 12.5 psi, - 65
cm Hg, - 85000 Pa).
The checking of the vacuum system pressure must be made by simulating a blocking without
a piece.
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14.8 Lubricating the X-drive devices (slide blocks and

rack)
Operation to be carried out only if the machine does not have its own automatic lubrication
system.
1. Fill the pump provided with CENTOPLEX H 0 lubricant.
2. Insert the pump into any one of the greasing nipples on the distributor A and pump in
approximately 3 grammes of lubricant (4 strokes of the pump).
3. Repeat this operation for each of the greasing nipples on the distributor A.
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14.9 Lubrication of the Y and Z drive devices (slide

blocks and lead nuts)
Operation to be carried out only if the machine does not have its own automatic lubrication
system.
2. Insert the pump into any one of the greasing nipples on the distributors A and pump in
3. Repeat this operation for each of the greasing nipples on the distributors A.
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14.10 Lubrication of the machine X-axis gears

To lubricate the machine X-axis gears, proceed as follows:
2. Insert the pump into the greasing nipple A and pump in lubricant until it starts to seep out of
the bleed hole B.
14.11 Lubricating the Rack type magazine drive

devices
2. Insert the pump into any one of the greasing nipples on the distributors A and pump in
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14.12 Topping up the grease level

To top up the grease, use the pneumatic greasing guns supplied. One gun must be used to grease
the automatic lubrication system of the main machine axes (see paragraph 14.13).
Each gun and lubrication system bears an adhesive label showing the type of grease to be used.
Only insert the same cartridges in the relative guns.
The main parts are listed below:
E C
F A
A Air input
B Quick connector
C Trigger
D Flexible tube
E Bleed valve
F Gun tank
G Locking lever
H Pushing lever
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Technical data
Air consumption 113 l/min
Tube diameter (recommended ) 9mm
Compressed air quality Lubricated and clean
Recommended pressure 6 bar
Inserting the cartridge

Observe the following procedure:
1. Pull the pushing lever A as far as it will go, then loosen the head of the gun tank B.
2. Insert the cartridge in the gun tank, remove the cartridge cap, then tighten the head on the gun
again.
3. Press on the blocking lever C and push the pushing lever until it is fully inwards.
4. Press the trigger D until grease comes out. The gun is self-purging.
5. Open the bleed valve E if the grease does not come out at once.
E D
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14.13 Topping up the lubrication pump

If the lubricant level in the pump has reached minimum, a message will appear on the numerical
control. In this case, top up as described below.
1. Fill the pneumatic greasing gun (supplied) with the type of lubricant indicated on the lubrication
system (KLUBER CENTOPLEX H0).
2. Insert the flexible tube of the greasing gun (see paragraph 14.12) in the greasing nipple A, and
inject lubricant until it seeps out of the drainage hole B.
14.14 Topping up the boring unit lubrication pump

If the lubricant level in the pump has reached minimum, a message will appear on the numerical
control. In this case, top up as described below.
1. Depressurise the pneumatic system.

2. Fill the pump provided with the type of lubricant that is quoted in the plate of the boring unit.
3. Insert the pump into the greasing nipple A and pump in lubricant until it seeps out through the
bleed hole B, indicating that maximum level has been reached.
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14.15 Cleaning the carriage filters

Use compressed air to clean the filter A on each of the work table carriages. In order to clean it
properly, the filter must be removed from the carriage and the air must be blown onto its inner
surface, as shown alongside.
To avoid excessively frequent clogging of the filter, always fit the carriages with covers,
suction cups or clamps before using the machine.
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Lubrication of WX# machine axes ball blocks

To lubricate the ball blocks, observe the following instructions:
1. Fill the pump provided with CENTOPLEX H 0 type lubricant.
2. Insert the pump in the greasing nipple A, and pump in lubricant until it starts to seep out from
the sides of the slide blocks.
Cleaning the cams to detect the carriage position

There are two types of cleaning operation: complete cleaning and partial cleaning, which must be
carried out alternately every three months.
To carry out complete cleaning, proceed as follows:

1. Extract the cam unit A by removing the screws B with the spanner supplied C.
A
D
B
After extracting the cam unit A, turn it slightly (ref. D).
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2. Extract the spring E and the piston F. Clean the piston and the seat G with a clean, soft cloth.
F
G
3. Apply LUBERING ST grease on the G seat.
4. Reassemble the cam unit and fix it to the carriage with the appropriate screws B.
To carry out partial cleaning, proceed as follows:
1. Loosen the cap A.
2. Insert the nozzle of the compressed air gun in the hole B, then inject air for about 30 seconds.
3. Replace the cap A.
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Replacing the outer gasket of the shapeable suction cups

To replace the outer gasket of the shapeable suction cups, follow the procedure below:
1. Insert the gasket, starting from any one of the corners.
2. Insert the gasket in the opposite corner.
3. Insert the gasket in one of the two remaining corners.
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4. Insert the gasket in the last corner.
5. Fit the whole gasket in.
14.16 Interventions on the operating section

The following paragraph lists the scheduled maintenance operations for the operating section
parts.
Checking the electrospindle tool locking, page 193.
Checking and cleaning the collet spindles, page 194.
Checking and cleaning the electrospindle, page 195.
Checking the connections of the electrospindles, page 196.
Cleaning the C-axis, page 197.
Cleaning and partial lubrication of the chip deflector, page 198.
Complete cleaning and lubrication of the chip deflector, page 199.
Lubricating the HSK F63 - HSK E63 electrospindle release device, page 201.
Lubrication and cleaning of the boring spindle gears, page 202.
Lubricating the multifunction unit (ball blocks), page 203.
Lubricating the horizontal milling unit (ball blocks), page 203.
Checking the electrospindle tool locking

To carry out this check, fit a tool on each of the electrospindles present and, after stopping the
machine, check manually to ensure they are perfectly locked. Also check that air is coming out of
the electrospindle connection device area.
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Checking and cleaning the collet spindles

Before using the collet spindles, make sure that the conical coupling A is properly clean, without
dust, grease, coolant, oil, metallic particles, limestone, and signs of oxidising substances.
Carefully clean the conical coupling A and the stop surface B with a clean and soft cloth. It is
forbidden to use aggressive products like acids or similar, and abrasive elements like wire wool,
metallic brushes, emery cloth, etc.
A
A
For safety reasons, to guarantee accurate machining and to minimise collet spindle
wear, keep these areas as clean as possible.
After cleaning, to prevent the coupling from sticking in the electrospindle with the
consequent risk of breaking the tool change device, spray surfaces A of the HSK F63
or HSK E63 type couplings with KLÜBER LUSIN PROTECT G 31 and distribute it
evenly using a clean, dry cloth.
At the end of the machining operation, avoid problems of sticking by always

removing the collet spindle from the electrospindle and replacing it with a clean one
at room temperature. Warning! Wear gloves to avoid burns.
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Checking and cleaning the electrospindle

Before using the collet spindle, make sure that the conical surfaces A and the stop surfaces B are
thoroughly clean, without dust, grease, coolant, oil, metallic particles, scale, or traces of oxidising
substances.
Clean the surfaces A and B carefully with a soft, clean cloth. It is forbidden to use aggressive
products like acids or similar, and abrasive elements like wire wool, metallic brushes, emery cloth,
etc.
ISO 30 HSK F63

HSK E63
A A
For safety reasons, to guarantee accurate machining and to minimise electrospindle

wear, keep these areas as clean as possible.
The electrospindle may get damaged if any dirt gets into the coupling area. If,
therefore, you want to use compressed air to clean the outer surface of the
electrospindle, protect this area with a plug or a clean collet spindle.
Do not direct jets of compressed air into the electrospindle shaft when the collect
spindle is not fitted.
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Cleaning of the gluing unit electrical manifold

Proceed as follows for the cleaning of the electrical manifold of the gluing unit:
1. Remove the cover, unscrewing the appropriate screws.
2. Clean the inside of the manifold with compressed air.

3. Close the cover by tightening again the screws.
Checking the connections of the electrospindles

Inspect the following:
Check the electrical cables are not damaged.
Check that the connectors are firmly fixed (see the figure).
A = pneumatic connections.
B = electrical connections.
Check the seal of the pipes of the pneumatic system and the cooling circuit connections.
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Checking the 5-axis milling unit connectors

Inspect the following:
Check the electrical cables are not damaged.
Check that the connectors are firmly fixed (see the figure).
A, B, C = pneumatic connections.
B A
C D, E, F, G = hydraulic connections.
E
D
G
F
Check the seal of the pipes of the pneumatic system and the cooling circuit connections.
The gaskets that isolate the fluid circuits inside the 5-axis milling unit are made of
NBR; use additives that do not degrade this material.
Cleaning the C-axis

Thoroughly clean the seats A, every day.
A
Before using the C-axis, make sure that the conical surfaces
B are properly clean, without dust, grease, coolant, oil,
metallic particles, limestone, and signs of oxidising
substances.
Clean both the A and B surfaces carefully with a soft, clean
cloth.
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Cleaning and partial lubrication of the chip deflector

To clean the chip deflector, follow the procedure given below:
1. Thoroughly clean the external part of the deflector together with all the seats of both the
screws and the dowels.
2. Dismantle the casing A.
Check the wear on the deflector blade and replace it if necessary.
3. Remove the snap ring and take out the elements shown in the enlargement B, then clean
them with a brush and some thinner. Finally, grease the housing and individual components
with KLÜBER ISOFLEX NBU 15 lubricant.
4. Remove the valve C and the gasket D. Remove any dust from the gasket housing and from
the whole body E.
5. To reassemble the chip deflector, carry out the above operations in reverse order.
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Complete cleaning and lubrication of the chip deflector

To clean the deflector, follow the procedure given below:
1. Thoroughly clean the external part of the deflector together with all the seats of both the
screws and the dowels.
2. Dismantle the casing A, remove the valve B and the gasket C, and carry out points 3 and 4 of
“Cleaning and partial lubrication of the chip deflector”.
A
C
B
3. Dismantle the pneumatic valve A, clean all the components with degreasing products only. Do
not use solvents. Do not grease the pneumatic valve components.
4. Lock the deflector C using a clamp, then take out the snap ring and the retainer G.
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5. Lift the locking ring D, which will remain connected to the main body by the springs E. Clean
the four pins F - see point 3 of “Cleaning and partial lubrication of the chip deflector”. Clean
the housings of the springs E and the whole of the deflector. Grease the spring housings F and
the areas inside the deflector using KLÜBER ISOFLEX NBU 15.
E E
6. To reassemble the chip deflector, carry out the above operations in reverse order taking care
to check that:
• the various components are in their proper positions;
• the fixing ring D rotates correctly after having locked the deflector by means of a clamp;
• the dowels work correctly after having inserted retainer G.
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Lubricating the HSK F63 - HSK E63 electrospindle release device

To avoid problems during tool changing operations, periodically apply METAFLUX Fett-Paste 70-
8508 grease for metals on the electrospindle unlocking device.
Use only the above-mentioned grease. Other products are not compatible with the
ones used the manufacturer during the initial greasing. If different types of
incompatible greases are mixed or subsequently used, they can cause deposits of
substances detrimental to the unlocking device operation, thus impairing safety.
1. Apply grease in the expeller A and in the gap between the locking collet segments B, with the
help of a thin clean plastic implement.
2. Spread the grease evenly, using a collet spindle which should be inserted in the unlocking
device and disconnected a dozen times.
3. Remove the collet spindle and wipe off any visible excess grease with a clean cloth.
Excess grease is harmful as it can hold chips or other material residue, which in turn
dirties the locking collet, conical surfaces and stop surfaces. For safety reasons, in
order to guarantee accurate machining operations and to minimise wear of the
unlocking device and the collet spindle, keep these areas as clean as possible.
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Lubrication and cleaning of the boring spindle gears

To lubricate the boring spindle gears on the boring units, proceed as follows:
1. Fill the pump provided with the type of lubricant that is quoted in the plate of the boring unit.
2. Insert the pump into the greasing nipples A and pump 5 grammes of lubricant (5 strokes of the
pump) into each one.
BH17L BH 24 L
BH 9
To maintain the boring unit's efficiency in the event of long periods of non-use,
perform a general lubrication every 4 months.
3. At the end of the manual lubrication operation described above, manually rotate the spindles
to distribute the lubricant evenly. To carry out this operation, proceed as follows:
• Lower a spindle (preferably one that is not fitted with a tool). For the boring unit with snap-on
coupling spindles it is necessary to lower 2 spindles, one right and one left.
• Insert the screw into the tool fixing bore, so that it can be used to turn the spindles easily.
• Turn the spindles, turning 5 times in one direction and 5 in the opposite direction.
standard spindle spindles with snap-on coupling
A spindle that is not used often may rust, so that it is difficult to lower or blocks. After lubricating the
boring unit it is therefore advisable to clean the outside of rusty spindles and apply a Teflon spray.
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Lubricating the multifunction unit (ball blocks)

2. Insert the pump in the greasing nipple A and pump in lubricant until it starts to seep out from
Lubricating the horizontal milling unit (ball blocks)

2. Insert the pump in the greasing nipple A and pump in lubricant until it starts to seep out from
Cleaning the PUR glue bowl

This operation must be carried out before prolonged stoppage of the machining operation, or when
the type of glue changes (from a machining with PUR glue to a one with EVA glue).
The glue treatment area is at high temperature. Wear clothing with adequate
Handle the bowl by means of the appropriate handles.
PUR glue must not be left unused in the gluing unit for longer than the period
indicated by the supplier.
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2. Disassemble the pellet loading tank labelled “PUR”.
3. After placing a tank beneath the pellet loading tube, perform 3 loading operations to
completely free the system of PUR glue pellets.
4. Switch the heating off and stop the machine.
5. Fasten the handle A on the glue bowl; dismantle the glue bowl from the gluing unit by
loosening the screws B and disconnect the resistances C.
C
B C
6. Fit the cleaning glue bowl with drainage hole
7. Place a collection tank under the bowl drainage hole.
8. Fill the bowl up with Cleaner .
9. Switch on the machine with a work temperature suitable for PUR, and start up the glue roller.
10. Fully drain the PUR glue gluing unit
11. Switch off and cool the glue bowl.
12. Replace the cleaning bowl with the other cleaning bowl containing EVA .
13. Switch on the machine with a work temperature suitable for EVA, and start up the glue roller.
14. Fully drain the Cleaner product from the gluing unit
Cleaning the EVA glue bowl

The glue treatment area is at a high temperature. Wear clothing with adequate
Handle the bowl by means of the appropriate handles.
2. Activate the glue heating cycle (see page 168).
3. When the temperature has reached 110°C, deactivate the heating cycle and stop the machine.
4. Screw the handle A onto the glue bowl.
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5. Dismantle the glue bowl from the gluing unit unscrewing screws B and unplugging, if
necessary, heating elements C.
6. Remove the glue that is still liquid from the glue bowl, from the glue roller, from the sensor and
from the endless screw. For this operation do not use tools that could damage the non-stick
surface of the glue bowl.
7. Blow the glue bowl, the glue roller and the endless screw with compressed air to cool and
remove all excess glue.
C
B C
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Lubrication of the glue roller

The glue treatment area is at a high temperature. Wear clothing with adequate
1. Fill up the pump supplied using KLÜBER BARRIERTA L55/2 lubricant.
2. Connect the pump on the greasing nipple A and pump in 3 grammes of lubricant
(approximately 2 strokes of the pump). Repeat the operation for each grease nipple A.
A
A
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14.17 Interventions on the electrical cabinet

The following paragraph lists the scheduled maintenance operations for the electrical cabinet
parts.
Cleaning the air conditioner

1. Turn the machine off.
2. Loosen the screws A and take out the casing.
3. Blow downwards with a jet of compressed air (not exceeding 4 bar).
4. Replace the casing.
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14.18 Interventions on the FR unit

The following paragraph lists the scheduled maintenance operations for the FR unit.
Cleaning/replacing the filter

When the filter needs to be replaced, to avoid any pressure drop, follow the procedure below:
1. Make sure there is no pressure in the system; the supply pressure gauge (see page 182) must
indicate 0 bar.
2. Remove cup A by turning it anticlockwise.
3. Unscrew the baffle unit B.
4. Extract the cartridge C and clean it with soap, water and compressed air.
C B
208 BIESSE S.p.A. © - a714k0113.fm030518

14 Maintenance
Replacing the oil separator filter cartridge

The oil separator filter cartridge must be replaced when the red indicator light A rises more than
halfway up the green indicator light B.
To change the cartridge, proceed as follows:
1. Make sure there is no pressure in the system; the supply pressure gauge (see page 182) must
indicate 0 bar.
2. Remove the cup C by turning it anticlockwise.

3. Loosen the cartridge D and replace it.
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209
14 Maintenance
14.19 Interventions on the Becker Picchio 2200

vacuum pump
The following section lists the maintenance operations planned for the 90 m³/h Becker Picchio
2200 vacuum pump.
Cleaning
1. Unfasten the screw A to eliminate any residual vacuum from inside the pump.
2. Remove the covers B.
3. Remove each air filter C and clean it using a jet of compressed air and blowing from the inside
out. Replace blocked or greasy filters.
4. Clean the cooling grooves D, using a jet of compressed air.
B C
A
D D
C
B
B C
210 BIESSE S.p.A. © - a714k0113.fm030518

14 Maintenance
Lubrication
To do this first remove the covers A and B and spread grease onto the bearing C (grease type
KLÜBER AMBLYGON TA 15/2) from the tube D (5g).
A
C B
Blade wear check

The blades, which rub continuously against the inside of the pump, are subject to wear. Check the
width of the blades and replace them if they reach the minimum limit of 26mm. When carrying out
this operation, also check the conditions of the bearing on the inside of the cover C, and if it is dry,
lubricate with grease (KLÜBER AMBLYGON TA 15/2) from the tube E.
A
E
D B
1. Unfasten the screw A to eliminate any residual vacuum from inside the pump.
2. Remove the covers B and C.
3. Take out the blades D and check them for wear; replace them if necessary.
4. If the bearing on the inside of the cover C is dry, lubricate it with the grease (KLÜBER
AMBLYGON TA 15/2) in tube E (2g).
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211
14 Maintenance
14.20 Operations on the Becker VTLF2.250 vacuum

pump
The following section lists the maintenance operations planned for the 250 m³/h Becker
VTLF2.250 vacuum pump.
Cleaning the cooling ducts

To guarantee adequate ventilation, clean the cooling ducts A by blowing with compressed air.
Cleaning the filters

Remove the air filters A and clean them using a jet of compressed air and blowing from the inside
out. Replace blocked or greasy filters.
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14 Maintenance
Lubricating the bearings

The vacuum pump bearings must be lubricated through the greasing nipples A with the pump
operating, using the syringe provided filled with KLÜBER AMBLYGON TA 15/2 type grease (pump
in 10 grammes of grease).
A
A
Blade wear check

Make sure everything is kept as clean as possible during this operation.
1. Remove the cover A.
2. Remove the cover B. To carry out this operation, after unscrewing the bolts that fasten the
cover, screw two bolts evenly into the holes C, making sure the cover is not tilted to the side.
3. Remove the blades D and check they do not exceed the minimum limit of 41mm. If necessary,
replace them. Make sure you assemble the blades the right way round.
4. When performing this operation, also check the gaskets and bearing for wear.
5. Replace the cover B, centring it perfectly on the rotor and on the pins, and screwing up the
relative fixing bolts evenly. On completing the operation, check the rotor turns easily.
6. Replace the cover A.
D
C C
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213
14 Maintenance
14.21 Interventions on the Busch Mink vacuum pump

The following paragraph lists the maintenance interventions scheduled for the 300m³/h Mink-type
MM 1322 AVM Busch vacuum pump.
Before carrying out maintenance operations, switch off the vacuum pump.
Cleaning the net filter

Check the net filter and clean it (see the instructions supplied with the vacuum pump).
Cleaning and replacing the air filters

Remove the air filters A/B and clean them by blowing compressed air from the inside to the
outside. If the filters are clogged, replace them.
214 BIESSE S.p.A. © - a714k0113.fm030518

14 Maintenance
Checking the oil level

The oil level in the gear box can be checked with the indicator A.
If the oil level is below the minimum notch, this means there is a leakage. Contact the Service
Centre.
Cleaning the fans and the cooling tubes

1. Remove the soundproof casing A.
2. Clean the fans, the cooling tubes, the grilles and the cooling louvres (see the instructions
supplied with the vacuum pump).
3. Replace the soundproof casing .
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215
14 Maintenance
14.22 Interventions on the Becker U 4.250 SA/K

vacuum pump
The following section lists the maintenance operations planned for the 250m³/h Becker U 4.250
SA/K vacuum pump.
Checking the oil level and topping-up with oil

The oil level in the pump tank can be checked through the indicators A (indicating maximum oil
level) and B (indicating minimum oil level). If the oil level drops below the minimum level, more oil
must be added.
To fill the pump tank, it is recommended that you use DIN 51506 standard VC type oil, or original
BECKER LUBE S 100 oils.
1. Remove the plug C.
2. Fill the tank until the oil level reaches the maximum level marker. The tank has a capacity of 7
L.
3. Seal the bore with the plug.
4. Start up the pump and run it for approximately one minute, checking that the oil level is correct.
216 BIESSE S.p.A. © - a714k0113.fm030518

14 Maintenance
Changing the oil

The oil must be changed when the pump is warm, after it has been turned off and the compressed
air has been discharged.
1. Remove the plug A from the drain bore, drain out the old oil, tilting the pump and then close
the drain bore again with the plug A.
2. Start the pump and run it for a few minutes, then unscrew plug A again to drain off any
remaining oil. At the end of the operation, replace the plug.
3. Top up as explained in “Checking the oil level and topping-up with oil”.
Cleaning the air filter

Remove the air filter A and clean it with compressed air from the inside out. If it is obstructed or
greasy, replace it.
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14 Maintenance
Checking and cleaning the fan

Keep the fan cover A clean to avoid the risk of blocked air passages compromising proper
ventilation, resulting in the pump overheating.
Replacement of the oil separator filter

To replace the oil separator filter, proceed as follows:
1. Turn the screws A and remove the cover B, the rubber gasket, the grid and any nuts and
washers.
2. Replace the filters C.
B A
218 BIESSE S.p.A. © - a714k0113.fm030518

14 Maintenance
14.23 Interventions on the Becker U 4.100 SA/K

vacuum pump
The following section lists the maintenance operations planned for the 100m³/h Becker U 4.100
SA/K vacuum pump.
Cleaning
To find out how often this operation should be carried out, refer to the table on page 178.
1. To avoid any overheating, clean the fan's cover, the fan's grill, the cooling louvres and the
compressor's surfaces.
2. Daily clean the filter cartridge A.
3. Make a daily check to ensure the oil level is not below the average level shown by the indicator
light B.
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219
14 Maintenance
Replacing the oil

To find out how often this operation should be carried out, refer to the table on page 178.
1. Drain off the oil from the still hot pump by unscrewing screw A.
2. Loosen the cap B and top up the oil until it reaches the max. level shown by indicator C. Use
MOBIL DTE OIL HEAVY vacuum pump oil, or SAE 15W-40 motor oil.
C
A
3. Filter D must be replaced each time the oil gets changed or in case it is filled in. While fitting it
pay attention to the seam that must be downwards.
4. Check separator E and clean it if is dirty. Loosen the oil tank cover F and the oil pipe G.
G E
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14 Maintenance
14.24 Operations on the magazines

The following paragraph lists the scheduled maintenance operations for the magazines on the
machine.
Lubricating the Flexstore magazine ball blocks

To lubricate the ball blocks of the Flexstore magazine, observe the following instructions:
1. Fill the pump provided with CENTOPLEX H 0 type lubricant.
2. Insert the pump in the greasing nipples A and pump in lubricant until it starts to seep out from
Cleaning and control of the banding material container

To clean the edgebanding material magazine, follow the instructions below:
Clean the banding material presence sensors A and the related reflectors B with compressed air
and a cloth.
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221
14 Maintenance
14.25 Interventions on the refrigerator

The following paragraph lists the scheduled maintenance operations for the refrigerator.
Checking and topping up the coolant

To avoid damaging the refrigerator, be careful not to let dirt fall into the tank.
Indicator A allows to check that the level of the coolant is not too low, that is not too old or contains
traces of rust, metallic particles or scale. If the coolant is below the minimum notch (B), remove the
plug D and fill the tank until you reach the maximum notch (C).
MAX C D
min B
To avoid damaging the cooler, use the coolant known as Artic-Flu-5 (made up of
demineralised water with 10% glycol and anti-corrosion additives). Alternatively, you
can use a mixture of demineralised water with 10% ethylene glycol and anti-corrosion
additives, or an equivalent product.
Cooling characteristics
Input cooling temperature: t = 20°C - 30°C
Anti-corrosion means: Vmax = 25 Vol%
Solid materials filter < 100 µm
Types of water additives

Brand Type
ARAL SAROL 340 -2 - 3%
CINCINNATI CINCINNATI CIMCOOL MG 602 - 4 %
HENKEL P3 - PREVOX 6710 - 2 ÷ 3 %
CASTROL SYNTILO R PLUS - 2 ÷ 3 %
222 BIESSE S.p.A. © - a714k0113.fm030518

14 Maintenance
Cleaning the cooler

1. Make sure that the cooler is turned off.
2. Extract the filter A and clean it.
Changing the coolant

To avoid damaging the refrigerator, be careful not to let dirt fall into the tank.
1. Make sure that the refrigerator is turned off and disconnect the relevant cable from the power
supply.
2. Using the indicator A, check the level of the coolant in the tank is above the minimum notch.
Never allow the fluid in the tank to drop below the minimum level; danger of breaking
the pump.
3. Take a container B to collect the liquid to be replaced.
4. Remove the plug C.
5. Disconnect the pipe D from the coolant inlet tap and put it into the container B.
D
A
MAX B
C
min
6. Connect the power supply cable, turn the refrigerator on and make sure the coolant circulation
pump is working.
7. Gradually fill the refrigerator tank with water as the level of the coolant drops. Finish the
operation only when clean water is coming out of the pipe inserted into the container.
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223
14 Maintenance
8. Turn the refrigerator off and disconnect the cable from the power supply.
9. Connect up pipe D to the tap again, and continue to fill the tank; the fluid level must not reach
the maximum level mark, but must be just below it.
MAX
min
10. Pour the coolant into the tank (see characteristics on page 222).
11. Turn the refrigerator on again and make sure there are no leaks.
14.26 Comparative lubricant table

Below follows a list of recommended lubricants which may be used instead of those indicated.
Lubricant Brand Type
Grease KLÜBER CENTOPLEX H 0

AGIP GR MU EP 0
BP ENERGREASE LS EP 0
MOBIL MOBILUX EP 0
SHELL ALVANIA EP GREASE R 0
TEXACO MULTIFAK EP 0
ESSO BEACON EP 0
Do not mix different types of lubricant: they might be incompatible.
224 BIESSE S.p.A. © - a714k0113.fm030518

Appendices
A.1 Main machine axes X, Y, and Z

X Y Z
maximum programmable speed (m/min) 83 60 20* - 30**
acceleration (m/s ) 2 3 4 4
*
Boring unit
** 5-axis milling unit
A.2 Types of electrospindles

maximum power
Maximum rotation
(service type S6) at
speed (rpm)
12000 rpm (kW)
ES959 - ISO 30 (air-cooled) 13.2 24,000
ES959 - HSK F63 (air-cooled) 13.2 24,000
ES959 - HSK F63 (liquid-cooled) 19.2 24,000
ES959 - HSK E63 (PEAK POWER air- 19.2 18,000
cooled)
ES959 - HSK E63 (PEAK POWER 19.2 18,000
liquid-cooled)
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227
A.3 Collet spindles

ISO 30 HSK F63 HSK E63
collet type* ERC 32 ERC 40 ERC 40 ERC 40
maximum rotation speed (rpm) 24,000 24,000 24,000 18,000
*
Different collets are available to fit tools with shanks with a maximum diameter of 25mm. Each collet is designed
to take a specific diameter of shank.
ISO 30 ISO 30 HSK F63 HSK E63
63 63
3.2
3.2
electrospindle nose
49
57
72
72
M40 M50
ERC 32 ERC 40 ERC 40 ERC 40
The geometry of the taper must comply with standard DIN69871 for ISO30 cones, and
standard DIN69893 for HSK cones.
The ISO30 tool holder cone must have an AT3 degree of accuracy.
Avoid the presence of plugs, slots or other forms that could disturb the dynamic balance of
the collet spindle.
At the maximum rated speed of the electrospindle, the dynamic balance must be G = 2.5 or
higher.
The balance is obtained with the collet spindle assembled.
The screw dowel of the ISO30 cone must be supplied by the manufacturer only.
228 BIESSE S.p.A. © - a724k0114.fm030518

A.4 Boring unit

BH 30 2L BH24 L BH 17 L BH9
Motor power (kW) 1.7 1.7 1.7 1.7
rotation speed of vertical spindles (rpm) 6,000 6,000 6,000 6,00
0
rotation speed of horizontal spindles (rpm) 4740 4740 4740 4740
distance between spindle centres (mm) 32* 32* 32* 32*
maximum spindle rotation speed for circular blade 6,000 6,000 6,000 -
(rpm)
circular blade spindle data see figure -
* The value indicated is only reached after a proper warm-up (see 6.5 “Operating
section warm-up cycles” on page 80).
A: spindle with standard coupling

B: spindle with snap-on coupling
A B
M6
17
3
M6
Ø 10
3
Ø 59
Ø 35
2.5
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229
A.5 Horizontal milling unit

Motor power (kW) 3.5
maximum rotation speed (rpm) 24,000
Spindle rotation direction right
spindle characteristics
32
ERC 32
maximum length of the tool from the nose of the spindle (mm) 170
A.6 Motorised rotating milling unit

Motor power (kW) 5
nominal rotation speed (rpm) 18,000
spindle rotation direction with ERC 32 clamp right
spindle rotation direction with ERC 25 clamp left
maximum length of the tool from the nose of the spindle with ERC 32 130
clamp (mm)
maximum length of the tool from the nose of the spindle with ERC 25 120
clamp (mm)
maximum diameter of the tool that can be installed (mm) 16
maximum depth (mm) 10
forward speed 4* - 6
spindle characteristics
32
ERC 32
ERC 25
* value
for hardwoods (oak-mahogany)
230 BIESSE S.p.A. © - a724k0114.fm030518

A.7 Multifunction unit

power (kW - HP) 5 - 6.7
A.8 C-axis
maximum rotation speed (turns/min) 40.65
rotation speed during rapid machining (rpm) 34
rotation speed during interpolation (rpm) 23
A.9 5-axis milling unit

HS353H - HSK F63 (liquid-cooled)
maximum power (service type S6) at 12000 rpm (kW) 16.5
HS353S - HSK F63 (liquid-cooled)

maximum power (service type S6) at 12000 rpm (kW) 13
maximum power (service type S6) at 20000 rpm (kW) 13
HS570 - HSK F63 (liquid-cooled)

HS570 - HSK E63 (liquid-cooled)

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231
A.10 Chip deflector
45 *
45 *
169 Ldef. **
=
200 Ldef. **
170 **
=
170 **
185 **
169
O 180 **
O 180 **
31°
118,2
• A; layout when using Uniclamps.

• B; layout when using shapeable suction cups.
O 180 • *; minimum value in mm.
• **; maximum value and/or diameter that must not be
exceeded.
• Formula; Ldef - Lut + Z <84.5 - 11 = 73.5
the result of the calculation Ldef - Lut + Z must be less
than 84.5mm (Ldef = 170mm); you must subtract 11mm
281 from the result of the previous calculation if there is an
O 18° overturning side stop C on the work table.
A B
*45
C
*45
Lut
Lut
Ldef
Ldef
84,5
84,5
Z
Z
11
A.11 Rack type tool magazine

The technical characteristics of the Rack tool magazine are indicated in the layouts supplied with
the machine.
A.12 Revolver tool magazine

The technical characteristics of the Revolver tool magazine are indicated in the layouts supplied
with the machine.
232 BIESSE S.p.A. © - a724k0114.fm030518

A.13 Chain type tool magazine

The technical characteristics of the Chain tool magazine are indicated in the layouts supplied with
the machine.
A.14 Dimensions of the shapeable suction cups

shapeable suction cup size 132 x 172 x 74mm;
shapeable suction cup size 132 x 146 x 29 or 74 mm;
shapeable suction cup size 132 x 146 x 29 or 74 mm, with help loading device;
centred shapeable suction cup size 132 x 75 x 29 or 74 mm;
centred shapeable suction cup size 132 x 75 x 74 mm with pins;
A.15 Dimensions of the CFT table

CFT table of 630 x 775 x 48 mm, 50 kg.
A.16 Working field in X-Y

The technical characteristics of the working field in X-Y of each machine are indicated in the
layouts supplied with the machine.
A.17 Working field in Z

The technical characteristics of the working field in Z of each machine are indicated in the layouts
supplied with the machine.
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233
A.18 Noise level

The correct noise pressure level, measured from the operator's workstation, is:
LP = 78 dB (A), during boring
LP = 78.5 dB (A), during milling
The noise power level is:

LWA = 93.5 dB, during boring
LWA = 95.5 dB, during milling
Uncertainty factor K = 4 dB
Reference standards: EN ISO 3746 - EN ISO 11202.
The noise levels indicated are output levels and do not necessarily represent safe
operational levels.
Even though there is a relation between emission levels and exposure levels, this cannot be used
reliably to establish whether or not further precautions are necessary.
The factors determining the noise levels to which the operative personnel are exposed include the
length of exposure, the characteristics of the work area, as well as other sources of dust and
noise, etc. (i.e. the number of machines and processes concurrently operating in the vicinity). In
any case, the information supplied will help the user of the machine to better assess the danger
and risks involved.
The noise level depends on:

• the wear condition of the tool
• forward speed
• the rotation speed
• material being machined
234 BIESSE S.p.A. © - a724k0114.fm030518

B Transport
B Transport
The machine can be dispatched using various forms of transport (road, rail, sea, air), and the
method is usually agreed with the customer at the time of purchase. The machine is divided into a
number of parts to allow transport, and the procedure used to lift and unload the machine and its
components is described in this appendix.
B.1 Notices on lifting and unloading the machine

Before lifting and transporting the machine, read the following notices carefully:
The lifting and transporting operations must be carried out by suitably qualified personnel who
shall follow the indications given below.
Use equipment of a suitable load-bearing capacity to perform lifting operations. The gross
weight is shown on every package.
Don't use a forklift to lift the machine.
Check that the lifting materials are in good condition. During lifting and movement make sure
that there are no unauthorized persons within the range of action of the machine.
Before lifting the machine, check the position of the load's centre of gravity and avoid any
sudden, dangerous swings that could damage the load itself and check the machine's weight
on its identification plate. Make sure that flat straps are spread out to their proper length.
On completing positioning of the machine the lifting devices must be removed and kept for
possible future movements.
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235
B Transport
Lifting the machine

To lift the main structure of the machine use the method illustrated below. No particular procedures
are necessary to lift the remaining parts.
E C
E
A
C
Material Quantity Supplied

A 1 yes
B 2 yes
C 2 no
4 yes
D
2500mm / 5000kg
2 no
E
1200mm / 5000kg
The equipment supplied must not be used for other machines or other purposes.
236 BIESSE S.p.A. © - a725k0111.fm030518

B Transport
Removal of the boards and vibration damper plates

Before resting the main structure on the ground, unscrew the nuts A and remove the wooden
boards B and the vibration damper plates C from under the base.
C
B
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237
B Transport
238 BIESSE S.p.A. © - a725k0111.fm030518

C Installation
C Installation
This appendix contains indications for the installation of the machine.
C.1 Warnings regarding machine installation

Before proceeding, please read the following warnings carefully:
The area in which the machine is installed must be properly illuminated, ventilated, of
adequate size and fitted with connections to the various supply systems (electricity,
compressed air, etc.). In this regard, refer to “Working dimensions and connection points” on
page 240. The systems to which the machine is connected, and the environment where it is
installed, must possess the requisites indicated on page 241.
The machine cannot be installed in explosive environments.
Assembly, levelling and connection of the machine must be carried out exclusively by the
Service Centre staff. Do not remove the packing, open any cases of material, or above all turn
the machine on without the consent of trained, experienced staff. Should the safety seals on
the boxes of accessories be tampered with, the manufacturer will not be liable for any missing
objects.
Before starting any installation work, check that the various parts of the machine are free from
any physical damage caused by bumping, tearing or abrasion. Damage to electrical cables or
sheathing will compromise the safety of the machine’s electrical system.
Check the plug A of the air filter has been removed; if not, remove it immediately.
BIESSE S.p.A. © - a726k0148.fm030518

239
C Installation
C.2 Working dimensions and connection points

The machine layout shows:
• Overall dimensions
• Connection points
• Technical specifications
Example of layout:
1 2 3 4 5 6 7 8 9 10 11
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A0
RIPRODUZIONE E/O DIFFUSIONE VIETATA
FIRMA /
REV. DESCRIZIONE REVISIONE / REVISION DESCRIPTION N° REV DATA / DATE
SIGN

PESO / SCALA / FOGLIO /
DISEGNATO / DRAWN BY CONTROLLATO / CHECKED BY APPROVATO / APROVED WEIGHT : SCALE : SHEET :
DATA QUOTE SENZA INDICAZIONE DI TOLLERANZA

GREZZO DI /
RAW : POSITIONS WITHOUT TOLERANCE INFORMATION
DATE - LAVORAZIONI MECCANICHE /
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MATERIALE /
MATERIAL : (UURUH1HVVXQULIHULPHQWR - SALDOCARPENTERIE /
WELDMENT :
(UURUH1HVVXQULIHULPHQWR
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HEAT TREATMENT :
RIVESTIMENTO CICLO DI
SUPERFICIALE / VERNICIATURA /
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TREATMENT :
DRAWING N°
DENOMINAZIONE /
REVISIONE
ARTICOLO
REVISION
/$<287$//(6759%*)7&21)% $
CODICE
DESCRIPTION :
The connection points are as follows:
Suction manifold
Location of the vacuum pump.
Compressed air system connection outlet
Electric power socket
Network connection outlet
Entrance door
(*) Positions for the holes to anchor the machine to the floor
The technical specifications are as follows:

- Compressed air consumption Nl/min
- Mains voltage V - Hz
- Power installed kWatt - A
- Suction air speed m/sec
- Suction air consumption m3/h
- Compressed air mains supply pressure bar
240 BIESSE S.p.A. © - a726k0148.fm030518

C Installation
C.3 Installation area requisites

The following describes the essential requisites both for the various systems to which the machine
will be connected and for the environment in which it is to be installed.
Electrical system requisites

Before starting up the machine, check the electric system data on the rating plate provided.
Make sure the supply voltage is right for the equipment.
The quality of the electric system must guarantee the essential requirements indicated in CEI
60204-1, unless otherwise agreed with the customer.
Supply voltage: (see rating plate) with tolerance ± 10%
Supply voltage frequency: (see rating plate) with tolerance ± 2%
Maximum absorbed power: (see rating plate)
Harmonic distortion: from second to fifth < 10% + from sixth to thirtieth < 2%
Three-phase supply voltage imbalance: < 2%
Voltage peaks: duration less than 1.5 ms and < 200% of supply voltage
Voltage gaps: duration < 3 ms; period > 1 second
Voltage drops: value < 20% of peak supply voltage; period > 1 second
Protection of the machine against indirect contacts has been designed for TN type supply
networks, so no differential protection has been foreseen. In the event of another type of
mains connection (TT, IT), or if required by local laws or regulations, make sure a differential
protection device is installed.
For supply voltages up to 400V, the machine's electrical cabinet must be connected at a point of
the system with a short-circuit current less than 10 KA R.M.S.
For supply voltages higher than 415V, the machine's electrical cabinet must be connected at a
point of the system with a short-circuit current less than 5 KA R.M.S.
The machine's electrical equipment is not protected against atmospheric power surges.
The machine is not fitted with phase advancing capacitors.
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241
C Installation
Differential protection
No differential type protection is foreseen for the machine’s electric system.
If local laws or regulations require this type of protection, it must respect the characteristics of the
electric system of both the factory and the machine.
The customer is responsible for guaranteeing the installation of such protection and, to prevent
any accidental triggering of the device, must also ensure its compatibility with the electric system
of both the factory and the machine.
A single differential protection device cannot be used for more than one machine.
Bear in mind the following machine characteristics to ensure you make the correct choice:
1. Electromagnetic disturbance protection devices (mains filter and screening) may produce high
frequency leakage current sand pulse leakage currents exceeding 30 mA.
The 30 mA differential protective devices may not guarantee continuous operation under all
conditions.
2. There can also be earthing faults on the machine under continuous current.
You are advised to install differential switches with adjustable current and intervention times,
that are not affected by high frequencies.
The differential switch should be of the type with a strong resistance to impulsive overvoltages
of atmospheric and operating origin (EN 61008-1), and to the wave test at 8/20 µs > 1000A
(VDE 0432 T2).
Geometry laser installation requirements

A connection for the geometry laser is not provided in the electric cabinet.
A socket must be provided for connecting the laser, which must be suitably protected against short
circuits, overloads and must have a trip switch.
Power supply from local electricity generator

If the electricity is supplied by a local generator rather than mains supply, the generator must
guarantee the above indicated requisites for the electric system, while taking also into account that
the starting current for the vacuum pumps is 8 to 10 times the machine's specification plate
current.
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C Installation
Installed electrical power
The power output depends on the number and capacity of vacuum pumps. The minimum installed
power indicated on the machine rating plate always comprises the power required for 2 vacuum
pumps, 90m3/h (or one 250m3/h), even if they are not present in the machine.
Fuses
At the mains electricity connection point there must be safety protection in the form of fuses for the
connection cable, for the cut-off switch and any autotransformer present. Uses Gl/Gg type fuses
for IEC regulations, or J type for UL and CSA (or equivalent) regulations. The sizes of the fuses
are shown in the layout supplied with the machine.
The power supply cable, the electrical cabinet cut-out and any autotransformers can be protected
by automatic switches. When selecting the type of automatic switch to be used, bear in mind the
following conditions:
The automatic switch thermal current must be calibrated to the same value as that of the cut-
out
the magnetic current must be set to between 7 and 12 times the rated thermal current
the automatic switch must have a cut-out power exceeding the short circuit current at the point
of installation.
the current limited by the switch must be less than 10 kA (5 kA for voltages >415V) with a short
circuit current equal to that at the installation point (see the switch limiting characteristics).
Connection cable
The mains connection cable must have a cross-section chosen according to the size of fuses, or
automatic switches, and the length of the connection itself. Both the minimum and maximum
sections are shown in the layout supplied with the machine.
It is advisable for the cable to be shielded or fed through a metal conduit so as to reduce possible
electromagnetic interference. The screening or metal raceway must be earthed.
Requisites for the compressed air system

The compressed air system must guarantee a supply pressure of at least 7.5 bar.
The machine consumes an average of approximately 400 NL/min of compressed air.
The compressed air fed into the machine must comply with the following purity requirements:
• Maximum oil content: Class 3 (1 mg/m3 )
• Dew point: Class 4 (≤ + 3°C)
• Solid particles concentration per m3 : Class 2
0.1 ÷ 0.5 µm 0.5 ÷ 1 µm 1 ÷ 5 µm
≤ 400,000 ≤ 6,000 ≤ 100
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243
C Installation
C.3.1 Network requirements

When the monitoring system is present, the following network requirements should be met.
The machine must be connected to the Internet. If the machine is connected to a LAN network,
this must be must be configured for the outgoing connection (without any proxy server) for the
following ports:
• TCP 80 (http)
• TCP 443 (https)
• TCP 61716 (stomp SSL)
• TCP 61717 (stomp SSL)
• UDP 123 (NTP)
Those ports must be open through the windows firewall of the machines. The output network
speed must be at least 1 Mb/sec.
Suction system requisites

The suction system must be permanently connected to the machine, it must operate with the
machine and must be capable of supplying a constant minimum flow rate of 30 m/sec.
The static pressure in the point of connection to the operating section (main manifold) is 3000
Pa.
The air consumption for aspiration is 5300 m3/h.
A guillotine valve type device must be provided on the pipe connecting the suction system to
the machine, so that the machine can be cut off when necessary from the main system. This
valve must be in an easily accessible position and in full view of the operator.
No potential difference are allowed between the parts and the manifolds of the machine.
All the conductive parts must be earthed.
All the flexible hoses must have the same features as the flame retardants. They must be of
antistatic material or must direct the load to ground potential through a metal coil.
Both the ends of the flexible hoses must be earthed.
Insufficient system performance may damage health.
Make daily checks to ensure there are no system leaks or malfunctions.
Check the air flow speed after installing the system and after any significant
modifications.
If PUR glue is used the hood must be connected to a suitable suction system.
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C Installation
Flooring requisites
The floor must be even, made of concrete, and must comply with the following requisites:
Compression resistance 30 N/mm
Maximum slope in any direction 0,5%
Maximum planar error, non cumulative 25 mm/m
Environmental requisites
Temperature: from +5 to +40 °C
Maximum relative humidity: 80% (without condensation)
Maximum altitude: 1000m (unless agreed otherwise with the customer)
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245
C Installation
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D.1 Decommissioning
During the machine's life cycle, it may be necessary to transfer it to another location. In this case,
contact the Service Centre.
D.2 Scrapping
When the machine reaches the end of its technical working life, it must be totally decommissioned
so that it can no longer be used for the purposes for which it was designed and built. If any parts
are used again, it must be for purposes other than those for which the individual part and the
machine as a whole was originally designed and constructed.
Contact specialised companies for demolition of the machine.
Certain parts of the machine might be under pressure. Fix all parts capable of moving
by gravity.
The machine uses lubricating oil and grease. To neutralise the lubricant fluids which remain
attached to parts of the machine and cannot be reused, use degradable solvents of an approved
type. To drain off the recoverable lubricant fluids, empty the tanks and deliver the fluids to the local
authority in charge of disposal. Any batteries, accumulators, buffer batteries for electronic cards
and conditioners that may be found in the machine must also be disposed of in a suitable manner.
The manufacturer declines all liability for damage to persons or things that may derive from any
secondary use of single parts of the machine for functions or assemblies other than those
originally contemplated. The manufacturer recognises no implicit or explicit suitability for specific
purposes of any parts of the machine which are used again after final decommissioning in view of
demolition.
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195
196 BIESSE S.p.A. © - a727k0005.fm030518

E.1 Warranty
For information about the warranty, please refer to the documentation issued on purchase of the
machine.
E.2 Customer service

The service department employs technicians with a high level of knowledge and experience on the
models manufactured, gained through special training in our factory, who are able to service
machines on site.
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197
198 BIESSE S.p.A. © - a728k0006.fm030518

BIESSE S.p.A.
Registered office:
Via della Meccanica, 16
61122 Pesaro (PU) Italy
Tel. +39 0721 439100
Fax +39 0721 439150
sales@biesse.it
www.biesse.com

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Rover A Edge 1643 User Manual English

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Translation of the original instructions

Information about the publication

Code Issue Code of previous issue

Revision Description of updates

BIESSE S.p.A. © - 5801a0520.fm030518

4 BIESSE S.p.A. © - 5801a0520.fm030518

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5 Commands and indicator devices

6 Using the machine

7 Using the safety devices

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7.4 Operating section guards ................................................................................................. 93

8 Carrying out machining operations

10 Preparing the operating section

11 Preparing the magazines

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12 Preparing the work table

8 BIESSE S.p.A. © - 5801a0520TOC.fm030518

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D.1 Decommissioning ........................................................................................................... 247

E Guarantee and customer service

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This document complies with the indications in Machinery Directive 2006/42/EC.

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Documents supplied with the machine

The following is a list of the documents supplied with the machine:

12 BIESSE S.p.A. © - a701k0034.fm030518

A - Name of the manufacturer, address.

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1.1 Main safety warnings

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The machine must never be left unattended during operation.

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Tooling, maintenance and repairs

1.2 Safety devices

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DANGER - Live components! Before carrying out any operations on the

DANGER - Hot surfaces!

Compulsory safety gloves

Refer to the user manual

DANGER - Magnetic fields

PROHIBITION - access with pacemaker

DANGER - Danger area

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1.4 Residual risks

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2.1 General description of the machine

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2.2 General overview and main parts

A Base; this is the load-bearing structure of the machine.

B Work table; for the description, see page 28.

C Operating section; for the description, see page 32.

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26 BIESSE S.p.A. © - a702k0133.fm030518

U bPad terminal: for the description, see page 66.

V Bar code reader; for the description, see page 37.

AA Synchro; it loads and unloads the machine.

Information about the Synchro is given in the specific User Manual.

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2.3 Work table

Description of the work table elements