Use and Maintenance Instruction SHARP

WORK STATION
Mod.: SHARP
Use and maintenance instruction

manual
(translation of original instructions)
Document: MAN_SHARP0411-00it
Edition: 04/2011 Revision: 00.0
Date 08-04-2011
SHARP – Instruction Manual
Instruction manual for the machine models and the versions listed below.
MACHINE MODELS AND VERSIONS DESCRIBED IN THE MANUAL

MODEL DESCRIPTION
SHARP WORK STATION
- -
- -
- -
- -
GENERAL INDEX
General index 0
Foreword 1
Safety information 2
Machine description and technical data 3
Installation 4
Controls and use 5
Maintenance 6
Messages – Alarms 7
Cap. 0
- III/4 -
SHARP – Manuale di istruzione
“Page intentionally left blank”
Cap. 0
- IV/4 -
CHAPTER 1 – Introduction / Foreward
CHAPTER1
Foreword
Cap. 1
- 1/16 -
INDICE
1 Foreword................................................................................................................................. 1
1.1 Objective of the manual ........................................................................................................................... 4
1.2 Manual addressees ................................................................................................................................... 5
1.2.1 Description of symbols, deadlines and abbreviations adopted ................................................................... 7
1.2.2 Symbols adopted, glossary of terms and illustrations ................................................................................ 7
1.3 Glossary of safety terms .......................................................................................................................... 9
1.3.1 Description of the documentation provided with the machine .................................................................. 10
1.4 Use and conservation of documentation .............................................................................................12
1.5 Manual updating .....................................................................................................................................12
1.6 How to request additional copies .........................................................................................................12
1.7 Manufacturer’s Identification and Contact Details ..............................................................................13
1.8 Technical support service .....................................................................................................................14
1.8.1 How to request spare parts ...................................................................................................................... 15
Chap. 1
- 2/16 -
Cap. 1
- 3/16 -
1.1 Objective of the manual
As foreseen in the Machinery Directive 2006/42/EC, this manual provides information on safety and the
life phases of the machine (transport, installation, use, maintenance, dismantling).
This technical publication must be thoroughly read and understood before intervening at an operational
level on the machine or performing adjustment and/or maintenance interventions.
Exclusively abide by the instructions provided and in case of doubt always contact the manufacturer.
This manual provides basic information that the user must know before using the machine. Furthermore,
it contains information on machine maintenance required to keep the machine efficient and safe over
time.
To use the machine safely and to perform maintenance effectively, it is COMPULSORY to follow the
instructions provided in section 1.7.4 of the Machinery Directive 2006/42/EC that may also be included in
this manual or annexed herein.
The configuration of certain parts or devices described or illustrated in the manual may differ from the
ones supplied with machine without, however, compromising comprehens of the manual.
Chap. 1
- 4/16 -
1.2 Manual addressees
All operations described will be accompanied by a symbol (pictograph) corresponding to the operator
considered more suitable for the task; the symbols at the head of each paragraph correspond to the
addresses of the information provided. Please find below the instructions necessary for the identification
of the different professional figures.
A - Operators
Personnel with no specific skills capable of performing only simple tasks, such as
operating the machine using the controls located on the pushbutton panel, loading
and unloading the materials used in production with installed and enabled
protection guards and service settings.
B - Mechanical maintenance men

Personnel with specific mechanical skills capable of carrying out the tasks of the
"operators" and work with the machine in standard operating conditions with
disabled protection guards for maintenance and/or repair work. Not authorised to
work on the electrical system.
C - Electric/electronic maintenance men

Personnel with specific electrical skills capable of carrying out the tasks of the
"operators" and work with the machine in standard operating conditions with
disabled protection guards for maintenance and/or repair work. Not authorised to
work on mechanical parts.
D - Mechanical support technicians

Qualified personnel with specific mechanical skills capable of carrying out the
tasks of item B and further, they can skilfully make any possible settings and/or
replace mechanical parts. Not authorised to work on the electrical system.
E - Electrical/electronic support technicians

Qualified personnel with specific electrical/electronic skills capable of carrying out
the tasks of item C, work with the machine in standard operating conditions with
disabled protection guards and skilfully carry out any adjustments and/or
replacements of electrical/electronic parts. Not authorised to work on mechanical
units.
F- Lifting and handling equipment operator

Operator authorised to use devices designed to lif and handle materials and
machinery (strictly following the manufacturer’s instructions), in compliance with
the regulations in force in the machine user’s country.
DANGER!
The operator must not perform operations that are specified as the competency of
Maintenance personnel in this manual, unless the operator him/herself possesses the
necessary skills and authorisation to do so.
Certain information in the manual may address non-professional figures (e.g. cleaning personnel of the
premises where the machine is installed) who are not authorised to operate the machine, but may be
close to the premises for different reasons.
Cap. 1
- 5/16 -
G – Common Individual
Non-qualified individuals who are not suitable for carrying out any tasks intended
for the professionals described under items A, B, C, D, E, F and thus not
authorised to operate the machine.
INFORMATION!
Remember that information, training and supervision of common persons (par. G) is up to the
employer.
Chap. 1
- 6/16 -
1.2.1 Description of symbols, deadlines and abbreviations adopted
For optimum machine use, we recommend you are familiar with the terms and symbols contained in the
manual.
1.2.2 Symbols adopted, glossary of terms and illustrations
Information addressees
Refer to paragraph “1.2 Addressees of the manual”
DANGER, WARNING and INFORMATION notes
DANGER!
The information marked by the symbol on the left and this style denote dangerous situations for the
exposed individual.
WARNING!
The information marked by the symbol on the left and this style denote situations that may damage the
machine.
INFORMATION!
The information marked by the symbol on the left and this style denote useful suggestions and
recommendations for the user.
ENVIRONMENTAL INFORMATION!
The information marked by the symbol on the left refer to environment-related information, such as
handling hazardous substances, waste or recycling of the used materials produced by the machine.
Information symbols on the machine

Symbols are located on the machine to show the user there are residual risks during use. For the
explanation of these symbols see paragraph 2.4.
Cap. 1
- 7/16 -
INFORMATION!
The colours of the photos shown this manual illustrating the machine's structure or
constituting parts may differ from the ones installed on your machine. Remember that the
content of this manual refers to technically comparable machines that represent the machine
you possess and that different colours do not mean that the information provided is incorrect,
except for the cases in which a colour define aspects concerning the safety of exposed
persons.
If the illustrations of this manual are used to explain certain machine functions, they could differ from
the functions of your machine or they could be incomplete. If necessary, and in addition to the
instructions of this manual, it is advisable to consult the specific design of the component or unit on
which intervention is required. For the specific design (e.g. installation layout, assembly unit etc.)
please address the manufacturer.
INFORMATION!
For the sake of clarity, the machine is illustrated without panels and/or protection devices in
this technical manual. Do not use the machine when protection devices are dismantled,
removed and/or disabled.
Chap. 1
- 8/16 -
1.3 Glossary of safety terms
In compliance with European Directives 89/391/EEC, 89/654/EEC, 89/655/EEC, 89/656/EEC,

90/269/EEC, 90/270/EEC, 90/394/EEC, 90/679/EEC, 93/88/EEC, 95/63/EEC, 97/42/EEC, 98/24/EEC,
99/38/EEC and 2001/45/V concerning the improvement of workers’ safety and health during work,
please find below the definitions used in this instruction manual.
PERSONAL PROTECTIVE EQUIPMENT (PPE)

Personal protective equipment (PPE) is equipment worn by the operator to minimize exposure to a
variety of safety and health hazards at work, as well as any complement or accessory serving the same
purpose.
The following are not pieces of personal protective equipment:
• Work clothes and overalls that do not specifically protect workers’ safety and health;
• Equipment of aid and rescue services;
• Personal protective equipment of armed forces, police forces and service personnel for keeping
public order;
• Personal protective equipment of means of road transport;
• Sports materials;
• Self-defense and determent materials;
• Portable devices for the identification and reporting of risks and harmful factors.
WORKER
A person who is hired by an employer to perform labour, except people in charge of domestic and family
services, even with a special subordinate work relationship.
Partners of cooperatives or companies who perform their job on behalf of companies and organisations
and users of school, university and professional guidance and training services that have started working
for employers to facilitate or optimize their professional choices are intended as workers.
Students of educational and university institutes and the participants of professional training courses
where one can use laboratories, machines, devices and work equipment in general; chemical, physical
and biological agents are also considered workers. The forenamed subjects are not included in the
calculation of the number of workers for whom particular obligations arise in accordance with this decree.
EMPLOYER
The person who holds an employment relationship with the worker or, in any case, the subject who,
depending on the company type and organisation, is responsible for the company or the productive unit
and has decision making powers and expenses.
Cap. 1
- 9/16 -
1.3.1 Description of the documentation provided with the machine
To support and integrate the information contained in this technical manual, Paolino Bacci S.r.L.
provides the series of documents listed following.
A) INSTRUCTION MANUAL
The folder that contains this manual also contains the following documents:
• MACHINE TECHNICAL AND PERFORMANCE DATA: consult this document for the exact
technical features and performance data of the machine.
• SPARE PARTS CATALOGUE: consult this document to precisely identify all the parts making
up the machine so as to order the required spare parts.
• SYSTEM DIAGRAMS: provides the diagrams of all machine systems. The diagrams show not
only the circuits but also the codes required to order spare parts.
o Electrical system
o Pneumatic system
• DOCUMENTATION OF INSTALLED COMPONENTS: where present, this section provides the

documentation regarding the commercially bought components installed on the machine (motors,
pumps, valves etc.).
B) EC DECLARATION OF CONFORMITY OR DECLARATION OF ASSOCIATION

The EC Declaration of Conformity or declaration of association as per annex IIA or IIB of the Machinery
Directive No. 2006/42/EC is supplied, depending on the model, only for machinery intended for the
European market.
C) ELECTRICAL DIAGRAM
All the electrical diagrams for the electrical system installed on the machine are provided in a single
binder.
This document is for consultation by technical servicing experts.
D) PNEUMATIC DIAGRAM
All the electrical diagrams for the pneumatic system installed on the machine are provided in a single
binder.
This document is for consultation by technical servicing experts.
E) CNC USER MANUAL:

Contains information regarding the operations and procedures required for the creation of the
programmes that may be used with the basic software connected to the machine.
F) PITAGORA SOFTWARE MANUAL: (Optional)

Contains information regarding the operations and procedures required for the rapid creation and
optimisation of the programmes that may be used with this advanced software connected to the
machine.
Chap. 1
- 10/16 -
E) SUPPLY DOCUMENTATION
This binder contains all the information regarding the supply that complete the machine documentation
and include, as required, all the information not contained in the machine manual.
DANGER!
If the electrical or pneumatic system or a single component of either or both systems requires servicing,
please consult the attached diagrams.
NOTE: SUCH WORK MUST BE CARRIED OUT EXCLUSIVELY BY QUALIFIED PERSONNEL.
DANGER!
During component disassembly, all European Community Directives regarding worker safety must be
observed, especially as regards the use of personal protective equipment (PPE).
Cap. 1
- 11/16 -
1.4 Use and conservation of documentation
The consultation of this manual and the documentation provided with the machine is of paramount
importance in order to train users on how to use the machine correctly for productive purposes, on how
to abide by the safety standards and understand the residual risks in the product. The user is required to
know the content of the manual concerning the duties he/she is to perform.
Even if the manual provides information on how to use the machine correctly and residual risks
connected with machine use, it cannot replace the user’s experience; users must necessarily be
“experts” who are familiar with the sector and related operational and safety procedures.
The documentation delivered and its content must be checked upon receipt and upon completion of the
training session.
Keep the manual and all attached publications in a place that can be easily accessed by all users.
The information contained in this manual is property of Paolino Bacci S.r.L.; total or partial reproduction
is forbidden without prior authorisation. If you need additional copies of the documentation intended for
machinery users, please send a request to Paolino Bacci S.r.L.
If doubts arise during consultation of this manual, please contact Paolino Bacci S.r.L. before performing
any operation.
Paolino Bacci S.r.L. reserves the right to modify the characteristics of the product and content of this
manual without prior notice.
Paolino Bacci S.r.L. reserves the right to provide a soft copy of the manual. The publication on file is in
PDF (Portable Document File) format; for consultation you need to set up the Adobe® Acrobat®
Reader™ software beforehand. Instructions on installation and use of the Adobe® Acrobat® Reader™
software are available together with the set up file. Further information can be found on the website of
Adobe Systems Incorporate, from which it is possible to download a free version of the Adobe®
Acrobat® Reader™ software.
1.5 Manual updating
If modifications or updates are performed during the lifecycle of the machine by Paolino Bacci S.r.L., a
reviewed copy of this document will be sent to the customer. All contractual copies of the customer will
be destroyed and replaced upon prior contact with Paolino Bacci S.r.L..
1.6 How to request additional copies
Further copies of this document apart from the contractual ones are available upon request by sending a
regular purchase order to Paolino Bacci S.r.L..
Chap. 1
- 12/16 -
1.7 Manufacturer’s Identification and Contact Details
Company name:
PAOLINO BACCI S.R.L.
Address:
Viale Palermo, 32
56021 CASCINA (PI) - ITALY
Tel. :
+39 050 754 91
Fax:
+39 050 754 975
Fax - assistance:
+39 050 975
E-mail – general information:

bacci.info@bacci.com
E-mail – assistance:
service@bacci.com
E-mail – spare parts:

service@bacci.com
Website:
www.bacci.com
Cap. 1
- 13/16 -
1.8 Technical support service
To guarantee our customers optimum use of the product purchased, Paolino Bacci S.r.L. provides the
following technical support services:
Customer service:
Office services provided by qualified operators, who are able to diagnose and decide upon the
interventions required to restore damaged and malfunctioning machinery components. These services
are provided mainly over the phone; they provide assistance to maintenance technicians during
troubleshooting and repair works. Technical assistance uses the diagnostic service provided via
MODEM if it is installed on the machinery.
Spare parts support:

Office service provided by qualified operators who can be contacted to request spare parts for the
machinery.
Support services are open during the working hours and days mentioned in the following tables. The
office hours outlined in the tables below are based on the time zone of Rome (GMT+1,00 h).
WORK DAYS (FROM MONDAY TO FRIDAY) 1 of 1

HOURS SERVICE PROVIDED
Customer Service
8.00 – 18.00 (GMT + 1.00h)
Spare parts support
Paolino Bacci S.r.l.

Viale Palermo, 32
Italy - 56021 Cascina (PISA)
Tel.+39 050 754 91
Fax. +39 050 754 975
service@bacci.com
www.bacci.com
Remember to always provide the data specified on the machine’s identification plate.
Ordinary maintenance is the responsibility of user personnel. Servicing on electrical, pneumatic, etc. systems must
be carried out by qualified personnel, duly authorised by Paolino Bacci S.r.l.
Chap. 1
- 14/16 -
1.8.1 How to request spare parts
Spare parts must be ordered by contacting the spare parts service and specifying, in the following order:
• Serial number
• Type of machine
• Paolino Bacci S.r.L. warehouse code*
• Description*
• Quantity*
NOTE: * If these data are not available, contact la Paolino Bacci S.r.L.
INFORMATION!
The codes and description of the parts to be ordered are contained in the "Spare parts book" or on the
electrical, pneumatic, hydraulic etc. diagrams provided with the machine.
DANGER!
Original spare parts must be used. The customer will be fully liable for replacement of machine parts with
non original spare parts or parts that are not authorised by Paolino Bacci S.r.L. and this will result in the
immediate annulment of the warranty and of all applicable European Community Directive certifications.
Machine performance rates, operating efficiency and safety are guaranteed only by the use of original
parts, as provided for by the original machine design.
Paolino Bacci S.r.L. is not responsible for malfunctions, breakdowns and damage to persons or
property deriving from the use of non original spare parts.
Cap. 1
- 15/16 -
Chap. 1
- 16/16 -
CAPITOLO 2 – Informazioni di sicurezza
2
CHAPTER
Safety information
Chap. 2
- 1/36 -
CHAPTER CONTENTS
2 Safety information.................................................................................................................. 1
2.1 Personnel Qualification ............................................................................................................................ 3
2.2 General Safety Rules ................................................................................................................................ 4
2.3 Use of Personal Protective Equipment (PPE) ........................................................................................ 6
2.3.1 Minimum equipment ................................................................................................................................... 7
2.4 Safety and warning signals ..................................................................................................................... 8
2.4.1 Description of hazard images ..................................................................................................................... 8
2.4.2 Description of prohibition images ............................................................................................................. 12
2.4.3 Description of obligation symbols ............................................................................................................. 13
2.4.4 Description of miscellaneous and customised symbols ........................................................................... 14
2.4.5 Location of the symbols on the machine .................................................................................................. 15
2.5 Foreseen Use ..........................................................................................................................................17
2.6 Reasonably foreseeable misuse ...........................................................................................................18
2.7 Information regarding the work environment ......................................................................................19
2.8 Illumination and airing ...........................................................................................................................19
2.9 Dust removal system ..............................................................................................................................19
2.10 Vibrations ................................................................................................................................................19
2.11 Electromagnetic emissions ...................................................................................................................20
2.11.1 Noise risk typical of the wood machining sector ....................................................................................... 21
2.12 Elimination or reduction of risks during machine designing ............................................................21
2.13 Safety devices installed on the machine ..............................................................................................22
2.14 Work stations ..........................................................................................................................................25
2.14.1 Identification of work areas....................................................................................................................... 27
2.14.2 Responsibilities of the operator in charge of running the machine ........................................................... 27
2.14.3 Responsibilities of the operator in charge of loading/unloading the machine ........................................... 27
2.14.4 Warnings regarding conduct inside the machine enclosure ..................................................................... 28
2.15 Safety rules for spindle use and maintenance ....................................................................................29
2.16 Safety rules for use and maintenance of mechanical components ..................................................29
2.17 Safety rules for enclosure use and maintenance ................................................................................30
2.18 Safety rules for programming ...............................................................................................................30
2.19 Safety rules for electrical maintenance ................................................................................................31
2.20 Safety rules for pneumatic maintenance .............................................................................................32
2.21 Typical risks present during machine readying ..................................................................................33
2.22 Residual risks..........................................................................................................................................34
2.23 Residual risks for the operator..............................................................................................................34
2.23.1 Tool holder / tool ...................................................................................................................................... 34
2.23.2 Noise ........................................................................................................................................................ 35
2.23.3 Crushing of the upper limbs ..................................................................................................................... 35
Chap. 2
- 2/36 -
2.1 Personnel Qualification
This manual provides instructions on use and maintenance, lists the hazards and residual risks of the
machine but does not take into account the risks of the work environment and the specific work
modalities of the company using the machine.
As to the choice of the personnel responsible for operating the machine, it is up to the
employer to make sure that the duties assigned to workers are compatible with the
qualification and level of information and training required. It is indispensable that
qualified personnel such as operators, maintenance personnel and technicians, for
definitions see chapter 00, is exclusively made up of Expert Persons (EXP), and
Informed Persons (INFP) and not Common Persons (COMP).
INFORMATION!
Remember that it is up to the employer to inform and train the personnel
who is going to run the machine; this must be done on the basis of
available knowledge, information and instructions, before working activities
are assigned to workers.
The instructions of use and maintenance provided in this manual are not addressed to
Common Persons (COMP), who are not authorized to run the machine. However,
information on the safety of these persons is provided in this manual to facilitate the
employer to fulfil his duty of instruction and supervision.
INFORMATION!
Remember that instruction and supervision of common persons is up to the
employer.
Chap. 2
- 3/36 -
2.2 General Safety Rules
A series of general rules on the correct use of the machine, which must be added to the specific
information on the operations to be performed, is listed below.
It is up to the purchaser:
• to conduct a risk evaluation of the machine concerning the characteristics of the

installation environment and those of the company working modalities, assess and
understand the residual risks included in the manual in order to take the necessary
safety measures (personal protective devices, working procedures etc.).
• Choose the suitable personnel for the use and maintenance of the machine and
train it.
• Define safe working processes and authorisation to working methods.
• Choose and equip personnel with suitable personal protective equipment (PPE) for
the tasks to carry out.
• Check that personnel is mentally and physically fit to perform the tasks assigned.
The user actively participates in maintaining a high level of machine safety in the
long term. Please consider the following aspects concerning one’s responsibility
for use:
• Before starting any operation, read the instruction manual and abide by the safety
operational rules.
• Comply with the warnings located next to the dangerous areas.
• Use suitable clothing for the tasks to perform; avoid clothing with flapping parts and
do not use any hooking accessories to avoid entanglement and dragging.
• Always use personal protective equipment (PPE) such as safety boots, gloves,
googles etc., if necessary, in accordance with the specific instructions of the
manual and company standards.
• Before performing any operation, take off watches, bracelets, rings, chains and pull
up your long hair or put on a cap.
• If there are considerable noise producing sources (over 80 decibel) always use
suitable ear protective devices (earmuffs, earplugs).
• Take on ergonomically correct positions to avoid strains or excessive tiredness
while performing these tasks.
• Make sure that there are no production residues or superfluous objects in the
working area or on the machine.
• Check the efficiency of all machine protections and safety devices every day and
before use; do not operate in case of malfunction; before using the machine restore
effective operation.
• Do not run the machine if protections have been removed.
• Do not circumvent the guards and safety devices voluntarily.
• Keep the characteristics of the machine and avoid making any modifications,
altering the function of the machine or tampering with protections or safety devices.
• Do not use the machine if there are operational malfunctions, defects, faults or
damage.
Chap. 2
- 4/36 -
Maintenance personnel is required to:
• Implement a correct machine maintenance timetable.

• Check the state of the machine on a daily basis and immediately replace parts that
are worn or damaged.
• Do not perform maintenance or lubrication operations while the machine is moving.
• Perform all the operations foreseen for the machine to be safe.
• Use appropriate tools to repair the machine.
• Remove all tools used for maintenance from the work area.
• Restore all protections and safety devices that have been removed and check that
they function correctly.
Chap. 2
- 5/36 -
2.3 Use of Personal Protective Equipment (PPE)
If the use of personal protective equipment (PPE) is required according to the manual or signs/warnings
on the machine, remember that the choice of the most suitable type for the level of protection required is
up to the employer.
Personal protective equipment is defined by Directives 89/686/EEC and 89/656/EEC. In Italy reference
must also be made to Ministerial Decree No. 277/91, which has transposed into national law Council
directives 80/1107/EEC, 82/605/EEC, 73/477/EEC, 86/188/EEC and 88/642/EEC. The use of PPE is
indicated in the manual and on the machine with the symbols listed below:
Symbol Explanation
You are obliged to use protective clothing.
You are obliged to use PVC protective clothing.
You are obliged to use safety boots.
You are obliged to use protective gloves against general mechanical

risks.
You are obliged to use protective gloves against heat or fire related
risks.
You are obliged to use protective gloves against acides and corrosive
agents.
You are obliged to use protective gloves against chemical risks

(arising from lubricants).
You are obliged to use a safety helmet.
You are obliged to use safety goggles with side shields.
Chap. 2
- 6/36 -
Symbol Explanation
You are obliged to use a shield protector.
You are obliged to use a respiratory facial mask (facemask for

covering the nose and nostrils).
You are obliged to use hearing protection devices (earplugs or

earmuffs).
You are obliged to use a safety belt for work at height.
2.3.1 Minimum equipment
The minimum workers’ personal protective equipment (PPE) the employer is required to provide
comprises the following devices:
Symbol Explanation
You are obliged to wear safety clothing.
You are obliged to wear safety shoes.
You are obliged to wear safety gloves against general mechanical

risks.
You are obliged to wear hearing protection or earmuffs.
You are obliged to use safety goggles with side shields.
It is indispensable as a minimum requirement that the operator uses the personal protective equipment
(PPE) mentioned above during all stages of machining of the machine.
Therefore, reference will be made to specific PPE as operators are considered to be equipped with the
devices mentioned above.
Chap. 2
- 7/36 -
2.4 Safety and warning signals
2.4.1 Description of hazard images
DANGER IMAGES 1 of 4
SYMBOL DESCRIPTION OF HAZARD INDICATIONS/WARNINGS
If manual equipment is used, take care to
prevent cuts and shears. Follow the safety
Cutting, shearing
provisions and wear the appropriate PPE
(safety gloves against general risks).
Keep a safe distance from the indicated
zones to prevent guillotining or excision
Guillotining, excision hazards due to the movement of machine
parts or to the presence of sharp parts.
Follow the safety provisions.
zones to prevent snagging and dragging
Snagging and dragging hazards with the product or moving belts
and consequent dragging. Follow the
safety provisions.
Keep a safe distance from the areas
indicated so as to avoid dangers of
Dragging
dragging between rollers and rotating
components. Follow the safety provisions.
zones to prevent snagging and dragging
Snagging and dragging
with moving members or mechanical
components. Follow the safety provisions.
zones to prevent limb crushing. Do not
insert your hands into the sliding guides of
the machine units to prevent hazards due
Crushing of upper limbs
to the movement of the devices. Watch out
for all movements of the unit where the
image is located. Follow the safety
provisions.
zones to prevent lower limb crushing.
Crushing of lower limbs Watch out for all movements of the unit
where the image is located. Follow the
safety provisions.
Chap. 2
- 8/36 -
IMAGE HAZARD DESCRIPTION INDICATIONS/WARNINGS
Be careful near protruding or sharp
Impact machine parts. Follow the safety
provisions.
Be careful near protruding or sharp

Shock hazard (head or parts of the
machine parts and any hindrances. Follow
body) or snagging
the safety provisions.
Watch out for holes in the floor and for any

Falling in openings/hatches
ports or trap doors.
Watch out for objects or slippery
substances on the floor. Immediately
Slipping and falls
remove the objects and clean the floor
from substances.
Watch out for foreign matter laying on the
Tripping and falls floor that could cause tripping. Immediately
remove the obstacles.
In case of overhead work. Comply with the
Danger of falling from above safety dispositions and adopt the
appropriate PPE (safety belt).
Danger of falling due to height Watch out for any differences in the height
differences of different machine zones.
Be careful near the indicated zones.

Maintain a safety distance in order to avoid
dangers stemming from direct or indirect
Dangers of an electrical nature contact with parts or equipment with
voltage. Follow the safety provisions and,
in case of operations, wear the appropriate
PPE (safety gloves against electrical risks).
Be careful near the indicated zones.
Maintain a safety distance to prevent burns
caused by high temperatures. Follow the
Heat-related hazards
safety provisions and wear the appropriate
PPE (safety gloves against heat and fire-
related hazards).
Follow the safety provisions and adopt the
Hazards generated by noise for
appropriate PPE (ear safety devices or
values above 80 Db
soundproof headsets).
Chap. 2
- 9/36 -
Be careful for the presence of chemicals or
toxic products that may be present.
Contact with the skin is harmful for the
workers' health. In case chemicals must be
Corrosive agents used refer to the warnings and instructions
shown on the product sheets. Follow the
PPE (safety gloves against acids,
corrosive agents).
Be careful for the presence of chemicals or
toxic products that may be present.
Contact with the skin is harmful for the
workers' health. In case of use, refer to the
Irritating agents warnings and instructions shown on the
product sheets. Follow the safety
(safety gloves against acids, irritating
agents).
Be careful for the presence of flammable
agents or products that may be present. In
Flammable agents case of use, refer to the warnings and
instructions shown on the product sheets.
Always stay outside the protections which
Machine with automatic start-up permit the start-up of automatic cycles of
the machine.
zones to prevent various hazards during
Radio-controlled components remote controlled operations. The machine
may start automatically. Follow the safety
provisions.
Pay attention to the presence of residual
energy in all or part of the circuit. Always
disconnect the electricity before performing
maintenance work. Use the charts to
Residual electrical energy disconnect parts of the installation when
necessary. Pay particular attention to the
orange-coloured circuits which remain
under voltage even after the disconnection
of the electricity.
Chap. 2
- 10/36 -
Be careful near the indicated zones. Keep a
safe distance to prevent the injection of
fluids under pressure (pneumatic or
Injection of pressurised fluids
hydraulic system). Follow the safety
(safety screen).
Pay attention to the intense magnetic fields
near the pictogram. Persons wearing
Intense magnetic fields pacemakers must maintain a safety distance
from the machine or parts of it when it is
dismantled for maintenance.
Check that there are no potentially falling
objects or cables that could become
entangled. Do not stand or move during the
Suspended loads
load lifting and handling steps. Follow the
PPE (safety helmet).
General hazard
Adopt the precautions indicated in the
(the image is completed with the
warning text.
hazard description)
Chap. 2
- 11/36 -
2.4.2 Description of prohibition images
PROHIBITION IMAGES 1 of 1
IMAGE DESCRIPTION MEANING
No access to unauthorised personnel.

Access prohibited
It is forbidden to work without guards or

protection with exposed chains, gears or
moving components. Install any safety
Prohibition to remove the guards
devices and guards removed during
maintenance before starting the machine.
It is forbidden to perform repair operations
Prohibition to fix or adjust moving and/or adjustments to the machine, or
parts components, when it is moving. Follow the
safety provisions.
No water should be used for extinguishing
fires due to the presence of live
Prohibition to use water to components. Use powder extinguishers or
extinguish fires similar devices for the extinguishing
operations in the event of a fire. Follow the
safety provisions.
Do not climb onto the machine or machine
Prohibition to climb onto the
parts that are not designed to bear the
machine or machine parts
weight of a person.
Prohibition to climb on machine Do not climb on machine frames or safety

frames or safety panels. panels.
Chap. 2
- 12/36 -
2.4.3 Description of obligation symbols
OBLIGATION SYMBOLS 1 of 1
IMAGE DESCRIPTION MEANING
It is mandatory to disconnect and isolate the
Obligation to disconnectn and sources of energy before starting
isolate the sources of energy. maintenance and adjustments on the
machine.
It is mandatory to refer to the instructions
(User’s manual and Maintenance, wiring
Use instructions
diagrams, etc.) provided with the machine,
before operating it.
It is mandatory to use personal locks to block
Use of padlocks for the blocking
the electrical system, pneumatic supplies etc.
of the supply or access to the
or to access the machine and avoid untimely
machine
start-ups during works.
Using personal protective Please refer to the paragraph “2.4 Use of

-
equipment (PPE) personal protective equipment (PPE).
Chap. 2
- 13/36 -
2.4.4 Description of miscellaneous and customised symbols
MISCELLANEOUS AND CUSTOM IMAGES 1 of 1

SYMBOL MEANING
Indication of the machine or its
component centre of gravity. This
Machine barycentre
indication is essential to arrange proper
machine or component lifting.
Indication of the machine lifting point.
This indication is essential for proper
Lifting point
machine or component lifting and
transport.
Chap. 2
- 14/36 -
2.4.5 Location of the symbols on the machine
1
3,4
POS. SYMBOL DESCRIPTION
1 Lifting point
2 Electrical hazard
Moving parts.
3 Danger of being snagged and
dragged
Chap. 2
- 15/36 -
POS. SYMBOL DESCRIPTION
Moving parts.
4 1 Danger of being snagged and
1 dragged
2 Crushing hazard
3 Lifting point
4 Electrical hazard
3 2
Chap. 2
- 16/36 -
CHAPTER 2 – Safety Information
2.5 Foreseen Use
The machine in question is designed and manufactured to mill, bore and cut wood materials, wood
derivates or other similar materials (*). It must not be used to machine other types of materials; using the
machine for purposes or in ways that differ from that for which it was intended may cause damage to the
machine and engender hazards for the operators.
To avoid possible misuse of the machine, we recommend taking into consideration the consistency of
the material in relation to the power of the spindle motor fitted on the machine. Also, we recommend not
using the machine for pieces that do not fit into the maximum working runways specified in the
“Technical and Ambient Data” section of this manual.
* Similar material: materials whose machining parameters for milling, boring and cutting are comparable
to the machining parameters for wood materials (for example: ureic resins, PVC, ...).
Chap. 2
- 17/36 -
2.6 Reasonably foreseeable misuse
An assessment of reasonably foreseeable misuses shows that the machine may not be used in the
following cases:
• To work materials different from those specified (sheet metal, marble, cardboard, etc.) or that do
not respect the technical data regarding machining limits (machining parameters).
• In environments classified according to the 1999/92/CE ATEX European Community Directive,
where, in normal working conditions an explosive atmosphere exists or may probably form for
short or long periods of time, unless the machine has been specifically requested for use in such
environments.
• Outdoors or in environments whose characteristics do not respect the technical data regarding
the work environment present in the instruction manual.
• If used by operators that are not of minimum work age based on the laws in force in the
respective countries of use.
• If used by operators who have not been previously trained for use of the machine, informed
regarding the risks and trained on safety issues.
• Without using the personal protective equipment (PPE) as required by the user instructions and
by current regulations in force in the country of use.
• Not abiding by the installation, use and/or maintenance information that are described in the
instruction manual.
• To perform installation, use and maintenance operations that are expressly forbidden in the
instruction manual.
• If unauthorised alterations have been made on the machine.
• If guards of safety devices fitted on the machine have been bypassed even temporarily.
• Continued use of the machine even when it shows signs of malfunction or is partly
malfunctioning.
• If used contemporaneously by two or more operators who may put each other or other exposed
persons in danger.
• If started-up by the sole operator designated for use, without having checked that there are no
exposed persons in the machine danger areas before using the manual controls.
INFORMATION!
In performing the risk analysis, the Manufacturer, in compliance with current laws, did not take into
account (nor was the relative information available) risks associated to the work environment and
specific work procedures of the user company.
Chap. 2
- 18/36 -
2.7 Information regarding the work environment
The machine is designed is designed to work in closed, well-lit and well-aired environments. The
temperature and humidity of the work environment must be within the range specified in the technical
data provided with this manual.
Ambient conditions different from those specified may cause serious damage to the machine, especially
electronic equipment.
Installing the machine in work environments that do not meet specifications renders the warranty for
replacement parts null and void.
Storage of the machine while it is not being used must be done taking all precautions provided for in this
manual. The ambient temperature and humidity of the locale where the machine is stored must be within
the limits specified in the specific technical data provided along with this manual.
2.8 Illumination and airing
The work environment where the machine is to be installed must have lighting that is adequate to the
work to be carried out, avoiding shadow areas, annoying strong lights and dangerous stroboscopic
effects.
Please consult current regulations regarding lighting of work places. Please note that inadequate lighting
may lead to risks for exposed persons.
The machine must work in an environment that is properly aired.
2.9 Dust removal system
The machine is not equipped with a dust removal system.

For correct and safe use, the machine must be connected to a dust removal system that meets the
following specifications.
Specifications of the machining dust vacuum system
CRITERIA SPECIFICATION
Number of suction mouths 2
Mouth diameter 120 - 160 mm
Vacuuming speed 20 - 25 m/s
Overall flow/min. 2500 mc/h
2.10 Vibrations
Mechanical vibrations which, if transferred to the hand-arm joints and/or to the entire human body create
a risk for the worker’s health and safety have been assessed in accordance with European Community
Directive 2002/44/CE.
Chap. 2
- 19/36 -
2.11 Electromagnetic emissions
The machine contains electronic components subject to regulations regarding Electromagnetic

Compatibility, influenced by conducted and irradiated emissions.
The values of such emissions are conformant to regulation requirements thanks to the use of
components that are conformant to the Electromagnetic Compatibility directive, appropriate connections
and the installation of filters where required.
Hence, the machine is conformant to European Community Directive 89/336/CE regarding

Electromagnetic Compatibility (EMC).
Chap. 2
- 20/36 -
2.11.1 Noise risk typical of the wood machining sector
The wood machining sector is traditionally characterised by machining work with high noise exposure
levels, due to a series of concomitant factors such as the use of tools that generate powerful noise levels
in work environments that are often relatively small. The work logistics typical of wood-working plants,
where the interchangeable nature of the tasks and variable machining times are the norm, do not allow
for a clear and precise definition of the workers’ exposure to noise.
Here below, purely a san example, are the machine’s noise emission levels during a typical work cycle:
Material: beech wood parts; rough-milling, average thickness 25 mm

Machining: milling and tenoning
Tools: HM hard metal milling machine; diameter 10 mm
HM milling machine; diameter 18 mm
Milling machine for tenoning
Milling machine for rough-milling; diameter 30 mm
Noise measurement without the use of a dust removal system.
ACOUSTIC EMISSIONE
Background noise 68.50 dB(A)
Run on empty 74.60 dB(A)
Work cycle 78.80 dB (A)
During machining, especially when the tool enters the material, noise peaks up to 109.80 dB (A) were
reached.
The noise measurements shown above are emission levels and not necessarily safe working levels.
While there is a correlation between emission levels and exposure levels, this may not be used reliably
to determine whether or not further precautions are required.
Factors influencing the real operator exposure levels include:
• Duration of the exposure,

• Characteristics of the work environment,
• Other noise sources, for example the number of machines other machining nearby.
Moreover, admissible exposure levels may vary from one country to another.
However, the information provided above is sufficient to allow the machine user to better assess hazards
and risks.
2.12 Elimination or reduction of risks during machine designing
When the machine was being designed, one or more solutions among those recommended in UNI EN
ISO 12100-1:2005 and UNI EN ISO 12100-2:2005 Standards were adopted.
Chap. 2
- 21/36 -
2.13 Safety devices installed on the machine
1
4
3
1
POS. NAME DESCRIPTION

The machine has emergency pushbuttons located in the following
positions:
on the main pushbutton panel
1 Emergency pushbuttons on the left and right bench pushbutton panels
on the tool change safety guard (optional)
These pushbuttons turn off the machine and cut-off power to the
axes and spindles.
The enclosure consists in an all-around safety guard that protects
2 Enclosure the entire machine. The enclosure may be accessed through
doors fitted with interlocked microswitches, for safe access.
The access doors are fitted with interlocked microswitches for
3 Interlocked microswitch
safe access.
The sliding doors are used to access the machine. The doors are
fitted with microswitches that signal when they are opened. To
Sliding doors with sensitive
4 avoid being crushed when the door closes, they have a sensitive
edges
edge; if the edge is touched as the door closes, the door will
reopen.
Chap. 2
- 22/36 -
6
5

This consists in a transparent Lexan panel that
5 Intermediate dividing panel
divides the two loading areas.
This consists in a transparent Lexan panel that
6 Dividing panel
divides the loading area from the work area.
The pressing devices that block the piece close at
reduced pressure. The pressure increases to the
7 Low pressure device
maximum pressure value when the access door
has closed.
Chap. 2
- 23/36 -

The remote pushbutton device has a Life Man
Switch.
• Press the switch to confirm operations with
8 2-hand control
the remote pushbutton device.
When the switch is released, operations using the
remote device terminate.
Chap. 2
- 24/36 -
2.14 Work stations
The machine is designed and manufactured taking considering only one operator, whose task it is to
supply the machine for production and remove the machined piece, as well as to man the manual
controls, only after having verified that there are no exposed persons in the danger areas.
INFORMATION!
During regular machine work, operators may occupy only the areas specified below.
INFORMATION!
The work area must always be kept clear, so that nothing may interfere with the operator’s freedom of
movement.
In the event of an emergency, designated personnel must be guaranteed immediate access to the
machine.
1 2
Pos. Name Position

In front of the work table for
1 Left loading / unloading area: loading/unloading of the material to be
machined.
In front of the work table for
2 Right loading / unloading area: loading/unloading of the material to be
machined.
Chap. 2
- 25/36 -
Pos. Name Position

In front of the main pushbutton panel to
3 Control and programming area operate the commands and control correct
machine operation.
Chap. 2
- 26/36 -
2.14.1 Identification of work areas
The left and right loading / unloading areas (position 1 and 2) are the only areas inside the
machine enclosure where operator in charge of loading / unloading may access.
The area near the main pushbutton panel is one of the main work areas of the operator in
charge of running the machine, to activate the control, programme the machine and
controlling correct machine operation. To install tools on the machine and carry out
maintenance, the operator must access the enclosure.
2.14.2 Responsibilities of the operator in charge of running the machine
Before starting work, the operator in charge of running the machine must be perfectly
familiar with the location and operation of all the controls and the machine features. The
machine may be used only by operators instructed as to its use and who have read the
instructions contained in this manual thoroughly. All instructions, warnings and general
accident prevention rules contained in this manual must be fully respected.
2.14.3 Responsibilities of the operator in charge of loading/unloading the machine
Before starting work, the operator in charge of running the machine must be perfectly
familiar with the location and operation of all the controls and the machine features. The
machine may be used only by operators instructed as to its use. Loading and unloading
personnel must have read the instructions regarding the loading and unloading of the
pieces to be machined and the general safety instructions contained in this manual. All
instructions, warnings and general accident prevention rules contained in this manual
must be fully respected.
Chap. 2
- 27/36 -
2.14.4 Warnings regarding conduct inside the machine enclosure
• Work inside the enclosure may be carried out only by qualified personnel. Before
beginning any such work, a “MAINTENANCE IN PROGRESS” sign must be posted.
• The doors must be blocked open during work inside the machine enclosure.
• Before accessing the enclosure, remove the key from the “Use mode” selector
switch. Keep the key on you during work.
• In the event of an emergency, press one of the emergency pushbuttons or touch the
edge of one of the loading/unloading doors and exit the enclosure through one of
the doors.
Chap. 2
- 28/36 -
2.15 Safety rules for spindle use and maintenance
Before starting spindle rotation, it is fundamental to:

• Make sure that the tools have been fitted only after having cleaned the conical spindle seat.
• Make sure that the tools are fastened tightly.
• Make sure that the number of revolutions programmed is less than the maximum number
permitted for the tools fitted on the machine.
• Make sure that the size and weight of the tool as well as the number of programmed revolutions
are compatible with the spindle power characteristics.
• Make sure that the programmed direction of rotation is correct for the tools fitted when they are
working.
• If a spindle must rotate in the opposite direction with respect to the standard turning direction,
check the presence and tightness of the counter-block ring (or of other, appropriate blocking
systems).
• If there is an all-around guard or a cabin, make sure that all the doors are closed and that nobody
is inside the enclosure or cabin.
• Check tool wear and conditions and make sure that they are not chipped or deformed in any way
that may compromise tool balance.
• Make sure that tools, spaces and tool shafts meet the specifications contained in the machine’s
instruction manual.
Before bringing the spindle to the programmed number of revolutions per minute, turn on the spindle at a
reduced speed of rotation and make sure (by listening to the noise) that the tools fitted on the spindle are
balanced correctly and do not generate excessive vibrations.
Before disabling spindle rotation during machining of a piece, make sure that the tool is not in contact
with the piece and/or parts of the template.
2.16 Safety rules for use and maintenance of mechanical components
Do not remove safety devices (guards and bellows) except during ordinary and extraordinary
maintenance. Never start the machine if the safety guards are not in place.
Do not touch moving or rotating mechanical parts.
Do not carry out maintenance or clean the machine when it is running.
Do not carry out any machine movement if someone is inside the cabin.
Do not enable blocking devices if someone is inside the cabin

.
Chap. 2
- 29/36 -
2.17 Safety rules for enclosure use and maintenance
Periodically check the proper functioning of the safety microswitches on the cabin doors.
Periodically check the integrity of the panels.
Do not tamper with the safety devices in any way and, specifically, do not remove the safety
microswitches.
2.18 Safety rules for programming
Before starting any programme, including automatic homing, we recommend making sure that the
remote keypad is enabled, in order to be able to reduce the speed if needed, and stop machine
movements.
When carrying out a programme for the first time, by-pass spindle start-up (with all safety measures
described in the respective section) and work at reduced speed using the potentiometer on the keypad.
Abide by technological parameter for tools and machining, especially as regards machining speed and
the number of spindle revolutions.
Do not use the potentiometer to reduce or adjust speed during normal work cycles.
Chap. 2
- 30/36 -
2.19 Safety rules for electrical maintenance
Knowledge of basic first aid is required in the event of accidents of an electrical nature. Before starting
electrical maintenance, the designated work supervisor must make sure that safety rules have been
abided by. Comply with current national safety regulations for maintenance on electrical systems.
• All work must be carried out using only appropriated and isolated tools.
• Abide by safety signs! Do not remove the safety signs.
• Before carrying out maintenance, adopt the following precautionary measures.
Follow the procedure below.

STEP OPERATION RESULT
Disconnect electrical power. When cut off, the machine is not live. The
1 Turn the main switch to "0". connections up to the main switch are still
live.
Wait a few seconds before opening the The inverter capacitor loads only a few
2 electrical cabinet. seconds after the main switch has been
turned off.
Adopt all safety measures required
3 against machine start-up. Padlock the
main switch.
Verify that electrical power does not reach
4
the machine.
• Do not insert or remove plugs if the machine is powered.

• The yellow/green safety lead (earth) must not be disconnected, removed or used for other
purposes. At the end of all maintenance, check that it is working efficiently!
• Use only original spare parts. P. Bacci S.r.l. will not be liable if non original electrical components
are used.
• If components are replaced, check that the safety and control devices of the new component are
properly set and adjusted.
• Safety and control devices required for machine safety must not be disconnected, moved or
modified without previous authorization. These devices may be used only for the intended
purposes. Do not modify circuits, components, etc. or machine software!
• At the end of machine maintenance and repair, tighten the electrical connection screws in the
area involved in the maintenance or repair work.
• At the end of maintenance and repair, check all safety devices.
• Do not wet working electrical machine components nor expose them to humidity.
• Before cleaning electrical equipment, cut-off power!
• Keep the doors of the main cabinet and the various electrical boxes closed!
• In case of fire, cut-off electrical power to all the components of the electrical system that are
hazardous or exposed to risk, provided that cutting-off the power to such components does not
generate further risks. Use only appropriate fire-fighting measures and equipment.
Chap. 2
- 31/36 -
• Do not use compressed air to clean the machine or the electrical cabinet, but only industrial
vacuums.
2.20 Safety rules for pneumatic maintenance
• Maintenance may be carried out only by qualified maintenance technicians. Before beginning any
such work, post a “MAINTENANCE IN PROGRESS” sign, stop the machine and disconnect
electrical and pneumatic power supplies. In order to do so, close the main pneumatic supply
valve (pos. 1), then turn off the main switch (pos. 2) and adopt all safety measures required to
avoid machine start-up.
• To work on the pneumatic system, first discharge all pressure by acting on the EMERGENCY
STOP pneumatic switch (pos. 3) discharge residual compressed air.
• For proper disassembly and reassembly, use appropriate tools and means.
• Use only appropriate lifting equipment. Before lifting the load, check the weight, the position of
the barycenter and the fastening points. Please read the specific lifting instructions in the
installation chapter.
• Before starting up the system, check there are no residual defects.
• Make sure that the machine safety devices are present and working. Do not remove the safety
devices and other machine protections. If any such device must inevitably be removed, for
example for maintenance and repair, upon completion of the work, replace them immediately and
check proper functioning.
• When handling oils, greases and other chemical substances, respect current safety regulations in
force regarding handling of such substances.
Chap. 2
- 32/36 -
2.21 Typical risks present during machine readying
RISK FACTORS
DESCRIPTION EXPECTED DAMAGE
PREVENTION
NAME (estimate if (subjectivity if detected)
detected)
Muscular-skeletal injuries,
Manual handling of discopathy. Use of compressed air
loads Panel lifting. pushers
Subjective disorders: And/or other devices.
Dorsal-lumbar pain.
Insertion of tool Handling sharp

Cutting hands and fingers Use of safety gloves
holder / tool tools
Chap. 2
- 33/36 -
2.22 Residual risks
The machine is manufactured and protected to provide maximum safety only if used in respect of all
specifications. The machine is fitted with safety devices to protect worker health and safety.
Some risks cannot be completely eliminated. As a result, personnel are exposed to some residual risks.
Such risks are specified here below, along with the possible causes and the precautions to be taken to
avoid them.
2.23 Residual risks for the operator

2.23.1 Tool holder / tool
SOURCE OF
RISK Flying tool holder or fragments of the tool
Tool holder or fragments of the tool may fly off due to:
Inaccurate cleaning of the tool holder

Dirt or excess oil on the contact surface reduces blocking force.
Tool, tool holder and spacers may not be properly balanced
Improper balancing causes vibrations. Such vibrations may increase and involve
the entire machine. The force of the vibrations may exceed the blocking force.
POSSIBLE Gradual tool wear
CAUSES Cutting force increases with tool wear.
Increased cutting force results in increased wear of the electro-spindle.
Sudden damage to the tool
Significant variations in the hardness of the material being machined may damage
the tool; a fragment chips or comes off the support. This damage generates
vibrations. Such vibrations may increase and involve the entire machine. The force
of the vibrations may exceed the blocking force.
OPERATION /
This risk exists during normal machine operation.
PROCEDURE
Keep the tools clean. See the “Maintenance” Chapter.
Balance the tools, the tool holders and any spacers fitted on the machine. See the
Chapter “Equipping the Machine”.
Keep the tools sharp. See the “Maintenance” Chapter.
PRECAUTIONS / Take heed of:
SAFETY
• Sudden noise
MEASURES
• Sudden vibrations
Immediately stop the machine and inform the operator running the machine.
The operator running the machine must identify and clear the cause before
proceeding with the machining.
PPE
SYMBOL
Chap. 2
- 34/36 -
2.23.2 Noise
SOURCE OF
RISK Noise
Noise emitted by the machine varies based on:
POSSIBLE • The type of machining
CAUSES • Machining parameters
• The type of tool and its conditions.
OPERATION /
PROCEDURE
PRECAUTIONS /
SAFETY Acoustic protections must be worn (ear plugs or headphones).
MEASURES
PPE
SYMBOL
2.23.3 Crushing of the upper limbs
SOURCE OF
RISK Crushing
POSSIBLE While blocking the piece to be machined, the operator enables closing of the
CAUSES clamps. The clamps close at reduced pressure.
OPERATION /
PROCEDURE
PRECAUTIONS /
SAFETY Keep hands away from the clamps.
MEASURES
PPE
SYMBOL
Chap. 2
- 35/36 -
Chap. 2
- 36/36 -
CHAPTER 3 Machine description and technical data
3 CHAPTER
Machine description
and technical data
Chap. 3
- 1/26 -
CHAPTER CONTENTS
Machine description and technical data ........................................................................................................ 1
3.1 Description of machine functioning ............................................................................................. 4
3.2 Foreseen use ................................................................................................................................... 4
3.3 Characteristics of machinable materials...................................................................................... 4
3.4 Maximum load sizes ....................................................................................................................... 5
3.5 Machining performed ..................................................................................................................... 7
3.5.1 Vertical and horizontal boring ......................................................................................................... 7
3.5.2 Vertical and horizontal milling ......................................................................................................... 7
3.5.3 Open flat milling .............................................................................................................................. 7
3.5.4 Vertical and horizontal milling performed ........................................................................................ 8
3.5.5 Open milling 4/5 axes ..................................................................................................................... 8
3.5.6 Cutting ............................................................................................................................................ 8
3.6 Manufacturing characteristics ...................................................................................................... 9
3.7 Machine layout .............................................................................................................................. 10
3.8 Description of main units............................................................................................................. 11
3.8.1 Machine body and carriage 2 ....................................................................................................... 11
3.8.2 Z axis carriage .............................................................................................................................. 11
3.8.3 Operating head ............................................................................................................................. 12
3.8.4 Electrical cabinet .......................................................................................................................... 12
3.8.5 Numerical control .......................................................................................................................... 13
3.8.6 Variable geometry table "TVG" ..................................................................................................... 14
3.8.7 Centralised grease lubrication ...................................................................................................... 15
3.8.8 Machine axes ............................................................................................................................... 16
3.8.9 Guards and safety devices ........................................................................................................... 17
3.8.10 Electrical cabinet .......................................................................................................................... 17
3.9 Technical data ............................................................................................................................... 18
3.9.1 Machine technical data ................................................................................................................. 18
3.9.2 Machine electrical system data..................................................................................................... 19
3.9.3 Power and consumption ............................................................................................................... 19
3.9.4 Pneumatic system data (compressed air)..................................................................................... 20
3.9.5 Tool technical characteristics........................................................................................................ 20
3.9.6 Static and dynamic loads .............................................................................................................. 21
3.9.7 Overall measurements.................................................................................................................. 22
3.9.8 Overall measurements.................................................................................................................. 23
3.9.9 Space requirements for use and maintenance ............................................................................. 24
3.10 Machine identification .................................................................................................................. 25
3.11 EC declaration of conformity ...................................................................................................... 26
Cap. 3
- 2/26 -
Chap. 3
- 3/26 -
3.1 Description of machine functioning

The SHARP work station with 6 interpolated axes has a high-stability support frame and is
particularly suited for the production of pieces for chairs, tables, beds, frames, stair components
and musical instruments.
The exceptionally large transverse beam allows for wide transversal movements of the head (X
axis).
The elevated dynamics of the SHARP work station derive from the use of precision reducers that
have no tolerance and require no periodical adjustments, as well as from the perfect automatic
lubrication "from the inside out". In addition to traditional programming systems, the SHARP
machine may be programmed using the exclusive Bacci PITAGORA Software, capable of making
the most of the high dynamics of the machine and therefore of obtaining exceptional machine
performance yields.
3.2 Foreseen use

The machine is intended to be used in line with other machines. The material to be machined must
be manually loaded and unloaded by the operator onto the machine’s work bench.
If the size of the piece along the X axis allow for it (see the section “Characteristics of machinable
materials), the piece may be loaded and unloaded on one side of the work bench while the
operating unit works on the opposite side, so as to reduce production times (tandem use).
.
3.3 Characteristics of machinable materials

The machinable materials are the following:
• Wood (hardwood, plywood, block board, blockboards, multilayer wood, lamellar wood,
veneered wood).
• Wood by-products (chipboard, MDF, OSB) or similar material*.
• Plastic and composite materials, such as polymers (e.g. PVC, ABS, cast methacrylate,
Lexan), resins (e.g. fiberglass), thermoplastics (intended as the result of the treatment of
polymers) and rubber.
* similar material: material where machining parameters in the milling, boring and cutting
operations are comparable to the machining parameters of woody material. (e.g.: urea resins,
PVC, ...)
The machining of materials different from those mentioned above is not allowed.
Cap. 3
- 4/26 -
3.4 Maximum load sizes

The maximum sizes of the pieces that may be loaded on the machine must not exceed those
shown in the table below.
L3
L2
S1
L1
CHARACTERISTICS OF MACHINABLE MATERIALS 1 of 1

TYPE DESCRIPTION
L1 (table width) 1170 mm
L2 (open space between the columns) 2750 mm
L3 (table length) 2200 mm
S1 (maximum thickness) 750 mm
The measurements L1 and L3 correspond to the resting surface of the piece on the work table
respectively in the direction of axes X and Y;
The L2 measurement corresponds to the open space between the columns of the X axis door.
The S1 measurement corresponds to the maximum thickness that the piece may have so as so not
interfere with the work unit during its movement.
Chap. 3
- 5/26 -
The machining data of the piece must be gradually gathered considering the maximum movements
that can be executed by the working unit assembly involved in machining, the position of the piece
on the locking system, the size of the tool and the overall dimensions of the other assemblies
present on the working unit.
Always check before starting machining that the piece is correctly supported and locked.
The minimum size is not easy to define and depends on the type of machining to perform and their
position vis-à-vis the piece.
In any case, P. BACCI S.r.l. will be happy to provide any explanation.
Cap. 3
- 6/26 -
3.5 Machining performed

All types of machining that can be performed by the machine are described below. Certain types of
machining can only be by means of optional units.
3.5.1 Vertical and horizontal boring
3.5.2 Vertical and horizontal milling
3.5.3 Open flat milling
Chap. 3
- 7/26 -
3.5.4 Vertical and horizontal milling performed
3.5.5 Open milling 4/5 axes
3.5.6 Cutting
Cap. 3
- 8/26 -
3.6 Manufacturing characteristics

The machine is divided into two work stations. The control panel, located on one side of the
machine, is fitted with independent controls for each station.
The machine is composed of the following main units:
• Z axis carriage
• Machine body
• External safety enclosure
• Centralised lubrication system
• Electrical cabinet
• Variable geometry table "TVG" / Piece resting system
The following optional units may be installed on the machine, even at a later time:
• Blocking devices
may require modifying the systems
• Boring head
unit to be blocked in the electro-spindle
• Angular heads
unit to be blocked on the electro-spindle
• “PITAGORA” programming software
intelligent, user-friendly CAM software system for machine programming and machining
optimisation
• “ALPHACAM” programming software
market software for programming of up to 5 axes
• “MICROSCRIBE” system
system that finds paths and surfaces on an existing piece
Chap. 3
- 9/26 -
3.7 Machine layout

Below are the main units and the optional units making up the machine.
6 2
MAIN UNITS 1 of 2
POS. COMPONENT DESCRIPTION
Z axis carriage:
[1]
assembly of devices that allow for the execution of the machining required.
Machine body:
[2]
main machine frame
Enclosure:
[3] consists in an all-around safety guard that encloses the entire machine. The
enclosure may be access through doors fitted with microswitches, for safe entry.
Lubrication system:
[4] automatically distributes lubricant to all the connected points: axis skids and
recirculation ball screws.
Electrical cabinet:
[5] contains the main controls and electronic equipment used to manage machine
functions, including the numerical control and the operator panel.
Variable geometry table "TVG" / Piece resting and blocking system:
[6]
assembly of parts that serve to position and block the piece to be machined.
Cap. 3
- 10/26 -
3.8 Description of main units
3.8.1 Machine body and carriage 2

The machine body consists in a fixed bridge structure made of stabilized and strongly ribbed steel,
to guaranty maximum solidity and uprightness over time and in all load conditions.
The running guides of the Z axis carriage along the X axis are positioned on the machine body.
3.8.2 Z axis carriage
The Z axis carriage is the assembly of

devices that allow the tools to machine the
piece.
The Z axis carriage consists in the X axis
carriage of the operating head (pos. 1). The
two balancing cylinders (pos. 2) compensate
the weight of the Z axis carriage to reduce
stress on the moving parts.
The operating head holds the electro-
spindles (pos. 3) on which the tools are fitted.
Thus, the head moves vertically and rotates
around the C and A axes.
POS. NAME
1 Operating head
2 Balancing cylinder
3 Electro-spindle
Chap. 3
- 11/26 -
3.8.3 Operating head
The standard work unit has 4 independent

electro-spindles with a power of 7.5 kW, a
1 rotating speed that may vary from 0 to 24,000
rpm and ceramic bearings. The spindles are
inserted in a pressurised box sealed against
chips. Spindle cooling is guaranteed even as
2 lower turning speeds used for smoothing tools
or for large diameter circular blades.
POS. NAME
1 2-armed fork
2 Electro-spindle
The operating head is held by a 2-armed fork. The fork allows for the use of tools up to 140 mm
long as well as circular blades with diameters up to 200 mm.
3.8.4 Electrical cabinet
The electrical cabinet contains the main controls

3 and electronic, electric and electro-mechanic
equipment that serves to manage machine
operation, including numerical control CN (pos.
1 1) and the operator panel (pos 2).
The electrical cabinet also has an air-
2 conditioner (pos 3) to keep internal temperature
at a low and constant level and guarantee
proper function of numerical control CN.
The whole electrical cabinet is protected by a
dust insulation device.
POS. NAME
1 Numerical control with monitor

2 Main operator panel
3 Air conditioner
Cap. 3
- 12/26 -
3.8.5 Numerical control
The OSAI series 10/510 numerical control consents the best use of the SHARP work centre,
thanks to its elevated (standard) performance:
• ISO programming system

• RTCP: automatic perpendicularity of the tool with respect to the surface to be machined
• UPR: programming on tilted surfaces
• VFF: high precision shaping
• USB: USB port
• HDU: hard disk (to memorise programmes)
• TEACH PENDANT: remote pushbutton panel for programming in auto-teach mode and
manual machine handling.
Chap. 3
- 13/26 -
3.8.6 Variable geometry table "TVG"
The work centre is fitted with two variable

geometry tables (Bacci patent) that are
both independent and controlled by
means of numerical control NC. The two
tables move along the Y axis. This
movement allows for machining in
maximum rigidity conditions and therefore
maximum precision. This configuration
1 also consents shifting the piece sideways
off the work surface during loading and
2
unloading.
4 3
Each TGV table supports two (2) steel shelves (pos 2) with adjustable space between the centres
of the two.
The minimum value along the X axis is 200 mm while the maximum value is 1170 mm.
Each shelf bears a 900 mm long resting bar (pos. 1) used to anchor the piece using pressure.
The shelf is therefore chequered 50 x 50 mm. The flat surface of the resting bars for piece loading /
unloading is at a height of 850 mm from the ground.
There are two dovetailed milling marks on both long sides of the bar (pos. 4) to block the
pneumatic pressing device, easily adjustable along the Y axis, allowing for optimal piece
anchoring.
The recirculation guide system (pos. 3) of the tables is protected against chips and machining
scraps. This allows avoiding frequent disassembly to clean and service the guides themselves or
any winding rollers that may be installed on the machine.
Cap. 3
- 14/26 -
3.8.7 Centralised grease lubrication
The centralised and automatic system is

connected with progressive distributors at all
recirculation bearing carriages and all axis worm
screws.
The system lubricates all the connected points
according to the set lubrication frequency, using
the grease contained in the lubrication tanks
(pos. 1).
POS. NAME
1 Grease tank
2 Grease pump
3 Working pressure gauge
The pump (pos 2) is applied in the lower section of the tank and pumping is controlled by a single-
action piston powered by means of compressed air.
The pressure is set at *** bar (pos. 3). Return to the start position is spring-controlled. A
compression spring with a pressure disk is inserted inside the tank. The system is also equipped
with an electrical minimum level signal and filling filter.
Chap. 3
- 15/26 -
3.8.8 Machine axes
Z+
C+
A+
X+
Y1+
Y2+
The controlled machine axes are:
• Longitudinal X axis of the head

• Transversal Y1 and Y2 axis of the 2 TGV tables
• Vertical Y axis of the Z axis carriage
• Rotating B axis of the working head
• Rotating C axis of the working head
Each axis has a positive and a negative direction.

The drawing shows the positive direction of each axis.
Cap. 3
- 16/26 -
3.8.9 Guards and safety devices
Guards and safety devices are fitted on danger areas to protect moving mechanical parts (for
example, chains, gears, transmissions and moving organs) described in the chapter “2 Safety
Information”, section “2.10 Machine safety devices”.
Guard and safety device efficiency must be assessed after the user has installed the machine in its
final working position, when all risks related to interconnection with other existing machines may be
evaluated, providing for any guards and/or safety devices deemed necessary.
3.8.10 Electrical cabinet
The machine has a main electrical cabinet

located on board the machine, that contains the
control electronics and, at the upper level, the
operator controls.
Chap. 3
- 17/26 -
3.9 Technical data
INFORMATION!
The sections that follow contain the main machine technical data or, in any event, the
minimum and maximum obtainable performance yields; these data may differ based on
specific customer requests.
3.9.1 Machine technical data
MACHINE TECHNICAL DATA 1 of 2

TYPE DESCRIPTION
Number of interpolated axes 6
Axis stroke
Longitudinal X axis of the head 3000 mm
Transversal Y axis of the 2 tables 1800 mm
Vertical Z axis of the head 750 mm
Rotating A axis Unlimited
Rotating C axis -200° - +200°
Speed
X axis 1.66 m/s
Y, Z axes 1 m/s
A, C axes 12,000 °/min
Electro-spindles
Rated power (S1) 7.5 kW
Rotating speed 0 – 24,000 1/min
Direction of rotation Clockwise and counter-clockwise
Work table
Number of tables 2
Bench height (from the ground) 850 mm
Space between shelf centres adjustable: 200 mm - 1170 mm
Pressure-hold system: checkering 50 mm x 50 mm
Cap. 3
- 18/26 -
MACHINE TECHNICAL DATA 2 of 2

TYPE DESCRIPTION
Piece blocking
Pressure device type Pneumatic
Number of pressure devices 4 (2 per table)
Sizes
Open space between the columns 2750 mm
Panel passageway 450 mm
3.9.2 Machine electrical system data
MACHINE ELECTRICAL SYSTEM DATA 1 of 1

TYPE DESCRIPTION
Electrical voltage in Volts See machine plate
Electrical frequency in Hz See machine plate
Electrical absorption in kW See machine plate
Contemporaneous factor 0.7
3 phases + 1 ground
Type of connection Star connection:
TT;TN-C;TN-S
Max. resistance to ground 2 Ohm
Max. power See machine plate
Type B device
Protection With delayed action (0.3 sec.)
With 0.3A adjustable differential current.
3.9.3 Power and consumption
System power and consumption values are written in the specific “Data sheet” attached to the
instruction manual.
Chap. 3
- 19/26 -
3.9.4 Pneumatic system data (compressed air)
The pneumatic system to which the machine is connected must meet the following requirements.
Machine efficiency is guaranteed only if all specifications are met.
PNEUMATIC SYSTEM DATA 1 of 1

TYPE DESCRIPTION
Recommended diameter for
1/2"
compressed air line tube
25 mm external
Rubber tube connection diameters:
17 mm internal
200 L/min for version with 2 spindles
Air consumption at 6 bar
360 L/min for version with 4 spindles
Optimal line pressure 6.5 bar
DANGER!
Dust, condensation and oil may damage the electro-spindle.
Use only clean, dry filtered, non-lubricated and condensation-free air.
3.9.5 Tool technical characteristics
Use only tools with diameters and weights that correspond to those shown in the table below.
TOOL TECHNICAL DATA 1 of 1

JOINT SIZE MAX DIAMETER ROTATING SPEED MAX TOOL MAX TOOL
TOOL SHAFT (MM) (RPM) DIAMETER (MM) WEIGHT (KG)
6000 / 9000 150 10
9000 / 12000 130 7
ER40 25
12000 / 15000 110 5
15000 / 18000 80 5
6000 / 9000 140 4
9000 / 12000 130 4
ER32 20
12000 / 15000 110 2.5
15000 / 18000 80 2.5
DANGER!
Risk of flying tool parts
Improper tool balancing may result in:

• The tool breaking or
• The tool breaking free of the electro-spindle
• Balance to tools and tool holders in G1. Re-balance the tools after sharpening.
Cap. 3
- 20/26 -
3.9.6 Static and dynamic loads
Machine static and dynamic loads are specified in the installation layout for civil work.
Chap. 3
- 21/26 -
3.9.7 Overall measurements
The figure below shows the main overall measurements. Please refer to the main installation
layout for all measurements not shown in the figure.
L1
L3
L4
L2
L5 L6
L7
VARIABLE MEASUREMENT VARIABLE MEASUREMENT

L1 4000 mm L5 1560 mm
L2 4000 mm L6 1050 mm
L3 500 mm L7 325 mm
L4 575 mm
Cap. 3
- 22/26 -
3.9.8 Overall measurements
The figure below shows the main overall measurements. Please refer to the main installation
layout for all measurements not shown in the figure.
W
L
H
VARIABLE MEASUREMENT
“L” 2300 mm
“H” 3300 mm
“W” 3270 mm
Chap. 3
- 23/26 -
3.9.9 Space requirements for use and maintenance
INFORMATION!
Space requirements for use and maintenance indicated below must be verified on the main
machine installation layout, which must always be consulted.
The presence of building elements, such as walls, columns, etc., or work equipment in the area
destined for machine use and maintenance may render proper assembly impossible and the user
may therefore be required to restructure the workplace before machine installation and start-up.
Spaces for use and maintenance and any required restructuring requirements are shown on the
main machine installation layout.
1m
1m
1m
Measurement “A” must be greater than the length of the machine material, to allow infeed.
Cap. 3
- 24/26 -
3.10 Machine identification
Machine and electrical panel identification data are shown on the identification plates. The plates are located
on the machine as shown in the figure below.
The symbol appears on the machine identification plate only for machines sold within the European
Community, accompanied by the relative EC declaration of conformity, as per Annex II A of the 2006/42/CE
Machine Directive.
• The symbol is not present for machines sold in countries that are not members of the European
Community.
INFORMATION!
Do not remove the machine or electrical cabinet identification plate nor replace it with other plates. If a plate
is damaged, always contact the manufacturer.
MACHINE AND ELECTRICAL CABINET IDENTIFICATION PLATES

2 3
1 4 5 6 7 8
PLATE DATA:
IDENTIFICATION:
2. MODEL / TYPE (machine).
1. Position of the machine identification plate. 3. SERIAL N. (machine).
4. YEAR OF MANUFACTURE (machine).
5. VOLTS (supply tension).
6. HZ (supply frequency).
7. KW (power).
8. KG (machine weight).
Chap. 3
- 25/26 -
3.11 EC declaration of conformity
If the machine is destined to the European market, it will be accompanied by the relative EC declaration of
conformity, as per Annex II A of the 2006/42/EC Machine Directive. The EC declaration of conformity, a
facsimile of which is shown below, is delivered signed along with the machine.
EC DECLARATION OF CONFORMITY
(according to 2006/42/EC)
THE MANUFACTURER PAOLINO BACCI S.R.L.

VIA PALERMO 32
56021 CASCINA (PISA) - ITALY
In the person of Mr. AGOSTINO BACCI, Legal Representative
DECLARES THAT THE MACHINE
NAME (FUNCTION)
TYPE (MODEL /TRADE NAME)
SERIAL NUMBER
YEAR OF MANUFACTURE
IS CONFORMANT TO ALL PROVISIONS OF THE DIRECTIVES
2006/42/EC (MACHINE)
2006/95/EC (LV)
2004/108/EC (EMC)
IDENTIFIES:
as the person authorised to prepare the Technical File, Mr. AGOSTINO BACCI, at PAOLINO BACCI
s.r.l., via Palermo 32 56021 CASCINA (PI) - Italy.
CASCINA, THE LEGAL REPRESENTATIVE

A.BACCI
Cap. 3
- 26/26 -
CHAPTER 4 – Installation
CHAPTER 4
Installation
Chap. 4
- 1/32 -
CHAPTER CONTENTS
4 Installation .............................................................................................................................. 1
4.1 Information required on load handling and installation ....................................................................... 3
4.1.1 Load handling equipment provided by the customer .................................................................................. 4
4.1.2 Installation equipment provided by the customer ....................................................................................... 5
4.1.3 Installation preparations made by the customer ......................................................................................... 5
4.2 Packaging, handling, transport ............................................................................................................... 6
4.2.1 General recommendations on safety concerning load handling ................................................................. 6
4.2.2 Information on shipment and delivery ........................................................................................................ 8
4.2.3 Packaging and shipment precautions and tactics ...................................................................................... 9
4.3 Preparing the machine for shipment ....................................................................................................11
4.3.1 Disconnecting the electrical cabinet ....................................................................................................... 11
4.3.2 Disassembly of the balancing cylinders and X axis cable holder chain ................................................ 12
4.3.3 Moving the Z axis ..................................................................................................................................... 14
4.3.4 Safety devices for transport...................................................................................................................... 15
4.4 Identification and handling of components and load units ...............................................................16
4.4.1 Machine hoisting diagram ........................................................................................................................ 18
4.4.2 Hoisting procedure of the electrical cabinet.............................................................................................. 19
4.4.3 Table hoisting procedure .......................................................................................................................... 20
4.5 Installation site requirements ................................................................................................................21
4.5.1 Flooring specifications .............................................................................................................................. 21
4.5.2 Environmental data .................................................................................................................................. 21
4.5.3 Illumination and aeration .......................................................................................................................... 22
4.5.4 Suction plant ............................................................................................................................................ 22
4.6 Loading, transportation and unloading ................................................................................................23
4.7 Assembly .................................................................................................................................................24
4.7.1 Machine anchoring ................................................................................................................................... 24
4.7.2 Anchoring the TGV tables to the floor ...................................................................................................... 26
4.7.3 Removing safety guards and blocking devices for transportation ............................................................ 29
4.8 Connections to power supplies ............................................................................................................30
4.8.1 Data for electrical connections ................................................................................................................. 31
4.8.2 Data for the pneumatic system................................................................................................................. 32
Chap. 4
- 2/32 -
4.1 Information required on load handling and installation
The following paragraphs provide the minimum information required on how to handle loads correctly
and install the machine.
For installation always refer to this manual and the documents mentioned for the different procedures.
This chapter contains all the necessary information on the installation phase of the machine.
This phase includes the preparation, loading and unloading of the machine for transport purposes.
Furthermore it describes the positioning of the machine components and its fastening to the floor. Finally,
it illustrates how to assemble the components removed in order to facilitate transport and connect the
machine to the electric and pneumatic system.
All operations described in the Installation chapter must be performed by qualified personnel authorised
by P. BACCI S.r.l.
Chap. 4
- 3/32 -
4.1.1 Load handling equipment provided by the customer
To handle loads and install the machine you need the equipment listed in the following tables.
Upon receipt of machinery, unless otherwise agreed, all the material must be available in the installation
site.
LOAD HANDLING EQUIPMENT 1 of 1

EQUIPMENT
Crane
Stacker
Hoisting beam
Galvanised screw pin shackles
Hoisting accessories (e.g. chains, belts, lashing

ropes)
INFORMATION!
The choice of the means to use for load handling must be based on the evaluation of the
mass to hoist and the existence of environmental limitations, such as the height of the
installation site and accesses.
Chap. 4
- 4/32 -
4.1.2 Installation equipment provided by the customer
INSTALLATION EQUIPMENT 1 of 1
EQUIPMENT
Extension leads
Drill with drill bits
Grinding wheel with disks for metal
Welding machine
4.1.3 Installation preparations made by the customer
The installation site must be equipped with the following:
• 220 volt power supply points, close to the machine assembly site, to which the different work
equipment (drills, welding machine etc.) can be connected.
• any necessary civil works must be implemented and the foundations and/or installation site must
be prepared.
Chap. 4
- 5/32 -
4.2 Packaging, handling, transport
The following paragraphs provide the main information on the preparation of the machine for transport or
shifting. Certain machine parts are actually disassembled before transport to facilitate handling or to
reduce the maximum dimensions of the machine. Thus the maximum height of the machine is reduced
less than 2.5 m and the machine can be transported in a standard truck or inside a container.
The following paragraphs also include the main information on how to handle the machinery; they make
reference to the procedures to adopt, the means used and safety measures.
4.2.1 General recommendations on safety concerning load handling
Given the specific nature of operations, it is obligatory to employ informed and trained personnel who will
work using hoisting means and will be aware of the operational and safety procedures to follow when
handling loads.
Before starting the transport of the machine and its components, consult the shipment list for information
on sizes.
During the loads hoisting and handling operation it is OBLIGATORY to abide by the following rules:
• It is OBLIGATORY that all hoisting and load handling operations are performed only by qualified
and authorised personnel.
• IT IS OBLIGATORY to use personal protective equipment (PPE), such as safety boots, work
clothing, crushing protection gloves, protection helmet and safety slings, if works at height are
foreseen.
• IT IS OBLIGATORY that only the staff authorised to handle loads must work in the work area in
compliance with the common safety rules imposing restricted areas around hanging weights,
stackers and/or moving gantries.
IT IS NOT ALLOWED:
• Unauthorised personnel IS NOT ALLOWED to access restricted areas where handling of loads is
performed.
• It is absolutely NOT ALLOWED to pass or remain under hanging weights.
Please take the following PRECAUTIONS:
• Parts over 25 kg must not be handled manually. They bear the position indication of the centre of
gravity and are arranged for hoisting using appropriate accessories (slings, ropes, eyebolts,
shackles, .....).
• Assess which is the safest track before hoisting any load.
• Exclusively use ropes or chains that enable you to guide the load and remain at a safe distance
at the same time.
Chap. 4
- 6/32 -
• Save for the stop and start phases, handling must be performed without speeding up or slowing
down in order to avoid tears or advances of impulsive nature.
• Before hoisting, always make sure that hoisting is performed longitudinally vis-a-vis the centre of
gravity of the load being hoisted; if necessary, adapt the position of hoisting parts or distribute
loads.
• During horizontal shifting pitching must be avoided as much as possible, particularly during starts
and stops.
• Direction changes must be performed after a stop.
• The load hoisted must be kept away from obstacles and at a minimum distance from the ground
as much as possible.
• If the symbols below appear on the package as illustrated, i.e. crossed out, the type of hoisting
illustrated is expressly forbidden.
• To place the machine on the loading platform of a truck or, provisionally, on the ground, wooden
battens of equal height must be arranged on the base (bed); they must represent a stable
supporting base and must not cause damages to machinery (when possible, place the machinery
on the side frames).
• The machine and/or devices, components, must be placed on the ground slowly and carefully to
avoid damage.
• Carefully inspect load hoisting accessories (hooks, slings, chains, eyebolts, shackles) before use.
• If defects are detected, replace accessories with new ones and make sure the components
replaced are off. The defects that may appear are the following:
o Lack or illegibility of labels with capacity information;
o Presence of curvings, holes or tears on synthetic belts;
o Distorsions or squeezing of ropes or metal wires;
o Corrosion signs on metal details;
o Abrasion or wear traces due to excessive friction on components.
• The presence of curvings is the main cause of collapse of bands and belts made of synthetic
material. Cuts are generally produced when belts are rubbed against straight edges and corners
found on the load to transport.
• To guarantee the integrity of belts and thus the safety of operations, we recommend edges and
corners are covered with soft material.
•
Chap. 4
- 7/32 -
4.2.2 Information on shipment and delivery
The machine is shipped in perfect operational conditions after having being tested at our plant.
According to the type and size of the components to ship, P. Bacci will use appropriate packaging to
guarantee the integrity of machines and keep them in good conditions during transport until they are
delivered.
Depending on the distance from the delivery site, the customers’ prescriptions and the time during which
the machine remains in the package, the machine will be shipped directly on a truck loading platform or
inside a container.
In view of a long stay in packaging or sea freight, machine parts subject to oxidation (such as screws,
chains etc.) are covered with protective rustproof paint.
Inside electrical switchboards anti-humidity salts are placed to absorb humidity/condensation. When
salts are put, necessary precautions must be taken to avoid that contact with metal parts causes
corrosion. On the basis of the type of transport, the entire electrical switchboard can be further wrapped
in a barrier bag to prevent humidity from entering.
To hoist and handle freight units it is OBLIGATORY to consult the related specifications in this manual.
Upon machine delivery check that the package has not been damaged during transport and the product
is in line with the specifications of the agreement.
If the machine has been damaged, please inform the carrier and the Bacci technician immediately.
During transport operations blocks (made of wood or metal) can be used to guarantee the stability of the
machinery and will have to be removed afterwards.
While the machine remains inactive it is advisable:
• to protect it with polyethylene sheets or large sheets to avoid that dust is deposited on anticrush
mechanisms or packaging to prevent possible damage.
• Never let it in the open or expose it to bad weather.
• Always check that storage temperatures remain within the minimum and maximum limits
described in the technical data and performances of the machine.
All operations must be performed by qualified personnel authorised by P. BACCI S.r.l..
Chap. 4
- 8/32 -
4.2.3 Packaging and shipment precautions and tactics
Packaging is designed so that possible stresses or stains owing to transport do not exceed the
admissible values established by specific standards and do not cause permanent deformations or
damage that could negatively affect the performance of the machine or its components.
The machine can be transported using different types of packaging depending on destination and
transport modalities.
INFORMATION!
In the event of damage or lack of certain parts, contact P. Bacci to agree upon the
procedures to adopt.
Depending on the characteristics of the machine or its parts, different devices and materials are used to
protect the machine or its parts during transport.
PACKAGING PRECAUTIONS 1 of 2
TYPE DESCRIPTION COMPONENTS
• Nylon protective film is used as a dust-proof cover and
protection against light collisions and scratches of painted
• Structure.
Nylon parts.
• Control
protective film • The film also partly protects the machine from gentle
panels
atmospheric phenomena and prevents foreign material (dirt)
from depositing on the machine.
• Joints.
• The application of grease on surfaces or machine components • Articulations.
Grease aims to protect the components from atmospheric agents and
prevent accumulation of foreign material on the machine. • Guides.
• Bearings.
• Application of protective rustproof paint on surfaces or machine
components aims to protect components from atmospheric
agents and corrosion phenomena.
• Machine parts subject to rust are covered with protective paint:
o if the period between shipment and installation is over 3
days.
o if the machine must be shipped by sea. • Structure.
o in winter and in climatic zones where there is high • Screws
Protective humidity.
rustproof paint • Uncovered
parts
INFORMATION!
Before the first start-up of the machine it is necessary
to clean the different components that underwent
protective treatment for shipment purposes. Refer to
the rustproof paint supplier’s card for safety information
on using masks/shields and clothing to avoid contact
with paint.
Chap. 4
- 9/32 -
PACKAGING PRECAUTIONS 2 of 2
TYPE DESCRIPTION COMPONENTS
• Bags of anti-humidity salt are placed inside electrical
switchboards and control panels.
• When the machine is shipped in a container anti-humidity salt
is placed inside the barrier bag. • Electrical
Anti-humidity
switchboards
salts
INFORMATION! • Barrier bag
Before the first start-up of the machine it is necessary
to remove all bags of anti-humidity salt.
• Wooden crates are normally used to ship the machine or other

• Miscellaneou
Wooden crates disassembled machine parts, equipment or spare parts of the
s
machine, equipment or material for assembly purposes.
• Should the machine be shipped inside a container, all the • All
material in the container is contained inside the barrier bag and components
Barrier bag is hermetically sealed. The barrier bag aims to protect placed inside
components from atmospheric agents and corrosion a single
phenomena. container.
ENVIRONMENTAL INFORMATION!
The disposal of packaging material must be performed in accordance with the current waste
disposal standards of the country where the machine will run.
Chap. 4
- 10/32 -
4.3 Preparing the machine for shipment
4.3.1 Disconnecting the electrical cabinet
PREPARING FOR SHIPMENT – DISCONNECTING THE ELECTRICAL 1 of 1

CABINET
STEP ACTION DESCRIPTION
• Before intervening on any machine circuit or component, it is
OBLIGATORY to check the absence of residual voltage or pressure in
the plants; always make sure you work in safety; to this end check the
Safety checks correct function and position of safety devices making sure that the
1 personnel working in the area has been informed of the operations
under way.
Check that all operators are in a safe position and are informed of the
phases under way.
• Collision hazard in the machine structure and parts. Move

Warnings /
cautiously during operations.
Precautions
2
• Danger of slipping, stumbling and falling inside the machine.
Move cautiously during operations.
• The majority of electrical connections between the electrical cabinet and

the various machine parts are made using cable connectors: 2 cable
connectors for each control (pos. 1 and pos. 2) and all the cable
connectors of the lower terminal board (pos. 3).
Disconnecting
2 the electrical
1
wiring
2
3
• To disconnect the electrical connections without cable connectors, mark

all wires and, possibly, the wire paths.
Chap. 4
- 11/32 -
4.3.2 Disassembly of the balancing cylinders and X axis cable holder

chain
To lower the maximum machine height, the balancing cylinders and X axis chains must be partly
disassembled.
PREPARING FOR SHIPMENT – DISASSEMBLING THE BALANCING 1 of 2

CYLINDERS AND X AXIS CABLE HOLDER CHAINS
under way.
phases under way.

Warnings /
Precautions
2
• Disconnect all the cables and tubes of the two balancing cylinders and
unscrew the blocking nuts (2).
Disconnecting
3
the tubes
• Disassemble the two balancing cylinders, including the two anchoring

brackets (1).
Chap. 4
- 12/32 -
PREPARING FOR SHIPMENT – DISASSEMBLING THE BALANCING 2 of 2

CYLINDERS AND X AXIS CABLE HOLDER CHAINS
• Remove the four anchoring screws (3 - 4) of the cable holder chain of
the X axis.
Removing the
5 anchoring
screws
Chap. 4
- 13/32 -
4.3.3 Moving the Z axis
This procedure applies only for machines with a Z axis stroke > 750mm.
The Z axis carriage is moved along its support to reduce the machine height.
PREPARING FOR SHIPMENT–Z AXIS 1 of 1

under way.
phases under way.

Warnings /
Precautions
2
• Anchor the two tubular sections (1) above the Z axis carriage using the
four screws (2).
Anchoring the
3 tubular
sections
• Anchor the two tubular sections (1) to an appropriate hoisting device: a

Anchoring the travelling crane, a crane or a fork lift-truck.
tubular
4
sections to the • Make sure that the hoisting equipment is in perfect working order
hoisting device and capable of hoisting the Z axis.
• Lift the hoisting equipment cautiously so it will bear the weight of the Z
5 Hoisting
axis carriage.
Chap. 4
- 14/32 -
4.3.4 Safety devices for transport
To avoid the movement of any machine parts during transport, all the linear X, Y1, Y2 and Z axis are
mechanically blocked in position.
PREPARING FOR SHIPMENT–Z AXIS 1 of 1

under way.
phases under way.

Warnings /
Precautions
2
• Wrap a part of the recirculation bearing screw (1) with a copper sheet
(4) to protect its shape.
• Screw in the block (2) on the covered part of the screw (4). Tighten the
screws (5) against the surface of the structure (3).
Inserting the
3
safety blocks
Chap. 4
- 15/32 -
4.4 Identification and handling of components and load units
If the machine is shipped in a CONTAINER, the largest part of the machine (base plus spindle holder
head) must be unloaded using a crane and four ropes (2), each about four metres long, and two tubular
sections (5) to be inserted in the hoisting holes in the base. Hoisting ropes and tubular sections are not
supplied with the machine and must be properly sized, as must be the hoisting crane and, in general,
any other hoisting equipment used. The two ropes anchored to the tubular sections in the rear part of the
base (side opposite to the spindle holder head) must be near the base itself, while at the front they must
be positioned at about 400 mm from the base, so as to balance the oscillation created by the distribution
of the machine weight.
LOAD UNITS AND COMPONENTS 1 of 2

UNIT HANDLING
Hoisting components:
• 1) crane; load capacity 4500 kg;

• 2) ropes; quantity four; length 4m, load capacity: 1500 kg.
• 3) bar for hoisting using fork lift-truck; quantity three; length 1.5 m; diameter
80 mm.
• 4) fork lift-truck; for handling, in alternative to crane quantity two; load capacity
2500 kg
• 5) tubular sections for hoisting using a crane; quantity two; length 1.5 m;
diameter 80mm
Handling
• MACHINE WEIGHT 4000 Kg
Chap. 4
- 16/32 -
LOAD UNITS AND COMPONENTS 2 of 2

UNIT HANDLING
The alternative of positioning the machine using two lift-trucks (4) must be chosen
only for small movements.
Handling with lift-

truck
The diameter of the holes for the hoisting tubes (3) is 80 mm.
Chap. 4
- 17/32 -
4.4.1 Machine hoisting diagram
The table below shows the machine hoisting diagram for shipment, the type of hoisting points and where
they are located and the weight to be lifted.
HOISTING POINTS 1 of 1
UNIT HANDLING
Machine body
400
• MACHINE WEIGHT 4000 Kg
Chap. 4
- 18/32 -
4.4.2 Hoisting procedure of the electrical cabinet
The following table shows the hoisting diagram of the electrical cabinet for shipment purposes, the points
and type of hoisting, the weight of the load to hoist.
The electrical cabinet of the machine (6) has four eyebolts (7) located on the upper part of the cabinet
which allow the cabinet’s hoisting by means of a special hoisting device, e.g. a crane (1) and four cables
(2).
The weight of the electrical cabinet amounts to app. 400 kg.
If the electrical cabinet has been wrapped in a barrier bag (3) for shipment purposes, it can be
transported by means of a stacker (5).
Once the protection case (4) has been removed, the electrical cabinet can be handled by means of a
crane (1) through four cables (2) and four eyebolts (7).
HOISTING POINTS OF ELECTRICAL CABINET 1 of 1

UNIT HANDLING
Electrical cabinet
• WEIGHT OF ELECTRICAL CABINET 400 Kg
Chap. 4
- 19/32 -
4.4.3 Table hoisting procedure
The machine’s two TGV tables may be unloaded and handled using a crane or a lift-truck.
To hoist the tables using a crane, anchor the ropes (1) around the table edges.
Place the ropes on the outside of the transportation beams (5).

The rope on the cable holder chain side (3) must be placed between the table structure (4) and the cable
holder chain (2) to avoid it being crushed.
TABLE HOISTING POINTS 1 of 1

UNITS HANDLING
Tables
• ELECTRICAL CABINET WEIGHT 900 Kg
Chap. 4
- 20/32 -
4.5 Installation site requirements
The site where the machine will be installed must meet specific characteristics. It will be up to the
purchaser to provide the premises where the machine will be installed.
4.5.1 Flooring specifications
The site where the machine will be installed must meet specific characteristics. It will be up to the
purchaser to provide the premises where the machine will be installed.
For the installation of the machine an at least 20 cm thick industrial type floor made of normal concrete
(or similar material) is required.
The surface must be falt (maximum acceptable inclination 2:1000).

If steel grating is used to reinforce concrete, it must be at a sufficient distance from the ground, given
that the machine is fastened using anchorage screws reaching a depth of 15 cm.
Any ditches for the removal of dust and chips must be at least at a 10 cm distance from the machine
support feet.
FLOORING SPECIFICATIONS 1 of 1
TYPE DESCRIPTION
Type of flooring industrial, concrete
Thickness of flooring at least 20 cm
Flatness of the surface 2:1000
Distance of reinforcing grating from the > 15 cm
ground
Distance of possible ditches from support > 10 cm
feet
4.5.2 Environmental data
For the good operation of the machine the following environmental conditions must be met:
ENVIRONMENTAL DATA 1 of 1
CRITERION SPECIFICATION
Temperature between +5°C and 47°C
Relative humidity between 10% and 90%
Chap. 4
- 21/32 -
4.5.3 Illumination and aeration
Make sure the natural or artificial environmental illumination provided can adequately protect the
operators’ safety and health.
Make sure the premises are well ventilated to protect the operator’s health.
4.5.4 Suction plant
A dust control plant is not provided with the machine.

For the machine to be used correctly and safely, it must be connected with a dust suction plant meeting
the following specifications
DUST CONTROL SYSTEM SPECIFICATIONS 1 of 1

TYPE DESCRIPTION
Number of vents 2
Diameter of vents 120 -160 mm
Suction speed 20 - 25 m/s
Min. total capacity 2500 mc/h
Chap. 4
- 22/32 -
4.6 Loading, transportation and unloading
The procedure below describes the main instructions for machine loading, transportation and unloading.
PROCEDURE 1 of 1
MEANS DESCRIPTION
• Loading and unloading must be performed only by skilled and authorised
Safety checks personnel.
• Mark off the loading and unloading area and war exposed persons of the work
in progress.
• The machine is shipped in more than one piece; parts are anchored using wood
beams, straps or similar methods, required for storing and blocking the load.
Loading
• The load is always protected against environmental agents by PVC sheets.
• Special care must be taken with large loads.

• The maximum height for a load travelling by road is 4 metres, considering the
height of the vehicle and of the load being carried. Some loads are shipped on
special depressed centre flat-cars in order to respect the 4 metre height limit.
Transportation • Take care of machines shipped in extra-high OPEN TOP containers. In these
cases, Bacci guarantees transportation up to the ship. Unless otherwise agreed
upon, the customer is responsible for arranging road transportation from the
port of arrival to the installation site, choosing vehicles suited to the loads to be
transported.
• Visually inspect the load, checking that the PVC sheets are not ripped or cut.
• Once the PVC sheets are removed, check that the load has not shifted; the
Checks upon straps must be taut and the wood beams well anchored to the load.
delivery • If the machine is damaged, immediately inform the carrier and the Bacci
technician.
• Always start by unloading the smallest and easiest to reach parts.

• Unload one load unit at a time.
• Identify the hook-up points for the load units and always fasten the hoisting
Unloading devices before removing the anchoring straps and beams that block the load.
• Begin hoisting gradually, moving the load without bumping into the transport
vehicle.
Chap. 4
- 23/32 -
4.7 Assembly
The machine is assembled by Bacci technicians, since assembly may entail risks for non qualified
personnel and requires the manufacturer’s special and specific knowledge.
This manual provides a minimum description of the operations to perform.
During cleaning and installation operations the personnel must use all proper personal protective
equipment (overalls, gloves, glasses etc.) and be aware of the machinery access procedures and the
residual risks associated to the operations performed.
The personnel must be informed of the safety procedures and existing risks in the customer’s plant.
4.7.1 Machine anchoring
To position the machine please proceed as described below:
MACHINE ANCHORING OPERATIONS 1 of 2

under way.
phases under way.

Warnings / cautiously during operations.
Precautions
2
• Measure levelling vis-a-vis axis X by placing the spirit level on the

Spirit levelling recirculating ball screw of axis X along half of its length or on one of the
3
check linear guides of axis X along half of its length.
Chap. 4
- 24/32 -
MACHINE ANCHORING OPERATIONS 2 of 2

• Act on the four adjustment screws (2) located on the extremities of the
machine body. Turn screws by 1/4 of a round each time.
4 Registration
• Measure levelling vis-a-vis axis Y by placing the spirit level on the

Spirit levelling
5 support plate.
check
• Act on the four adjustment screws (2) located on the extremities of the
machine body. Always turn a pair of screws on the opposite sides by ¼
of a revolution each time.
Level
6
adjustment
• Act on the adjustment screws (2) to place all other pans uniformly on
the ground. Always turn a pair of screws on the opposite sides by ¼ of a
7 Setting pans revolution each time.
• Check the levelling vis-a-vis axis X and axis Y.

8 Spirit levelling
Fastening of • Lock adjustment screws by means of counter-nuts (4)

9
screws
• Use fastening holes (1) as a template to apply fastening holes for floor
Plug
10 plugs.
application
• Fasten the machine body on the floor with plugs (3).

11 Fastening
Chap. 4
- 25/32 -
4.7.2 Anchoring the TGV tables to the floor
Place the TGV tables by resting the rear ends on the base resting plate, respecting the measurements
shown in the diagram below.
ANCHORING THE TGV TABLES 1 of 3

under way.
phases under way.

Precautions
2
Chap. 4
- 26/32 -

Positioning
3
diagram
Chap. 4
- 27/32 -

• Measure the levelling in the direction of the Y axis by resting the level
4 Adjustment midway along the length of the Y axis recirculation bearing screw or
midway along one of the linear guides of the Y axis.
• Act on the four adjustment screws (2) located at the table edges. Turn
the screws by 1/4 turn at a time.
Check
5
levelling
Levelling • Measure the levelling in the direction of the Y axis to make sure the
6
adjustment table is perfectly level.
Setting the • Measure the levelling in the direction of the Y axis by resting the level
7
pans on the linear guides of the shelf.
• Act on the four adjustment screws (2) located at the table edges. Turn
the screws by 1/4 turn at a time.
8 Levelling
Blocking the • Measure the levelling in the direction of the X axis to make sure the
9
screws table is perfectly level.
• Check whether the X and Y axes are perpendicular to one another.
Fasten the base of the comparator to the body of the motorised
Inserting
10 spindle. Rest the point of the comparator against the table resting
wedges
bars. Move the Y axis to the two end strokes and check that the axes
are perpendicular.
Chap. 4
- 28/32 -
4.7.3 Removing safety guards and blocking devices for transportation
To keep all machine parts from moving during transportation, all the linear X, Y1, Y2 and Z axes are
mechanically blocked into position.
To remove safety blocks, proceed as described below.

under way.
phases under way.

Precautions
2
• Remove the block (2) by unscrewing the two fastening screws (5)
Removing the
3
block
• Remove the protective copper sheet (4).
Removing the
4
protective sheet
Chap. 4
- 29/32 -
4.8 Connections to power supplies
Connection wires between the machine and the electrical cabinet have been removed to facilitate
shipping. Connect the machine wires to the electrical cabinet by following the wiring diagram.
LOCATION OF MACHINE POWER POINTS 1 of 1

1 2
Key:
1. Compressed air system connection point.
2. Electrical grid connection point
DANGER!
The customer will be liable for any damage caused by connection of the machine to electrical power
and/or compressed air supply systems that do not meet the specifications provided here following.
Chap. 4
- 30/32 -
4.8.1 Data for electrical connections
The electrical grid to which the machine is connected must meet the following requirements.
Proper machine efficiency is guaranteed only if all specifications are fully met.
DANGER!
In particular, abide by the value of 2 Ohm for max. grounding resistance.
ELECTRICAL SYSTEM DATA 1 of 1

CRITERIA SPECIFICATION
Electrical frequency in Hz See machine plate
Electrical absorption in kw See machine plate
Contemporaneity factor 0.7
Type of connection 3 phase + 1 ground wire, star connection:
TT;TN-C;TN-S
Max grounding resistance 2 Ohm
Max. power See machine plate
Protection B type device with delayed action with 0.3A adjustable
differential current.
Chap. 4
- 31/32 -
4.8.2 Data for the pneumatic system
The pneumatic system to which the machine is connected must meet the following requirements.
PNEUMATIC SYSTEM DATA 1 of 1

CRITERIA SPECIFICATIONS
Recommended diameter for the 1/2"
compressed air tube
Coupling diameters for connection 25 mm external
tube: 17 mm internal
Consumption of air at 6 bar 200 L/min for model with 2 spindles
360 L/min for model with 4 spindles
Optimal line pressure 6.5 bar
DANGER!
Risk of motorised spindle breaking.
Dust, condensation and oil damage the motorised spindle.
Use only dry, clean air:
 filtered,
 non lubricated
 condensation free.
Chap. 4
- 32/32 -
CHAPTER 5 – Controls and use of the machine
5
CHAPTER
Controls and use of the
machine
Chap. 5
- 1/62 -
CHAPTER CONTENTS
5 Controls and use of the machine ......................................................................................... 1
5.1 Location of machine control panels ....................................................................................................... 3
5.2 Machine controls ...................................................................................................................................... 4
5.2.1 Main switch ................................................................................................................................................ 6
5.2.2 Main pushbutton panel ............................................................................................................................... 7
5.2.3 Portable pushbutton control ..................................................................................................................... 10
5.2.4 Left-hand and right-hand bench pushbutton panel ................................................................................... 13
5.2.5 Left-hand and right-hand bench control pedal .......................................................................................... 14
5.3 Operating procedures ............................................................................................................................15
5.4 Machine turn on, start up and running procedures ............................................................................15
5.4.1 Start up procedure – preliminary operations ............................................................................................ 16
5.4.2 Start up procedure – turning on the machine ........................................................................................... 18
5.4.3 Start up procedure – Reset to zero .......................................................................................................... 20
5.4.4 Pre-heating the spindles........................................................................................................................... 23
5.5 Machine turn off procedures .................................................................................................................24
5.5.1 Procedure to turn off the machine for longer than two hours.................................................................... 26
5.6 Machine stop and start procedures ......................................................................................................27
5.6.1 Stop and start procedure for EMERGENCY events ................................................................................. 28
5.6.2 Stop and start procedure for controlled stop event - STOP ...................................................................... 30
5.6.3 Stop and start procedure for controlled stop event - RESET.................................................................... 31
5.6.4 Machine stop during machining................................................................................................................ 32
5.7 Operating procedures ............................................................................................................................33
5.7.1 Operating modes ...................................................................................................................................... 33
5.7.2 Operating mode - Manual......................................................................................................................... 34
5.7.3 Operating mode - Automatic .................................................................................................................... 36
5.7.4 Work cycles .............................................................................................................................................. 37
5.8 Equipping the machine ..........................................................................................................................39
5.9 Tools ........................................................................................................................................................40
5.9.1 General information regarding machine tools........................................................................................... 40
5.9.2 Diameter and weight of machine tools ..................................................................................................... 41
5.9.3 Sharpening machine tools ........................................................................................................................ 41
5.9.4 Machine tool assembly information .......................................................................................................... 42
5.9.5 Balancing machine tools .......................................................................................................................... 43
5.9.6 Cleaning machine tools ............................................................................................................................ 44
5.10 Tool loading and presetting...................................................................................................................45
5.11 Loading and blocking pieces for machining .......................................................................................47
5.11.1 Variable geometry table - “TGV” .............................................................................................................. 47
5.11.2 Adjusting the variable geometry table “TGV”............................................................................................ 48
5.11.3 Join the 2 variable geometry tables .......................................................................................................... 48
5.11.4 Rotation of resting surfaces...................................................................................................................... 49
5.11.5 Use of counter templates ......................................................................................................................... 49
5.11.6 Checking that the piece is blocked correctly ............................................................................................ 50
5.12 Checking machining ...............................................................................................................................51
5.13 Programming...........................................................................................................................................52
5.13.1 Overview .................................................................................................................................................. 52
5.13.2 Provideo: Part programme management ................................................................................................. 54
5.13.3 Softkey ..................................................................................................................................................... 55
5.13.4 Part Program Softkey Bar ........................................................................................................................ 55
5.13.5 Editor Softkey Bar .................................................................................................................................... 56
5.13.6 BACCI Softkey Bar................................................................................................................................... 57
5.14 ISO programming ...................................................................................................................................59
5.14.1 Management codes .................................................................................................................................. 59
5.14.2 Management plus variables ..................................................................................................................... 60
5.14.3 The SHARP programme .......................................................................................................................... 60
5.14.4 Example of “SHARPped”.......................................................................................................................... 61
5.14.5 Comments or hidden text ......................................................................................................................... 62
5.14.6 Operating sequence in automatic mode (AUTO) ..................................................................................... 62
5.14.7 Operating sequence in manual mode (MANUAL) .................................................................................... 62
Chap. 5
- 2/62 -
5.1 Location of machine control panels

Work and/or machine control parameters may be modified using the pushbutton panels on board the
machine and the control panel. A description of the controls present on the various machine control
panels is provided here following.
The machine must be run by qualified and authorised personnel who have read and fully comprehended
the instructions provided in this manual and who are familiar with the machine’s safety equipment and
devices.
In the event of serious malfunctions, or of unrecognised malfunctions, stop the machine and wait for the
intervention of qualified technicians.
LOCATION OF THE CONTROL PANELS 1 of 1
2,3,4
5 5
6
1. Main switch
2. main pushbutton panel
3. Industrial PC keyboard
4. Mobile pushbutton panel
5. Right and left bench pushbutton panel
6. Right and left bench pedals
Chap. 5
- 3/62 -
5.2 Machine controls

MACHINE CONTROLS 1 of 2
POS. IDENTIFICATION OF CONTROLS
1 Main switch
Main push-
2
button panel
Industrial PC
3
keyboard
Chap. 5
- 4/62 -
MACHINE CONTROLS 2 of 2
POS. IDENTIFICATION OF CONTROLS
Mobile push-
4
button panel
Right and left

bench
5
pushbutton
panel
6 Right and left

bench pedals
Chap. 5
- 5/62 -
5.2.1 Main switch
MAIN SWITCH 1 of 1
[1]
DESCRIPTION OF CONTROLS
POS. CONTROL DESCRIPTION
Two-position main switch (0 – 1)

Rotate the switch to switch the machine on or off:
[1] Main switch • When the switch is turned to the "0" position the machine
is off.
• When the switch is turned to position "1" the machine is
on. The electrical cabinet is supplied with power by the
electrical grid.
Chap. 5
- 6/62 -
5.2.2 Main pushbutton panel
CONTROLS ON THE MAIN PUSHBUTTON PANEL 1 of 3
[1]
When the pilot light is on, the machine is connected to the power
grid.
“Grid inserted” signal pilot
1
light
When the pilot light is off, the machine is disconnected from the
power grid.
Backlit control When the pushbutton is lit, the vacuum pump is on.
pushbutton: "LH bench
2
vacuum pump ON" Press the pushbutton to turn off the pump and block the pieces
with the press devices.
Backlit control When the pushbutton is lit, the vacuum pump is on.
pushbutton: "RH bench
3 vacuum pump ON" Press the pushbutton to turn off the pump and block the pieces
with the press devices.
Backlit control pushbutton: When the pushbutton is lit, the vacuum pumps are on.
4 "Stop vacuum pumps" Press the pushbutton to turn off the pumps and block the pieces
with the press devices
Chap. 5
- 7/62 -
Use this key selector switch to choose between manual and
automatic machine operating mode.
The 2 operating modes differ in terms of the degree of safety. The

degree of safety in manual operating mode is lower than that in
automatic mode. Only the machine operator is authorised to use
"Automatic / Manual"
5 this selector.
mode key selector switch
Remove and store the key to avoid unauthorised use.
Select “manual” mode only for operations to be carried out on

board the machine, such as: equipping the machine, machining
trial runs and maintenance tests, etc.
Select “automatic” mode for normal piece machining work.
When an axis goes into extra-stroke, use this selector to return
the axis to operating stroke limits.
"Return from extra-stroke”
6
key selector switch.
Only the machine operator is authorised to use this selector.
Remove and store the key to avoid unauthorised use.
Use this pushbutton to stop the axes and spindle. It does not turn
off the machine.
7 Working stop pushbutton
Re-start the cycle using the restart automatic cycle pushbutton.
"Turn on auxiliaries" Use this control to turn on the auxiliaries. Power supplies
8
control pushbutton (compressed air and electricity) must be connected.
9 RESET pushbutton Press the RESET pushbutton to reset the machine after a stop.
Chap. 5
- 8/62 -
“Start automatic cycle" Press this pushbutton to start the work programme.
10
control pushbutton
11 Pushbutton not present
Stops the machine in emergency mode and turns it off.
Cuts off power to axes and spindles 1).
Emergency stop This pushbutton has a mechanical block that keeps it in position;
12
pushbutton to reset, turn to the left.
Use this emergency pushbutton in case of imminent danger for

the operator.
Chap. 5
- 9/62 -
5.2.3 Portable pushbutton control
CONTROLS ON THE PORTABLE PUSHBUTTON CONTROL 1 of 3
When the pilot light is on, the pushbutton control panel is enabled.
"Pushbutton panel The control panel is enabled by pressing the? Soft key.
1
enabled" pilot light
When the pilot light is off, the control panel is disabled.
Use the potentiometer to vary axis and spindle speed at percents
between 0 and 100%.
2 "Override" potentiometer
The potentiometer is enabled in Manual and Automatic modes.
Press this pushbutton to confirm the operations of the portable

pushbutton control panel.
When the pushbutton is released, the operation of the portable
pushbutton control panel terminates.
“Life Man Switch” Collision hazard.

3 For all manual movements: observe axis orientation.
Pushbutton
The speed of all movements is reduced to a maximum of 2

m/min.
Rotation of the motorised spindle in manual mode is not
permitted.
“Move axis Z+” Control Use this control to move the Z axis is manual mode in the
4
Pushbutton positive direction.
“Move axis Z-” Control Use this control to move the Z axis is manual mode in the
5
Pushbutton negative direction.
Chap. 5
- 10/62 -
“Move axis C+” Pushbutton Use this control to move the C axis is manual mode in the
6
control positive direction.
“Move axis C+” Pushbutton Use this control to move the C axis is manual mode in the
7
control negative direction.
"CU" Pushbutton control Use this control to rotate the magazine into a more forwards
8
(Tool change, optional) position.
Use this control in "Programming for auto-teach” mode.
“Digitalise axis position”
9 To be used to reset the axes in JOG mode or to
pushbutton
BLOCK/UNBLOCK execution of programmes in MEM mode.
Use this control to stop axes and spindles.
10 "Stop" Pushbutton The STOP control does not turn off the machine.
“Move axis Y+” Pushbutton Use this control to move the Y axis is manual mode in the
11
“Move axis Y+” Pushbutton Use this control to move the Y axis is manual mode in the
12
Chap. 5
- 11/62 -
“Move axis X+” Pushbutton Use this control to move the X axis is manual mode in the
13
“Move axis X+” Pushbutton Use this control to move the X axis is manual mode in the
14
“Move axis A+” Pushbutton Use this control to move the A axis is manual mode in the
15
“Move axis A+” Pushbutton Use this control to move the A axis is manual mode in the
16
“Move axis Y2+” Use this control to move the Y2 axis is manual mode in the
17
Pushbutton control positive direction.
“Move axis Y2+” Use this control to move the Y2 axis is manual mode in the
18
Pushbutton control negative direction.
Chap. 5
- 12/62 -
5.2.4 Left-hand and right-hand bench pushbutton panel
CONTROLS ON THE LEFT-HAND AND RIGHT-HAND BENCH PANELS 1 of 1
Use this control to select sliding doors opening mode.
1 "Door” control pushbutton
Manual mode: opens and closes the loading sliding doors.
Automatic mode: closes the loading sliding doors.
Free for future applications
2 Not present
Stops the machine in emergency mode and turns it off.
Cuts off power to axes and spindles 1).
Emergency stop This pushbutton has a mechanical block that keeps it in position;
3 to reset, turn to the left.
pushbutton
Use the emergency pushbutton only in case of imminent

danger for the operator.
Chap. 5
- 13/62 -
5.2.5 Left-hand and right-hand bench control pedal
LEFT-HAND AND RIGHT-HAND BENCH CONTROL PEDAL 1 of 1
Use this control to select piece blocking mode.
• Manual mode:
The piece is blocked:
• For machines with T.G.V. tables with press devices:

The piece is blocked with low pressure exerted.
• For machines with T.G.V. tables, suction surface or suction

cup system:
The piece is vacuum blocked.
• Re-press the pedal to release the piece.

Premise: the loading door is open.
1 “Block piece” pedal • Automatic mode:

The piece is blocked:
• For machines with T.G.V. tables with press devices:

• The piece is blocked with low pressure exerted.
• For machines with T.G.V. tables, suction surface or suction

cup system:
• The piece is vacuum blocked.
• Re-press the pedal to release the piece.

The automatic release control releases the piece
automatically at the end of the cycle.
• Premise: the loading door is open.
Chap. 5
- 14/62 -
5.3 Operating procedures

The paragraphs that follow describe operator interventions required for proper machine functioning.
We recommend reading and comprehending the instruction manual, especially as regards operating
instructions and safety information.
5.4 Machine turn on, start up and running procedures

First machine start up must be carried out by our technical assistance service or by the maintenance
technician, after having been duly trained and qualified for initial start up operations.
The initial start up procedure must be carried out without loading pieces to be machined, to verify proper
functioning of the machine units and, subsequently, positioning a piece to check machine functioning
and proper efficiency of the piece holding devices.
Machine production is a function (with the exception of the limits specified in this manual) of the
customer choices. All types of production require preparing the machine based on the characteristics of
the piece to be produced.
The paragraphs that follow describe the procedures to turn on, start up and run the machine.
Chap. 5
- 15/62 -
5.4.1 Start up procedure – preliminary operations
MACHINE START UP PROCEDURE – PRELIMINARY OPERATIONS 1 of 2

Before beginning the procedures for machine start up, abide by the
following safety instructions:
Safety checks
• It is MANDATORY for the machine to be used by only one,
authorised operator and therefore, simultaneous use by two or more
persons is PROHIBITED.
• It is MANDATORY to check that if the machine has been stopped
1 for maintenance work, the servicing has been completed and the
machine safety devices have been restored (ex. guards, emergency
devices, etc.), and that the machine may be started up.
• It is MANDATORY to check that all safety devices have been
properly fitted on the machine and are efficient.
It is MANDATORY to check that all persons exposed to risks due to the
start up of mechanical parts are outside the machine safety enclosures
and warned of imminent machine start up.
Warnings /
Precautions • Risk of colliding with the machine frame or parts. Move cautiously
during machine start up operations.
2
Risk of slipping, tripping and falling near the machine control
stations. Move cautiously during machine start up operations.
Periodical • It is MANDATORY to always check proper efficiency of guards and
check of safety devices on the machine. To this end, carry out all the checks
3 guards and described in the “safety information” chapter.
safety devices
• It is FORBIDDEN to use the machine if the guards and safety devices
have been removed, are not working or are disabled, even momentarily.
• Open the main cut-off valve (9): Press and turn the knob clockwise.
Opening the
4
cut-off valve
Chap. 5
- 16/62 -
MACHINE START UP PROCEDURE – PRELIMINARY OPERATIONS 2 of 2

Check the pneumatic supply pressure.
Check
pneumatic Initial regulation of the pressure gauges:
5 • Check that the pressure gauge of the balancing cylinders (2) shows a
supply
pressures. working pressure of 6 bar.
If the pressure shown is not the correct working pressure, act on
the balancing cylinder pressure regulator (1) to increase or decrease
the pressure.
• Check that the pressure gauge of the door close/piece block (5) shows
a working pressure of 6 bar.

the respective pressure regulator (4) to increase or decrease the
pressure.
• Check that the pressure gauge of the spindle cooling system shows a
working pressure of 6 bar.

the respective pressure regulator (7) to increase or decrease the
pressure.
.
Chap. 5
- 17/62 -
5.4.2 Start up procedure – turning on the machine
START UP PROCEDURE – TURNING ON THE MACHINE 1 of 2

Safety checks
Warnings /
2
Periodical
check of • It is MANDATORY to always check proper efficiency of guards and
guards and safety devices on the machine. To this end, carry out all the checks
3 safety devices described in the “safety information” chapter.
• Turn the main switch to the "I" position.
Opening the
4
cut-off switch
Chap. 5
- 18/62 -
START UP PROCEDURE – TURNING ON THE MACHINE 1 of 2

Wait for the CN operating system to start up.
System start
5 The “log in” window will appear on the screen for password entry.
up
Reset the “Emergency” pushbuttons, if they have been pressed, by pressing

and turning them to the left.
Reset the
6 emergency
pushbuttons
Press "Reset".
7 RESET
• Press the "Turn on auxiliaries” (8) pushbutton

• The “Grid inserted” light (1) turns on to indicate that the machine is
powered.
Turn on
8
auxiliaries
Chap. 5
- 19/62 -
5.4.3 Start up procedure – Reset to zero
START UP PROCEDURE - RESET TO ZERO 1 of 3

Safety checks
Warnings /
2
Periodical
check of • It is MANDATORY to always check proper efficiency of guards and
guards and safety devices on the machine. To this end, carry out all the checks
3 safety devices described in the “safety information” chapter.
Chap. 5
- 20/62 -

Enable the portable pushbutton control from the main Menu
• The softkey changes colour.
The remote pushbutton panel PILOT LIGHT (1) turns on.
Enable the
portable
4
pushbutton
panel
• Turn the "Overdrive" potentiometer (2) gradually to "0%"
Reset the
5
potentiometer
Chap. 5
- 21/62 -

Reset the axes through the panel. From the main menu, press the Softkey F
RESET.
6 Reset axes
Turn the "Overdrive" potentiometer gradually to 100%.
Set
7
potentiometer
Chap. 5
- 22/62 -
5.4.4 Pre-heating the spindles
During the first daily start up and whenever the motorised spindle have cooled to ambient temperature,
all the motorised spindle must be put through a brief heating cycle, to permit the bearings to gradually
reach a uniform working temperature.
For this purpose, a programme must be created in which every motorised spindle is used in the following
manner:
SPINDLE PRE-HEATING PROCEDURE 1 of 1

STEP ROTATING SPEED CYCLE TIME
1 50% of max speed (12000 1/min) 5 min
Chap. 5
- 23/62 -
5.5 Machine turn off procedures

Per eseguire lo spegnimento procedere seguendo la seguente procedura:
MACHINE TURN OFF PROCEDURES 1 of 2

Press "Reset".
Machine
1 Reset
Press one of the emergency pushbuttons on the pushbutton panels.
Emergency
2
pushbuttons
• Exit the submenu of the Interface panel by returning to the main

Exiting the page.
3
submenu
Turn off the Windows operating platform:

• Click on START
• Click on CLOSE SESSION
Turn off
4 • Click on STOP SYSTEM
Windows
• Click on OK
The message “Now you may turn off the machine” will appear.
Chap. 5
- 24/62 -
MACHINE TURN OFF PROCEDURES 2 of 2

Turn the main switch to "0".
Cutting off
electrical
4 power to the
machine
Chap. 5
- 25/62 -
5.5.1 Procedure to turn off the machine for longer than two hours
For machine stops longer than 2 hours, follow the procedure described below.
MACHINE TURN OFF PROCEDURE – FOR LONGER THAN TWO HOURS 1 of 1

Close the main cut-off valve (turn the knob counter clockwise) and padlock
Cutting off it.
pneumatic The pneumatic system is disconnected from the pneumatic system. The
power to the filters discharge any impurities that may be present
machine .
DANGER!
Safety warning
2 The balancing cylinders remain pressurised even after the main valve has
been turned.
• Do not tamper with the respective pneumatic tubes to avoid sudden
movements of the work unit.
Chap. 5
- 26/62 -
5.6 Machine stop and start procedures

The paragraphs that follow describe the procedures to be followed to stop the machine and interrupt or
cut-off power supplies.
Indeed, there are three different types of machine stops that the user may perform to stop machine
operation
.
• The “Emergency” stop is performed if it becomes necessary to immediately stop machine operation
due to a hazard situation or an unexpected event. Press the closest “Emergency” pushbutton. The
programme being run is immediately interrupted, all movements are stopped with maximum
deceleration, electrical power is disconnected and the auxiliaries turn off.
• The "Stop" is used to stop the programme being carried out without fully stopping all machine
functions. Press the “STOP” key located on the main panel. The programme being run is immediately
interrupted; all movements are stopped with the deceleration set in the software parameters.
Electrical power is not disconnected. The auxiliaries remain turned on.
• The “Reset” stop is used to stop only a machining cycle and disable the programme by pressing the
Reset pushbutton on the main panel or the “Reset” key in the lower right-hand corner of the monitor.
We recommend this type of stop only for cycle standby purposes.
Chap. 5
- 27/62 -
5.6.1 Stop and start procedure for EMERGENCY events
If an accidental or intentional sudden machine stop has occurred, proper functional reset depends on
how the machine was stopped.
Proceed as described below.
STOP AND START PROCEDURE FOR EMERGENCY EVENTS 1 of 2

• Before using the machine, all persons involved must be familiar with the
location and use of all emergency pushbuttons on the machine control
panels, as shown in the photos that follow.
Press the
emergency
1 pushbutton
INFORMATION!
Pressing an emergency pushbutton (12) stops the machine in emergency
mode and the stop signal is sent. Moreover, pressing the emergency
pushbutton cuts off power to the axes and spindles.
To restart the machine:

• Clear the cause for the emergency stop
• Release the Emergency pushbutton (12)
Turn the pushbutton to the left.
• Press "Reset" (9)
Restart
2
procedure
Press the “Auxiliaries on” pushbutton (8)

The "Grid inserted" pilot light (1) turns on.
Turn on
3
auxiliaries
Chap. 5
- 28/62 -
STOP AND START PROCEDURE FOR EMERGENCY EVENTS 2 of 2

• If a person is in a hazard condition, press the emergency stop pushbutton

on any control panel.
4
Activating • The emergency stop is a safety measure and has priority over all other
the control controls. It is not synchronised with the feeding of the machined piece
that may therefore become jammed in one or more points on the machine
after the stop.
Chap. 5
- 29/62 -
5.6.2 Stop and start procedure for controlled stop event - STOP
STOP AND START PROCEDURE FOR CONTROLLED STOP EVENT - STOP 1 of 1

Press the
STOP Before using the machine, all persons involved must be familiar with the
pushbutton location and use of all STOP pushbuttons on the machine control panels.
1
To restart the machine after a machine STOP:

• Clear the cause for the stop
Restart
2
procedure
Press the “Start automatic cycle” pushbutton (10)
3 Start cycle
Chap. 5
- 30/62 -
5.6.3 Stop and start procedure for controlled stop event - RESET
STOP AND START PROCEDURE FOR CONTROLLED STOP EVENT - RESET 1 of 1

Press the Before using the machine, all persons involved must be familiar with the
RESET location and use of all RESET pushbuttons on the machine control
1 pushbutton panels.
To restart the machine after a machine STOP:

• Clear the cause for the stop
Start
2
procedure
Press the “Start automatic cycle” pushbutton (10)
3 Start cycle
Chap. 5
- 31/62 -
5.6.4 Machine stop during machining
If the machine is stopped during machining, the operator must remove the motorised spindle from the piece.
NOTE
Safety DANGER!
warning Risk of collision between the motorised spindle and the piece.
The system of coordinates may be turned with respect to the machine axes. The
direction to remove the tool from the piece is always Z+.
Remove the motorised spindle from the piece using the “Movement of axis Z+"
pushbutton
Chap. 5
- 32/62 -
5.7 Operating procedures

The paragraphs that follow describe the operator interventions required for proper machine functioning.
We recommend reading and comprehending the instruction manual, particularly as regards operating
instructions and safety regulations.
5.7.1 Operating modes
The machine may work in two modes.
• Manual
• Automatic
These two modes differ in terms of degree of safety. Manual mode is not as safe as automatic mode.
Only the operator running the machine may change the operating mode.
Chap. 5
- 33/62 -
5.7.2 Operating mode - Manual
Only the machine operator may use the machine in “manual” mode.
• The machine operator must use "manual" mode only for those operations that
must be followed closely.
• Insert the key in the operating mode selector switch and turn the selector to
“MANUAL” mode. Remove and store the key.
• The machine operator enters the enclosure while the machine is moving:
Speed of all movements is reduced to a maximum of 2 m/min.
• To enable any movement, the operator must press the specific movement
pushbutton on the remote pushbutton panel as well as the “Life Man Switch” and
keep it pressed until the desired position has been reached. When the pushbutton
is released, the movement stops.
• Rotation of the motorised spindle is not enabled in manual mode.
NOTE
DANGER!
Safety
warnings Crushing hazard
The operating head moves in all directions.
• Hold the remote control in one hand.
• Rest the other hand on the STOP pushbutton.
• Beware of moving machine parts.
NOTE
DANGER!
Safety
warnings Danger of flying dust, chips and machining scraps
• All machining scraps fly off the tool.
• The direction in which scraps fly may change rapidly.
• Use the following PPE: ,
Chap. 5
- 34/62 -
OPERATIONS IN MANUAL MODE 1 of 1

USER DESCRIPTION
The operations to be carried out with the machine in manual mode
are the following:
• Equipping the machine

• Cleaning the machine
Maintenance personnel • Maintenance
INFORMATION!
Any other operation with the machine in manual mode is forbidden.
Chap. 5
- 35/62 -
5.7.3 Operating mode - Automatic
Only maintenance personnel and the machine operator may use the machine in
“automatic” mode for normal machining of materials.
OPERATIONS IN AUTOMATIC MODE 1 of 1

USER DESCRIPTION
The operations to be carried out with the machine in automatic
mode are the following:
• Work cycles
Operator – Maintenance
personnel
INFORMATION!
Any other operation with the machine in automatic mode is
forbidden.
Chap. 5
- 36/62 -
5.7.4 Work cycles

ACTION DESCRIPTION
Load the part programme.
1
Press the “start cycle” pushbutton.
Load the piece on the bench.

3
Block the piece. Press the “Block piece” pedal.
Exit the loading area.

5
Chap. 5
- 37/62 -

ACTION DESCRIPTION
Close the door. Press the DOOR pushbutton (3).
The loading/unloading operator must carry out only steps from 3 to 6.
The machine operator may carry out all the steps.
Chap. 5
- 38/62 -
5.8 Equipping the machine
Only the machine operator may carry out the operations described in this section.
This section contains all the information inherent to equipping the machine.
It is divided in two parts. The first part deals with the tool, including safety instruction, choosing the right
tool, maintenance and presetting. The second part deals with how to block the piece.
Chap. 5
- 39/62 -
5.9 Tools
5.9.1 General information regarding machine tools
MAINTENANCE NOTE
Machine
maintenance
information INFORMATION!
The tools installed on the machine must be conformant to the EN 847-1:1997
directive.
TOOL INSTRUCTIONS 1 of 1
Pos. DESCRIPTION
Check the following parameters – information on the tool:
• Tool marking
• Manufacturer name
• Max number of revolutions
• Measurements: diameter, length...
• Tools must be marked.
• Work cycles
INFORMATION!
Tools must be marked and conformant to European Community directives. Check
the data on the plate (1).
NOTE
DANGER!
Cutting hazard
Safety The tool edges are sharp and may:
warning • Cut
• Puncture.
Handle tools with extreme care.
Use the following personal protection equipment (PPE): with metal mesh,
during tool replacement and handling.
Chap. 5
- 40/62 -
5.9.2 Diameter and weight of machine tools
Use only tools with diameters and weights correspondent to those specified in the table below.
Coupling Max diameter Rotation speed Max tool diameter Max tool weight
size tool shaft (mm) (rpm) (mm) (kg)
6000 / 9000 150 10
9000 / 12000 130 7
ER40 25
12000 / 15000 110 5
15000 / 18000 80 5
6000 / 9000 140 4
9000 / 12000 130 4
ER32 20
12000 / 15000 110 2,5
15000 / 18000 80 2,5
5.9.3 Sharpening machine tools
MAINTENANCE NOTE
Machine
maintenance INFORMATION!
information Tools must be kept sharp to reduce cutting force and motorised spindle working
temperature.
The heat generated by the motorised spindle itself may overheat the bearings and
lubricant. The overheated lubricant loses in efficiency and reduces the service life
of the motorised spindle bearings.
Chap. 5
- 41/62 -
5.9.4 Machine tool assembly information
MAINTENANCE NOTE
INFORMATION!
Use only spacers that correspond to the diagram below.
Machine
maintenance
information
Chap. 5
- 42/62 -
5.9.5 Balancing machine tools
Tools, tool holders and spacers must be dynamically balanced in G1.
MAINTENANCE NOTE
INFORMATION!
Rebalance the tool and tool holder after sharpening.
Machine
maintenance
Improper tool balancing may cause:
note
• Tool breaking
• Tool dislodging from the motorised spindle.
Balance tools and tool holders in G1.

Rebalance tools after sharpening, in G1.
NOTE
DANGER!
Danger of flying tool parts
Safety
warning
Use the following personal protection equipment (PPE): gloves with wire
mesh, during tool replacement and handling.
Use the following personal protection equipment (PPE): safety glasses when
sharpening tools.
Chap. 5
- 43/62 -
5.9.6 Cleaning machine tools
Gli utensili, i portautensili ed eventuali distanziali devono essere equilibrati dinamicamente in G1.
MAINTENANCE NOTE
INFORMATION!
Keep the following components clean:
• Cones
• Shafts
• Tool clamps
DANGER!
Machine Hazard of tool holder unit breaking
maintenance
information The presence of dust deposits on the tool stem may cause:
• Tool misalignment
• Improper tool blocking.
If the operator exerts too much torque when closing the clamp holder ring nut, the
shaft or tool holder threading may be damaged.
Clean tools with care.

Do not close the ring nut with a torque greater than that recommended.
RECOMMENDED TORQUE
Chap. 5
- 44/62 -
5.10 Tool loading and presetting
To preset, proceed as described below.
MACHINE PRESETTING 1 of 2
• Rotate the operating unit using the manual controls:
Portable control: Movement Axis A+ pushbutton (15) Movement Axis
A- pushbutton (16)
Positioning
1 spindle head
1
The spindle to be equipped is positioned upwards.
Unscrew the ring nut (1).
Unscrew ring
2
nut
Choose a clamp with a diameter suited to the tool. Insert the clamp in the
Choose cone.
3
clamp
Insert the tool in the clamp and after having positioned it in its seat, tighten the
4 Insert tool ring nut.
Chap. 5
- 45/62 -
MACHINE PRESETTING 2 of 2
• Rotate the operating unit using the manual controls:
Portable control: Movement Axis A+ pushbutton (15) Movement Axis
A- pushbutton (16)
Reposition
5
the head
The spindle to be equipped returns to work position.

Using an appropriate measuring device, measure tool length.
Tool
6
measurement
Update Enter the tool length in the programming software.

7
parameters
Repeat the above procedure for all other spindles on the head.
8
Chap. 5
- 46/62 -
5.11 Loading and blocking pieces for machining
5.11.1 Variable geometry table - “TGV”
Pieces may be positioned and blocked on the variable geometry table in various ways. Based on the
geometry, the shape and the weight of the piece, blocking may be carried out using pneumatic presses
and/or a vacuum pump.
POS. NAME
1 Vacuum pump connection point
2 50mm x 50mm chequering
For vacuum blocking
3 Metric ruler: Y axis
4 18 holes for 2 purposes:
 Blocking holes for counter templates
 Holes for vacuum block air passage
5 4 blocking screws for the resting surface on the
shelf
6 Dovetail milling
7 Shelf: steel support
8 4 fastening levers
After blocking, lift the lever and turn it inwards.
9 Metric ruler: X axis
Chap. 5
- 47/62 -
5.11.2 Adjusting the variable geometry table “TGV”
The table may be adjusted to better suit the piece, in the following manner.
L direction: Release the levers (8) and shift the shelf to the desired position.
P direction: The pneumatic presses move inside of the dovetail milling (6) along the bar.
5.11.3 Join the 2 variable geometry tables
To machine large pieces, the tables may be joined together in the CN programme. Table movement is
therefore synchronised.
Chap. 5
- 48/62 -
5.11.4 Rotation of resting surfaces
To adjust the TGV table for optimum piece blocking, the resting surfaces may be rotated by 90°.
5.11.5 Use of counter templates
Counter templates are not supplied with the machine.

The example shown below is only for information purposes.
POS. NAME
1 Holes to fasten the counter template on the table
2 Piece blocking presses
3 Piece end-stops
Chap. 5
- 49/62 -
CONSTRUCTION NOTE
Construction INFORMATION!
information When evaluating the creation of a counter template, take into account the following
considerations.
• Provide for at least 2 anchoring points at the ends.

• Provide for at least 2 piece blocking presses.
• Provide for 2 end-stops perpendicular to the piece.
5.11.6 Checking that the piece is blocked correctly
Counter templates are not supplied with the machine.

The example shown below is only for information purposes.
NOTE
DANGER!
Safety Danger of the piece or tool parts flying off the machine.
warning If the piece is not blocked adequately with respect to the force exerted by machining,
it may lead to:
 The piece flying off the machine or
 The tool breaking and flying off the machine.
Check that the piece is properly blocked before starting the work cycle.
After having assembled and adjusted the blocking devices, including counter templates if used, carefully
check that the piece is blocked properly. Check that the piece is blocked in all directions in which work
pressure will be applied.
Chap. 5
- 50/62 -
5.12 Checking machining
NOTE
DANGER!
Safety
Danger of the piece or tool parts flying off the machine.
warning
A wrong part programme or a part programme applied to the wrong piece or with the
piece not properly blocked may cause the tool to break and pieces of the tool to fly
off the machine.
Check the part programme before starting production.
After the machine has been equipped, the machine operator must check the work cycle. Usually
checking in original conditions works best. The only difference between this and the definitive cycle is
that the operator holds the remote control and reduces operating speed using the potentiometer, so as to
be able to intervene quickly in case of programming or equipment errors, etc.
Chap. 5
- 51/62 -
5.13 Programming
5.13.1 Overview
This chapter deals with machine programming. The fundamental parts of programming are the numerical
control and the software.
Machine programming is carried out in 3 steps.
STEP FUNCTION 1 of 2
Programming machining
By means of ISO programming (standard) or using a CAM software (optional) the

machine operator creates a part programme (PP) that contains all the machining to be
carried out on the piece.
This programming step is easily carried out, whatever the specific user requirements,
using various systems:
 ISO programming system (included in the standard configuration)

This system uses all the parameter programmes (MACRO), created by BACCI:
tenon execution; mortising-boring; shearing-boring; shearing-milling-boring, etc.
•
Therefore, one part of the system is customised to programme this machine. All the
information inherent to this customising is contained in this chapter.
For details regarding numerical control programming in general, please consult the
numerical control manual.
1  Self-teach system (included in the standard configuration).

This system also uses all the parameter programmes (MACRO), created by BACCI:
tenon execution; mortising-boring; shearing-boring; shearing-milling-boring, etc.
For details regarding programming, please consult the numerical control manual.
 ALPHACAM (optional).
This commercially sold software is a highly flexible software dedicated to

programming up to 5 axes, starting from a drawing or a sample. If this software is
loaded, Paolino Bacci provides a specially designed Post-Processor to improve
production performance simplify operations.
For details regarding programming, please consult the ALPHACAM manual.
 PITAGORA (optional)
This is a CAM-intelligent software, very easy to use but with all the power required
for machining. BACCI designed and intended this software specifically for
programming CNC work centres.
For details regarding programming, please consult the PITAGORA manual.
Chap. 5
- 52/62 -
STEP FUNCTION 2 of 2
Managing part programmes (PP).
In this step, the operator combines the part programme (PP) with the mechanical
characteristics of the equipped machine. The operator also specifies the size and
position of the tools and piece zero point.
This programming step is described in the section: Programme piece management and
2 Softkey.
MICROSCRIBE (optional)
This system finds paths and surfaces on an existing piece. For details regarding
programming, please consult the MICROSCIBE manual.
SHARP programme
The operator coordinates management of piece blocking and door opening based on
3 the machine operating mode: tandem or simultaneous.
This programming step is described in the section: ISO programming.
Chap. 5
- 53/62 -
5.13.2 Provideo: Part programme management
The CNC OSAI Series10 has a platform for part programme management.
To start the programme, click on the “ProVideo” icon on the WINDOWS desktop.
The programme has 5 modes:
N. MODE
1 Select
2 Set UP
3 Origin/Tool
4 Part Programme
5 Utility
Further details may be found in the CN manual.
Chap. 5
- 54/62 -
5.13.3 Softkey
Softkeys are controls enabled using the F5 - F9 function keys. The Softkeys are grouped in a bar located
at the bottom, in the “classic” screen view of the CN OSAI.
There are different Softkey bars based on the user mode.
Softkey will be abbreviated to SK hereinafter.

As an example, a brief explanation of the SK bars of the Part Program and the Editor is provided below.
Further details regarding these and other SK bars may be found in the CN manual.
5.13.4 Part Program Softkey Bar
From the main menu select the Softkey sequence.

• Part Program
Key
SOFTKEY FUNCTION
COPY Copies the name of the part programmes (PP hereinafter) into another with a
different name.
DELETE Cancels the selected part programme (PP).
RENAME Renames the selected part programme (PP).
BACCI UPR Starts the utility programme.
HELP Launches the help file of the corresponding menu.
EDIT Launches the editor programmes on PP. If the specified PP does not exist, one will
be created with that name.
SELECT DIR Displays the list of all the files present in the current folder. Pressing this Softkey
(SK) repeatedly automatically displays the PP contained in the other folders in the
system.
DIRECTORY Gives access to a submenu for the management of all the files/folders in the
system.
ACTIVATE Launches the selected PP for execution.
DEACTIVATE Deactivates the selected PP.
PP MANAGEMENT (Disabled)
Chap. 5
- 55/62 -
5.13.5 Editor Softkey Bar
From the main menu select the Softkey sequence.

• Part Program
• EDIT
The line editor is a programme used to draft and modify part programmes.
This editor may be used both to write programmes in a standard ISO language and for SELF-
PROGRAMMING.
CONFIG CYCLE CUT&PASTE HELP

MODIFY
DEL-LINE OLD-LINE SEARCH INCLUDE SEQUENCE
GEOMETRY CYCLE EXIT
F5 F6 F7 F8 F9
Key
SOFTKEY FUNCTION
CONFIG Modifies the Editor configuration.
CYCLE MODIFY (not to be used)
CUT&PASTE Used to select a group of lines and then erase, move and copy them.
HELP Displays help information.
DEL-LINE Erases the highlighted line.
OLD-LINE Restores the line deleted using DEL-LINE.
SEARCH Searches for numbers and words.
INCLUDE Inserts another PP in a predefined point in the current PP.
SEQUENCE Numbers a list of lines with the desired sequence.
GEOMETRY (disabled)
CYCLE (not to be used)
EXIT Exits the menu.
Chap. 5
- 56/62 -
5.13.6 BACCI Softkey Bar
The BACCI Softkey bar is a CN customisation to better adapt it to machine requirements.
From the main menu select the Softkey sequence:

• BACCI
Key
SOFTKEY FUNCTION 1 of 2
POS DISPLAY Displays axis position
If the contents are divided onto more than one page, use this SK to view the next
NEXT DISPLAY
page.
SELECT PROCESS Used to select a process.
ENLARGE Used to enlarge the screen view.
HELP Launches the help file for the corresponding menu.
Used to execute complete homing of all axes:
 During the cycle the CN must remain in MANUAL mode.
HOME
 The OVERRIDE potentiometer must not be at 0% or the homing cycle will not be
executed.
LUBRICATION Used to carry out a complete lubrication cycle.
Used to rotate a spindle after having pressed the ENABLE SPINDLE SK.
Following specify the parameters:
 Spindle number (optional): specify the number of the spindle to be activated
ROT. SPINDLE (1...4). Enter "1" if there is only one spindle.
 Number of rotations: specify the number of rpm.
 Direction of rotation: +1 = forwards; -1 = backwards
In manual mode, spindle rotation is disabled.
Used to access the Programming menu.
PROGRAMMING
Connected topic: Programming section.
Used to enable the portable remote control. In MANUAL mode the axes may be
KEYPAD moved using the corresponding pushbutton.
Connected topic: Machine controls chapter.
Used to enable spindle rotation. This function must be used whenever:
 Spindle start up is programmed with M3 from part programme.
ENABLE SPINDLE  The ROT SPINDLE SK is used.
In particular use conditions, the SK must be disabled and re-enabled for
proper machine functioning.
Chap. 5
- 57/62 -
SOFTKEY FUCNTION 2 of 2
This function may be used only by Paolino Bacci authorised personnel and is
password protected.
SPINDLES OFF This function is used to bypass spindle functioning even if they are programmed in a
part programme.
This SK works only together when the ENABLE SPIPNDLE SK is enabled.
BLOCKS OFF This function may be used only by Paolino Bacci authorised personnel and is
password protected.
Chap. 5
- 58/62 -
5.14 ISO programming

5.14.1 Management codes
To facilitate programming, the following “G” codes are present in the numerical control
CODE VARIABLE FUNCTION

G175 @OKWK_DX OK RH BENCH WORK (blocked and door not open)
G176 @OKWK_SX OK LH BENCH WORK (blocked and door not open)
G177 @OKRP_DX OK RH BENCH REST (not blocked and door open)
G178 @OKRP_SX OK LH BENCH REST (not blocked and door open)
@OK_SPA
@OK_SPB
G190 w <> SPEED REACHED AND SPINDLE w ROTATING
@OK_SPC
@OK_SPD
@SBL_DX
G231 RH BENCH UNBLOCK REQUEST
@SBLDX_OK
@SBL_SX
G232 LH BENCH UNBLOCK REQUEST
@SBLSX_OK
@SPA_FW
G281 SPINDLE 1 FORWARD (default)
@SPAFW_OK
@SPB_FW
G282 SPINDLE 2 FORWARD (default)
@SPBFW_OK
@SPC_FW
G283 SPINDLE 3 FORWARD
@SPCFW_OK
@SPD_FW
G284 SPINDLE 4 FORWARD
@SPDFW_OK
@SPA_RV
G285 SPINDLE 1 REVERSE
@SPARV_OK
@SPB_RV
@SPBRV_OK
@SPC_RV
@SPCRV_OK
@SPD_RV
@SPDRV_OK
G291 TURN ON SPINDLE ACCENSIONE MANDRINO
w< >  w number tool holder (1-4)
S< >  S numb of revolutions
R< >  R direction of rotation +1=right –1=left
@ST_DX
G601 AUTOMATIC UNBLOCKING RH BENCH
@STDX_OK
@ST_SX
G605 AUTOMATIC UNBLOCKING LH BENCH
@STSX_OK
Chap. 5
- 59/62 -
5.14.2 Management plus variables
To facilitate programming, the following “G” codes are present in the numerical control
CODE VARIABLE FUNCTION

@TIME_LUB 18000 Axis movement time between two subsequent lubrication
cycles
@S1,@S2,@S3@S4 Spindle 1,2,3,4 rotation speed
5.14.3 The SHARP programme
A part programme (PP) requires all the commands and controls for proper functioning and
synchronization between the doors and the centre of the work table. All these functions are managed by
a SHARP programme; the name of the programme to be executed must be entered in the SHARP
programme.
There are four different SHARP programmes:
SHARPPEND = to use the left and right benches in alternation

SHARPAND = to use both benches simultaneously
SHARPSX = to use only the left bench
SHARPDX = to use only the right bench
Chap. 5
- 60/62 -
5.14.4 Example of “SHARPped”
PROGRAMME CODE EXPLANATION
G0 M3 Enable spindle
G1 Safety positioning
G1 G79 Z0 F20000 preliminary
G1 G79 X-1500 P0 Q0 F20000 see up
G1 G79 B-90 C0 F10000 see up
"START" beginning of cycle label
(UAO,0) reset origins
(UDA) reset dual axes
(DAN) reset axes names
(DAN,YP) ; PROGRAM TABLE LH rename Y with P
G16 XY redefines interpolation plane
L393=2 ; USE P INTO TCP (TOOL TIP) uses the P axis in TCP compensation
L359=0 ; m o n PROGRAMMING OFF disables compensation 5 axes
h0 ; TOOL OFFSET TO ZERO disables tool offset table
G176 ; WAIT BLOCKING AND DOOR CLOSED LH standby for blocking and LH door closing
;-------- PROGRAM TO EXECUTE TABLE LH --------------
(CLS,nomefile.ext) ;------------------------------------------------ enter the name of the file to be executed on the left
; SPINDLES OFF all spindles turned off for precaution
G291 w1 r1 S0 see up
G291 5 see up
w3 r1 S0 see up
G605 ; AUTO UNBLOCKING LH Automatic unblocking LH
G232 ; OPEN DOOR LH Open left door
;--------------- TABLE RH --------------------------------------------
(UAO,0) reset origins
(UDA) reset dual axes
(DAN) reset axes names
(DAN,YQ) ; PROGRAM TABLE RH rename Y with Q
G16 XY redefines interpolation plane
L393=3 ; USE Q INTO TCP (TOOL TIP) uses the Q axis for TCP compensation
L359=0 ; m o n PROGRAMMING OFF disables compensation 5 axes
h0 ; TOOL OFFSET TO ZERO disables tool offset table
G175 ; WAIT BLOCKING AND DOOR CLOSED RH standby for blocking and RH door closing
;-------PROGRAM TO EXECUTE TABLE RH -----------------
(CLS,nomefile.ext) ;---------------------------------------------------- enter the name of the file to be executed on the right
; SPINDLES OFF
G291 w1 r1 S0
G291 w2 r1 S0
G291 w3 r1 S0
G291 w4 r1 S0 unblock RH loader
G601 ;AUTO UNBLOCKING TABLE RH open RH door
G231 ; OPEN DOOR RH skip to “start” label
(GTO,START)
Chap. 5
- 61/62 -
5.14.5 Comments or hidden text
Everything written on the line after the semicolon is ignored by the CN. Therefore, text not be carried out
may be “hidden” by preceding it with the “ ; ” or comments may be added to improve code
comprehension.
5.14.6 Operating sequence in automatic mode (AUTO)
When SHARP is launched for the first time (first cycle), the axes move to the initial position (safety
position) and the machine waits for the operator to block the piece and close the door. The repeated
sequence will be:
• Standby for left-hand blocking
• Standby for left-hand door closing
• [execution of left-hand programme]
• Piece unblocked and left-hand loading door opened
• Standby for right-hand blocking
• Standby for right-hand door closing
• [execution of right-hand programme]
• Piece unblocked and right-hand loading door opened
When the door is closed, blocking pressure increases from 2 to 6 bar for safety reasons. Low pressure
may also be adjusted by means of two pressure regulators (left and right) located inside the pneumatic
box.
Note: when the loading door is closed, the blocking/unblocking pedal is disabled.
To use vacuum blocking, just turn on the corresponding pump (using the respective pushbuttons on the
operator panel) and follow the same blocking procedure as that used for press blocking. The vacuum
gauge located near the loader will show the operator if blocking is effective or not.
5.14.7 Operating sequence in manual mode (MANUAL)
The loading doors may be opened in closed in manual mode by pressing the black pushbutton (“DOOR”
or “START”) located beside the doors. Blocking and unblocking (at low pressure) may be carried out
using the respective pedal, but only when the door is open.
As in automatic mode, blocking pressure increases from about 2 bar (low pressure) to 6 bar when the
doors are closed.
NOTE
Safety DANGER!
warning
Risk of piece or tool parts flying off.
Vacuum pumps may be turned off only when the blocking systems on both
benches are blocking.
Chap. 5
- 62/62 -
CHAPTER 6 – Maintenance
CHAPTER 6
Maintenance
Chap. 6
- 1/30 -
SHARP – Instruction manual
CHAPTER CONTENTS
6 Maintenance ........................................................................................................................... 1
6.1 Maintenance .............................................................................................................................................. 3
6.2 Safety instructions ................................................................................................................................... 4
6.2.1 Other interventions ..................................................................................................................................... 5
6.3 Maintenance timetable ............................................................................................................................. 6
6.3.1 Ordinary and extraordinary maintenance timetable .................................................................................... 6
6.4 6
6.4.1 Maintenance frequency for use of the machine in multiple shifts ............................................................... 8
6.5 Daily maintenance .................................................................................................................................... 9
6.5.1 Machine cleaning at the end of each work shift.......................................................................................... 9
6.5.2 Cleaning the FRL unit (Filter - regulator – lubricator) ............................................................................... 11
6.5.3 Recommended types of oil ....................................................................................................................... 12
6.5.4 Cleaning of tools and tool holders ............................................................................................................ 13
6.5.5 Recommended lubricant .......................................................................................................................... 14
6.6 Weekly machine maintenance ...............................................................................................................15
6.7 Monthly machine maintenance .............................................................................................................17
6.7.1 Recommended greases ........................................................................................................................... 18
6.8 Maintenance of the lubrication system ................................................................................................19
6.8.1 Checking and filling the automatic lubrication system .............................................................................. 20
6.8.2 Recommended greases ........................................................................................................................... 22
6.9 Six-monthly checks and controls .........................................................................................................23
6.10 Table of oils and greases .......................................................................................................................26
6.11 Extraordinary maintenance ...................................................................................................................27
6.12 Decommissioning ...................................................................................................................................28
6.13 Dismantling .............................................................................................................................................28
Chap. 6
- 2/30 -
6.1 Maintenance
This chapter contains the information required to keep the machine in optimal working condition.
MASTER has been designed so as to minimise maintenance operations.
To avoid any damage or inconvenience, the following maintenance instructions must be abided by.
MAINTENANCE NOTE
INFORMATION!
• A machine that is not regularly cleaned may entail risks for the operator's
Machine health. Bad maintenance causes early wear and increases the probability of
maintenance failures and breakdowns.
information
Clean the machine regularly with the recommended frequency.

Follow cleaning procedures.
All interventions must conform to the safety guidelines, and safety rules must be
rigorously complied with for the operator's integrity.
INFORMATION!
The concept of maintenance is closely linked with that of functionality. Maintenance stands for a series of
operations that must be performed for a product to remain effective and functional and meet the aims for
which it has been designed; product stands for a building, a machine, a system or a road. The
maintenance activity comprises a series of operations, such as tests, repairs, replacements of pieces or
parts of a product etc.
INFORMATION!
Lubrication maintenance operations can either be performed independently by operators, who intervene
during the work shift when a malfunction, such as low oil level, squeaking etc., arises (autonomous
maintenance intervention), or maintenance mechanics (planned maintenance intervention).
INFORMATION!
Before carrying out any maintenance operation which is not described in this manual, or in case you
have doubts on the information provided please contact Bacci S.r.L..
INFORMATION!
• All planned mechanical and electrical maintenance operations must be correctly carried out
according to the recommended timetable.
• All use and maintenance operations of the main commercial components of the system, which are
not mentioned in this manual, are contained in the suppliers' publications.
Chap. 6
- 3/30 -
6.2 Safety instructions
Maintenance interventions can only be performed by qualified personnel.

Unless otherwise specified, any maintenance operation must be performed while the machine is off.
Make sure in particular that the main switch (see Chapter 5: Machine controls) is on “0 off”, and all the air in
the pneumatic plant has been discharged through activation of the disconnecting valve (see Chapter 5: Switch
the machine on and off).
Both the main switch and the disconnecting valve must be locked with padlocks to prevent the machine
from being turned on again.
NOTE
DANGER!
Safety Electrocution hazard
warning
The machine must be switched off before performing maintenance operations. Live
parts or parts under pneumatic pressure could cause very serious lesions.
Switch off the machine and stop pneumatic supply of the machine. Lock the main
switch and the main disconnecting valve with a padlock.
NOTE
DANGER!
Safety Squeezing hazard
warning
Balancing cylinders remain under pressure even after activating the main
disconnecting valve.
Do not tamper with the respective pneumatic tubes to avoid sudden movement of
the working unit.
NOTE
DANGER!
Safety Danger of accidents and machine damage
warning
Never use compressed air to clean the machine. Air jets may move chips and
dust suspended in the air into the milling device or between contacts of
electrical components in the electrical cabinet.
Clean the machine by means of an industrial vacuum cleaner!
Chap. 6
- 4/30 -
NOTE
Safety ATTENTION!
warning Danger of machine damage
Rigorous compliance with periodic maintenance interventions is of

paramount importance: all machine components must be regularly checked
to prevent damage.
• Before starting the machine again, make sure that all maintenance interventions have been duly
completed and the start of the machine does not entail any risks for any operators and ordinary
persons (PES) that are present in the area.
• Immediately after termination of the maintenance intervention, restore and check the safety
devices that were removed during maintenance or repair.
• EXCLUSIVELY use original spare parts. Spare parts that are not original may not be compatible
and damage the machine.
• All interventions must be compatible with and rigorously meet the safety rules concerning
operators’ integrity.
6.2.1 Other interventions
If the need for maintenance and repair interventions that are not contained in this manual arises while
you use the machine, you are recommended to address the Technical Support department of Paolino
Bacci S.r.L.
For telephone and fax contact details please refer to Chap 1 "Manufacturer’s Identification and Contact
Details". In your requests of technical support, always mention the machine identification data referred to
in Chap 1 "How to request spare parts"
Keep the machine clean and in order:

• Avoid any possible damage
• Avoid that provisional repairs become permanent
Chap. 6
- 5/30 -
6.3 Maintenance timetable
6.3.1 Ordinary and extraordinary maintenance timetable
The following table contains the maintenance interventions of the machine and indicates the frequency
of maintenance. The frequency has been evaluated on the basis of one week made up of 5 workdays,
each made up of 8 hours, in normal ambient work conditions. To use the machine during more than one
work shift a day, please refer to paragraph "Frequency of maintenance for machine use during more than
one work shifts".
6.4
ORDINARY MAINTENANCE SCHEDULE – MECHANICAL TECHNICIAN 1 of 2
Personnel Interval – Product
qualification – frequency
Machine part / component
Mechanical hours
technician
1st degree machine cleaning:
• Resting surface
8h
• Cylinders and counter-template
• Microswitches and cams
• Bellows
Frl group:
• Check clean and top up if 8h See oils table

required
Centralised lubrication table:
8h NLGI-0
• Level check
1000 h NLGI-1
• Visual inspection
1000 h
• Pressure check
2nd degree machine cleaning:
• Silencing filters of the balancing

filters
• Conditioner filter of the electrical 40 h
cabinet
• Electrical board
• Inside the machine and under
the dust guards
Monthly maintenance:
NLGI-0
• Lubricate skids* and guides* 320 h
NLGI-1
• Discharge condensation from
electrical cabinet conditioner
Chap. 6
- 6/30 -
ORDINARY MAINTENANCE SCHEDULE – MECHANICAL TECHNICIAN 2 of 2

Mechanical hours
technician
Pneumatic system:
• Visual inspection of tubes, 1000 h

couplings, etc.
Mechanical system:
• Visual inspection of mechanical

components (guides, skids, 1000 h
recirculation screws) and of
components subject to wear
(bellows, guards)
*1 skids and guides that are not included in the automatic lubrication system.
ORDINARY MAINTENANCE SCHEDULE – ELECTRICAL / ELECTRONIC 1 of 1

TECHNICIAN
Electrical hours
technician
Electrical system:
• Visual inspection: wires and 1000 h

connections
• Check safety devices
ORDINARY MAINTENANCE SCHEDULE – MECHANICAL ASSISTANCE 1 of 1

TECHNICIAN
Electrical hours
technician
Pneumatic system:
• Check efficiency of solenoid 2000 h

valves (heating and punching)
and replace as required
• Check frl units and replace as 2000 h
required
Mechanical:
• Check transmission belt tension 2000 h

• Check tightness of mechanical 2000 h
parts (ring nuts, flanges, etc.)
Chap. 6
- 7/30 -
ORDINARY MAINTENANCE SCHEDULE – ELECTRICAL / ELECTRONIC 1 of 1

ASSISTANCE TECHNICIAN
qualification– Frequency
Machine part / component Mechanical hours
assistance
technician
• Overhaul electrical cabinet
conditioner
10.000 h
Electrical system:
• Electric, electronic and electro-
mechanical components
• Check electrical manifold of 2000 h
operating head and replace
brushes
• Electrical cabinet conditioner fan
Frequency is shown in h = working hours.
6.4.1 Maintenance frequency for use of the machine in multiple shifts
All maintenance intervals refer to use of the machine for one daily work shift. If the machine is used for
multiple shifts, the maintenance frequency must be increased.
• Every 8h hours of work after each shift; (every day for only one shift)
• Every 40 hours of work, that is every 5 shifts;.(once a week for only one shift)
• Every 160 hours of work, that is every 20 shifts; (once a month for only one shift)
• Every 320 hours of work, that is every 40 shifts.(every 2 months for only one shift)
• Every 1000 hours of work, that is every 125 shifts.(every 6 months for only one shift)
• Every 2000 hours of work, that is every 250 shifts.(once a year for only one shift)
• Every 10.000 hours of work, that is every 250 shifts.(every 5 years for only one shift)
INFORMATION!
The employer must provide appropriate PPE for maintenance work.
Chap. 6
- 8/30 -
6.5 Daily maintenance

6.5.1 Machine cleaning at the end of each work shift
PROCEDURE – MACHINE CLEANING AT THE END OF EACH WORK SHIFT 1 of 2

• Remove all chips and other machining waste.
Suction all chips with an appropriate industrial suction fan
Removal of
1
chips
• It is not allowed to clean by blowing compressed air as chips could enter

in-between the gears and jeopardise normal machine operation.
Machine
2
cleaning
During cleaning operations use the following PPE:
Chap. 6
- 9/30 -
PROCEDURE – MACHINE CLEANING AT THE END OF EACH WORK SHIFT 2 of 2

In particular, clean:
• The motorised spindle (1)

• The X axis bellows (2) (optional)
• The Z axis microswitch (3), the X axis microswitch (5) and the X and Z
axis cams (4)
• The variable geometry table "TGV"/ TGV piece resting system (7)
including the resting surface (6) and any cylinders and counter
templates
Clean
3 machine
components
MAINTENANCE NOTE
Machine INFORMATION!
maintenance • Risk of damage to the machine.
information
Do not use compressed air to clean the machine. The air jet may bring dust and
chips inside the dust guards.
Use an industrial vacuum to clean the machine.
Chap. 6
- 10/30 -
6.5.2 Cleaning the FRL unit (Filter - regulator – lubricator)
PROCEDURE – CLEANING THE FRL UNIT 1 of 1

Check proper working order of the balancing cylinder lubricator (1) and the
lubricator regulator for door closing/piece blocking (3).
Check
1 lubricator
and oil level
Check the oil level in the balancing cylinder oil tank (2) and in the door
closing/piece blocking oil tank (4).
Check and empty the spindle cooling condensation well (5), the door
closing/piece blocking condensation well (6) and the balancing cylinder
condensation well (7).
Check
2
condensation
Chap. 6
- 11/30 -
6.5.3 Recommended types of oil
Use one of the products listed in the table below or a type of hydraulic oil class ISO/UNI F or ISO/UNI H.
TRADEMARK TYPE OF OIL
AGIP Oso 10
ESSO Nuto H 5
MOBIL Velocite Oil No. 4
Q8 Puccini 4P
TEXACO 300 Oil 5
TOTAL Azolla ZS 15
MAINTENANCE NOTE
INFORMATION!
Machine • Danger of machine damage.
maintenance
information Exclusively use one of the forenamed types of oil.
Products different from those illustrated above can be incompatible with the oil
used by the manufacturer for the first filling.
Oils that are incompatible mixed together or used one after the other may form
substances that may be harmful to operation and seriously affect safety.
Chap. 6
- 12/30 -
6.5.4 Cleaning of tools and tool holders
CLEANING PROCEDURE FOR TOOLS AND TOOL HOLDERS 1 of 1

PHA
ACTION DESCRIPTION
SE
Dirt and/or excess of oil on contact surfaces reduce the clamping force.
• Clean the shank of tools (2) and the conical surface of tool holders (1).
• Apply a light layer of lubricant on the conical spindle housing.
• Check the state of tool cutting edges. Replace the tool if one of its
cutting edges is damaged or is not sharp.
• Only use tools/tool holders balanced in G1. Re-balance the tool after
each grinding session.
1 Cleaning
NOTE
DANGER!
Danger of projection of tool parts.
Safety
warning
Negligence in the maintenance of tools is one of the major causes of accident.
Clean and sharpen tools
Keep tools clean and sharpened.
Balance the tools in G1 after each grinding session.
Chap. 6
- 13/30 -
6.5.5 Recommended lubricant
Use only the product listed in the following table.
TRADEMARK TYPE OF LUBRICANT
METAFLUX Paste spray 70-81
Chap. 6
- 14/30 -
6.6 Weekly machine maintenance
AUTONOMOUS MAINTENANCE SCHEDULE – WEEKLY CLEANING 1 of 1

MAINTENANCE
TYPE OF PERSONNEL
PERSONNEL MACHINE STATUS
MAINTENANCE REQUIRED
QUALIFICATION
1 (one) MACHINE CUT-OFF

Cleaning Operators
MAINTENANCE EQUIPMENT AND MATERIALS
ACTIVITY
• Before working on any circuit or component, it is MANDATORY to
always check that there is no residual voltage or pressure in the
systems, making sure that work is carried out in safe conditions.
Risk of colliding with the machine frame or parts. Move cautiously
Safety checks during maintenance work.
1 • Risk of slipping, tripping and falling on machining scraps.
Move cautiously.
• Risk of flying dust and materials / risk of inhaling dust and materials.
• Based on the work performed, in addition to commonly work PPE, also
use one of the following: , PVC coveralls; ; , .

After 5 work shifts, in particular clean:
• The balancing cylinder silencer filters (n. 2 filters) (4)

• The filter of the conditioner on the electrical cabinet. Remove the grid
of the electrical cabinet conditioner (1)
• The inside of the electrical cabinet (2)
• The inside of the machine and under the dust guards
2 Cleaning
Chap. 6
- 15/30 -
NOTE
DANGER!
Danger of accidents and machine damage
Safety
warning Never use compressed air to clean the machine. Air jets may move chips and
dust suspended in the air into the milling unit or between contacts of
Clean the machine and the inside of the electrical cabinet by means of an
industrial vacuum cleaner
NOTE
DANGER!
Electrocution hazard
Safety
warning Never use compressed air to clean the machine. Air jets may move chips and
dust suspended in the air into the milling unit or between contacts of
Clean the machine and the inside of the electrical cabinet by means of an
industrial vacuum cleaner
Chap. 6
- 16/30 -
6.7 Monthly machine maintenance
AUTONOMOUS MAINTENANCE SCHEDULE – MONTHLY CLEANING 1 of 1

MAINTENANCE
TYPE OF PERSONNEL
QUALIFICATION
1 (one) MACHINE CUT OFF

Cleaning Operators
ACTIVITY
Move cautiously.

• Grease the skids (3) of the TGV tables using a manual or
automatic pump.
• Grease the guides (2 - 4) of the TGV system shelves using a
paintbrush.
• Discharge condensation from the conditioner (1) of the electrical
cabinet. See the attached manual.
2 Cleaning
Chap. 6
- 17/30 -
6.7.1 Recommended greases
Use only one of the products listed in the table below.
TYPE OF GREASE
NLGI-0 (or equivalent)
MAINTENANCE NOTE
INFORMATION!
• Risk of damage to the machine.
Machine
maintenance Use only grease that is resistant to high pressures. Otherwise, in case of
information separation of the oil soaps in the lubricant grease, the soaps may solidify and clog
the pneumatic system.
Use only the greases indicated above. Other products may not be compatible with
that used by the manufacturer for initial greasing. Greases that are not cross-
compatible, if mixed or used one following the other, may form substances that
may compromise functioning, with serious consequences for safety.
.
Chap. 6
- 18/30 -
6.8 Maintenance of the lubrication system
NOTE
DANGER!
Safety Risk of the spring flying free .
warning
Inside the well is a compressed, and therefore fully loaded, spring (1) (see plate 2).
Do not open the lubricant well.
Top up the well through the coupling joint (see procedure).
Chap. 6
- 19/30 -
6.8.1 Checking and filling the automatic lubrication system
AUTONOMOUS MAINTENANCE SCHEDULE – MONTHLY CLEANING –

1 of 2
CHECKING THE LUBRICANT LEVEL
MAINTENANCE
TYPE OF PERSONNEL
QUALIFICATION
Inspection Operators 1 (one) MACHINE CUT OFF
• lubricant
• pneumatic filling pump
ACTIVITY
Move cautiously.

Check the level of the lubricant grease in the well. Keep the well topped
up (electrical minimum level signal). A pump working on an empty well
2 Inspection may pump air into the system causing difficulties in increasing the
pressure or making it difficult to pump.
Inspect the entire system, including the rigid and flexible tubes (replace if
damaged), couplings (must be sealed) and all bearings (a small amount of
3 Visual inspection lubricant should be visible on the edge of each).
Check that the lubrication pump is working properly.
MAINTENANCE NOTE
Machine INFORMATION!
maintenance • Risk of damage to the machine.
information
It is important to bleed all air from the system. Correct pressure readings depend
on a circuit that is full of lubricant. Distributors containing air bubbles cannot signal
blocked points. To eliminate air from the system, follow the bleeding procedure
described in the attached manual.
Chap. 6
- 20/30 -
AUTONOMOUS MAINTENANCE SCHEDULE – MONTHLY CLEANING -

2 of 2
CHECKING THE LUBRICANT LEVEL
MAINTENANCE
TYPE OF PERSONNEL
QUALIFICATION

Inspection Operators
• lubricant
• pneumatic filling pump
ACTIVITY
Use clean lubricant because foreign bodies may clog the pump filling filter.
4 Fill the tank
Connect the pneumatic filling system to the centralised system coupling

point.
Connect the
5
system
Fill the tank to "maximum level".
6 Fill the tank
Chap. 6
- 21/30 -
MAINTENANCE NOTE
INFORMATION!
Machine
MAINTENANCE NOTE
Machine
maintenance INFORMATION!
information • Risk of damage to the machine.
Check system pressure. Follow the procedure described in the attached manual.
6.8.2 Recommended greases
Use only the products shown in the table below.
TYPE OF GREASE
MAINTENANCE NOTE
INFORMATION!
Machine
Chap. 6
- 22/30 -
6.9 Six-monthly checks and controls
AUTONOMOUS MAINTENANCE SCHEDULE – MONTHLY CHECKS 1 of 3

MAINTENANCE
TYPE OF PERSONNEL
QUALIFICATION

ACTIVITY
Move cautiously.

• Visually inspect the integrity of the electrical wires and wire holder
chains and replace any damaged components.
2 Inspection • Check that the electrical connectors are firmly fastened.
• Check the electrical, electronic and electro-mechanical components as
well as the electrical cabinet wiring.
Chap. 6
- 23/30 -
1
7
4 1
2
5 3
4
1

MAINTENANCE
TYPE OF PERSONNEL
QUALIFICATION
ACTIVITY
Check that the mechanical guards are present and not damaged.
• Enclosure (pos. 2)
• Divider wall (pos. 5) and (pos. 6)
Check that the pneumatic safety devices are working properly.

• Low pressure device (pos 7).
Check safety
3
devices Check that the electro-mechanical safety devices are working properly:
• Emergency pushbuttons (pos 1)
• Sensitive edges on the doors (pos 4)
• Interlock on the additional door (pos 3)
• Two-hand control on the remote control
This check is to be considered supplementary for all class I and III safety
devices, in that they are redundant systems.
Chap. 6
- 24/30 -

MAINTENANCE
TYPE OF PERSONNEL
QUALIFICATION
ACTIVITY
Check the • Visually inspect that the pneumatic tubes are not damaged.
4 pneumatic • Check that the pneumatic couplings are firmly fastened.
system
Visually inspect that the mechanical parts in continuous movement and
Check the subject to wear are not damaged:
5 mechanical • Guides, skids and recirculation bearing screws
components • Components subject to wear: bellows, guards
Chap. 6
- 25/30 -
6.10 Table of oils and greases
UNIT BRAND TYPE

Automatic lubrication NLGI-0 (or equivalent)
system: NLGI-1 (or equivalent)
axis guides, recirculation
screws
AGIP Oso 10
ESSO Nuto H 5
Pneumatic system: FRL MOBIL Velocite Oil No. 4
Units Q8 Puccini 4P
TEXACO 300 Oil 5
TOTAL Azolla ZS 15
Tool holders METAFLUX Paste spray 70-81
Chap. 6
- 26/30 -
6.11 Extraordinary maintenance
Knowledge, experience and special equipment are required for the interventions listed below.
Said interventions must only be performed by the technical assistance staff of Paolino Bacci S.r.l. or
technical staff authorised by Paolino Bacci S.r.l.
Pneumatic plant:
• Check of operation of solenoid valves (heating and jams), possible check of the FRL units and
replacement, if necessary
Electrical system:
• Electrical, electronic and electromechanical components
• Check of electrical collector of the working head and replacement of brushes
• Conditioner fan of electrical cabinet
• Review of electrical cabinet conditioner
Mechanics:
• Check of correct tensioning of transmission belts
• Check that mechanical parts (ring nuts, flanges etc.) are correctly fastened.
Chap. 6
- 27/30 -
6.12 Decommissioning
If the machine is not used for a long period of time, perform the following operations:
• Clean thoroughly
• Lubricate all moving parts
• Surface anti-corrosion treatments on all metal parts which are not painted (apply oil or spray MoS2).
• Cover the machine with a waterproof piece of cloth to protect it against dust and humidity.
6.13 Dismantling
The machine may have to be moved to different premises during its life cycle. In this case proceed as
follows.
Follow the steps listed below:
STEP OPERATION
1 Shut down the machine and disconnect it from power supply.

2 Remove and put back all tools located in the machine.
Clean the machine and protect the corrosion-prone products using
3
special products.
To transport and install the machine in the new premises, use the
4
means and methods described in this manual.
Once the machine has reached the end of its technical life, it must be decommissioned and must not be
used again for the purposes for which it was originally designed and manufactured; however, you must
make sure the parts and raw materials it is made up can be re-used. Said re-use must be performed
according to modalities and functions that differ from those for which individual machine parts and the
machine as a whole were designed and manufactured.
PAOLINO BACCI S.r.l. declines any responsibility arising from damage incurred by persons or objects
due to the re-use of individual machine parts for functions or assembly different from the original
functions or assembly. PAOLINO BACCI S.r.l. shall not implicitly or explicitly acknowledge the suitability
of machine parts that were reused after the final de-activation of the machine for dismantling purposes.
Electronic parts
Electronic cards, batteries, storage batteries and buffer batteries of the electrical cabinet are considered
to be hazardous and toxic waste. These parts must be disposed of by special authorised companies
according to directive: 2002/96/CE.
Chap. 6
- 28/30 -
Oil types
The oil types used during the work cycle of the machine and/or its maintenance must be disposed of
according to the EEC European Directive 75/439 of 16 July 1975.
In accordance to this directive all companies that dispose of used oil are obliged to provide the
competent authorities with information pertaining to the elimination and disposal of used oil and oil
residues.
Please note that according to Presidential Decree (DPR) N° 691 of 23 August 1982, it is obligatory to
address the CONSORTIUM OF USED OIL.
Chap. 6
- 29/30 -
Chap. 6
- 30/30 -
CHAPTER 7 – Messages - Alarms
CHAPTER 7
Messages – Alarms
Chap. 7
- 1/31 -
CHAPTER CONTENTS
7 Messages – Alarms ................................................................................................................ 1
7.1 Chapter contents ...................................................................................................................................... 3
7.2 List of alarms and messages................................................................................................................... 3
7.2.1 Alarm 01 – Logic initialising ........................................................................................................................ 3
7.2.2 Alarm 02 – Home axes ............................................................................................................................... 3
7.2.3 Alarm 03 – Machine off .............................................................................................................................. 4
7.2.4 Alarm 04 – Mode change not consented in Homing................................................................................... 4
7.2.5 Alarm 05 – Spindles together not permitted ............................................................................................... 5
7.2.6 Alarm 08 – Spindle reference timeout ........................................................................................................ 5
7.2.7 Alarm 09 – Axis servo error ........................................................................................................................ 6
7.2.8 Alarm 10 – Skew error................................................................................................................................ 6
7.2.9 Alarm 11 – Encoder error ........................................................................................................................... 7
7.2.10 Alarm 12 – Tolerance error ........................................................................................................................ 7
7.2.11 Alarm 13 – Emerg. Estop ........................................................................................................................... 8
7.2.12 Alarm 14 – CN Emergency......................................................................................................................... 8
7.2.13 Alarm 17 – SPINDLE REFERENCE ERROR............................................................................................. 9
7.2.14 Alarm 18 – OVER-TORQUE TIMEOUT ..................................................................................................... 9
7.2.15 Alarm 19 – LUBRICATION TIMEOUT ........................................................................................................ 9
7.2.16 Alarm 20 – LUBRICATION IN PROGRESS ............................................................................................. 10
7.2.17 Alarm 21 – LUBRICANT LEVEL LOW ..................................................................................................... 10
7.2.18 Alarm 22 – SPINDLE MANAGEMENT ERROR ....................................................................................... 10
7.2.19 Alarm 24 – SOFT EMERGENCY ............................................................................................................. 11
7.2.20 Alarm 25 – ENCLOSURE DOOR OPEN .................................................................................................. 11
7.2.21 Alarm 27 – AIR MISSING ......................................................................................................................... 12
7.2.22 Alarm 28 – AXIS CONTROL NOT OK...................................................................................................... 12
7.2.23 Alarm 29 – RH BLOCK MALFUNCTION .................................................................................................. 13
7.2.24 Alarm 30 – LH BLOCK MALFUNCTION .................................................................................................. 13
7.2.25 Alarm 33 – SPINDLE OR BLOCK OFF! ................................................................................................... 14
7.2.26 Alarm 34 – ENABLE LH OR RH BENCH! ................................................................................................ 14
7.2.27 Alarm 36 – LH SENSITIVE EDGE TRIGGERED! .................................................................................... 15
7.2.28 Alarm 37 – RH SENSITIVE EDGE TRIGGERED! .................................................................................... 15
7.2.29 Alarm 38 – LH GATE CLOSING TIMEOUT ............................................................................................. 16
7.2.30 Alarm 39 – RH GATE CLOSING TIMEOUT ............................................................................................. 16
7.2.31 Alarm 42 – LH A.P. BLOCKING TIMEOUT .............................................................................................. 17
7.2.32 Alarm 43 – RH A.P. BLOCKING TIMEOUT ............................................................................................. 17
7.2.33 Alarm 45 – AXIS C SW EXTRA-STROKE................................................................................................ 18
7.2.34 Alarm 46 – SPINDLE 1 CONTROL NOT OK ........................................................................................... 18
7.2.35 Alarm 47 – NOT PERMITTED IN POWER OFF ...................................................................................... 19
7.2.36 Alarm 48 – SPINDLE 2 CONTROL NOT OK ........................................................................................... 19
7.2.37 Alarm 49 – SPINDLE NOT ENABLED ..................................................................................................... 20
7.2.38 Alarm 51 – AXIS IN EXTRA- STROKE .................................................................................................... 21
7.2.39 Alarm 52 – CLAMP OPEN TIMEOUT ...................................................................................................... 22
7.2.40 Alarm 53 – CLAMP CLOSE TIMEOUT .................................................................................................... 23
7.2.41 Alarm 54 – TOOL CHANGE SPINDLE ROTATION NOT PERMITTED ................................................... 23
7.2.42 Alarm 58 – A.P. 2 RH BLOCK TIMEOUT ................................................................................................. 24
7.2.43 Alarm 59 – DISABLE RETURN FROM EXTRA-STROKE........................................................................ 24
7.2.44 Alarm 60 – RET. FROM EXTRAS. ONLY IN MANUAL ............................................................................ 25
7.2.45 Alarm 61 – A.P. 2 LH BLOCK TIMEOUT ................................................................................................. 25
7.2.46 Alarm 62 – WRONG DIRECTION RETURN FROM EXTRA-STROKE .................................................... 26
7.2.47 Alarm 68 – CANBUS NODE N ALARM .................................................................................................... 26
7.2.48 Alarm 70 – SERVODRIVE ALARM .......................................................................................................... 27
7.2.49 Alarm 71 – INVERTER 1 OVER-TORQUE .............................................................................................. 27
7.2.50 Alarm 72 – INVERTER 2 OVER-TORQUE .............................................................................................. 28
7.2.51 Alarm 74 – RESET ................................................................................................................................... 28
7.2.52 Alarm 76 – A AXIS SW EXTRA-STROKE ................................................................................................ 29
7.3 Other alarms ............................................................................................................................................30
7.3.1 Control alarms .......................................................................................................................................... 30
7.3.2 Inverter alarms ......................................................................................................................................... 30
Chap. 7
- 2/31 -
7.1 Chapter contents
This chapter provides information regarding the alarms and messages of the machine Numerical Control
system.
7.2 List of alarms and messages
7.2.1 Alarm 01 – Logic initialising
ALARM 01 – LOGIC INITIALISING 1 of 1

CONDITION / CHECK DESCRIPTION
Machine logic not initialised correctly.
MALFUNCTION
Various possible causes, including specifically:
• NC malfunction
POSSIBLE CAUSE
• Corrupted PLC Software
Contact technical assistance

REMEDY
7.2.2 Alarm 02 – Home axes
ALARM 02 – HOME AXES 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
At least one axis is not homed.
MALFUNCTION
There are various possible causes, in particular:

POSSIBLE CAUSE • The machine has just been turned on
Use:
 HOMING Softkey
REMEDY
 Home single axis (MANUAL -> HOME)
Chap. 7
- 3/31 -
7.2.3 Alarm 03 – Machine off
ALARM 03 – MACHINE OFF 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The machine is not powered.
MALFUNCTION
 Machine turned on but not yet powered
POSSIBLE CAUSE  A CNC error has turned off the machine
 The machine logic has caused a power drop
Insert power:
 Press the TURN ON AUXILIARIES pushbutton
 If this is not possible:
 Check for other error messages and read the relative description and
measures to be taken
 Check that the emergency mushroom pushbuttons (red) are released
REMEDY
Only for qualified technicians:
 Check that the automatic switches inside the electrical cabinet are
inserted
 Check the position of the red selector (cabinet door bypass open)
inside the electrical cabinet
7.2.4 Alarm 04 – Mode change not consented in Homing
ALARM 04 – MODE CHANGE NOT CONSENTED IN HOMING 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The NC is in HOLD condition. Axis movement is impeded.
MALFUNCTION
POSSIBLE CAUSE • The CN mode was changed during axis homing.
 Press RESET.
REMEDY  Home the axes.
Chap. 7
- 4/31 -
7.2.5 Alarm 05 – Spindles together not permitted
ALARM 05 – SPINDLES TOGETHER NOT PERMITTED 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
At least two spindle contactors activated together on the same inverter.
MALFUNCTION
POSSIBLE CAUSE • PLC or NC error

REMEDY
7.2.6 Alarm 08 – Spindle reference timeout
ALARM 08 – SPINDLE REFERENCE TIMEOUT 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Inverter serial malfunction
MALFUNCTION
• NC serial door not working
POSSIBLE CAUSE • Inverter serial door not working
• Error or damage to connection wires
 Check the connection between the NC serial door (COM2) and the
inverter
 Check NC status
 NC errors or other PLC alarms
REMEDY  Go to process 2 (softkey SELECT PROCESS) and check the error
message of the management programme (RIFSER)
 Check inverter status
 Message on display
Chap. 7
- 5/31 -
7.2.7 Alarm 09 – Axis servo error
ALARM 09 – AXIS SERVO ERROR 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The axis position error has exceeded the threshold set in the NC parameters.
MALFUNCTION Machine power drops and the error message appears. Error CN EE001

• A collision
• Speed too high,
POSSIBLE CAUSE • An interruption along the connection between servomotor and activation
or
• A missing phase along the power supply line (ex. blown fuse).
 Find and remove the cause

 Press RESET
REMEDY  Press the TURN ON AUXILIARIES pushbutton.
 Check for other error messages.
7.2.8 Alarm 10 – Skew error
ALARM 10 – SKEW ERROR 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The position error of a slave axis with respect to SHARP (dual axis) exceeds
MALFUNCTION the threshold value set in the NC parameters. Error CN EE002

• A collision
POSSIBLE CAUSE • Excessive motor strain
• Motor or drive malfunction
 Check the possible causes of a collision

 Check status of drives and motor
REMEDY
 Check wiring between NC, drive and motor
 Check the mechanical connection between the motor and the axis
and the movement mechanics.
Chap. 7
- 6/31 -
7.2.9 Alarm 11 – Encoder error
ALARM 09 – ENCODER ERROR 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Axis encoder malfunction. Error CN EE003
MALFUNCTION
• Encoder connection error
POSSIBLE CAUSE • Damaged wire
• Damaged encoder
 Check motor encoder and drive connection wires

REMEDY  Check motor and motor encoder status
7.2.10 Alarm 12 – Tolerance error
ALARM 12 – TOLLERANCE ERROR 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Axis requested position not reached in the maximum permitted time. Error CN
MALFUNCTION EE004

 A collision, a obstacle to movement
POSSIBLE CAUSE
 Excessive friction during a movement
 Check the possible causes of a collision
REMEDY Only for qualified technicians:

 Check movement mechanics
Chap. 7
- 7/31 -
7.2.11 Alarm 13 – Emerg. Estop
ALARM 13 – EMERG. ESTOP 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The chain of emergencies has been interrupted.
The elements of the emergency chain are:
 Emergency pushbuttons,
 The door of the electrical board and the selector switch (disable door
micro),
MALFUNCTION If the board is open, the machine cannot be started without turning the
selector clockwise. The selector is usually located to the left of the main
switch. Similarly, the machine will not turn on if the selector inside the board is
turned to the left to work with the door open (red light turned on) when the
door is closed.

• An emergency pushbutton is pressed.
POSSIBLE CAUSE
• Interruptions or short circuits along the emergency line
 Check that all emergency pushbuttons are released.

 Check that the selector (disable door micro) is turned to the left.
 Press RESET.
REMEDY
 Press the TURN ON AUXILIARIES pushbutton.
If the error persists, contact technical assistance.
7.2.12 Alarm 14 – CN Emergency
ALARM 14 – CN EMERGENCY 1 of 1
ALARMCONDITION /
DESCRIPTION
CHECK
NC command error from
MALFUNCTION
• PLC or NC malfunction
POSSIBLE CAUSE
REMEDY
Chap. 7
- 8/31 -
7.2.13 Alarm 17 – SPINDLE REFERENCE ERROR
ALARM 17 – SPINDLE REFERENCE ERROR 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Number of revolutions requested for spindle is out of permitted range.
MALFUNCTION
• Spindle programmed speed exceeds permitted limits.
POSSIBLE CAUSE
 Check spindle speed settings in the part programme.
REMEDY
7.2.14 Alarm 18 – OVER-TORQUE TIMEOUT
ALARM 18 – OVER-TORQUE TIMEOUT 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The spindle is subjected to over-torque for a prolonged time.
MALFUNCTION
There are various possible causes:
• Excessive machining parameters
POSSIBLE CAUSE
• Excessive resistance of material
 Reduce feeding speed, or

 Reduce the material to be removed
REMEDY  Increase the number of tool revolutions (if provided for by the tool
manufacturer)
7.2.15 Alarm 19 – LUBRICATION TIMEOUT
ALARM 19 – LUBRICATION TIMEOUT 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The lubrication cycle was not completed correctly in the foreseen time.
MALFUNCTION
POSSIBLE CAUSE  Lubrication circuit clogged or leaking
 Check the lubrication system.

REMEDY
Chap. 7
- 9/31 -
7.2.16 Alarm 20 – LUBRICATION IN PROGRESS
ALARM 20 – LUBRICATION IN PROGRESS 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Automatic lubrication cycle in progress.
MALFUNCTION
 Automatic or manual lubrication request
POSSIBLE CAUSE
 No intervention required.
REMEDY
7.2.17 Alarm 21 – LUBRICANT LEVEL LOW
ALARM 20 – LUBRICANT LEVEL LOW 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The oil level in the lubrication pump tank is at a minimum.
MALFUNCTION
 Automatic or manual lubrication request.
POSSIBLE CAUSE
 Fill the tank. See Maintenance Chapter
REMEDY
7.2.18 Alarm 22 – SPINDLE MANAGEMENT ERROR
ALARM 22 – SPINDLE MANAGEMENT ERROR 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Two different rotation directions have been indicated for the same spindle.
MALFUNCTION
 PLC error
POSSIBLE CAUSE
REMEDY
Chap. 7
- 10/31 -
7.2.19 Alarm 24 – SOFT EMERGENCY
ALARM 24 – SOFT EMERGENCY 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
One of the Stop pushbuttons has been pressed.
There are 3 Stop pushbuttons:
MALFUNCTION  One at each of the sliding doors for material loading
 One on the portable remote control.

• Stop pushbutton pressed
POSSIBLE CAUSE
• Stop pushbuttons wired incorrectly or wiring interrupted
 Release the pushbutton that has been pressed: turn the pushbutton
counter clockwise
REMEDY  Press Reset
 Check wiring
7.2.20 Alarm 25 – ENCLOSURE DOOR OPEN
ALARM 25 – ENCLOSURE DOOR OPEN 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Each of the sliding side doors that access the machine cabin is equipped with
a micro.
MALFUNCTION
One of the micros is signalling that the door is open.

 One of the doors has opened automatically (selector)
POSSIBLE CAUSE  The connection of one of the micros is defective.
 One of the micros is defective.
 The micros are connected in sequence.

Systematically check the micro circuit: all the door micros must be
REMEDY closed during machining.
Chap. 7
- 11/31 -
7.2.21 Alarm 27 – AIR MISSING
ALARM 27 – AIR MSSING 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The pressure gauge signals that the air pressure is not sufficient.
MALFUNCTION
 Pneumatic supply interrupted.
 Pressure gauge calibration error.
POSSIBLE CAUSE
 Pressure gauge defective.
 Wiring to NC defective
 Check the supply tubes.

 Check the pressure gauge
REMEDY  Check the electrical wiring of the pressure gauge at NC ’input
 If the error persists, contact technical assistance.
 BP5
COMPONENT CODE
7.2.22 Alarm 28 – AXIS CONTROL NOT OK
ALARM 28 – AXIS CONTROL NOT OK 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
One of the drives of the axis motors is in alarm state.
MALFUNCTION
 Overload
 Encoder malfunction
POSSIBLE CAUSE  Motor malfunction
 Control malfunction
 Electrical circuit malfunction
 Turn off the machine: turn the main switch to the left.
 Leave the machine off for at least 30 seconds.
 Turn on the machine: turn the main switch to the right.
REMEDY
 Check electrical and signal wiring between motor – control - NC
 If the error persists, contact technical assistance.
Chap. 7
- 12/31 -
7.2.23 Alarm 29 – RH BLOCK MALFUNCTION
ALARM 29 – RH BLOCK MALFUNCTION 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
One of the piece blocking pressure gauges signals a pressure drop.
MALFUNCTION
• Pneumatic supply has been interrupted
• Pressure gauge calibration error
POSSIBLE CAUSE
• Pressure gauge defective
• Wiring error between pressure gauge and NC.

 Check pneumatic tubes and couplings
REMEDY  Check pressure gauge calibration
 If necessary, replace pressure gauge
In the upper section of the pneumatic box:

COMPONENT CODE  BP1D: right-hand loader (Q axis)
7.2.24 Alarm 30 – LH BLOCK MALFUNCTION
ALARM 30 – LH BLOCK MALFUNCTION 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
MALFUNCTION One of the piece blocking pressure gauges signals a pressure drop
POSSIBLE CAUSE
• Wiring error between pressure gauge and NC.

REMEDY  Check pressure gauge calibration
 If necessary, replace pressure gauge
In the upper section of the pneumatic box:

COMPONENT CODE  \
Chap. 7
- 13/31 -
7.2.25 Alarm 33 – SPINDLE OR BLOCK OFF!
ALARM 33 – SPINDLE OR BLOCK OFF! 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The SPINDLE OFF SK has been pressed, so the part programme is executed
with the spindle turned off, or the BLOCKS OFF SK has been pressed, so the
MALFUNCTION machine does not wait for the block OK signal and the loading door to be
closed.
SK pressed,
POSSIBLE CAUSE
Wiring error between pressure gauge and NC
7.2.26 Alarm 34 – ENABLE LH OR RH BENCH!
ALARM 34 – ENABLE RH OR LH BENCH! 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
TCP enabling has been requested using the TOOL TIP softkey without having
MALFUNCTION previously specified the bench.
SK pressed ,
POSSIBLE CAUSE
• Wiring error between pressure gauge and NC
 Before enabling the TCP using the softkey, choose one of the
REMEDY benches.
Chap. 7
- 14/31 -
7.2.27 Alarm 36 – LH SENSITIVE EDGE TRIGGERED!
ALARM 36 – LH SENSITIVE EDGE TRIGGERED! 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The loading door was closing. The sensitive edge detected an obstacle,
MALFUNCTION therefore the door reopened.

• Obstacle preventing door from closing
POSSIBLE CAUSE • Sensitive edge malfunction
• Wiring error between NC input card and sensitive edge
 Remove the obstacle

 Check wiring
7.2.28 Alarm 37 – RH SENSITIVE EDGE TRIGGERED!
ALARM 37 – RH SENSITIVE EDGE TRIGGERED! 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The loading door was closing. The sensitive edge detected an obstacle,
MALFUNCTION therefore the door reopened.

• Obstacle preventing door from closing
POSSIBLE CAUSE • Sensitive edge malfunction
• Wiring error between NC input card and sensitive edge
 Remove the obstacle

 Check wiring
Chap. 7
- 15/31 -
7.2.29 Alarm 38 – LH GATE CLOSING TIMEOUT
ALARM 38 – LH GATE CLOSING TIMEOUT 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The loading door did not close in time.
MALFUNCTION
• Mechanical obstacle to cylinder movement or door closing.
• Leaks in the pneumatic circuit
POSSIBLE CAUSE • Malfunction of the door cylinder end-of-stroke micro
• Wiring errors between the door micro and the PLC input card.
• Loading door control solenoid valve error or defective wiring
 Check movement of loading doors.

 Check the micros on the pneumatic cylinders that control the doors
and the electrical wiring.
REMEDY
 Check for possible air leaks
 Check the open/close control solenoid valve and the electrical wiring.
7.2.30 Alarm 39 – RH GATE CLOSING TIMEOUT
ALARM 39 – RH GATE CLOSING TIMEOUT 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The loading door did not close in time.
MALFUNCTION
• Mechanical obstacle to cylinder movement or door closing.
• Leaks in the pneumatic circuit
POSSIBLE CAUSE • Malfunction of the door cylinder end-of-stroke micro
• Wiring errors between the door micro and the PLC input card.
• Loading door control solenoid valve error or defective wiring
 Check movement of loading doors.

 Check the micros on the pneumatic cylinders that control the doors
and the electrical wiring.
REMEDY
 Check for possible air leaks
 Check the open/close control solenoid valve and the electrical wiring.
Chap. 7
- 16/31 -
7.2.31 Alarm 42 – LH A.P. BLOCKING TIMEOUT
ALARM 42 – LH A.P. BLOCKING TIMEOUT 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Part blocking pressure gauge malfunction.
MALFUNCTION
• Pneumatic supply interrupted
POSSIBLE CAUSE
• Wiring defect with NC

 Check pressure gauge and calibration
REMEDY
 Check wiring
In the upper part of the pneumatic box:

COMPONENT CODE  BP1S: left-hand loader (P axis)
7.2.32 Alarm 43 – RH A.P. BLOCKING TIMEOUT
ALARM 42 – RH A.P. BLOCKING TIMEOUT 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Part blocking pressure gauge malfunction.
MALFUNCTION
POSSIBLE CAUSE
• Wiring defect with NC

 Check pressure gauge and calibration
REMEDY
 Check wiring
In the upper part of the pneumatic box:

COMPONENT CODE  BP1D: left-hand loader (Q axis)
Chap. 7
- 17/31 -
7.2.33 Alarm 45 – AXIS C SW EXTRA-STROKE
ALARM 45 – AXIS C SW EXTRA-STROKE 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The un-homed axis is out of permitted software limits.
MALFUNCTION
• C axis out of stroke
POSSIBLE CAUSE
• PLC memory error
 In manual mode, bring the C axis within normal stroke, so that homing
does not damage the machine
 In case of PLC memory error, reset the variable @EXCSW_C from
REMEDY VARIABLES – PLUS VARIABLES, then press RESET and home the
axis. Subsequently, reset the variable @EXCSW_C to 1 (only
qualified technician).
7.2.34 Alarm 46 – SPINDLE 1 CONTROL NOT OK
ALARM 46 – SPINDLE 1 CONTROL NOT OK 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The spindle control (inverter) signals a malfunction
MALFUNCTION
• Inverter off or in alarm state
POSSIBLE CAUSE • Spindle – inverter wiring error
• Inverter – PLC input wiring error

 Check inverter conditions and alarms
 Check inverter fuses
 Check inverter – spindle wiring
REMEDY
 Check inverter – NC input wiring
 Turn the machine off and on again
 Contact technical assistance
Chap. 7
- 18/31 -
7.2.35 Alarm 47 – NOT PERMITTED IN POWER OFF
ALARM 47 – NOT PERMITTED IN POWER OFF 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
ENABLE SPINDLE SK pressed with power disconnected
MALFUNCTION
 Power the machine before enabling the spindles

REMEDY
7.2.36 Alarm 48 – SPINDLE 2 CONTROL NOT OK
ALARM 48 – SPINDLE 2 CONTROL NOT OK 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The spindle control (inverter) signals a malfunction
MALFUNCTION

 Check inverter conditions and alarms
 Check inverter fuses
 Check inverter – spindle wiring
REMEDY
 Check inverter – NC input wiring
 Turn the machine off and on again
Chap. 7
- 19/31 -
7.2.37 Alarm 49 – SPINDLE NOT ENABLED
ALARM 49 – SPINDLE NOT ENABLED 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Attempt to turn on spindle that is not enabled.
MALFUNCTION
 Press ENABLE SPINDLE SK

 In automatic mode, from the programme, check the presence of the
REMEDY
M3 code in the part programme (or in SHARP)
Chap. 7
- 20/31 -
7.2.38 Alarm 51 – AXIS IN EXTRA- STROKE
ALARM 51 – AXIS IN EXTRA- STROKE 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
An axis has exceeded the maximum permitted stroke limit, tripping a
MALFUNCTION mechanical end-stop.

• Axis out of maximum stroke (not homed)
• Presence of chips between the axis and the end-stop
POSSIBLE CAUSE
• End-stop defective
• Defective wiring
 If the axis is actually in extra-stroke, follow the procedure described in

the table below.

REMEDY
 Remove chips
 Check proper functioning of end-stop
 Check wiring
PROCEDURE TO CLEAR EXTRA-STROKE 1 of 1

AZIONE DESCRIPTION
1 Find which axis is in extra-stroke.
2 Turn the “Return from extra-stroke” selector to the right.
3 Press Reset
Turn on the machine again using the “Turn on auxiliaries” pushbutton.
4
The "Grid connected" light turns on.
5 Turn the "Automatic/Manual" selector to the right.
WARNING!
Risk of damaging the machine.
6
Check which direction the axis must be moved in to return it to operating range.
The axis is in the operating range.
Move the axis using the remote control in the operating range.
7
Warning: move the axis in the right direction!
8 Turn the "return from extra-stroke" selector to the left.
Chap. 7
- 21/31 -
7.2.39 Alarm 52 – CLAMP OPEN TIMEOUT
ALARM 52 – CLAMP OPEN TIMEOUT 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The tool change spindle clamp has not opened in time.
MALFUNCTION
• Surfaces “stuck together”
• Defective solenoid valve
• Pneumatic problem – tube crushed
POSSIBLE CAUSE
• Defective sensor
• Defective wiring between solenoid valve or sensors and NC i/o cards
• Obstacle to movement

 Periodically unblock the clamp to keep the surfaces from sticking
together
 Use grease to avoid the surfaces from sticking together
 Check the solenoid valve and the wiring
REMEDY
 Check the pneumatic system
 Check sensors and connections
 Clean tool change
Chap. 7
- 22/31 -
7.2.40 Alarm 53 – CLAMP CLOSE TIMEOUT
ALARM 53 – CLAMP CLOSE TIMEOUT 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
MALFUNCTION The tool change spindle clamp has not closed in time
• Defective solenoid valve
• Pneumatic problem – tube crushed
POSSIBLE CAUSE • Defective sensor
• Defective wiring between solenoid valve or sensors and NC i/o cards
• Obstacle to movement

 Check the solenoid valve and the wiring
 Check the pneumatic system
REMEDY  Check sensors and connections
 Clean tool change
7.2.41 Alarm 54 – TOOL CHANGE SPINDLE ROTATION NOT PERMITTED
ALARM 53 – TOOL CHANGE SPINDLE ROTATION NOT PERMITTED 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Tool change spindle rotation not permitted.
MALFUNCTION
• Clamp not closed
POSSIBLE CAUSE
• Tool missing from clamp
 Unblock and re-block tool

REMEDY  Check for other error messages
Chap. 7
- 23/31 -
7.2.42 Alarm 58 – A.P. 2 RH BLOCK TIMEOUT
ALARM 58 – A.P. 2 RH BLOCK TIMEOUT 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Part blocking pressure gauge 2 malfunction
MALFUNCTION
POSSIBLE CAUSE
• Defective pressure gauge
• Wiring with NC defective
• Check pneumatic tubes and couplings

• Check pressure gauge and calibration
REMEDY
• Check electrical wiring
7.2.43 Alarm 59 – DISABLE RETURN FROM EXTRA-STROKE

ALARM 59 – DISABLE RETURN FROM EXTRA-STROKE 1 of 1
ALARMCONDITION /
DESCRIPTION
CHECK
No axis in extra-stroke.
MALFUNCTION
• The extra-stroke selector is in return position and no axis is in extra-
stroke
POSSIBLE CAUSE
• Selector wiring defect
 Turn the “return from extra-stroke” selector to the left

 Press RESET
REMEDY
 Check selector wiring
Chap. 7
- 24/31 -
7.2.44 Alarm 60 – RET. FROM EXTRAS. ONLY IN MANUAL
ALARM 60 – RET. FROM EXTRAS. ONLY IN MANUAL 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The MDI and incremental JOG modes may not be used to return from extra-
MALFUNCTION stroke.
• Selector in return from extra-stroke position and NC not in MANUAL

POSSIBLE CAUSE mode
• Select MANUAL mode from NC

REMEDY • Mode selector in MANUAL
7.2.45 Alarm 61 – A.P. 2 LH BLOCK TIMEOUT
ALARM 61 – A.P. 2 LH BLOCK TIMEOUT 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Part blocking pressure gauge 2 malfunction
MALFUNCTION
POSSIBLE CAUSE • Pressure gauge calibration error
• Defective pressure gauge
• Wiring with NC defective
• Check pneumatic tubes and couplings
REMEDY • Check pressure gauge and calibration
• Check electrical wiring
Chap. 7
- 25/31 -
7.2.46 Alarm 62 – WRONG DIRECTION RETURN FROM EXTRA-STROKE
ALARM 62 – WRONG DIRECTION RETURN FROM EXTRA-STROKE 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
The direction of the return from extra-stroke is wrong.
MALFUNCTION
• Wrong direction of axis movement
POSSIBLE CAUSE • Axis homing micro malfunction
• Wiring defect between homing micro and NC input card
 Change the direction of return from extra-stroke

REMEDY  Check homing micro and wiring (qualified technician)
7.2.47 Alarm 68 – CANBUS NODE N ALARM
ALARM 68 – CANBUS NODE N ALARM 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
CANBUS I/O cards system alarm
MALFUNCTION
• CAN connection defect
• CAN node or card power supply defect
• CANBUS NC card malfunction
POSSIBLE CAUSE
• Module connection defect
• I/O module malfunction
• CAN node malfunction
Only qualified technicians:

 Check CAN-power supply connections
 Check I/O module connections (orange tab)
REMEDY
 Check status of the CAN node pilot light and type of flashing
Chap. 7
- 26/31 -
7.2.48 Alarm 70 – SERVODRIVE ALARM
ALARM 70 – SERVODRIVE ALARM 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Axis drive alarm
MALFUNCTION
• Excessive motor strain
• Motor or drive overheated
POSSIBLE CAUSE • Drive malfunction
• Motor malfunction
• Electrical wiring or encoder defect
 Check axis obstacles

 Check axis movement friction
Only qualified technical personnel:

 Check motor temperature
REMEDY
 Check drive temperature
 Check electrical cabinet conditioner – temperature
 Check drive alarm
 Check NC – drive – motor connections
7.2.49 Alarm 71 – INVERTER 1 OVER-TORQUE
ALARM 71 – INVERTER 1 OVER-TORQUE 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Inverter over-torque
MALFUNCTION
• Excessive tool machining strain
POSSIBLE CAUSE • Spindle rotation problems
• Problems with over-torque input connection from inverter to NC input
card
 Reduce machining speed
 Increase (if permitted) tool rpm
 Reduce amount of material removed from piece
REMEDY Only qualified technical personnel:

 Check spindle rotation
 Check inverter over-torque connections
Chap. 7
- 27/31 -
7.2.50 Alarm 72 – INVERTER 2 OVER-TORQUE
ALARM 72 – INVERTER 2 OVER-TORQUE 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Inverter over-torque
MALFUNCTION
• Excessive tool machining strain
POSSIBLE CAUSE • Spindle rotation problems
• Problems with over-torque input connection from inverter to NC input
card
 Reduce machining speed
 Increase (if permitted) tool rpm
 Reduce amount of material removed from piece
REMEDY Only qualified technical personnel:

 Check spindle rotation
 Check inverter over-torque connections
7.2.51 Alarm 74 – RESET
ALARM 74 – RESET 1 of 1
ALARMCONDITION /
DESCRIPTION
CHECK
NC reset in progress
MALFUNCTION
•
There Excessive tool machining strain
•
Spindle rotation problems
POSSIBLE CAUSE
•
Problems with over-torque input connection from inverter to NC input
card
Contact technical assistance only if the system never exits RESET;
REMEDY otherwise, there is no problem.
Chap. 7
- 28/31 -
7.2.52 Alarm 76 – A AXIS SW EXTRA-STROKE
ALARM 74 – A AXIS SW EXTRA-STROKE 1 of 1

ALARMCONDITION /
DESCRIPTION
CHECK
Un-homed axis is outside software limits.
MALFUNCTION
• Axis in extra-stroke
POSSIBLE CAUSE
• PLC memory error
 In manual mode, bring the axis within normal stroke, so that homing
does not damage the machine
 In case of PLC memory error, reset the variable @EXCSW_A from
REMEDY VARIABLES – PLUS VARIABLES, then press RESET and home the
axis. Subsequently, reset the variable @EXCSW_A to 1 (only
qualified technician).
Chap. 7
- 29/31 -
7.3 Other alarms
7.3.1 Control alarms
CONTROL ALARMS 1 of 1
REMEDY  Consult the control user manual.
7.3.2 Inverter alarms
INVERTER ALARMS 1 of 1
REMEDY  Consult the inverter user manual.
Chap. 7
- 30/31 -
Chap. 7
- 31/31 -

Use and Maintenance Instruction SHARP

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Use and Maintenance Instruction SHARP

Uploaded by

Copyright:

Available Formats

WORK STATION

Use and maintenance instruction

MACHINE MODELS AND VERSIONS DESCRIBED IN THE MANUAL

Machine description and technical data 3

Controls and use 5

“Page intentionally left blank”

“Page intentionally left blank”

1.1 Objective of the manual

1.2 Manual addressees

B - Mechanical maintenance men

C - Electric/electronic maintenance men

D - Mechanical support technicians

E - Electrical/electronic support technicians

F- Lifting and handling equipment operator

1.2.1 Description of symbols, deadlines and abbreviations adopted

1.2.2 Symbols adopted, glossary of terms and illustrations

DANGER, WARNING and INFORMATION notes

Information symbols on the machine

1.3 Glossary of safety terms

In compliance with European Directives 89/391/EEC, 89/654/EEC, 89/655/EEC, 89/656/EEC,

PERSONAL PROTECTIVE EQUIPMENT (PPE)

The following are not pieces of personal protective equipment:

1.3.1 Description of the documentation provided with the machine

• DOCUMENTATION OF INSTALLED COMPONENTS: where present, this section provides the

B) EC DECLARATION OF CONFORMITY OR DECLARATION OF ASSOCIATION

E) CNC USER MANUAL:

F) PITAGORA SOFTWARE MANUAL: (Optional)

1.4 Use and conservation of documentation

1.5 Manual updating

1.6 How to request additional copies

1.7 Manufacturer’s Identification and Contact Details

E-mail – general information:

E-mail – spare parts:

1.8 Technical support service

Spare parts support:

WORK DAYS (FROM MONDAY TO FRIDAY) 1 of 1

Paolino Bacci S.r.l.

1.8.1 How to request spare parts

“Page intentionally left blank”

2.1 Personnel Qualification

2.2 General Safety Rules

• to conduct a risk evaluation of the machine concerning the characteristics of the

Maintenance personnel is required to:

• Implement a correct machine maintenance timetable.

2.3 Use of Personal Protective Equipment (PPE)

You are obliged to use protective clothing.

You are obliged to use PVC protective clothing.

You are obliged to use safety boots.

You are obliged to use protective gloves against general mechanical

You are obliged to use protective gloves against chemical risks

You are obliged to use a safety helmet.

You are obliged to use safety goggles with side shields.

You are obliged to use a shield protector.

You are obliged to use a respiratory facial mask (facemask for

You are obliged to use hearing protection devices (earplugs or

You are obliged to use a safety belt for work at height.

2.3.1 Minimum equipment

You are obliged to wear safety clothing.

You are obliged to wear safety shoes.

You are obliged to wear safety gloves against general mechanical

You are obliged to wear hearing protection or earmuffs.

You are obliged to use safety goggles with side shields.

2.4 Safety and warning signals

2.4.1 Description of hazard images