Makino EDGE-2 Preinstallation Manual
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Makino EDGE-2 Preinstallation Manual

Ram electrical discharge machine with mgf control
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Productivity Inc®
Installation of your new Makino EDGE-2 can be smooth and rapid if preparations are made prior to the delivery of
your machine. Any questions regarding machine installation should be directed to our service department for
clarification. We hope this checklist will aid in a rapid installation of your new machine. NOTE: The following
must be completed prior to our service technician arriving to install your new machine.
Power Requirements for your machine:
*Voltage of 200 to 480 at +/- 10% must be maintained. If not, an Automatic Voltage Regulator should be used.
Proper voltage per machine specifications should be ready at machine site. Do NOT power up the machine.
See Makino Installation Manual for more information, or contact our Service Department with any
questions.
Customer should furnish and have available the proper supply and types of lubricants required for machine
operation.
ITEM
Dielectric Oil
You will need to have Dielectric Oil on hand for installation. Contact our Service Department for more
information.
Air lines should be routed to the machine location and operational for proper air pressure.
Clean, Dry Compressed Air of 70 psi. must be available; less than 40% relative humidity; In-line water trap
recommended.
Machine location should be planned to allow enough room for access panels to be opened and serviced with
ease. A minimum of 36" is required around the machine for operator and maintenance access.
Weight requirements should be checked to insure that the surface below the machine will have sufficient
strength for support and stability. The machine must be set on a solid, sound and stable, steel bar-reinforced
concrete slab poured directly on the grade. In general, the 6" concrete floor on industrial buildings is suitable
for machine placement.
The EDGE-2 is best moved with a forklift. See Makino Installation Manual for lifting instructions.
**NOTE 1: LIFTING EQUIPMENT, ROPES, SCHACKLES, LIFTING BARS, LIFTING BEAMS, ETC. ARE
OPTIONAL EQUIPMENT AND ARE NOT PROVIDED WITH THE MACHINE. ITEMS MUST BE
PURCHASED PRIOR TO MACHINE DELIVERY IF LIFTING WITH OVERHEAD/CRANE.
your machine, uncrate and immediately check for visible damage.
SHIPPING WEIGHT
8,377 # (Skidded/wrapped)
See Makino Installation Manual for floor space requirements/dimensions – will vary depending upon the
options you purchase.
Remove as much preservative from the machine as possible without having to power up (tables –
slides, pulleys, etc.). We recommend mineral spirits to clean. Apply oil when finished to prevent rust.
PLEASE FORWARD THIS TO THE APPROPRIATE PERSON. THANK YOU.
15150 25th Avenue North, Minneapolis, MN 55447-1981
For Service: MN 763-476-4191 IA 319-632-4288 NE 402-330-2323
Visit us at:
www.productivity.com
Makino EDGE-2 PRE-INSTALLATION CHECKLIST
30 Amp/3 phase/9kVa
CAPACITY
52.8 Gal
SHIPPING DIMENSIONS OF MACHINE
91" L x 91" W x 96" H (Skidded/wrapped)
Phone 763-476-8600
Fax 763-476-4092
Productivity is ISO 9001:2000 Certified
FLUID TYPE
IONO Plus+
– Rev 01/2009
Upon arrival of

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  • Page 1 Makino EDGE-2 PRE-INSTALLATION CHECKLIST – Rev 01/2009 Installation of your new Makino EDGE-2 can be smooth and rapid if preparations are made prior to the delivery of your machine. Any questions regarding machine installation should be directed to our service department for clarification.
  • Page 2 INSTALLATION INFORMATION METRIC ENGLISH Machine Tool (WxDxH)........1625 mm x 1770 mm x 2290 mm ......64" x 69.7" x 90.2" Power Supply................................Included Dielectric Supply................................. Include Machine Tool................3000 kg..............6600 lbs Power Supply ................................Included Dielectric Unit ................................Included Estimated Shipping Weight.............3000 kg..............6600 lbs Transportation The EDGE2 is Shipped FOB Port of Entry in One Container weighing 6600 lbs.
  • Page 3 All specifications and designs may change without notice. Every attempt was made to ensure that the information in this publication was correct at the time of printing. As specifications and designs change, Makino is not responsible for information that becomes incorrect or inaccurate after publication.
  • Page 4 • In addition, all safety requirements and guidelines found in Chapter 1 - Safety, the ANSI safety guidelines the Makino Safety Manual, shipped with the machine, and established company safety requirements and regulations must be followed. Taking personal responsibility for safety will prevent most accidents.
  • Page 5 ('*( 3UH,QVWDOODWLRQ*XLGH To contact Makino, for service after the sale: Makino 7680 Innovation Way Mason, Ohio 45040 USA Technical Support Services (888) Makino4 (625-4664) Mon.-Fri. 7:00 a.m. to 8:00 p.m. Fax: (513) 459-1825 Sat. 8:00 a.m. to 2:00 p.m. (Eastern Standard Time)
  • Page 6 ('*( 3UH,QVWDOODWLRQ*XLGH AVISO! Las personas que no pueden leer o entender en Ingles deben mandar traducir este manual y solicitar entrenamiento antes de operar o mantener la maquina. Todos los que trabajen en esta maquina deberan saber como operarla con toda seguridad y en forma correcta para evitar un posible dano.
  • Page 7 ('*( 3UH,QVWDOODWLRQ*XLGH CONTENTS Chapter 1 Safety Precautions Chapter 2 Specifications Chapter 3 Installation Process Overview Chapter 4 Pre-Delivery Preparations Chapter 5 Machine Delivery Appendix A Conversion Factors 20ED3A1863...
  • Page 8 ('*( 3UH,QVWDOODWLRQ*XLGH...
  • Page 9 ('*( 3UH,QVWDOODWLRQ*XLGH Chapter 1 Safety Precautions For a Safe Working Environment Makino EDGE2 Ram Electrical Discharge Machine with MGF Control 01_20ed3a Safety.fm...

  • Page 10: Table Of Contents

    ('*( 3UH,QVWDOODWLRQ*XLGH Chapter 1 Safety Precautions Contents 1.1 Overview ..........1 - 1 1.2 General Safety.
  • Page 11 ('*( 3UH,QVWDOODWLRQ*XLGH 1.11 Installation Safety Instructions......1 - 25 01_20ed3a Safety.fm...
  • Page 12 ('*( 3UH,QVWDOODWLRQ*XLGH OTES KETCHES...

  • Page 13: Overview

    This includes, but is not limited to, allowing only prop- erly trained and technically qualified personnel program, operate, and maintain the machining center. It is Makino’s policy and responsibility to design, manufacture, and market machining centers that are as reasonably safe as possible for their intended use.

  • Page 14: Danger, Warning, Caution Statements And Symbols

    You have read and understand all technical information, including the following sections of this safety chapter. Questions Regarding Safe Operation Before you operate this machine – contact your Makino service group for answers to any questions about safety and your Makino machine. 1.2.1...
  • Page 15 ('*( 3UH,QVWDOODWLRQ*XLGH ABLE DEFINITION OF DANGER WARNING AND CAUTION STATEMENTS Statement Meaning DANGER is the most severe safety statement. This statement means DANGER that either severe personal injury or death may result if the instruc- tion(s) is not followed. WARNING is the next level of safety statement. It indicates that if the WARNING instruction(s) is not followed severe personal injury could result.

  • Page 16: Access To Information

    ('*( 3UH,QVWDOODWLRQ*XLGH 1.2.2 Access to Information We strongly recommend that a copy of these safety instructions and all provided guides, manuals, and technical information be kept near the machine. This information should be organized for quick access and used by operators, maintenance, and other personnel with duties related to the machining center.

  • Page 17: Lockout/Tagout Procedure

    ('*( 3UH,QVWDOODWLRQ*XLGH 1.2.4 Lockout/Tagout Procedure The machining center is powered by high voltage and other energy sources that represent potential hazards. To reduce the risk of injury or death establish, define, and practice a Lockout/Tagout procedure for the equipment in your facility. Lockout/Tagout defines a minimum safe procedure to be followed by per- sons who might be confronted with unexpected energizing, start-up, or release of stored energy that could cause injury or death.

  • Page 18: Personal And Professional Safety

    ('*( 3UH,QVWDOODWLRQ*XLGH Personal and Professional Safety General safety precautions should be practiced everyday, but never become common place. Safety is the responsibility of every person on the job site. In this regard, consider yourself responsible for safety in your workplace. No one is better positioned to eliminate or prevent unsafe con- ditions than you.

  • Page 19: Equipment And Operation Safety

    ('*( 3UH,QVWDOODWLRQ*XLGH • Obtain an MSDS for each chemical (such as cutting fluids, lubricating oils, greases, etc.) used on or around the machining center. Practice safe working habits and wear all protective equipment required. Know and understand the procedures to follow in the event: Your skin is exposed to the chemical.
  • Page 20 ('*( 3UH,QVWDOODWLRQ*XLGH Be sure to Always: • Take steps to protect the machine tool and control cabinets from mois- ture and condensation. Moisture can damage electrical components, causing unwanted machine motion, leading to injury or machine dam- age. • Maintain the exact original color and vividness of any machine areas that are color coded as safety precautions.
  • Page 21 Never paint, alter, deface, or remove any danger, warning, or cau- tion label. (Replacement labels are available from Makino) Never change or by-pass the location of the stroke limit dogs, limit switches, interlock circuitry, etc.

  • Page 22: Environmental Safety

    ('*( 3UH,QVWDOODWLRQ*XLGH Environmental Safety Follow these specific practices when working at the machining center: • The area around the machine should be well lighted, dry, and free from obstructions. Keep the area around the machine clean and in good order at all times. •...

  • Page 23: Lifting Safety

    ('*( 3UH,QVWDOODWLRQ*XLGH Lifting Safety These lifting safety precautions must be followed by all persons responsi- ble for lifting. This includes, but is not limited to, lifting machinery, machine components, and workpieces: • All lifting equipment must be properly rated for the weight being lifted. •...

  • Page 24: Hooks

    ('*( 3UH,QVWDOODWLRQ*XLGH 1.6.3 Hooks When using hooks: • Never exceed the lifting capacity of any lift hook. • Do not repair lifting hooks. • Destroy and discard bent lifting hooks. 1.6.4 Eye Bolts To ensure a safe load carrying capacity: •...

  • Page 25: Lifting The Machine Or Components

    Pre-Installation Guide. Before lifting, refer to shipping documents to obtain the weight of the machine or component being lifted. If the necessary weights cannot be determined, consult Makino. In addition: • Only qualified riggers should perform machine lifting operations. •...

  • Page 26: Mechanical Maintenance Safety

    ('*( 3UH,QVWDOODWLRQ*XLGH Mechanical Maintenance Safety Mechanical maintenance procedures for Makino machining centers should be performed by properly trained and technically qualified person- nel. They should adhere to these specific practices when working with the machining center: • Always perform Lockout/Tagout before removing any safety guard, cover, barrier, or any basic component of the machining center.

  • Page 27: Electrical Maintenance Safety

    Volt/Ohm Meters. • Oscilloscopes. • Static Ground Wrist Straps. Machine Grounding All Makino machining centers must be properly grounded at the time of installation. • JIS class 3 grounding (resistance of 100 Ohms or less) is recom- mended. • Proper grounding requires an isolated earth ground.

  • Page 28: Edge2 Ram Electrical Discharge Machine Safety

    RAM type EDM uses a dielectric fluid in the machining process. This fluid is flammable and may ignite, if improperly applied. All Makino RAM machines are provided with the following fire related safety features: 1. Dielectric Temperature Detector – to immediately stops the machining process when the temperature of the dielectric fluid rises above a set value of 53°C.
  • Page 29 ('*( 3UH,QVWDOODWLRQ*XLGH Be sure to Always: • Keep all fire extinguishers fully maintained and operational and train all personnel in their proper use. • Ensure the automatic fire extinguisher is fully operational. Perform a functional test at the prescribed intervals. Never operate the machine with the fire extinguisher testing knob in the "LOCK"...

  • Page 30: Edm Fire Conditions

    ('*( 3UH,QVWDOODWLRQ*XLGH 1.9.1.1 EDM Fire Conditions The following conditions may result in fire during machining operations Figure 1-1 1. Fire hazard caused by spraying dielectric fluid onto workpiece. Work- piece should be submerged in the dielectric fluid to ensure safe burn- ing.
  • Page 31 ('*( 3UH,QVWDOODWLRQ*XLGH Legend Electrode Jet Nozzle Workpiece Table Dielectric Clamp Shank IGURE EDM FIRE CONDITIONS 01_20ed3a Safety.fm 1 - 19...

  • Page 32: Machine Safety Features

    ('*( 3UH,QVWDOODWLRQ*XLGH 1.9.2 Machine Safety Features The EDGE2 provides the following safety features: • [EMERGENCY] button, to immediately halt all machine functions. • Automatic Fire Extinguisher and other fire related equipment, see sec- tion 1.9.1 (pg 1-16) Descriptions, operational detail, and precautions related to these safety features are described in the Operation Guide.

  • Page 33: Location Of Safety Labels

    ('*( 3UH,QVWDOODWLRQ*XLGH 1.9.4 Location of Safety Labels Labels attached to the machine at specific areas, identify safety risks and provide important instructions that must be read and followed. • Machine safety labels ( Figure 1-3 • Oilmatic safety labels ( Figure 1-4 (pg.
  • Page 34 ('*( 3UH,QVWDOODWLRQ*XLGH IGURE OILMATIC SAFETY LABELS 1 - 22...

  • Page 35: Edge2 Equipment And Operation Safety

    • Check with the manufacturer to ensure proper and safe operation in a RAM EDM environment, of any accessory NOT specifically built, designed, or supplied by Makino. • Use extreme caution when changing electrodes. Make sure that all electrodes are properly loaded and secured and that they will not come into undesirable contact with items in the work area during operation.
  • Page 36 Prior to Machining • Check with the manufacturer of any accessory not designed, built, or supplied by Makino to ensure the device will operate properly and safely under the proposed operating conditions. • Prior to unattended operation, prove out part programs to ensure clear- ance between machine parts, fixturing, and the workpiece.
  • Page 37 ('*( 3UH,QVWDOODWLRQ*XLGH 1.11 Installation Safety Instructions The following information is related to installation of the machining center. Adhere strictly to the installation instructions provided in the Pre-Installa- tion Guide: • Review the general lifting safety rules in and the specific section 1.6 procedures in the Pre-Installation Guide, prior to moving the machine.
  • Page 38 ('*( 3UH,QVWDOODWLRQ*XLGH OTES KETCHES 1 - 26...
  • Page 39 ('*( 3UH,QVWDOODWLRQ*XLGH Chapter 2 Specifications Machine Unit and Control Specifications Makino EDGE2 Ram Electrical Discharge Machine with MGF Control 02_20ed3a Specifications.fm...
  • Page 40 2.5 Makino MGF Control ........

  • Page 41: Overview

    ('*( 3UH,QVWDOODWLRQ*XLGH Overview Makino’s EDGE2 provides fully automated functional machine capabili- ties. Machine and MGF control specifications follow. Information Subject to Change Every effort was made to ensure the accuracy of the data presented in this chapter at the time of publication. Machine and control specifications are subject to change without prior notification.

  • Page 42: Layout Drawings

    ('*( 3UH,QVWDOODWLRQ*XLGH 2.2.1 Layout Drawings Legend Work Table NC Unit Flexible Pendent Panel Work Tank Main Operation Panel EDGE2 IGURE FRONT VIEW 2 - 2...
  • Page 43 ('*( 3UH,QVWDOODWLRQ*XLGH Legend Dielectric Unit Air Filter Regulator Oilmatic Automatic Fire Extinguisher Work Tank NC Unit Work Table EDGE2 IGURE LEFT AND RIGHT VIEWS 02_20ed3a Specifications.fm 2 - 3...
  • Page 44 ('*( 3UH,QVWDOODWLRQ*XLGH Legend Dielectric Unit NC Unit Oilmatic Main Operation Panel EDGE2 IGURE GENERAL ARRANGEMENT DRAWING 2 - 4...

  • Page 45: Foundations

    ('*( 3UH,QVWDOODWLRQ*XLGH 2.2.2 Foundations The machine should be placed on a continuous concrete pad. The required floor space (including standard accessories) is 2225 2370mm × for a standard machine. The required floor space increases with ATC or booster options. • The recommended concrete thickness is 300mm.

  • Page 46: General Information

    ('*( 3UH,QVWDOODWLRQ*XLGH General Information This section contains general information on EDGE2 environment, machine size, power, and air requirements. 2.3.1 Machine Environment The EDGE2 performance is directly affected by the environment. Table 2-1 lists key environmental specifications. EDGE2 ABLE ENVIRONMENTAL SPECIFICATIONS Item Specification Ambient Temperature Range...

  • Page 47: Electrical Power

    ('*( 3UH,QVWDOODWLRQ*XLGH 2.3.3 Electrical Power A 3-phase power source, with stable voltage regulation (±10%) and a JIS class 3 ground, of 10 ohms or less, must be provided. The EDGE2 operates on 200/220VAC ±10%, 50/60Hz ±1% connected to a terminal in the machine tool cabinet. •...

  • Page 48: Air

    ('*( 3UH,QVWDOODWLRQ*XLGH 2.3.4 Dry and clean compressed air at 0.6MPa must be available. The air sup- ply line should be permanently piped. • A pressure switch detects if air pressure drops below 0.3MPa and stops machine operation. ABLE AIR SPECIFICATIONS Item Specification Standard machines...

  • Page 49: Unit Specifications

    ('*( 3UH,QVWDOODWLRQ*XLGH Unit Specifications Specifications for each machine component follow. These specifications are presented to serve as a quick reference. 2.4.1 Head The head can be purchased in several configurations. On standard heads the electrode is bolted directly to the platen. shows the platen Figure 2-4 bolt pattern.

  • Page 50: C Axis (Option)

    ('*( 3UH,QVWDOODWLRQ*XLGH 2.4.1.1 C Axis (option) The C axis is available in a MA or MR configuration ( ). The C axis Table 2-6 allows programmable indexing of the head for positioning the electrode to a specific angle. The MA and MR heads also provide a rotary function for rotating the electrode.

  • Page 51: Table

    ('*( 3UH,QVWDOODWLRQ*XLGH 2.4.2 Table shows table detail and lists table specifications. Figure 2-5 Table 2-7 IGURE TABLE AND T SLOT DETAILS ABLE TABLE SPECIFICATIONS Item Specification Table Size 500x350mm Number of T-Slots / Size 10mm x 4 rows Maximum Workpiece Weight 500kg Table Surface Height 840mm...

  • Page 52: Axis Components (Spindle, Ram, Saddle)

    ('*( 3UH,QVWDOODWLRQ*XLGH 2.4.3 Axis Components (Spindle, Ram, Saddle) lists work zone and machine travel specifications. Table 2-8 Figure 2-6 shows axis configuration and work cube. ABLE AXIS COMPONENT SPECIFICATIONS Item Specification X,Y Axis Travel 300×250mm Z Axis Travel 250mm Worktank Dimensions (WxDxH) 650×450×300mm Platen to Table Distance Bottom Point 250mm Chuck Face to Table Bottom Point...
  • Page 53 ('*( 3UH,QVWDOODWLRQ*XLGH Legend Machine Reference Table IGURE AXIS CONFIGURATION AND WORK CUBE 02_20ed3a Specifications.fm 2 - 13...

  • Page 54: Atc

    ('*( 3UH,QVWDOODWLRQ*XLGH 2.4.5 An ATC (Automatic Tool Changer) provides several advantages in extend- ing no or low-attendant machining, automatic multiple operations, and assigning spare tools for long job runs. The standard ATC is an A4 rack type with an A8, A16, or A24 carousel types available. lists ATC Table 2-10 specifications.
  • Page 55 ('*( 3UH,QVWDOODWLRQ*XLGH The maximum electrode length, shown in , is for the work tank in Figure 2-7 full up position and is also affected by chuck type. 02_20ed3a Specifications.fm 2 - 15...

  • Page 56: Dielectric Fluid Supply

    ('*( 3UH,QVWDOODWLRQ*XLGH 2.4.6 Dielectric Fluid Supply The dielectric supply unit (DI unit) consists of an integrally designed tank, filters [1], and cooler unit. This system filters machining sediments from the fluid and supplies clean fluid to the work tank for optimum machining. For increased accuracy, the cooler maintains fluid temperature within a set range of the...

  • Page 57: Dielectric Fluid

    ('*( 3UH,QVWDOODWLRQ*XLGH 2.4.6.1 Dielectric Fluid Dielectric Fluids 1. Always use a highly refined oil with a minimum of PAH’s. Use an oil similar to EDM- 244 or EDM-250 to minimize any health risks. 2. Never use a dielectric fluid with a flash point under 70°C. Dielectric fluid is used in the machining process and is required at time of installation and start up.

  • Page 58: Makino Mgf Control

    ('*( 3UH,QVWDOODWLRQ*XLGH Makino MGF Control Standard MGF control configuration is listed below. 2.5.1 Operation Panel Feature Detail 10.4 inch Color display MDI (Manual Data Input) Function Display Operation Record Display Panel Run Hour Dynamic Graphic Display Automatic Reference Return Measurement...

  • Page 59: Operational Support

    ('*( 3UH,QVWDOODWLRQ*XLGH 2.5.3 Operational Support Feature Detail Label Skip Single Block Program Stop – M0 Optional Stop – M1 End of Program Block Skip - / Dry Run Machine Lock Auxiliary Function Lock XY Axes Exchange Manual Absolute Automatic Return Operational Support Workpiece Edge Positioning...

  • Page 60: Maintenance And Safety

    ('*( 3UH,QVWDOODWLRQ*XLGH 2.5.4 Maintenance and Safety Feature Detail Emergency Stop Axis Overtravel Protection - 2 systems - Hard and Stored Stroke Limit Work Limit Diagnostic Function Maintenance Regular Check Function Maintenance Function Safety Parameter Output by Machine Number (G150) Machining Condition Output (G151) Machining Time Output (G152) Machining Status Record Output (G153) Data Backup (G154)

  • Page 61: Auxiliary Functions And Machining Conditions

    ('*( 3UH,QVWDOODWLRQ*XLGH 2.5.6 Auxiliary Functions and Machining Conditions Feature Detail Machining (M17/M18) Auxiliary Functions Work Tank Up/Down (M28/M29) Selection: E4 digit (E0001 – E9999) Machining Conditions Registered area: 600 2.5.7 Interpolation and Feeds Feature Detail Rapid Positioning – Manual G0 Linear Interpolation –...

  • Page 62: Programming

    ('*( 3UH,QVWDOODWLRQ*XLGH 2.5.8 Programming Feature Detail Memory – 369,000 characters (1000m of tape) Storage Number of registrable programs – 9999 Standard CNC Language Minimum Input Increment – 0.001mm (0.0001mm) Standard or High Resolution (Parameter Selectable) Control Unit – 0.00005mm Maximum Programmable Increment - ±99999.999mm Methods Sub-Programming –...
  • Page 63 ('*( 3UH,QVWDOODWLRQ*XLGH OTES KETCHES 02_20ed3a Specifications.fm 2 - 23...
  • Page 64 ('*( 3UH,QVWDOODWLRQ*XLGH 2 - 24...
  • Page 65 ('*( 3UH,QVWDOODWLRQ*XLGH Chapter 3 Installation Process Overview Makino EDGE2 Ram Electrical Discharge Machine with MGF Control 03_20ed3a Install Process.fm...
  • Page 66 ('*( 3UH,QVWDOODWLRQ*XLGH Chapter 3 Installation Process Overview Contents 3.1 Overview ..........3 - 1 3.2 The Installation Process .

  • Page 67: Overview

    The success and efficiency of your installation rests, in large part, on your participation and involvement in the installation process. Sixty days before the delivery of your Makino machine take time to: • Review the information and requirements related to pre-installation •...

  • Page 68: The Installation Process

    Your participation and assistance are critical to an effective installation. 3.2.1 Customer Installation Duties Makino asks that you be an active participant in the installation process. Your duties are listed below. Makino recommends that you: •...

  • Page 69: Fse Installation And Set-Up Duties

    3UH,QVWDOODWLRQ*XLGH 3.2.2 FSE Installation and Set-up Duties The Makino FSE is responsible for installing the machine and training your personnel. The FSE installation process should be completed in five work- ing days. These duties have a logical order and a built-in flexibility allowing the FSE to work around unexpected delays or problems and still complete the installation on time.
  • Page 70 ('*( 3UH,QVWDOODWLRQ*XLGH 5. Power On Ensure the machine is ready for power, BEFORE applying power. After applying power, verify phase and confirm voltages are within the allowable range. 6. Checks and Adjustments Install any required custom programs. Check and confirm proper operation of all machine systems and functions (i.e.

  • Page 71: On-Site Training

    1. Operators/Programmers not familiar with this control model attend the appropriate training classes at Makino. 2. Maintenance personnel new to CNC or Makino machines and controls attend the appropriate training classes at Makino. 3. Companies interested in increasing their capabilities and production should review Makino’s formal learning opportunities.
  • Page 72 1. This training can be modified, to some extent, to suit the needs of your personnel. 2. Specific questions will be answered on the spot when possible or referred to the appropriate personnel at your distributor or Makino. 3. Although FSEs are familiar with programming, they are not programming experts.
  • Page 73 1. This training can be modified, to some extent, to suit the needs of your personnel. 2. Questions will be answered on the spot when possible or referred to the appropriate personnel at your distributor or Makino. Options Training Machine options expand capability or provide additional utility, features, or functionality to the basic machine tool.
  • Page 74 ('*( 3UH,QVWDOODWLRQ*XLGH OTES KETCHES 3 - 8...
  • Page 75 ('*( 3UH,QVWDOODWLRQ*XLGH Chapter 4 Pre-Delivery Preparations Makino EDGE2 Ram Electrical Discharge Machine with MGF Control 04_20ed3a Pre Delivery Prep.fm...
  • Page 76 ('*( 3UH,QVWDOODWLRQ*XLGH Chapter 4 Pre-Delivery Preparations Contents 4.1 Pre-Installation Preparations ......4 - 1 4.2 Pre-Installation Checklist .

  • Page 77: Pre-Installation Preparations

    ('*( 3UH,QVWDOODWLRQ*XLGH Pre-Installation Preparations The Pre-Installation worksheet ( ) outlines key tasks in Table 4-1 (pg. 4-2) preparing for machine delivery and installation. The items checked in the “required” column must be completed for an efficient machine installation. Use this Guide to accomplish these pre-installation tasks: •...
  • Page 78 ('*( 3UH,QVWDOODWLRQ*XLGH ABLE INSTALLATION CHECK LIST Date Date ACTION Required Required Scheduled Complete MACHINE REQUIREMENTS " Select machine site " Ensure proper foundation " Check floor space requirements " Check environment " Ensure power, air, and water DELIVERY REQUIREMENTS " Provide clearance from truck to machine location "...
  • Page 79 ('*( 3UH,QVWDOODWLRQ*XLGH OTES KETCHES 04_20ed3a Pre Delivery Prep.fm 4 - 3...

  • Page 80: Pre-Installation Checklist

    FSE. In special cases and with prior approval, completion of all Checklist items is not mandatory; however, it is essential that Makino is informed of the status of your preparations prior to sending the FSE to your facility.
  • Page 81 ('*( 3UH,QVWDOODWLRQ*XLGH CUSTOMER SUPPORT FAX: 513-459-1825 PRE-INSTALLATION CHECKLIST Customer Support Customer Request For Installation Services Request ID__________ FROM: COMPANY INFORMATION Company name Phone Customer Contact Title Phone 2nd Contact Title Phone 3nd Contact Title Phone Shipping Address Please complete to confirm the data in our records Street P.O Box Suite #...
  • Page 82 Machine condition checked. The condition of the machine proper and all system components has been inspected for damage or other unacceptable conditions (in addition to immediately contacting Makino, note any discrepancies on a separate sheet, send to the shipper, and include with this document).

  • Page 83: Selecting The Machine Location

    ('*( 3UH,QVWDOODWLRQ*XLGH Selecting the Machine Location Key factors in selecting the machine location include: • Access and required floor space. • Your manufacturing process. • Work and machine environment. • Foundation. Proper environment and foundation are of the utmost importance and more than any other factors, ensure machine accuracy and dependability.

  • Page 84: Environment

    ('*( 3UH,QVWDOODWLRQ*XLGH 4.3.3 Environment A sub-standard environment can cause control, machine, and component failures of all types. Do NOT locate the machine: • In direct sunlight. • Near a source of heat. • In a place subject to large temperature variation. •...

  • Page 85: Foundation

    When locating the machine on an upper floor of a building, be sure to: • Consult a structural engineer for load bearing capacity. • Consult Makino for acceptance or stipulations on this arrangement. Fixtures Fixtures typically require a long lead time. Address this issue before the delivery of the machine tool.

  • Page 86: Formal Training

    Though often overlooked, training is most important after a major invest- ment in new equipment or technology. To assist our customers in getting the most out of their Makino machines, Makino provides formal classroom training at our facility in Mason, Ohio.
  • Page 87 ('*( 3UH,QVWDOODWLRQ*XLGH OTES KETCHES 04_20ed3a Pre Delivery Prep.fm 4 - 11...
  • Page 88 ('*( 3UH,QVWDOODWLRQ*XLGH OTES KETCHES 4 - 12...
  • Page 89 ('*( 3UH,QVWDOODWLRQ*XLGH Chapter 5 Machine Delivery Makino EDGE2 Ram Electrical Discharge Machine with MGF Control 05_20ed3a Machine Delivery.fm...
  • Page 90 ('*( 3UH,QVWDOODWLRQ*XLGH Chapter 5 Machine Delivery Contents 5.1 Overview ..........5 - 1 5.2 Inspect the Machine .

  • Page 91: Overview

    Makino’s Installation process includes Pre-Installation duties to be performed by you. chapter 4 These duties are described in this chapter and Makino customers must perform these duties to provide the maximum amount of time for proper machine setup and training. Your participation and assistance are critical to an effective installation.

  • Page 92: Inspect The Machine

    1. Contact the carrier immediately. A. File a claim with the carrier immediately. B. Leave damaged material exactly as found and take photographs of the damage. 2. Contact Makino immediately with your name, company, machine type, and RID (Request IDentification) number. 5 - 2...

  • Page 93: Unloading, Lifting, And Moving

    Unloading and moving the machine and its ancillary components to their final site is the customer’s responsibility. • Makino recommends that professional riggers unload the machine and ancillary components and move them to their final site. After the initial checks for damage are complete: 1.

  • Page 94: Lifting And Moving The Machine

    . Rigging Detail Makino machines are designed to be lifted by overhead crane. The required rigging is shipped with the machine. If using a fork lift BE SURE to approach from the machine side (Not the NC side).
  • Page 95 ('*( 3UH,QVWDOODWLRQ*XLGH 7. Lower the machine onto blocking and install the NC unit leveling feet into the bottom of the cabinet. Run the leveling feet up to within 5mm of cabinet. Leveling feeet and machine leveling pads are shipped in the acces- sories crate or attached to the machine pallet.

  • Page 96: Leveling

    ('*( 3UH,QVWDOODWLRQ*XLGH Leveling Makino builds a highly rigid machine tool, and it’s accuracy depends on machine level. The importance of setting and maintaining proper machine level cannot be over-emphasized. Rough leveling prevents a twist or other distortion from setting into the iron.

  • Page 97: Leveling The Machine

    ('*( 3UH,QVWDOODWLRQ*XLGH 5.4.2 Leveling the Machine The EDGE2 uses a three point leveling system ( Figure 5-3 The leveling procedure described uses one level 1. Loosen the lock nut [1] on each leveling screw [2]. 2. Set the level in the X axis plane, note the reading.

  • Page 98: Initial Cleaning

    ('*( 3UH,QVWDOODWLRQ*XLGH Initial Cleaning A corrosion preventative is applied to the machined and sliding surfaces of the EDGE2 to prevent oxidation during shipping. This corrosion preventa- tive must be removed prior to operating the machine. • Use a clean, dry cloth and mineral spirits or another high flash-point, non-toxic solvent to remove the corrosion preventative.

  • Page 99: Air Source

    3UH,QVWDOODWLRQ*XLGH Air Source Incoming Air Supply Makino considers it the customer’s responsibility to ensure that the air supply to the machine is both clean and dry. Supplied air must NOT exceed 40% relative humidity. Connect the Air Supply The air source is connected at the filter/regu-...
  • Page 100 ('*( 3UH,QVWDOODWLRQ*XLGH Setting Optional Air Booster Adjust the filter/regulator to obtain an output pressure of 0.6MPa. To set the pressure: 1. Unlock adjusting cap [2] and [4], by pulling up on the knobs. 2. Turn adjusting cab [4], until the outlet pressure gage [5] reads 0.7MPa.

  • Page 101: Power Source

    ('*( 3UH,QVWDOODWLRQ*XLGH Power Source A 3-phase power source with stable voltage (±10%) must be provided. The EDGE2 runs on 200Vac at 60Hz. A step down transformer accepts incoming power from 480Vac down to 240Vac and regulates voltage to 200Vac. for machine power requirements (kVa ratings and calculat- chapter 2 ing required service).
  • Page 102 ('*( 3UH,QVWDOODWLRQ*XLGH 8. Connect incoming power at the top of CB1, terminals R, S, and T ( Figure 5-7 9. Connect the facility ground wire to earth ground ( Figure 10. Close the NC doors. Do NOT Apply Power Leave the power BUSS or disconnect Off, Locked Out and Tagged.
  • Page 103 ('*( 3UH,QVWDOODWLRQ*XLGH OTES KETCHES 05_20ed3a Machine Delivery.fm 5 - 13...
  • Page 104 ('*( 3UH,QVWDOODWLRQ*XLGH OTES KETCHES 5 - 14...
  • Page 105 $SSHQGL[ Appendix A Conversion Factors SI Metric System Basics and Inch-Metric Conversion Factors A1_comb inch-to-metric conversion.fm...
  • Page 106 $SSHQGL[ Appendix A Conversion Factors Contents A.1 Introduction ......... A - 1 A.2 Metric Basics .

  • Page 107: Introduction

    $SSHQGL[ Introduction Makino is a global company, which designs and produces its equipment in the metric system. Currently the JIS (Japanese Industrial Standard) is used, but the world market is driving toward the use of the SI (Systeme International d’Unites) standard.

  • Page 108: Metric Basics

    $SSHQGL[ Metric Basics The first Metric system was established in France after the French Revo- lution and several systems of metric units have been since developed and used. All metric systems are partially based on the International Metric Standards of the Meter and the Kilogram (or decimal multiples and sub- multiples of these standards).
  • Page 109 $SSHQGL[ ABLE MULTIPLES AND SUB MULTIPLES FOR METRIC UNITS SI Metric Prefixes and Their Meaning Prefix X Factor Detail Symbol tera Tera = 1,000,000,000,000 base units giga Giga = 1,000,000,000 base units mega Mega = 1,000,000 base units kilo kilo = 1000 base units hecto hecto = 100 base units deka...
  • Page 110 $SSHQGL[ , presents the basic SI units. The physical quantity, unit name and Table A-2 unit symbol are listed. presents SI units with special names. The unit name, physical Table A-3 quantity, derivation formula and unit symbol are listed. presents SI units with complex names. The unit name, physical Table A-4 quantity, and unit symbol are listed.
  • Page 111 $SSHQGL[ ABLE SI METRIC UNITS WITH SPECIAL NAMES SI Units with Special Names Unit Physical Unit Formula Name Quantity Symbol newton Force N = kg·m/s joule Work, Energy, J = N·m Quantity of Heat coulomb Electric Charge C = A·s volt Electric Potential V = W/A...
  • Page 112 $SSHQGL[ OTES KETCHES A - 6...

  • Page 113: Inch - Metric Conversions

    $SSHQGL[ Inch – Metric Conversions Inch to metric conversion values follow. Most tables are set-up using mul- tiplication and read from left to right so: A · B = C and C · D = A. The com- mon abbreviations are provided in parenthesis; e.g. Feet (ft, ‘). •...
  • Page 114 $SSHQGL[ ABLE LENGTH DISTANCE CONVERSIONS inch (in., ") x 25.4 = millimeter (mm) x .03937 = in. x 2.54 = centimeter (cm) x 0.3937 x 0.0254 = meter (m) x 39.37 foot (ft) x 304.8 = millimeter (mm) x 0.00328 = ft x 30.48 = centimeter (cm)
  • Page 115 $SSHQGL[ ABLE VOLUME CAPACITY CONVERSIONS Inch This Metric This = Inch cubic inch x 16,387 = cubic millimeter x 0.000061024 = in. (in. , cu in.) , sq mm) x 16.387 = cubic centimeter x 0.061024 (cc / cm x 0.00001638 = cubic meter x 61,024 , sq m cubic foot...
  • Page 116 $SSHQGL[ A-10 ABLE VELOCITY AND FLOW CONVERSIONS Inch This Metric This = Inch inch per minute x 25.4 = millimeter/minute x 0.03937008 = ipm (ipm, in./min.) (mm/min.) x 2.54 = centimeter/minute x 0.3937008 (cm/min.) x 0.0254 = meter/minute x 39.37008 (m/min.) foot per minute x 0.3048...
  • Page 117 $SSHQGL[ A-12 ABLE BENDING MOMENT OR TORQUE CONVERSIONS Inch This Metric This = Inch ounce-inch x 7.061552 = newton-millimeter x 0.1416119 = oz·in. (oz·in.) (N·mm) x 0.00706155 newton-meter x 141.6119 (N·m) pound-foot (lb·ft) x 1.355818 = newton-meter x 0.7375621 = lb·ft (N·m) For working in kg·m: newton-meter x 0.1019716 = kg·m and kg·m x 9.806650 = newton-meter.
  • Page 118 $SSHQGL[ A-14 ABLE ENERGY AND WORK Inch This Metric This = Inch British thermal x 1055.87 = joule (J) x 0.00094708 = Btu unit (Btu) calorie (cal) x 4.19002 = joule (J) x 0.2386623 = cal foot-pound (ft·lb) x 1.355818 = joule (J) x 0.7375621 = ft·lb...

  • Page 119: Electrical Consumption

    $SSHQGL[ Electrical Consumption To ensure safe and consistent A-17 ABLE ELECTRICAL CONSUMPTION sizing of electrical power sources, FORMULAE use the formulas in Table A-4 To Calculate Use Formula convert kVa to amps, then deter- Amperage × kVa 1000 mine service size. ------------------------------------ - amps ×...
  • Page 120 $SSHQGL[ OTES KETCHES A - 14...

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