® 1
Table of Contents The Darex Story ......................................................................... Safety Instructions ..................................................................... Cautions .................................................................................... XPS-16 Specification Sheet .......................................................... Capabilities & Performance .......................................................... Machine Axis Definition ........................
The Darex Story The Darex Story Darex Corporation began in 1973 in Beecher, Illinois. The D, A and R of Darex are the initials of three generations of the Bernard family; David, Arthur and Richard Bernard. David and his father Richard founded Darex. Grandfather Arthur Bernard, who earlier founded the Bernard Welding Company, contributed his energy and guidance to Darex. Art’s inventions revolutionized the welding industry. In 1978, Darex relocated to Ashland, Oregon.
Safety Instructions Safety Instructions GROUNDING INSTRUCTIONS • • For all grounded, cord connected tools: • Grounded, cord-connected tools intended for use on a supply circuit having a nominal rating less than 150 volts: This tool is intended for use on a circuit that has an outlet that looks like the one illustrated in Figure A. The tool has a grounding plug that looks like the plug illustrated in Figure A.
Safety Instructions Safety Instructions FOR YOUR OWN SAFETY, READ INSTRUCTION MANUAL BEFORE OPERATING MACHINE! Caution: DO NOT OPERATE MACHINE WITHOUT VACUUM SYSTEM RUNNING Airflow from vacuum cools grinding motor Grinding dust inhaled/ingested can be harmful to your health Grinding particles will cause damage to th e internal components Caution: WHEN USING ELECTRIC TOOLS, BASIC SAFETY PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO PREVENT THE RISK OF FIRE, ELECTRIC SHOCK AND PERSONAL INJURY, INCLUDING THE FO
Cautions CAUTION Do not operate machine without using vacuum system Grinding dust inhaled/ingested can be harmful to your health Grinding particles can cause damage or erratic operation of the sharpener Airflow from vacuum cools the grinding wheel & motor during sharpening • • • Do not alter length of vacuum hose Remove wheel before cleaning Do not operate machine in adverse environmental conditions Minimum 7°C (45°F) Maximum 32°C (90°F) • Do not remove jaws from springs OR springs from spindle insert
Material Safety Data Sheet US DEPARTMENT OF LABOR Form Approved Occupational Safety and Health Administration 0MB No 44-Ri 367 MATERIAL SAFETY DATA SHEET Required under USDL Safety & Health Regulations for Ship Repairing, Shipbuilding and Chip breaking 129 CFR 1915, 1916.19171 This page was intentionally left blank. SECTION I MANUFACTURERS NAME: Professional Tool Mfg LLC EMERGENCY PHONE NO: (541) 488-2224 ADDRESS: 210 E.
This page was intentionally left blank.
XPS-16 Specification Sheet CNC XPS-16 DRILL SHARPENER WHEEL GUARD COVER DRILL HOLDER EMERGENCY STOP CYCLE START CHUCK CYCLE STOP LCD TOUCH SCREEN DOOR GRIND WHEEL STORAGE GRIND WHEEL XPS-16 Auto Measurement Features Your XPS-16 has many features so carefully designed and engineered that you may not even be aware of their uniqueness. Once the cycle start button has been pushed, your Darex XPS-16 begins taking measurements of the drill, on the way to the grinding wheel.
Capabilities & Performance Capabilities & Performance • • • • • • Drill Types: Point Styles: Split Point Styles: Point Angles: Drill Diameter: Drill Length Two fluted HSS, Cobalt or Carbide SAE & Metric twist drills Four Facet & Standard Conic points Standard X split and Radius split 90° - 150° 3mm - 16mm (.118 to .629) 50.8mm - 222.3mm (2” to 8.750) Tolerances • • • • • Lip Height Accuracy: Point Angle: Relief: Split Angle: Fan Angle: ANSI B94.
Machine Axis Definition Machine Axis Definition 11
Machine Axis Definition Machine Axis definition 12
Touch Screen Icon Reference TOUCH SCREEN ICON REFERENCE For more information on Icons refer to the Touch Screen Details section pages 19 to 34 WEB THICKNESS DETECTION SCREEN Refer to information on page 20 CYCLE START (GREEN) Refer to information on page 32 CYCLE STOP (AMBER) Refer to information on page 32 CONTINUE HONE OPTION SELECTED Refer to information on page 21 STOP or EXIT NO HONE SELECTED Refer to information on page 21 HOME - SHUT DOWN/RETURN TO Refer to information on page 32 HONE ONLY Re
Touch Screen Icon Reference SPLIT POINT OFFSET Refer to information on page 29 AUTO MODE SELECTOR Refer to information on page 20 TOOLS, OFFSET & MAINTENANCE PAGE Refer to information on page 27 MANUAL ALIGN KEY Refer to information on page 21 QUICK START SET UP SCREEN *Found only in software with date code of CANCEL KEY 70129 or earlier CONIC GRIND - MAIN SET UP SCREEN AND QUICK START Refer to information on page 25 SAVE CHANGES BACKSPACE WILL ERASE TEXT CONIC STANDARD SPLIT GRIND QUICK START Ref
Touch Screen Icon Reference HONING WHEEL POSITION OFFSET Refer to information on page 31 HONE BRUSH EDGE OFFSET INACCESSIBLE TO CUSTOMER - FOR FACTORY USE ONLY Refer to information on page 27 ALARMS AND MAINTENANCE HONE BRUSH FACE OFFSET WHEEL POSITION OFFSET Refer to information on page 28 WHEEL EDGE OFFSET CONTROLLER DOWNLOADING WARNING Refer to information on page 45 WHEEL FACE OFFSET SPLIT POINT OFFSET Refer to information on page 29 DOWN LOAD Refer to information on page 27 UI Update Button (USER
Touch Screen Icon Reference MATERIAL TAKE OFF #1 ALARM UNABLE TO DETECT END OF DRILL Refer to information on page 63 CUTTING EDGE DETECTION ALARM - UNABLE TO LOCATE CUTTING EDGE Refer to information on page 63 MATERIAL TAKEOFF #2 ALARM Refer to information on page 63 CLOSE DOOR ALARM Refer to page 64 INSERT DRILL ALARM - NO DRILL DETECTED IN CHUCK Refer to information on page 63 REMOVE DRILL ALARM - DRILL LEFT IN CHUCK Refer to information on page 63 C-AXIS ALARM Refer to information on page 64 A-AXIS
Sharpening Your First Drill Sharpening Your First Drill Steps to sharpening your first drill on your CNC XPS16 Drill Sharpener. Connect vacuum hoses and vacuum power cord to sharpener. Refer to information on page 55 1. Plug in machine and release emergency stop button. 2. Located on the right side of the machine is the ON/OFF rocker switch. To power up machine, push rocker switch up. 3. Touch the on the LCD Screen; the Self Test Initialization program will run.
This page was intentionally left blank.
Touch Screen Details Touch Screen Details Power up the XPS-16 sharpener refer to information on page 17 and connect vacuum system, for details refer to information on page 55 Main Set-up Screen Self Test Initialization Screen The initialization screen displays important information. On the first line you will find the Darex toll free phone number, the 2nd line displays the machine serial #. The 3rd line has the current User Interface software version followed by the Controller software version.
Touch Screen Details Material Removal Selector Each touch of the icon will bring up the next material removal option.
Touch Screen Details Hone Selector edge. Refer to page 39 Web Detection Screen To manually input the web thickness, measure thickness of the web of the drill. Measure web thickness across two points of the chisel line with calipers • Type in web thickness, including decimal point. The web thickness, manually entered, will appear on the Main Screen “WEB THICKNESS” Selector button and will disable the auto mode.
Touch Screen Details of the primary Facet with thin web facet produced may be very thin. The thicker the web of your drill, the wider the primary facet will appear. Facet with thick web Split Point Selector With each touch of the icon you will bring up the next split style option. There are 3 split point options: No Split, X- split (Standard) and R- Split. (Radius) The XPS-16 will produce a chisel angle ground to approximately 130°. NOTE: Factory default is “SPLIT”.
Touch Screen Details • • • Use the “BACKSPACE” button to erase information incorrectly entered. Touch the “SAVE” button to store and transfer the “New” information to the Main Set-up Screen. Selecting “CANCEL” will delete any unsaved data, retrieving the most recently saved information, transferring you back to the Main Set-up Screen. Drill Material Selector With each touch of the icon you will bring up the next drill material option. You have two material options: HSS (High Speed Steel) or Carbide.
Touch Screen Details • • To delete a previously saved file, place cursor beside file and touch the “DELETE” button . To save a new file, touch the “SAVE” button , the “FILE SAVE” screen will be brought up. “File Save” Screen Touch the “CHECK” to complete the save over or the “X” to cancel, taking you back to the main setup screen. Lockable Drill Files The XPS-16 Drill Files can be locked so that they are secure from change or accidental deletion.
Touch Screen Details Quick Start Screen Selector *Found only in software with date code of • 70129 or earlier This page was intentionally left blank. Brings up the Quick Start Main Screen “Quick Start” Main • This screen provides quick, one touch point style set up.
This page was intentionally left blank.
Touch Screen Details Tools, Offset & Maintenance Screen Selector “SAVE” button . Any custom files or settings changed in temporary memory will be overwritten and permanently stored. Permanent Memory File Restoration Button Main “TOOLS, OFFSETS & MAINTENANCE” Screen Restore and retrieve the last 25 files and settings saved in Permanent Memory. To restore files touch the “PERMANENT MEMORY FILE RESTORATION” button .
Touch Screen Details Download Screen Wheel Position Offset Screen UI Update Button – From PC to XPS16 Upgrade your USER INTERFACE software by touching the “UI update” button. File Down Load Button File Down Load button - To PC From XPS-16 Send and store your custom files to your PC File Restoration Button File Restoration button - From PC To XPS-16 Restore saved custom files from your PC.
Touch Screen Details • • Α. Fan Angle: This option is more for drill aesthetics than functionality. Utilizing this option may be necessary to remove more or less of the heel to mimic a certain style. The selected split angle, amount of relief and degree of the point angle will determine the actual fan angle produced. Regard the degree entered as a reference number only, the fan angle produced has a tolerance of +/- 15°. • Touch the “FAN ANGLE” button, the Number Key Pad will come up.
Touch Screen Details Touch the Split Angle button, the Number Key Pad will come up. • Touch the “OFFSET” button, the offset keypad will come up. Radius Offset Key Pad Type in the desired split angle degree, a tolerance of +/-5° can be expected. • Touch the “SAVE” button to store the “New” information and transfer you back to the previous screen. • Selecting “CANCEL” will delete any unsaved data, retrieving the most recently saved information, transferring you back to the previous screen.
Touch Screen Details • • • • justment of the C axis will not be necessary. Adjustment may be needed if the factory default allows too much rotation and the grinding wheel nicks the cutting edge. The +C button will stop the rotation of the cutting edge further away from the grinding wheel. The -C button will stop the rotation of the cutting edge closer to the grinding wheel. Refer to page 35 for details on R-Split offsets.
Touch Screen Details Contrast Adjustment Screen Touch Key Delay Screen • • • Adjust screen contrast, using “ARROW UP” to increase the contrast number, making the screen lighter or “ARROW DOWN” button to decrease the number, making the screen darker. After adjustment is entered, touch the “SAVE” button to store the “New” information and transfer you back to the previous screen.
Touch Screen Details 90° Software Update With this software upgrade you will now have all the great features of your original XPS-16 but will now have the ability to sharpen below the 118° point angle range. After the software has been successfully installed in your XPS-16, your point angle range will increase. You can now sharpen drills from 90° - 150°. Please read through the accompanying operating manual.
This page was intentionally left blank.
Radius Spilt Offset Screen Why & How to Offset the Radius Split WHY: The Radius Split Offset feature is available and functional only after you have manually entered the web thickness in the Web Diameter Detection screen, located on the Main Screen Setup page. • Some drill styles have more of a radius on the split than others. When re-sharpening a drill, you may want to mimic an existing radius split or create even more of a radius. The Offset keypad allows you to change the default-offset value.
Radius Spilt Offset Screen Radius Offset Keypad The greater split angle, the less apparent the radius. See view B 160°radius Radius Split 160° Split B • Type in the offset amount. An offset amount of.001 will produce the largest possible radius. As your offset gets larger the radius will become smaller. • • Diagram of radius split showing offset variable. Larger offset creates smaller radius, smaller offset creates larger radius. Offset can be from 1% - 50% of web thickness dimension.
Radius Spilt Offset Screen • The +C button will stop the rotation of the cutting edge further away from the grinding wheel. Looking from rearof drill bit toward face of wheel. Drill bit rotating in C +direction during radius split. Selecting “CANCEL” will delete any unsaved data, retrieving the most recently saved information transferring you back to the previous screen.
Facet Overlap Adjustment 4-Facet Overlap Adjust Procedure NOTE: The XPS-16 is designed to create the 4Facet point with little or no facet overlap. Each machine is adjusted during factory calibration to have a facet overlap of 0.000” to 0.0025”. However, adjustment can be made through the calibration parameters of the machine. Hence, care must be taken to use these instructions carefully when one wants to modify the facet overlap.
Cutting Edge Advance Screen Cutting Edge Advance Screen WHY: Your drill is aligned with the aid of a fiber optic sensor. The fiber optic sensor locates and positions the cutting edge at 12 o’clock. (vertical) The true cutting edge will not be positioned correctly at 12 o’clock. (vertical) 12:00 3:00 This alignment process was designed for drills with a straight cutting edge. Drills with a hook in the cutting edge can still be sharpened, but the cutting edge may not align correctly.
Cutting Edge Advance Screen The web thickness must be entered manually. Measure web of drill, and type in web thickness. • Touch the ADVANCE button on the web detection screen. • The ADVANCE screen will come up. • ADVANCE SCREEN • Press the +C button to rotate cutting edge counter clockwise, 20° Cutting edge or the -C button to move the cutting edge clockwise. 20° A value larger than 0 must be entered to enable the advance feature.
Download Details Download Details Download Screen Selector Select this button for in system programming and download capabilities. As upgrades and optional custom point styles become available, your machine is equipped to receive these files from our factory to yours. • • • The UI Update Pause screen will flash on the screen. • After a few seconds the screen will go dark.
Download Details • USB Communication Port Setup Instructions Cont. After transfer is complete, a screen will appear prompting you to shut down machine and restart. At this point downloadin g software was successful. Turn the machine off and then on again and run the Initialization program. USB Communication Port Setup Instructions The computer interface to the XPS-16 is through an RS-232 (serial) port. Many PCs (especially notebooks) do not contain serial ports.
Download Details Get Drill Files (Custom File Download) • • On your PC, call up the Darex Software Loader program. Click on “Get Drill Files” tab. • Darex Software Loader Screen Get Drill Files Repeat until all desired files are selected. • • • • • Click on “Serial Port Settings” drop down and select the correct COM Port for your computer. Type the directory name in the Browse field or click on Browse button and navigate to desired directory.
Download Details Send Drill Files (File Restoration ) File Restoration Button - From PC To XPS-16 Connect the serial cable from PC to sharpener. Restore saved custom files from your PC by touching the “File Restoration” button. On your PC, call up the Darex Software Loader program. Click on “Send Drill Files” tab • • • • Darex Software Loader Screen - Send Drill Files • Select the file you wish to restore by highlighting the file. • Click on the top Transfer Icon located between the two columns.
Download Details Controller Update Controller Update Button - From PC to XPS-16 • • • • Connect the serial cable from PC to sharpener. Update your Controller software by touching the Controller Update button. On your PC, call up the Darex Software Loader program. Click on “Controller Update” tab Darex Software Loader Screen – Controller Update • • • Click on “Serial Port Settings” dropdown and select the correct COM Port for your computer. Locate file name in Browse field or type in file name.
• • 46 After transfer is complete, the RESTART MACHINE SCREEN will appear Turn the machine off and then on again and run the Initialization program.
Chuck Information CHUCK INFORMATION XPS-16 CHUCK The XPS-16 6-jaw chuck system was designed with accuracy and simplicity in mind. As a result, the XPS-16 chuck allows you to quickly change from the largest drill diameter to the smallest in seconds. The accuracy of the chuck will produce drill concentricity exceeding ANSI, NAS 907 & ISO 10899 standards. The chuck holds drills from .118 to .629 (3mm to 16mm). NOTE: Be careful when chucking up carbide drills.
Chuck Information TO REINSTALL: Reinstall in reverse order, making sure the diameter detector rod is oriented in spindle correctly. CAUTION: If diameter detector rod is reinstalled improperly, damage to rod will occur. • After chuck jaw assembly is properly replaced and before the 4; 4mm bolts are in place, open or close the chuck knob until the bolt hole pattern on the chuck knob is in alignment with the bolt hole pattern on each of the chuck knob retainers.
Chuck Information CNC-XPS-16CC - COLLET CHUCK PARTS DIAGRAM 1 - PP12512TF - COLLET CHUCK KNOB SECONDARY 2 - PP12518NF - ER-25 COLLET SET - METRIC 2 - PP12519NF - ER-25 COLLET SET - ENGLISH 3 - SA12511TA - PRIMARY COLLET KNOB ASSEMBLY 4 - PP12571SF - SWING CASTING COVER - COLLET CHUCK 5 - PP12500CF - CHUCK SWING CASTING 6 - SA12506TA - COLLET CHUCK SPINDLE ASSEMBLY NOT SHOWN - SA12501CA - COLLET CHUCK ASSEMBLY COMPLETE 49
Chuck Information XPS-16 Collet Chuck COLLET CHUCK USE: The XPS-16 Collet Chuck uses ER-25 collets to hold the drill. The chuck is designed to use one or two collets to clamp the drill. Depending on the drill type and length, either the forward collet, the rear collet or both collets can used to secure the drill. The collet system offers the same performance and size range as the standard chuck although use of the rear collet by itself will degrade the run-out precision somewhat.
Chuck Information XPS-16 Collet Chuck cont. Use of the rear collet is similar to the forward collet, first the Primary Knob must be installed in to the spindle omitting the ER collet. The collet is installed into the Secondary Knob as shown below. Certain lengths of step-shank drills may require use of the rear collet by itself or the use of both collets (see drill photo).
This page was intentionally left blank.
Honing Information HONING BRUSHES AND INFORMATION HONING ON YOUR XPS-16 Your sharpener is equipped with “honing” capabilities. Edge prepping is done a number of different ways, in the case of your XPS-16 sharpener it is achieved by brush honing. The hone brush is bolted to the center of the diamond-grinding wheel. The bristles of the nylon brush are impregnated with silicon carbide crystals. Optional Dia- mond Hone available.
Honing Information HONING BRUSH PART #’S PP12686NF – Brush 120 Grit – Silicon Carbide PP12680NF – Brush 180 Grit – Silicon Carbide PP12684NF – Brush 320 Grit – Silicon Carbide PP12688NF – Brush 240 Grit – Diamond PP12682TF – Brush Retainer PP12252FF – Bolts 3 each (4mm .7x18 SHCS) SA12680NA – Brush, Retainer & Bolts HOW TO CHANGE HONING BRUSH This can be done, leaving grinding wheel mounted. 1. Push the emergency stop button, unplug unit from power supply and use a “LOCK OUT” “TAG OUT” procedure. 2.
Vacuum System Information VACUUM SYSTEM AND INSTALLATION INSTRUCTIONS Do not use sharpener until vacuum system is connected to machine. The airflow from the vacuum system keeps the grinding wheel & motor cool while running. Damage to the motor may occur if vacuum is not running while sharpening on the XPS-16. XPS-16 VACUUM SYSTEM The XPS-16 sharpener comes equipped with an environmentally safe dust collection system. Hook up the vacuum to your sharpener before sharpening drills.
Vacuum System Information Vacuum parts list on page 83 & 84 exploded view on page 87 SA12070EA - 115V vac w/plug SA12080EA - 230V vac w/ plug VACUUM SPECS Weight: 30lbs (13.61kg) Diameter: 14” (35.56cm) Height: 19” 56 (48.
Wheel Information XPS-16 WHEEL INFORMATION The Darex XPS-16 comes equipped with electroplated, 180 Grit CBN (Cubic Boron Nitride) and 220 Grit diamond grinding wheels. The CBN wheel, ready to sharpen HSS and Cobalt drills has been calibrated to your sharpener. The diamond grinding wheel, for grinding carbide drills, has a honing brush mounted to it. You will find both the diamond and CBN wheel packaged in the tool kit.
Wheel Information HOW TO CHANGE A WHEEL 1. Push the emergency stop button, unplug unit from power supply and use a “LOCK OUT” “TAG OUT” procedure. 2. Remove Guard door cover. 3. Remove thumbscrews from cover. 4. Pull the wheel guard cover away from wheel, leaving the vacuum tube attached. 5. Insert spindle lock pin through access hole located on top of wheel guard casting. 7. Using a ½ inch socket wrench, loosen wheel retainer bolt in the counterclockwise direction until wheel is free of the spindle.
Wheel Position Offset Adjustment The calibration sheet shows all of the values stored in the machine when it left Darex. Normally, it is just reference information. If somehow the machine memory became corrupted then the data could be used to restore these parameters (very unlikely). These values are not changed when grind wheels are changed. The Wheel Offsets are the values that you should record and change when replacing grind wheels.
This page was intentionally left blank.
Sharpening Tips Sharpening Tips 1. Use MIN MTO when touching up your facet and conic ground drills. 2. Use MID MTO when sharpening chipped facet and conic ground drills. 3. Use MAX when changing point angles on conic ground drills only. Wite-out. Because the fiber optic sensor works from reflectivity, the color of the drill may interfere with the alignment. Drills Black and Gold in color, are the biggest culprits. Painting just behind the cutting edge will help the sensor locate the cutting edge. 4.
This page was intentionally left blank.
Trouble Shooting Section Trouble Shooting Icons Insert Drill Alarm No drill has been detected Insert drill or check to see if drill is loose and has pushed back in the chuck • Material Take Off Alarm #2 • Use compressed air to clean lens • MTO sensor failed, contact factory. Remove Drill Alarm Drill has been left in chuck during Self Test Initialization program and before machine goes into the Lube cycle. Remove the drill from the • Grind Motor Error The grind motor fuse is blown.
Trouble Shooting Section Wheel Change Reminder This reminder will prompt you to change the wheel as you select different drill material options. A AXIS ALARM • The XPS-16 does not know what type of wheel you have mounted; you must mount a CBN wheel for HSS or Cobalt drills and a Diamond wheel for Carbide drills. Failure to comply will damage or shorten the life of your grinding wheel. A axis has moved past the limit switch. • A axis sensor has failed.
Trouble Shooting Section Symptom Failed Initialization screen test Cause • Axis driver card failure • Limit sensors bad • Solenoid bad • Machine has moved past the limit switches Symptom LCD screen too light or dark to read Cause • Contrast needs adjusted Refer to page 32 • LCD back light failure • LCD bad Symptom LCD screen displays garbage or grossly inaccurate information.
Trouble Shooting Section Symptom Drill incorrectly split Cause • Check offsets on the split point offset. Page. Refer to page 29 • Wheel calibration is off • Check wheel edge offset on wheel offset page. Refer to page 28 & 59 • Did not align correctly Symptom Material take off varies Cause • Check wheel face offset on wheel offset page.
Trouble Shooting Section Identifying and checking LED and limit switches Identification of LED sensors refer to page 87 1. MTO 2 2. MTO 1 3. Rotate 4. Swing 5. X Feed 6. In Feed 7. Align 8. -5V 9. +5V 10. X Axis board 11. Z Axis board 12. A Axis board 13.
Trouble Shooting Section Solenoid Troubleshooting -Turn the machine power off. - Open the Electrical Panel and disconnect the solenoid cable (connector located in lower right corner of Power Supply with a yellow and brown conductor). Check the electrical resistance of the solenoid by probing on the side of the connector. The resistance should be about 33 +/-3 ohms. If the resistance is not correct, then remove the black cover on the Chuck Swing Assembly and recheck the resistance at the solenoid connector.
Trouble Shooting Section Z Axis Stage Behind the Limits NOTE: This condition usually occurs when the machine goes into the lube cycle and the cycle is interrupted before it has completed its run. SYMPTOM: When the machine is powered-up and the “Check” icon is pressed, the Z axis tries to go to its home position by moving in the –Z direction. Under normal conditions the axis moves back until it trips the sensor and then steps forward into the home position.
Trouble Shooting Section X-Axis Loose (Revised 012207) Concerning the lost motion in the "X" axis, make sure the Motor End Plate is not loose The plate is secured by two M5 cap screws, PP12285FF. If this plate is OK, then the other possibilities are a loose Lead screw Nut or a loose Anchor Bearing Assembly (see attached photo). Both are difficult to check. It will take about 2 hours to do this work for the first time and much less after you come over for training (about 30 minutes).
Trouble Shooting Section X-Axis Loose continued Grind Motor. The motor will rotate to tension the belt. Holding the motor in that position, tighten the motor mounting crews. Connect the vacuum hose and motor leads. Re-install the Motor Access Cover.
This page was intentionally left blank.
Drill Nomenclature DRILL NOMENCLATURE FACET & CONIC DRILL STYLE PICTURE AND NOMENCLATURE POINT SPLIT & RELIEF DIAGRAMS DEPTH OF SPLIT DIAGRAM Past Center To Center Below Center CENTER OF SPLIT DIAGRAM Past Center To Center Below Center SPLIT ANGLE DIAGRAM CONIC DRILL 12 0° 13 0° Pointed CLEARANCE 95 ° 10 5° Flat FACET FACET DRILL Past Center (over facet) To Center Below Center (under facet) RELIEF 73
This page was intentionally left blank.
Sample Drill File Form Sample Drill File Form 75
This page was intentionally left blank.
Drill Style Recommender Drill Style Recommender HSS, Standard Helix, 135-degree split point • • Cast Iron - Soft and Medium Stainless steel HSS, Parabolic Flute design, 135-degree split point – Effective in deep hole drilling of depths 4 times the diameter of the drill. • • Aluminum alloys Low to Medium Tensile Strength materials HSS, High Helix 118-degree point – En- gineered with a high helix angle and wide flute for improved chip ejection.
This page was intentionally left blank.
General Maintenance GENERAL MAINTENANCE To extend the life of your sharpener, we recommend a routine maintenance program be put in place. Every 200machine hours is suggested, or more often if necessary. Do not interrupt or stop machine once the lubing cycle has begun. If cycle is interrupted when the machine has moved beyond the limit switches, it will not be able to find the home position. If this occurs, call Darex, 800-547-0222.
General Maintenance Wheel cleaning: Always clean a brand new wheel before using. Wheels are packaged in rust preventative oil and will load up if not cleaned before grinding. These wheels are maintenance free from truing and dressing but will need cleaned periodically. • • • • Remove the wheel from the unit. Saturate the wheel with any type of oil-less solvent, such as Automotive Brake Cleaner. Use a soft bristle brush and lightly brush the saturated wheel loosening the impacted grinding particles.
General Maintenance tern on the chuck knob is in alignment with the bolt hole pattern on each of the chuck knob retainers. Contact Darex if you have a single bevel retainer. Chuck knob retainer showing bevel Top Cleaning Fiber Optic Lens: For good drill alignment function, keep the fiber optic lens clean. Normal service period is about every 14 days, depending on conditions, more often may be necessary. To service, lightly dust off lens with a soft bristled paint brush. Make sure lens is not loose.
General Maintenance 6. If you are replacing with new brushes, be sure to install them with the radius of the brush in line with the rotation of the motor. 7. After brushes are installed Refer to Section 24 Removing and Replacing Grind Motor Assembly Instructions to replace the motor. Removing Chuck Spindle Drive Belt: 1. Remove Chuck Jaw Assembly Refer to Section 24 2. Do not remove the jaws or springs from the assembly. They are ground in position for accuracy and are not to be removed.
(See page 84 for V4 and newer) 16 - PP12074FF - 115v - 7A-250v SLO Fuse (Vacuum) 16 - PP12057FF - 230v - 1.6A-250v SLO Fuse (Vacuum) 17 - SA12340MA - Step Motor w/ Coupling 18 - PP12645FF - 115v-3A - 250v SLO Fuse (Grind Motor) 18 - PP12648FF - 230v-3.
Revised 12/08/08 MISC Not Shown - PP10144EF - 115v Cord Set Not Shown - PP10148EF - 230v Cord Set Not Shown - PP12027EF - 6V lamp (Clear) Not Shown - PP12830NF - Machine Cover Not Shown - PP12850KF - Manual Not Shown - PP12860NF - Software Diskette Not Shown - PP04896VF - Video Not Shown - SA12800KA - 115v Tool Kit Not Shown - SA12805KA - 230v Tool Kit 11 - PP12005PF - Floor Mat 12 - SA12025PA - Guard Door Assembly 13 - SA12380EA - X Axis Sensor Assembly 14 - PP12610BF - Spindle Cartridge Block 15 - S
Exploded Views/Parts List XPS-16 All Models 115 V & 230 V Electronic Panel Grind Motor 115v & 230v SA12703BA ALIGNMENT ASSEMBLY 85
Exploded Views/Parts List XPS-16 Vacuum Assembly 87
Wiring Diagram ELECTRONIC PANEL ASSEMBLY SA12150EA & SA12155EA 1. MTO2 2. MTO1 3. C Axis 4. A Axis 5. X Axis 6. Z Axis 7. Align 8. -5V 9. +5V 10. X Axis board 11. Z Axis board 12. A Axis board 13.
Wiring Diagram RJ Notes: Unless Specified = Quick Disconnect Terminals = Locking connector (2) = Ring Terminal RJ RJ DRS Notes: Unless Specified (2) = Ring Terminal = Quick Disconnect Terminals = Locking connector (3) (1) (4) 11/14/06 Change Grind Motor Cable (3) 1/16/03 Added Darex part #s for C larity. (2) 6/19/02 Added chassis ground wire.
Wiring Diagram GRN / YEL POWER RECEPTACLE PP12065EF VACUUM MOT OR 115V AC PP12075EF OR 230VAC PP12072EF L1 L2 GN D LINE 1 LINE 2 P.E. 115 VAC 10 A (M IN.) 1 KVA OR 230 VAC 5 A (MIN) 1 KVA BRN BL U VACUU M F USE 115V - 7A SLO, PP12074FF X 2 230V - 1.
SERVICE PARTS REPLACEMENT SCHEMATICS & WORK INSTRUCTIONS USER SECTION CHUCK SWING CASTING ASSEMBLY EXPLODED VIEW: SA12500CA.... PAGE 1 CHUCK SPINDLE DRIVE BELT REPLACEMENT............................... PAGE 3 REMOVE/REPLACE CHUCK BELT IDLER ASSEMBLY ...................... PAGE 6 REMOVE/REPLACE CHUCK LOCKING SOLENOID .......................... PAGE 7 REMOVE/REPLACE NEMA DRIVE GEAR......................................... PAGE 8 REMOVE/REPLACE ROTATE SENSOR ............................................
User Manual Page 1 CHUCK SWING CASTING ASSEMBLY SA12500CA PP12581LF NEMA DRIVE GEAR
User Manual Page 3 Removing and Replacing the Chuck Spindle Drive Belt 1. Remove the three 3mm button head screws with 3. Do not remove the jaws or springs a 2mm Allen wrench and remove the cover from the assembly. They are ground in position for accuracy and are not to be 3MM button removed. head screws plate. 2. Remove the four, 4mm cap screws from the chuck knob with a 3mm Allen wrench. Lift the chuck knob straight up. The jaw assembly and knob will come out together. Set aside.
User Manual Page 4 4. To loosen and remove belt, insert a flat blade screw driver in the slotted bearing screw. Loosen 6. Replace the belt. Using two fingers on a flat blade screw driver, rotate slotted bearing screw clockwise until belt just pulls to a flat condition. There will be a noticeable increase in resistance past this point of rotation. Continue rotating another 1/16". Hold screw driver in this position and secure bearing lock screw. Tighten 5.
User Manual Page 5 Replace Chuck Spindle Drive Belt 1. Take the knob and jaw assembly and position all jaws in slots. Holding in your hand, align the black diameter detect rod in the corresponding notch in the spindle cone. (See drawing below). Make sure jaws are in spindle slots. Slide the assembly all the way in until it 3. Slip the knob retainer under the knob and locate threaded holes under counter bored holes in the knob. (Note the dotted lines).
User Manual Page 6 Removing and Replacing the Chuck Belt Idler Assembly Refer to the Chuck Spindle Drive Belt Replacement instructions for cover and chuck removal, belt adjustment and reassembly after replacement of belt idler. See Section 24 Schematics and Work Instructions page 3. 1. Remove the 4mm locking screw and lift the idler assembly out of the housing. 4MM locking screw Idler assembly To install the idler, position over screw hole outside of belt and thread screw into idler just until snug.
User Manual Page 7 Removing and Replacing the Chuck Locking Solenoid Refer to the Chuck Spindle Drive Belt Replacement instructions for cover and chuck removal and reassembly after solenoid change. See Section 24 Schematics and Work Instructions page 3. Hold the pin back and tuck it under and into the locking hole and seat it in the recess. Secure with the 2 screws and connect the connectors. Tuck the connectors back into 1. Remove the cover and chuck. Disconnect both connectors.
User Manual Page 8 Removing and Replacing the Nema Drive Gear Refer to the Chuck Spindle Drive Belt Replacement instructions for cover, chuck and belt removal and reassembly after Nema drive gear has been replaced. See Section 24 Schematics and Work Instructions page 3. 1. Rotate until set screw is easily accessible. Using a 1/16 Allen wrench loosen the set screw and remove the gear. To replace slip the gear over the shaft with the set screw over the flat.
User Manual Page 9 Removing and Replacing the Rotate Sensor 1. Remove the 3, 3mm button head screws with a 2mm Allen wrench and remove the cover plate. 3MM button head screws 2. Remove the four 4mm cap screws from the chuck knob with a 3mm Allen wrench. Lift the chuck knob straight up. The jaw assembly and knob will come out together. Set aside. 4MM cap screws 3. Do not remove the jaws or springs from the assembly. They are ground in position for accuracy and are not to be removed.
User Manual Page 10 4. With a small flat blade screw driver, reach down and pull the solenoid lock pin back out of the locking hole. Rotate the chuck so the sensor flag is out of the way as illustrated. Depress the clip on the sensor connector and pull apart. Using a 2mm Allen wrench, remove the 2 button head screws and lift the sensor out. Screw the new sensor in place and snap the connectors together. Tuck the connectors back into place. Sensor flag Solenoid lock pin 2.
User Manual Page 11 Removing and Replacing the A-Axis (Swing) Sensor Removing and Replacing the A-Axis (Swing) Sensor 1. Locate the marked swing sensor cable and unplug the sensor connector. 2. Note the access hole in the dust shield cover. 3. Swing the dust shield up or down to access the two 2mm screws securing the sensor. 4. Unscrew the screws and remove the sensor. 5. To replace the sensor reverse the process and snap the connector together.
User Manual Page 12
User Manual Page 13 CHUCK ASSEMBLY SA12520TA PP12255FF M4x.7x8 4 EA.
User Manual Page 15 Removing and Replacing Diameter Detect Rod Refer to the Chuck Spindle Drive Belt Replacement instructions for cover and chuck removal and reassembly after diameter detect rod has been replaced. See Section 24 Schematics and Work Instructions page 3. 3. Turn the jaw assembly counter clockwise until it bottoms out in the knob. Knob and jaw assembly 1. Remove cover and chuck only. 2.
User Manual Page 16
GRN / YEL POWER RECEPTACLE PP12065EF VACUUM MOTOR 115VAC PP12075EF OR 230VAC PP12072EF L1 L2 GND LINE 1 LINE 2 P.E. 115 VAC 10 A (MIN.) 1 KVA OR 230 VAC 5 A (MIN) 1 KVA BRN BLU VACUUM FUSE 115V - 7A SLO, PP12074FF X 2 230V - 1.
User Manual Page 19 Removing and Replacing the Cooling Fan Removing the Cooling Fan 1. Remove the 2 screws holding the panel to the machine. 5. On the front of the panel, snap the fan filter cover from the fan. 2. Swing the panel open. 3. There are red and black wires coming from the fan and a white and green wire coming from the power switch. They merge into a connector. Disconnect the connector. The panel will swing open further. 6.
User Manual Page 20 7. Disconnect the 2 sets of red and black wires that go to a connector above the fan on the back board. Replace the Cooling Fan 1. Snap the connector with the red and black wires into the connector above the fan on the back board. 2. Slip the fan into the panel with the red and black wires facing you and exiting to the left. 3. Put the 4 screws through the front fan cover and line up the fan with the screw holes from the inside.
User Manual Page 21 Removing and Replacing the LCD Display Removing and Replacing the LCD Display 1. Remove the screws on the door support and top cover. 2. Remove the door support cover and lift the top cover. 3. Located at the bottom of the LCD display is the interface board. Using two fingers on the outside of the board, pull from the LCD receptacle. Leave all wires connected to board. 4. Unplug the green five wire connector from the LCD. 5.
User Manual Page 22 6. Remove the 7, ¼” acorn nuts from the LCD. Note: One is inaccessible and has no nut. Slide the LCD out. 1. To replace the LCD, slip back through the front of the top cover. Hold in place with your hand and install acorn nuts just until one to two threads protrude past the surface of the nut. A thin wall ¼” socket is necessary for clearance. 2. Plug in interface board, green five wire connector and the RS232 connector and screw.
User Manual Page 23 Removing and Replacing Switches Removing and Replacing The E-Stop, Cycle Start and Feed Hold Switches To remove the power switches, remove the screws from the door support casting and top cover. Remove the support door casting and tilt it up. . E-Stop 1. Using a pair of needle nose pliers, hold the switch block down with your thumb. Grab the connectors and gently pull up while using a rocking motion and remove the 2 wires. 2. Connected to the switch is the switch block.
User Manual Page 24 3. Securing the switch in place is a plastic nut at the base of the threads. Use needle nose pliers to remove the nut and slide the switch out. move the plastic retainer nut, also same as EStop. 5. Slide the switch from the casting, but note the rubber gasket and locator pin that protrudes through the gasket and locates the switch on the top cover. It must locate in this position. Feed Hold (amber) 1. Follow Cycle Start switch replacement steps to replace Feed Hold switch. 4.
User Manual Page 25 GRIND MOTOR ASSEMBLY SA12640MA F-F3 Units
User Manual Page 27 Removing and Replacing Grind Motor Assembly F1, 2 &3 only 1. Turn the machine on. 2. Push the check icon. 4. Push the belt change icon. 5. The X-Axis will move into the belt change position and stop. Shut the machine off and disconnect power source. 3. Push the tool icon. 6. Refer to Grind Motor Belt Replacement instructions and remove belt. See Section 24 Schematics and Work Instructions page 29. 7. Unplug the motor connector wires.
User Manual Page 28 8. Remove the 4 screws and washers holding the motor in place. 9. Slide the motor down the slotted bracket and out of the machine. Remove the cooling hose connected to the motor. 10. To replace the motor assembly, the machine must in the belt change position. 11. Reconnect the cooling hose and slip the motor shaft with the pulley in place up the slotted bracket and aligned with slots and screw hole. 12. Install screws and washers just until they bring surfaces together. 13.
User Manual Page 29 Removing and Replacing Grind Motor Belt 1. 2. 3. 4. 5. 6. 7. 8. 9. Turn the machine on and push check. Push the tool icon. Push the belt icon in upper right hand corner. The X-Axis moves to the center and stops. Turn the machine off and unplug from power source. Remove the belt access panel at back of machine. Loosen the 4 mounting bolts and swing the motor up to loosen the belt. Tighten one bolt and remove the belt. Install the new belt and loosen the bolt.
User Manual Page 30 Removing and Replacing Grind Motor Brushes 1. Refer to Removing and Replacing Grind Motor Assembly instructions to remove and replace the motor. See Section 24 Schematics and Work Instructions page 27. 2. Once the motor is removed, note the slotted brush retaining screws on each side of the motor. 3. Unscrew and check brushes one at a time noting how they were oriented in the guide. Marking them is a good idea. 4. Check each brush for damage to the springs or for excessive wear.
User Manual Page 31 SPINDLE CARTRIDGE ASSEMBLY SA12615TA
User Manual Page 33 Removing and Replacing the Spindle Arbor Cartridge Assembly Removing and Replacing the Spindle Arbor Cartridge Assembly. 5. Remove the 4, 4mm screws holding the wheel casting in place. 1. Refer to Grind Motor Belt Replacement instructions and remove belt. See Section 24 Schematics and Work Instructions page 29. 2. Remove the 4, 3mm screws on the wheel cover. Remove, leaving hose attached to cover. The casting is pinned to the cartridge block.
User Manual Page 34 7. Loosen the 2, 3mm set screws in the top of the cartridge block that holds the cartridge in place. forward to allow clearance to do this. Leave the pulley set screw loose. 11. Take the wheel casting and align the dowel pins with the holes in the cartridge block. Push or tap into place. Secure with 4mm screws. 8. Slide the cartridge forward allowing enough room to remove the drive pulley. 12. Now slide the cartridge all the way forward until it stops against the wheel casting.
User Manual Page 35 1. Reinstall the wheel. 2. Reinstall the wheel cover. 3. Refer to Grind Motor Belt Replacement to install and set proper tension on belt. See Section 24 Schematics and Work Instructions page 29.
User Manual Page 36
User Manual Page 38 Phone: 800-547-0222 541-488-2224 Darex PO Box 730 Ashland, OR 97520 USA Fax: 541-488-2229 Email: techsupport2@darex.com Web: www.darex.
