Instruction Handbook for RH & RW Series Machining Centers

Milltronics Manufacturing Company

1400 Mill Lane
Waconia, MN 55387 USA
Phone 952-442-1410 Fax 952-442-6457
www.milltronics.net

Rev 1 12-13-2011
 INSTRUCTION HANDBOOK
SERVING THE METAL CUTTING INDUSTRY SINCE 1973
1400 MILL LANE • WACONIA, MN 55387
TEL: 952.442.6455 • FAX: 952.442.6457

Table Of Contents

Chapter 1 - Safety ........................................................................................................... 1

Safety Checklist............................................................................................................ 2
Basic Points Of Safety.................................................................................................. 2
Clothing and Personal Safety....................................................................................... 3
Safety Related to Workpiece Machining And Tooling................................................... 5
Safety Related To Machine Maintenance..................................................................... 5
Electrical Safety ........................................................................................................... 6
Release of Trapped Persons........................................................................................ 6
Machine Safety Labels ................................................................................................. 7
Safety and Maintenance Label Locations and Descriptions ......................................... 8
Chapter 2 - Specification ............................................................................................... 13
Machine Weights........................................................................................................ 13
Standard Current/Voltage requirements..................................................................... 13
Coolant Capacities ..................................................................................................... 13
Coolant Recommendation.......................................................................................... 13
Control Instructions, Schematics, Complete Specification Sheets ............................. 13
Retention Knob Chart................................................................................................. 14
RH20 & 30 Machine Layout ....................................................................................... 15
RW15 & 20 Machine Layout....................................................................................... 16
Item Identification ....................................................................................................... 17
Chapter 3 - Site Preparation.......................................................................................... 19
Machine Placement Considerations ........................................................................... 19
Power And Ground Requirements ............................................................................. 20
Connecting a Transformer.......................................................................................... 21
Autotransformer Connection Diagram ........................................................................ 22
Air Supply System ...................................................................................................... 23
Lifting By Crane or Hoist ............................................................................................ 24
Chapter 4 - Installation .................................................................................................. 25
Startup checklist ......................................................................................................... 25
Required Assembly .................................................................................................... 25
Finish Level and Tram the Machine ........................................................................... 28
Initial Checks of the Machine, its Guards and Safety Systems .................................. 29
General Checks ......................................................................................................... 29
Electrical Checks........................................................................................................ 29
Visually Check That Guards Are In Place .................................................................. 30
Safety Checks ............................................................................................................ 31
Test the Emergency Stop Circuit................................................................................ 31
Test the enclosure safety circuit (CE machines only)................................................. 32
Spindle Start up Procedure ........................................................................................ 33
 INSTRUCTION HANDBOOK
SERVING THE METAL CUTTING INDUSTRY SINCE 1973
1400 MILL LANE • WACONIA, MN 55387
TEL: 952.442.6455 • FAX: 952.442.6457

Chapter 5 - Failure Modes, Detection and Prevention................................................... 35

Minimizing Wear and Tear ......................................................................................... 35
Clearing Faults in Electrical Components................................................................... 35
Diagnosing Mechanical Faults ................................................................................... 36
Chapter 6 – Maintenance .............................................................................................. 37
Periodic Maintenance; Verification Of Safety Systems............................................... 37
Maintenance Schedule............................................................................................... 37
Always........................................................................................................................ 37
Daily ........................................................................................................................... 37
Weekly ....................................................................................................................... 37
Monthly....................................................................................................................... 38
Annually ..................................................................................................................... 38
Safety Checks, to be carried out monthly and after maintenance operations............. 38
Air System Maintenance ............................................................................................ 39
Way Lube Maintenance.............................................................................................. 40
Automatic Tool Changer (ATC) Maintenance............................................................. 41
Chapter 7 – 7200 CNC Operation ................................................................................. 43
Milltronics 7200 CNC Front Panel .............................................................................. 43
Power ON................................................................................................................... 43
Power OFF................................................................................................................. 43
Diagram of Main Screen............................................................................................. 46
Chapter 8 Machine Specifications ................................................................................. 50
RH Rigid Head Bed Mill Specifications....................................................................... 52
 Chapter 1 - Safety

The general principles for safe operation of Milltronics machines are outlined in this
manual. Every Milltronics machine is engineered for safety. You will note, for example,
that all rotating parts are protected by specially designed covers. On some models, the
entire machine will be enclosed to protect the operator from flying cutting chips and to
prevent an insecurely clamped work piece from being thrown out during cutting
operations. If a Milltronics machine is operated in accordance with the manufacturer’s
instructions, it will provide safe and reliable service. However, with machines of this
nature, serious injuries or death can occur from careless or improper operation. Do not
attempt to operate this equipment without reading and thoroughly understanding this
manual. Not every example of improper operation or unauthorized usage that may lead
to malfunction or accident can be anticipated. If a particular operation is not
documented in this or any other Milltronics manual as authorized usage for the
particular equipment, it should be assumed that this is an unauthorized or improper
usage with potential danger and should be avoided.

A. This machine is provided with various safety devices to protect the operator and the
machine. However, these cannot cover all aspects of safety, therefore the operator
must thoroughly read and understand all machine manuals before operating the
machine. The operator should also take into consideration other aspects of safety
related to the particular environment and conditions.

B. Three categories of safety guidelines have been used throughout this manual:
DANGER, WARNING, and CAUTION. The Ansi Z535.4 safety alert symbols and
their meanings are as follows:
DANGER: Indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION: Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.

1
Safety Checklist

• Always observe the safety instructions inscribed on the safety labels fixed onto the
machine. Do not remove or alter these labels.
• Do not attempt to operate this machine until you have read the manuals supplied
with the machine and understand each of the functions and operation methods.
• Operators should be trained formally either by a technical school or some form of
apprenticeship program in machining and machining safety.
• Installation and maintenance should be performed only by qualified personnel.
• Qualified personnel shall be trained and knowledgeable of the construction and
operation of this equipment and work methods. Such persons shall be trained to
recognize and avoid hazards that might be present with respect to this equipment
and work methods. Such persons shall also be familiar with the proper use of any
special precautionary techniques, personal protective equipment, including arc-flash,
insulating and shielding materials, and insulated tools and test equipment.

Basic Points Of Safety

1. DANGER
• There are high voltage terminals on the electrical panel, transformer, motors,
junction boxes and other equipment.
• DO NOT touch the high voltage terminals or components under any
circumstances when the power supply is on. Make sure that all doors and
safety covers are fitted before switching the power supply on. If any door or
safety cover is to be removed, first switch off the main circuit breaker.
• DO NOT enter the machining envelope at any time that the machine is under
power. The machine should be entered only when powered off and properly
locked out to prevent accidental energizing of the machine while persons are
inside.
2. WARNING:
• Memorize the location of the emergency stop button(s), so that you can press
emergency stop immediately from any position.

2
 CHAPTER 1 - SAFETY

• Take care not to touch any switches accidentally while the machine is in
operation.
• Under no circumstance touch any rotating work piece or tool in the spindle
with any object or hands.
• If in the slightest doubt about any procedure, consult appropriate persons or
manuals.
• Always press the emergency stop button when leaving the machine
unattended.
• If more than one person is operating the machine, do not proceed to next step
until notifying the other operator(s).
• Do not modify the machine in any way that will affect the safety of the
machine.
• Never machine flammable or explosive materials.
• Never use flammable cutting fluids.
3. CAUTION
• Do not subject the CNC control unit, the operator’s panel, or the electrical
control panel to strong voltage fluctuations.
• Do not change any machine parameter values without consulting Milltronics
service department. If it becomes necessary to change a value, first check if it
is safe to do so, then make a note of the original value so it can be reset if
necessary.
• Do not open any doors or remove any safety covers while the machine is
under operation.
• Stop all machine operations before cleaning the machine.
• Never leave the machine to run unattended.

Clothing and Personal Safety

1. DANGER
• Tie back long hair that could become entangled in machine mechanisms.
• Eye protection and hearing protection should be worn at all times when
operating the machine.
• Always use safety shoes with steel toecaps and oil resistant soles.

3
 • Do not operate the machine while wearing loose or baggy clothes.
• Always completely fasten buttons and hooks on the arms of clothing to avoid
danger of entanglement in machine mechanisms.
• Do not operate the machine under the influence of drugs or alcohol.
• If wearing gloves to load or unload parts, be sure the machine is in
emergency stop mode.

2. WARNING
• Close all doors and covers of the CNC unit, operation panel and electrical
panel to prevent damage from water, chips, and oil.
• Emergency stop the machine and turn off the main power during electrical
storms.
• Check all safety covers regularly to make sure they are properly fitted and not
damaged.
• Always obtain assistance when handling loads beyond your ability.
• Do not adjust coolant nozzles while the machine is in operation.
• Do not remove or interfere with any machine safety devices.
• Do not wipe the work piece with a rag while the spindle is rotating or the
machine is in motion.
• Always stop the machine before removing or inspecting a tool.
• Tools and tooling can be very sharp. Take care when handling.
• Never place an object or your hand in the carousel or tool changer without
putting the machine in emergency stop.
• Never place anything between the machine spindle and tool changer.
• Never use additional clip-on or poorly secured lighting.

3. CAUTION
• Do not allow chips to accumulate during heavy cutting.
• Never use compressed air to clean the machine bed.
• Never wear gloves while operating panel switches.

4
 CHAPTER 1 - SAFETY

Safety Related to Workpiece Machining And Tooling

1. DANGER
• Never operate the spindle above the rated speed of accessories mounted on
it (chucks, tooling, etc).
• Do not extend stock out of a lathe headstock without an appropriate bar feed
or support.
2. WARNING
• Always use tools suitable for the work and that conform to machine
specifications.
• Replace badly worn tools.
• Be sure that all workpieces and fixtures are secured properly.
• Do not overhang any work piece on a mill table.
• Never operate the machine beyond its specified power limits.
• Never machine flammable or explosive materials.
• Never use flammable materials as cutting fluid.

3. CAUTION
• Be sure the tool length is such that the tool will not interfere with any fixtures
or other objects.
• Perform test operations after mounting tools.

Safety Related To Machine Maintenance

•
• Maintenance should be performed only by qualified personnel as defined in
the safety checklist on page 2.
• Beware that the machine head can fall if unsupported while servicing the Z-
axis motor or ballscrew. Brace the head up while servicing in this area.
• Turn off the main power and install a lockout/tagout on the machine.
• Maintain a clean floor around the work area.
• Employ proper lighting in the area.
• Ensure any ladders used are safe, stable, and secure.

5
Electrical Safety

Read and understand the following list of cautions before attempting to perform service
on this equipment. Failure to observe these rules can result in death or serious
injury.
1. DANGER
• Only qualified personnel should attempt to take current and voltage readings
or perform service. See the safety checklist on page 2 for qualifications.
• Arc flash and shock hazard. Follow ALL requirements in NFPA 70E for
safe work practices and for Personal Protective Equipment before opening
electrical cabinet or performing adjustments or diagnostic measurements
while energized.
• Always keep hands and fingers away from live electrical terminals.
• Remove jewelry while servicing the machine to avoid shorting any electrical
circuits.
• Allow all components to discharge before servicing them. After removing
power, verify that the CHARGE LED indicator and 7-segment display on the
spindle drive have turned OFF before servicing.

FAILURE TO FOLLOW THESE RULES CAN RESULT IN SERIOUS INJURY OR DEATH

Neither the manufacturer nor the manufacturers representatives or dealers can

assume responsibility for any mishaps, damage, or personal injury that may
occur as a result of improper operation or from failure to observe safety
precautions.

Release of Trapped Persons

The purpose of covers and enclosures is to prevent persons from becoming trapped or
entangled in a machine. Be sure all machine covers are in place. Be sure the machine
enclosure is closed when the machine is operating in automatic mode.

Maintenance should be performed only by qualified personnel. They should follow the
guidelines in chapter one for safe maintenance practice. Maintenance should not be
performed on a machine under power. For even the most routine day-to-day
maintenance, such as cleaning the table or removing chips from the machining
6
 CHAPTER 1 - SAFETY

enclosure, the machine should be put in an emergency stop condition, de-energizing

the axis servo motors and spindle motor.

Following these precautions prevents someone from becoming trapped or entangled in

the machine.

If a person should become trapped in the machine, the safest procedure is to put the
machine in emergency stop by pressing the red EMERGENCY STOP button, then
powering the machine down using the main disconnect switch on the door of the
electrical cabinet at the rear of the machine.
When the machine is put into emergency stop mode, the servo motors and the spindle
motor are de-energized. If the machine has a horizontal tool change platter and the
platter is under the spindle, emergency stop causes the platter to withdraw from
underneath the spindle.

When there is no power to the machine, the ballscrews for the X and Y axes may be
moved by hand. The Z axis remains locked to prevent the head from falling. If
compressed air is disconnected from the machine, a horizontal tool change platter may
be moved in and out by hand.

Machine Safety Labels

Please read and understand all of the safety and warning labels on the machine prior to
using the equipment. Failure to observe these labels can result in injury or death.

7
Safety and Maintenance Label Locations and Descriptions

Item Description Page

1 Danger and Safety Precaution 9
2 Projectile Hazard 9
3 Chip Auger/Conveyor Hazard 9
4 Main Power hazard and Notice 10
5 ATC crush hazard 10
6 Auger warning 10
7 Warmup and daily checks 10
8 Spindle Operation and Precaution 10
9 Drawbar Maintenance (if equipped) For Inline spindle models only 10
10 Waylube maintenance 10
11 Air system maintenance 11
12 ATC maintenance 11

5
9 2
12 7

1 8

3 4

3
10
11
6

8
 CHAPTER 1 - SAFETY

Read and understand all Safety, Operation, and Maintenance labels affixed to
the machine to ensure safety and reliability.

Located near access doors on models

2 equipped with full enclosure.

Located around hazard areas on models

equipped with chip conveyor.

3
Located around hazard areas on models
equipped with chip auger.

9
 Located near main power disconnect
switch on all models.

Located near Automatic Tool Changers

5 and other potential crush hazard areas.

6 Located on chip auger chute if equipped.

All models, located near operator station.

7 Perform all checks to prevent damage
and ensure reliable operation.

All models, located near operator station.

8 Perform all checks to prevent damage
and ensure reliable operation.

Maintenance labels located on machine near

9 maintenance items. Various labels are used
depending on options/equipment.

10
 CHAPTER 1 - SAFETY

Maintenance labels located on machine near

10 maintenance items. Various labels are used
depending on options/equipment.

Maintenance labels located on machine near

11 maintenance items. Various labels are used
depending on options/equipment.

Maintenance labels located on machine near

12 maintenance items. Various labels are used
depending on options/equipment.

Maintenance label for two-speed gearbox

models only.

11
 Chapter 2 - Specification
Machine Weights

RW15 RW20 RH20 RH30

Lbs. 6,500 8,500 8,000 11,000
Kg 2,950 3,860 3,628 5,000

Standard Current/Voltage requirements

RW15 RW20 RH20 RH30

208-240
50 Amps 50 Amps 60 Amps 60 Amps
VAC
Transformer 11 KVA 11 KVA 20 KVA 20 KVA

Coolant Capacities

RW15 RW20 RH20 RH30

Gallons 50 50 7.5 15
Liters 190 190 13 25

Coolant Recommendation

Consult with a reputable coolant supplier in your area. You should use non-toxic, non-
corrosive, and non-flammable coolant. Avoid chlorine and sulfur, which may harm the
paint finish.

Control Instructions, Schematics, Complete Specification Sheets

• Detailed instructions for programming the machine and operating it from the front
panel are given in the CNC operation manual provided separately.
• Electrical schematics, pneumatic diagrams (if applicable) and hydraulic diagrams
(if applicable) are located in the electrical and mechanical manual.
• Machine specification sheets including travels, tool capacity, etc. are included at
the back of this manual.

13
Retention Knob Chart

14
 CHAPTER 2 - SPECIFICATION

RH20 & 30 Machine Layout

15
RW15 & 20 Machine Layout

16
 CHAPTER 2 - SPECIFICATION

Item Identification

17
1 Operator panel

2 Spindle

3 ATC, Carousel and ARM types

4 Auger Chute

5 Electrical cabinet

6 Y-axis cable track

7 Z-axis cable track

8 Leveling pad

9 Waylube unit

10 Air system

11 Z-axis motor

18
 Chapter 3 - Site Preparation

The following guidelines are intended to help you get the most out of your new machine
tool. The success of your machine tool depends largely on having proper air and power
supplied to it. Failure to adhere to the following guidelines will result in unsatisfactory
performance and component failure.

Machine Placement Considerations

Choose a location for the machine that offers the following:

1. At least 4” thick concrete slab free of cracks and not crossing any expansion joints.
Milltronics will not guarantee machine geometry unless this is adhered to.
2. Ample ceiling height, and clearance behind the machine to fully open the door of the
electrical cabinet at the rear of the machine. (see machine dimensions drawing
for distance)
3. Do not subject the machine to direct sunlight.
4. Do not allow the ambient temperature to exceed 100F or 37C. Temperatures
beyond 100F or 37C may cause unusual control behavior.

Note: Locate the leveling pads and install them into the base of
the machine before placing the machine on the floor!

19
Power And Ground Requirements

Check before turning the main power on!!

1. The standard voltage range is 208 to 240 VAC 3 phase. Voltage out of this
range could cause damage to the machine. Damage incurred through electrical
supply problems will not be warranteed.
2. Ensure that your electrical service is rated for proper current draw (Amps), and
that the appropriate wire size is used to feed the power. (See current/voltage
specifications on the serial data plate located on the door of the electrical
cabinet.)
3. Ensure that a copper wire equal to or greater in diameter than the power wires is
connected between our ground terminal and the main ground located at the
electrical service box. Also ensure that the electrical service box is tied to earth
ground.
4. Milltronics does not allow the use of a separate grounding rod.
5. Milltronics does not allow conduit or wire raceways be used as a ground.
6. If a transformer is used to step the voltage down to 220 refer to the transformer
grounding procedures immediately following this page. The secondary windings
of the transformer MUST be bonded to earth ground to avoid serious damage to
electrical components.
7. If there is a “wild leg” is must be connected to L2 on the main disconnect switch.
8. Failure to adhere to these requirements voids your warranty.
9. Milltronics does not accept responsibility for machine performance if the main
input power is not connected properly.

20
 CHAPTER 3 – SITE PREPARATION

Connecting a Transformer

It is important that proper grounding procedures be followed when hooking up machines

to power. Please review the following pages. They explain proper transformer
connections and checks to ensure proper connections. Refer to the autotransformer
diagram provided to verify that your connections are suitable.

** Spindle and axis drive damage results from incorrect transformer connection.**

Cautions!
1. Arc flash and shock hazard. Follow ALL requirements in NFPA 70E for safe
work practices and for Personal Protective Equipment before opening electrical
cabinet or performing adjustments or diagnostic measurements while energized.
2. Be sure to turn off all power to the transformer prior to making connections or
resistance readings. Disconnect the transformer completely from power.
3. Always measure voltage from line to line and from line to ground before applying
power to the machine electrics. Do this with or without the addition of a
transformer.
4. With or without a transformer any power leg of the three phase incoming power
to the machine should not exceed 240 VAC to ground, or from leg to leg. At least
two of the legs when measured between the leg and chassis ground should
measure the same voltage.
5. The grounding wire going into the machine must be connected to a neutral point
within the transformer windings and to earth ground. This is provided as a tap on
the transformer.
6. When a green wire appears to go to the transformer housing, never assume that
it is grounded properly. Follow the green wire to verify it is not merely a case
ground but instead is tied to a neutral point in the transformer windings.

Always call the factory if in doubt concerning transformer connections as serious

damage can result if the machine or transformers are not properly connected.

21
Autotransformer Connection Diagram

If your machine was ordered from Milltronics with a transformer option an

autotransformer is supplied. The diagram below illustrates the various input voltage
selections and proper ground wire connections.

Always call the factory if in doubt concerning transformer connections as serious

damage can result if the machine or transformers are not properly connected.

22
 CHAPTER 3 – SITE PREPARATION

Air Supply
pply System

Milltronics machining centers require a constant supply of quality air pressure in order to
perform optimally. 90-110 PSI at 10 CFM is required for RW15-20 and RH19-30
models.

Adjustments
• Do not adjust the air purge regulator unless instructed to do so by an authorized
Milltronics Representative.
• Set the drop rate on the lubricator to approximately 1 drop per every 1-2 tool
changes

Main air pressure Spindle air pressure

gauge. Adjust gauge. Do not alter
using knob “A”. from factory setting.
90 PSI A
B

Fill with Marvel

No.085, Mobil
Velocite No. 10
or equivalent.

Maintain fill
Water trap is self- levels weekly
draining. No need using specified
to drain manually. air tool oil.

23
 This machine should only be
moved, loaded/unloaded, or
Lifting By Crane or Hoist skidded/unskidded by a
trained and certified machine
mover.

24
 Chapter 4 - Installation
Startup checklist

The enclosed startup checklist guides the process of the machine installation and
checkout. The startup checklist forms must be completed and sent to Milltronics Mfg. to
activate the machine warranty. Use the startup checklist in conjunction with the
following outline when installing and setting up the machine.

Required Assembly

In some cases, parts of the machine are removed or adjusted for shipping purposes.
Qualified personnel (See the safety checklist on page 2 for qualifications) should install
and adjust as necessary according to the photos and descriptions.

Locate the leveling pads and bolts. Thread them into the
machine base before setting the machine on the floor.

A block of wood is used to support the head during

transportation. Once the homing process begins,
the head will move upward so the support block
can be removed. When pressure is relieved from
the block it can safely be removed.

On RH30 machines, the front panel / operator station is rotated beyond the stop position
and out of the way. Instructions are included that explain how to position the operator
station and install the stop bolt in the correct location.

25
Install or adjust the Z-axis cable track as shown
(if applicable). In many cases this track is
loosened or removed for shipping.

Connect the remote hand controller (if

equipped) cable into the 25-pin “D-sub”
connector to the right side of the operator
panel.

Connect all remaining cables to their respective plugs on the machine.

Once the machine is in place and assembled this far, have the power and air supplies
connected by qualified personnel as described in chapter 1. See the safety checklist on
page 2 for qualifications.

Level the machine (rough level) in both side to

side and front to back directions.

26
 CHAPTER 4 - INSTALLATION

Slide the flood coolant tank under from the

front of the machine (if equipped).

Install the auger chute (if equipped)

27
Finish Level and Tram the Machine

Note: This procedure is duplicated as part of the startup checklist enclosed. Please
make note of the final tram readings on the startup checklist forms to be returned to
Milltronics.

1. Center the table in the travels of both the X and the Y-axes.
2. Adjust the center leveling pads so the machine is resting on only the 4 corner pads
3. Use a precision level placed on the center of the table and adjust the pads until the
machine is level side to side firmly setting on the 4 corner pads.
4. Rotate the level 90 degrees on the table (or use two levels) and adjust the pads until
the machine is level front to back.
5. Re-check the side to side level again as it may have changed while adjusting front to
back. Repeat steps 6 & 7 until the machine is level in both directions.
6. Using a magnetic base with a dial indicator sweep the table to check tram. The tram
should sweep within .001” over a 10” diameter sweep. Adjust leveling pads if
necessary. At this stage it is more important to be level to tram and NOT level to the
precision level.
7. Extend the center pads to the floor. The center pads should have light pressure
applied to them. Be careful not to affect the level or tram while adjusting them.
8. With the level placed lengthwise along the table checking the X-axis level, move the
Y-axis in and out. If there is any twist in the Y-axis, the bubble will move as Y travels
in and out. Ideally there is no twist and the bubble will not move. If it does move, go
back through the process and re-level the machine.

Make note of spindle to table tram readings on startup checklist when complete

28
 CHAPTER 4 - INSTALLATION

Initial Checks of the Machine, its Guards and Safety Systems

General Checks

1. Check for missing parts. Do not operate the machine if parts are missing.
2. Visually check for damage outside of machine and inside. Do not operate the
machine if there has been shipping damage.
3. Check to see that all necessary guards and safety switches are in place. Do not
operate the machine if necessary guards and safety switches are not in place.

Electrical Checks

Read and understand the following list of Electrical Safety Rules in Chapter 1 before
attempting to perform service on this equipment.
DANGER: Failure to observe these rules can result in death or serious injury.
• Arc flash and shock hazard. Follow ALL requirements in NFPA 70E for safe
work practices and for Personal Protective Equipment before opening electrical
cabinet or performing adjustments or diagnostic measurements while
energized.
• Only qualified personnel should attempt to take current and voltage readings or
perform service. See the safety checklist on page 2 for qualifications.
• Always turn the main power off before servicing components within the
electrical cabinet.
• Always keep hands and fingers away from live electrical terminals.
• Remove jewelry while servicing the machine to avoid shorting any electrical
circuits.
• Allow all components to discharge before servicing them. After removing
power, verify that the CHARGE LED indicator and 7-segment display on the
spindle drive have turned OFF before servicing.
1. Check for loose components or loose wires. With the main power disconnect OFF,
open the electrical cabinet door at the rear of the machine. Visually check if any
components or wires came loose during shipment. Do not operate the machine if
they did. Find qualified personnel (as described in chapter 1) to correct the
problems.

29
WARNING:
DANGEROUS VOLTAGES EXIST FOR THE VOLTAGE LEVEL CHECKS!

2. Check voltage levels. As stated in the Electrical Safety Rules, only qualified
personnel (as described in chapter 1) should attempt to take these measurements.
With the electrical cabinet door open, turn on the main power at the disconnect
switch. Do not enable the drives, i.e. do not push the ENABLE button on the front
panel.
A. Check +24 VDC. Measure between terminal blocks 12 & 22
B. Check +5 VDC. Measure between + and – V pins on the 5 VDC power
supply if present.
C. Check 110VAC on the secondary side of the 110 Volt transformer, or
between terminal blocks 1 & 2. The AC voltage must be between 110 and
125VAC.

Turn the main disconnect switch to the OFF position, powering down the machine.
Close and lock the door of the electrical cabinet.

Visually Check That Guards Are In Place

1. Required Guards for Mills

Milling machines and machining centers should have way covers on all three
axes, closing off the pinch points associated with machine axis motion. All
machining centers, by definition, have a full enclosure around the machining
area. Check that the enclosure door operates smoothly. CE-compliant
machining centers should have a locking switch on the enclosure door.
Horizontal carousel tool changers should have a circular cover over the tool
platter.
Toolroom milling machines by definition do not have a tool changer or an
enclosure. CE-compliant toolroom machines are equipped with a table guard, an
enclosure fastened to the table itself. The table guard is open at the back in
order not to impede machine motion. On CE machines and non-CE machines,
there are splash guards on either side of the machine column.

30
 CHAPTER 4 - INSTALLATION

Safety Checks

Follow the sequences outlined below for Milltronics control.

Home the Machine

During this operation, the machine will move. Before starting the operation,
make sure any shipping clamps that might impede machine movement have
been removed and nothing else remains to interfere with machine motion.
Turn main power on.
Press the green ENABLE button to power up servos. Note: If the machine does
not ENABLE, check all emergency stop switches: conveyor, remote hand
controller, etc.
Press F1 (Home).
Press CYCLE START.
Start the Spindle (Operate only within proper startup/break in limits outlined on
page 33)
During the sequence outlined below, the spindle will rotate. If there is a tool in
the spindle (for mills) or if there is a workpiece in the spindle (for lathes), make
sure it is not going to hit anything when the spindle rotates. For lathes, the chuck
guard must be down. If the machine has an enclosure, close the door.

From the main menu:

Press F5 (MDI).

Key in "S" code for RPM followed by RPM value.

Example: S500 = 500 RPM

Key in "M" code for spindle direction: (M03)=CW, (M04)=CCW

Example: S500 M3

Press ENTER.

Press CYCLE START to start spindle, then use manual CW, CCW and STOP buttons.

Test the Emergency Stop Circuit

Having followed the steps outlined above for enabling the machine and starting
the spindle, then
Press the red EMERGENCY STOP button.

31
 Spindle rotation should stop. The emergency stop button is the most important
safety switch on the machine. It stops and then de-energizes the spindle motor.
(At the same time, it stops and de-energizes the axis servo motors, although they
are not running for this test.)
When the red emergency stop button is pushed, the spindle should brake to a
rapid stop. If the spindle does not stop at all, or if it coasts to a stop, then the
emergency stop circuit is not operating correctly. Call qualified service personnel
(as described in chapter 1) to fix the problem. The machine should not be
operated until the emergency stop circuit is operating correctly.
Repeat the same tests using all emergency stop buttons including conveyor,
remote hand controller, etc.

Test the enclosure safety circuit (CE machines only)

If the machine is still in emergency stop mode from the previous test, then twist the red
EMERGENCY STOP button clockwise to release it. Press the ENABLE button to re-
energize the axis motors and the spindle motor. Follow the directions in the previous
sequence for starting the spindle for manual use.

Now hold in the SETUP button and open the door to the machining enclosure (if
equipped). The spindle should brake to a rapid stop. If the spindle does not stop at all,
or if it coasts to a stop, then the enclosure safety circuit is not operating correctly. Call
qualified service personnel (as described in chapter 1) to fix the problem. The machine
should not be operated until the enclosure safety circuit is operating correctly.

Never operate the machine with the “door open” parameter turned off, or with the
operation of the door switch defeated.

32
 CHAPTER 4 - INSTALLATION

Spindle Start up Procedure

Daily Run-in procedure

1. Start the flood pump or chiller unit (if equipped) and run coolant through coolant
passages until the temperature stabilizes.

2. Clamp a tool holder into the spindle. Never operate the spindle without a tool holder
installed.

3. Verify that all auxiliary systems are operating properly.

a. If equipped with a spindle air purge system, the system should have
approximately. 15 PSI.
b. If equipped with the optional Vogel Air Oiler System, verify the reservoir tank
has adequate oil supply and proper air pressure.

3. Run the spindle at 50% of the maximum RPM for 10 minutes.

Measure temperature at various locations on the front of the spindle cartridge.
Be careful as the spindle is running! If at any time during the spindle run-
in procedure the temperature reaches 140 degrees Fahrenheit or 60 degrees
Celsius, stop the spindle and allow it to cool to room temperature. Resume
the procedure at the point it was halted.

The temperature can be measured with a pyrometer. If a pyrometer is not

available, a good indication of excessive temperature is if you cannot hold
your hand on the spindle cartridge for more than 5 seconds.

Warning: Do not put your hand on the rotating spindle, only on the
fixed spindle cartridge.

4. If the temperature is within normal operation parameters, the machine is ready for
operation.

Abbreviated Run-in Procedure for Spindle with ½ -2 hours Idle time

1. Follow Steps 1. and 2. listed under the Daily Run-in Procedure.

2. Run-in the spindle at 50% of the maximum RPM for 3 to 5 minutes.

3. Monitor the temperature at various locations on the front of the spindle cartridge. If
at any time during the spindle run-in procedure the temperature reaches 140
degrees Fahrenheit or 60 degrees Celsius, stop the spindle and allow it to cool to
room temperature. Resume the procedure at the point it was halted.

4. If the temperature is within normal operation parameters, the machine is ready for
operation.
Ref: Setco Publication No. R-0007

33
 Chapter 5 - Failure Modes, Detection and Prevention

Minimizing Wear and Tear

• The effects of everyday wear and tear may be minimized by good maintenance
practice. Items high on the maintenance list include keeping the machine clean,
providing clean dry compressed air with the correct oil drip into the air stream,
and continuous application of the correct way oil through the automatic oiler.
• Machine failure is most likely to be caused by everyday wear and tear.
• The effects of everyday wear and tear may be minimized by good installation
practice, including a flat and stable foundation and clean input power at the
correct voltage with a good ground.
• Please refer to Chapter 4 of this manual for installation guidelines.
• Please refer to Chapter 6 of this manual for a periodic maintenance checklist.

Clearing Faults in Electrical Components

• A wide variety of failure modes caused by electrical component faults are

possible for the machine. An accidental crash between tool and workpiece, even
if it does not do mechanical damage, will likely cause an axis drive fault, putting
the machine into emergency stop mode. Even without a crash, a drive fault
might be caused by machining conditions, where the machine is asked to deliver
more than its rated power for a prolonged period. The machine can operate
outside its ratings for a short period, but eventually under these conditions a drive
will overload. In these and other failure modes caused by electrical components,
cycling power is the best way to clear the fault.
• Press the red EMERGENCY STOP button to de-energize the drives (if the
machine is not already in emergency stop mode), then turn off power to the
machine using the main switch on the door of the electrical cabinet at the rear of
the machine. Wait a minute. Turn the power to the machine back on. Wait for
the CNC software to boot up. Enable the drives and home the machine.
• When an electrical component needs to be replaced, follow the guidelines in this
manual describing safe maintenance practice.
35
Diagnosing Mechanical Faults

• Eyes, ears and hands are the best tools for detecting mechanical failure modes.
As is the case for electrical faults, an accidental crash between tool and
workpiece is a likely way to cause mechanical damage. A wide variety of
mechanical failure modes also are possible even without a crash. A careful
inspection of the parts involved in a mechanical fault is the best way to assess its
extent.
• When a mechanical component needs to be replaced, follow the guidelines in
this manual describing safe maintenance practice.
• Regular maintenance is a good way of detecting mechanical faults before they
occur. Inspection of covers, belts and wear surfaces often will reveal an issue
before it has turned into a full-blown fault.

36
 Chapter 6 – Maintenance

Periodic Maintenance; Verification Of Safety Systems

Note: Before performing any of the procedures in this section, please read and follow
the directions in this manual covering safe practices for operation, setting and
maintenance. Maintenance operations should only be performed by qualified personnel
as described in chapter 1.
• Maintenance labels as outlined on pages 9 - 11 are affixed to the machine near
areas where maintenance is required. Become familiar with the various notices
affixed to the machine and there meaning.
• Keep a maintenance log to record all maintenance activity on each machine.
• Ensure all hardware is tight and properly torqued after performing maintenance
operations.

Maintenance Schedule

Always
• Remove chips as necessary from the chip pan area.

Daily
• Ensure the air lubrication unit dispenses oil, and that the oil reservoir remains
filled. (Use Marvel No. 085, Mobil Velocite No. 10 or equivalent oil, detailed
lubrication specifications can be found in the mechanical manual)
• Ensure the water trap is being drained as required.
• Ensure the waylube reservoir level is maintained (if equipped). (Use Mobil Vactra
No. 02, Amoco Waytec No 68, Sunoco Sunwaylube No1180, or equivalent oil,
detailed lubrication specifications can be found in the mechanical manual)
• Ensure that all guards are in place and functioning properly.

Weekly
• Check operation of all cooling fans.
• Check for proper air exhaust from the spindle air purge system (if equipped).
• Clean any chips from on top of the ATC carousel and ATC slides.

37
Monthly
• Lubricate the counterweight chains (if applicable).
• Inspect ballscrews and way surfaces. Adjust gibs if necessary.
• Visually inspect all oil lines, and repair or replace as necessary.
• Inspect all belts for excess wear, damage, and proper tension.
• Check operation of low air pressure switch (if equipped). Remove compressed
air source from the machine and verify that a red alarm message box appears at
the front panel display.

WARNING:
Arc flash and shock hazard. Follow ALL requirements in NFPA 70E for safe
work practices and for Personal Protective Equipment before opening electrical
cabinet or performing adjustments or diagnostic measurements while energized.
Only qualified personnel should attempt to take current and voltage readings or
perform service. See the safety checklist on page 2 for qualifications.
• Power down the machine. Open the door to the electrical cabinet at the back of
the machine. Check for loose wires or loose components.
Annually
• Check backlash to ensure proper axis motion and response.
• Check head tram to ensure proper machine geometry. Machine settling can
cause head tram to be out of specification, affecting machine geometry.
• Clean the intake screen on the way lube pump.
Safety Checks, to be carried out monthly and after maintenance operations

• Repeat the checks for correct operation of the emergency stop circuit and of the
safety enclosure circuit outlined in Chapter 4 of this manual.
• In brief, power up the machine, reset it and start the spindle. Verify that pushing
the red Emergency Stop button makes the spindle brake rapidly to a stop and
machine motion is halted.
• For CE-compliant machines, power up the machine, reset it, close the enclosure
door and start the spindle. Hold in the SETUP button and pull open the
enclosure door to verify that the spindle brakes rapidly to a stop and machine
motion is halted.

38
 CHAPTER 6 - MAINTENANCE

Air System
stem Maintenance

• Ensure the air lubrication unit dispenses oil, and that the oil reservoir fill level is
maintained. (Use Marvel No. 085, Mobil Velocite No. 10 or equivalent oil, further
details about lubrication type can be found in the mechanical manual)
• Ensure the automatic water trap drain is working.

Adjustments
• Do not adjust the air purge regulator unless instructed to do so by an authorized
Milltronics Representative.
• Set the drop rate on the lubricator to approximately 1 drop per every 1-2 tool
changes

Main air pressure Spindle air pressure

gauge. Adjust gauge. Do not alter
using knob “A”. from factory setting.
90 PSI A
B

Fill with Marvel

No.85, Mobil
Velocite No. 10
or equivalent.

Maintain fill
Water trap is self- levels weekly
draining. No need using specified
to drain manually. air tool oil.

39
Way Lube Maintenance

• Ensure the way lube reservoir level is maintained (if equipped). (Use Mobil
Vactra No. 02, Amoco Waytec No 68, Sunoco Sunwaylube No1180, or
equivalent oil, further details about this lubricant can be found in the mechanical
manual). Never re-use old way oil.
• Clean the intake filter screen annually

Adjustment
• Set the timer for 8 Seconds ON, and 28 Minutes OFF operation.

Fill here with

clean oil as
specified.

Adjustment controls

40
 CHAPTER 6 - MAINTENANCE

Automatic Tool Changer (ATC) Maintenance

16 Pocket arm style ATC

Fill to 1/3-1/4
Fluid level should be ¼ to 1/3
of the way to the top when
the arm is parked. Oil level
drops when “in cycle”.
16 Arm ATC
lubrication reservoir. Replace oil annually.
ISO VG32

16 or 24 Pocket carousel style ATC

Lubrication is automatic via the

lubrication system on the machine.

No scheduled maintenance is
required, but the area should remain
free of chips and coolant overspray.

41
Drawbar cylinder lubrication

Fluid level should be approximately

1/3 of the way to the top when the
drawbar cylinder is in the normal
position (retracted).

Replace oil annually, fill Mobil

DTE24 or equivalent to the mark
where indicated in the photo.

42
 Chapter 7 – 7200 CNC Operation

Milltronics 7200 CNC Front Panel

11

12

1 2 3 4 5 6 7 8 9 10

Power ON

The main power switch is located on the electrical cabinet at the back of the machine.
When main power is switched on, the power to the CNC is also applied.

Power OFF

Before switching off the main power, press the E-Stop button to ensure the machine is
in emergency stop mode.

43
1) Manual Pulse Generator (HANDWHEEL) - rotate this wheel to control axis feed
while in HDW mode.
2) FEEDRATE override rotary switch - labeled in percentages. Controls the
feedrate and rapid traverse (Exception - see #3) of the machine axes. Also
affects handwheel rate.
3) RAPID override buttons – By selecting 10% or 100%, rapid will run at the
selected rate regardless of feedrate override control. By selecting “%”, the
feedrate override setting controls the rapid speeds.
4) CYCLE START button – Starts automatic operation. In most cases the control
will prompt the operator when this button needs to be pressed.
5) FEEDHOLD button - illuminated when active. Pauses axis movement. When
feedhold is active and HDW mode is selected, the axes can be positioned with
the handwheel. Opening the chip pan enclosure doors may cause a feedhold
condition.
6) MACHINE FUNCTION buttons – illuminated when active. These control
dedicated machine functions. Configuration will vary by machine type and
options.
o SINGLE BLOCK – Single block program execution on/off.
o OPTIONAL STOP – Optional stop (M01) on/off.
o BLOCK SKIP – Block skip function (/) on/off.
o AIR – Air blast function on/off
o FLOOD COOLANT – Flood coolant function on/off.
o MIST COOLANT – Mist coolant function on/off.
o AUGER – Auger or Conveyor chip removal function on/off.
o WASHDOWN COOLANT – Washdown function on/off.
o SETUP - Releases the enclosure door safety interlock. Holding the switch
in with the enclosure door open will allow axis jog.
o TOOL RESET – This button is a safety interlock. It prevents the spindle
from starting during a manual tool change. It will flash during a tool
change and needs to be pressed after the tool change is completed before
program operation can be resumed. The control will display a prompt as
to when this button needs to be pressed.
o CTS – Coolant through spindle function (if equipped) on/off.
o SPINDLE JOG – Used to rotate (lathe) spindles at slow speed for setup
use. Especially useful for turning large chucks.
7) SPINDLE OVERRIDE rotary switch – labeled in percentage of programmed
spindle rpm. Controls the actual spindle rpm.
8) SPINDLE CW/STOP/CCW
o Spindle CW button – starts spindle in clockwise direction provided there is
a programmed spindle rpm.

44
 CHAPTER 7 – 7200 CNC OPERATION

o Spindle CCW button – starts spindle in counter-clockwise direction

provided there is a programmed spindle rpm.
o Spindle STOP button – stops spindle rotation.
9) EMERGENCY STOP button – Disables machine motion, control enable, and
axis waylube oiler. Emergency stop buttons lock down when pressed and
must be rotated to release.
10) ENABLE button – When pressed and released it enables axis and spindle
drives. All Emergency stop and limit switches must be released for drives to
enable.
11) Alphanumeric keypads – used to enter characters in MDI mode or program
mode.
12) Function keypad – used to select machine functions that are shown along the
bottom of the operator’s panel display.

45
Diagram of Main Screen

1 RunTime
When you are verifying a program the runtime displays the calculated time to
make the parts. When you are running a program it shows the elapsed time since
the program was started. The total of all program run times are kept in the “Job
Time” parameter (F7 Parms – F9 Ctrl).
2 History Line
History Line shows you where you are in the software and where you came from.
If you are modifying the tool table, the history line will say Main-Parms-Tool-Edit.
3 Active Program
Active Program displays the program that you are running or verifying. If you are
editing a program it will show the active edit program. If you are sending a file
over the RS-232 it will show the program being sent.
4 Current Position
Current Position is the position relative to the work offset zero.
5 Next Position
When running or verifying, the Next Position is the position that the machine is
going to.
6 Distance
Distance is the remaining distance the machine has left to go to finish the move
being executed.

46
 CHAPTER 7 – 7200 CNC OPERATION

7 The Function Keys

Highlighted Function Keys are active or available.
8 Status Window
Status Window displays detailed information on the state of the control. A
detailed description is given below.

Diagram of Status Window

1 The \ changes back and forth to / and \ each time the status window is updated.
2 Comp: Tool Radius Compensation (Left, Right or Cancelled)
3 Tool: The first two digits indicate the active tool number. The second two digits in
parentheses indicate the pending tool number. If you execute a T14 without the
M6 the pending tool number will be 14.
4 The tool length.
5 The tool radius.
6 Plane and work offset: The plane is XY (G17), ZX (G18), or YZ (G19). The work
offset shows the current work offset G54 (0)…G59 (9).
7 Clearance or R-Plane.
8 Interpolation, Linear (Feed), Linear (Rapid), Circular (CW), or Circular (CCW)
9 Feedrate: The programmed feedrate and its units (English feed per minute) ipm,
(Metric feed per minute) mmpm, (English feed per revolution) ipr, (Metric feed per
revolution) mmpr or (inverse feed) /min or /sec (If the machine is rapid mode the
units will always be ipm or mmpm.)
10 Feedrate override: The position of the feedrate override and the resulting
feedrate. If the machine is programmed to move faster than its maximum, the
clamped feedrate will be displayed, and an “*” will be displayed next to the %.
11 Units: (Absolute) Abs or (Incremental) Inc and English or Metric
12 Cycle: If there is a canned cycle or autoroutine active it will be displayed on this
line.
13 Dwell: When a dwell is executed the dwell time will count down to zero.

47
14 Spindle: The programmed revolutions per minute.
15 Spindle override and direction: The position of the spindle override and the
resulting rpm (if there is no spindle encoder) or the actual rpm (if there is a
spindle encoder). This line also displays whether the spindle is off or running CW
or CCW.
16 The spindle load meter will show the load on the spindle. It becomes longer and
changes color from blue to green to yellow to red as the load increases.
17 Coolant, Off, Mist, Flood or Mist/Flood

For complete detailed information about the 7200 control and its operation, refer to the
7000 Series CNC Operation Manual.

48
Chapter 8 Machine Specifications
RW15 & RW20 Specifications
Effective March 1, 2006
Machine Model RW15 RW20
Control Type Centurion 7 Centurion 7
Number of Axes 3 (Opt 4 or 5) 3 (Opt 4 or 5)
Functions: Automatic Auto spindle start/stop, mist, flood, RPM
CAPACITY
30 x 14" 30 x 18"
Standard Table Size
760 x 355 mm 760 x 455 mm
Table Travel - X Axis 25" 635 mm 25" 635 mm
Saddle Travel - Y Axis 15" 380 mm 20" 510 mm
Head Travel - Z Axis 20.5" 520 mm 20.5" 520 mm
Throat Distance Spindle to Column 16" 405 mm 21" 530 mm
4- 24.5" 4.5 - 25"
Spindle to Table Top
100 - 620 mm 115 - 635 mm
Maximum Table Load 750 lb 340 kg 1000 lb 450 kg
Machine Weight 6500 lb 2950 kg 8500 lb 3860 kg
T Slots (4) .63" 16 mm (5) .63" 16 mm
Saddle Width 30" 760 mm 30" 760 mm
Ball Screw Size: X,Y,Z Axis 32mm 32mm
Ball Screw Grade C5 C5
Ball Screw Pitch X,Y,Z Lead 10 mm 10 mm
SPINDLE
Heavy Duty Spindle Cartridge Assembly, Triplex
60 mm 60 mm
Bearing Design
Spindle Horsepower 1 minute / 30 minutes 12/10 HP 9/7.5 kw 12/10 HP 9/7.5 kw
Optional Spindle Horsepower 1 minute / 30 min. 18/12 HP 13/9 kw 18/12 HP 13/9 kw
Standard Triplex Bearing Spindle RPM 50 - 8000 50 - 8000
Optional Ceramic Duplex Bearing Spindle RPM
100 - 15,000 100 - 15,000
Req. Balanced Tooling
****** 15,000 RPM Spindle Tools Should Be
Balanced Tooling Requirements Balanced to 2.5 G's at 15,000 RPM******
PERFORMANCE
Servo Type AC Digital AC Digital
1000/800 ipm 1000/800 ipm
Rapid Traverse X,Y/Z
25.4/20.3 mpm 25.4/20.3 mpm
300 ipm 300 ipm
Maximum Feedrate
7620 mmpm 7620 mmpm
Position Accuracy See note ±0.00039" .01 mm ±0.00039" .01 mm
Repeatability See note .0002" .005 mm .0002" .005 mm
Resolution .00004" .001 mm .00004" .001 mm
X, Y: 800 lbs 360 kg X, Y: 800 lbs 360 kg
Thrust, Machine Duty Rating
Z: 2000 lbs. 900 kg Z: 2000 lbs. 900 kg

50
AUTOMATIC TOOL CHANGER
ATC Type Carousel Arm
Number of Pockets 16 16
Tool Change Time 7 Sec. 3.5 Sec.
4" / 11" / 10 lb 4" / 9" / 15 lb
Maximum Tool Diameter / Length / Weight 100mm / 280 mm / 100mm / 280 mm /
4.5kg 7kg
MISCELLANEOUS
1/4 HP Flood Pump Capacity 50 Gal. 50 Gal.
Optional in Package B 190 L 190 L
Drawbar Air Pressure Required 100 psi 6.8 bar 100 psi 6.8 bar
Power 208-240 VAC 50-60hz, 3Ø Single Range
50 amps 11KVA 50 amps 11KVA
Spindle Amp
Power 208-240 VAC, Single Phase Optional Optional
Req. 20 KVA Req. 20 KVA
Power 400-440 VAC
Transformer Transformer
73" x 73" 73" x 80"
Floor Space Requirement
1850 x 1850 mm 1850 x 2030 mm
Parts: One year or 2100 hours, whichever occurs first on all normal failures.
Warranty Service: One year or 2100 hours (whichever occurs first) from dealer or
available from factory during second six months if air ticket supplied
Extended Parts
Parts warranty for normal failures for up to two years or 4200 hours, whichever
Warranty for
occurs first.
Second Year
Measurements performed with Renishaw laser and ballbar systems. Measurements are linear over entire travel.
Temperature changes and table loads may affect tolerances. Tolerances are guaranteed over 10" sq. area.
Centurion features covered under separate literature. For machine duty rating, see "Truth in Specifications" on
www.milltronics.net.
Milltronics reserves the right to change specifications at any time without incurring obligation.

51
 RH Rigid Head Bed Mill Specifications
Effective March 1, 2006
Machine Model RH19 RH20 RH30 RH33
Control Type Centurion 7 Centurion 7 Centurion 7 Centurion 7
Software CNC or SLS CNC or SLS CNC or SLS CNC or SLS
Number of Axes 3 (Opt 4 or 5) 3 (Opt 4 or 5) 3 (Opt 4 or 5) 3 (Opt 4 or 5)
Functions: Automatic Auto operation of spindle start/stop, mist, flood, RPM
CAPACITY
50 x 15" 54 x 16" 73 x 24" 86 x 32"
Standard Table Size
1270 x 380 mm 1370 x 405 mm 1850 x 610 mm 2185 x 810 mm
Table Travel - X Axis 32" 810 mm 40" 1015 mm 60" 1525 mm 78" 2000 mm
Saddle Travel - Y Axis 19" 480 mm 20" 510 mm 30" 760 mm 33" 840 mm
Head Travel - Z Axis 22" 560 mm 24" 610 mm 28" 710 mm 28" 710 mm
Throat Distance Spindle to Column 19" 480 mm 21" 530 mm 30.5" 775 mm 34" 860 mm
4 - 26" 3 - 27" 4 - 32" 4 - 32"
Spindle to Table Top
100 - 660 mm 76 - 685 mm 100 - 810 mm 100 - 810 mm
1700 lb 2500 lb 3000 lb 3500 lb
Maximum Table Load
770 kg 1130 kg 1360 kg 1600 kg
6000 lb 8000 lb 11,000 lb 15,000 lb
Machine Weight
2730 kg 3628 kg 5000 kg 6800 kg
(4) .63" (5) .63" (5) .71" (5) .63"
T Slots
16 mm 16 mm 18 mm 16 mm
38" 46" 70" 87"
Saddle Width
965 mm 1160 mm 1780 mm 2220 mm
Ball Screw Size: X,Y,Z Axis 32mm 32/40/40mm 40mm Dbl Nut 50mm Dbl Nut
Ball Screw Grade C5 C5 C5 C5
Ball Screw Pitch X,Y,Z .2" .2" 10 mm 10 mm
SPINDLE - #40
Heavy Duty Spindle Cartridge Assembly 60 mm
60 mm 70 mm 70 mm
with Triplex Bearing Design Opt 70 mm
12/10 HP 18/12 HP 24/15 HP 24/15 HP
Spindle Horsepower 1 minute / 30 minutes
9/7.5 kw 13/9 kw 18/11 kw 18/11 kw
24/15 HP 24/15 HP 24/15 HP
Optional Spindle Drive System 18/12 HP 18/11kw 18/11kw 18/11kw
1 minute / 30 minutes 13/9 kw Single or two Two speed auto Two speed auto
speed shift shift
35/25 HP
Optional Spindle Drive System 26/18kw
N/A N/A N/A
1 minute / 30 minutes Two speed auto
shift
Standard Triplex Bearing Spindle RPM 50 - 8000 50 - 8000 50 - 8000 50 - 8000
Optional Ceramic Duplex Bearing Spindle
RPM
100 - 15,000 100 - 15,000 100 - 15,000 100 - 15,000
Requires balanced tooling, Recommend
HP Upgrade
For 15,000 RPM Spindle Tools Should Be Balanced to 2.5 G's at
Balanced Tooling Requirements
15,000 RPM
PERFORMANCE
Servo Type AC Digital AC Digital AC Digital AC Digital
X,Y: 500 ipm X,Y: 500 ipm X,Y: 500 ipm X,Y: 800 ipm
12 mpm 12 mpm 12 mpm 20 mpm
Rapid Traverse
Z: 300 ipm Z: 300 ipm Z: 400 ipm Z: 600 ipm
7.6 mpm 7.6 mpm 10 mpm 15 mpm
300 ipm 300 ipm 300 ipm 300 ipm
Maximum Feedrate
7620 mmpm 7620 mmpm 7620 mmpm 7620 mmpm

52
Machine Model RH19 RH20 RH30 RH33
±0.00039" ±0.00039" ±0.00039" ±0.00039"
Position Accuracy See note
.01 mm .01 mm .01 mm .01 mm
.0002" .0002" .0002" .0002"
Repeatability
.005 mm .005 mm .005 mm .005 mm
.00004" .00004" .00004" .00004"
Resolution
.001 mm .001 mm .001 mm .001 mm
X, Y: 1600 lb X, Y: 3000 lb X, Y: 3000 lb X, Y: 3000 lb
25 kg 1360 kg 1360 kg 1360 kg
Thrust, Machine Duty Rating
Z: 4000 lb Z: 4000 lbs Z: 4000 lb Z: 4000 lb
1800 kg 1800 kg 1800 kg 1800 kg
OPTIONAL AUTOMATIC TOOL CHANGER
5 Pocket Pick & Place Tool Changer –
N/A Optional Optional N/A
Table Mounted
4" / 11" / 10 lb 4" / 11" / 10 lb 4" / 11" / 10 lb 4" / 11" / 10 lb
Maximum Diameter / Length / Weight 100mm/280mm/4.5k 100mm/280mm/4.5k 100mm/280mm/4.5k
100mm/280mm/4.5kg
g g g
Tool Change Time 8 - 10 Sec. 8 - 10 Sec. 8 - 10 Sec. 8 - 10 Sec.
16 Pocket Automatic Carousel Tool
Optional Optional Optional Optional
Changer
24 Pocket Automatic Carousel Tool
N/A Optional Optional Optional
Changer
4" / 11" / 10 lb 4" / 11" / 10 lb 4" / 11" / 10 lb 4" / 11" / 10 lb
Maximum Diameter / Length / Weight 100mm/280mm/4.5k 100mm/280mm/4.5k 100mm/280mm/4.5k
100mm/280mm/4.5kg
g g g
Max. Length With Table Guard 8" 10" 10" 10"
Tool Change Time 7 Sec. 7 Sec. 7 Sec. 7 Sec.
MISCELLANEOUS
1/4 HP Flood Pump Capacity 10 Gal. 15 Gal. 15 Gal. 90 Gal.
Optional in Package B 40 L 25 L 25 L 150 L
100 psi 100 psi 100 psi 100 psi
Drawbar Air Pressure Required
6.8 bar 6.8 bar 6.8 bar 6.8 bar
Power 208-240 VAC 50-60hz, 3Ø Up to 24
40 amps 11KVA 60 amps 20KVA 60 amps 20KVA 60 amps 20KVA
HP
Power 208-240 VAC 50-60hz, 3Ø 35 HP N/A N/A N/A 100 amps 34KVA
Power 208-240 VAC, Single Phase Optional Optional Optional Optional
Req. 20 KVA Req. 20 KVA Req. 20 KVA Req. 20 KVA
Power 400-440 VAC Up to 24 HP
Transformer Transformer Transformer Transformer
Req. 34 KVA
Power 400-440 VAC 35 HP N/A N/A N/A
Transformer
127" x 78" 129" x 78" 169" x 91" 222" x 130"
Floor Space Requirement
3225x1980 mm 3280x1980 mm 4300x2310 mm 5660x3320 mm
Parts: One year or 2100 hours, whichever occurs first on all normal failures.
Warranty Service: One year or 2100 hours (whichever occurs first) from dealer or
available from factory during second six months if air ticket supplied.
Extended Parts Warranty for Second Parts warranty for normal failures for up to two years or 4200 hours,
Year whichever occurs first.
Measurements performed with Renishaw laser and ballbar systems. Measurements are linear over entire travel.
Temperature changes and table loads may affect tolerances. Tolerances are guaranteed over 10" sq. area.
Centurion features covered under separate literature. For machine duty rating, see "Truth in Specifications" on
www.milltronics.net.
Milltronics reserves the right to change specifications at any time without incurring obligation.

53
54
 WARRANTY INITIATION DOCUMENTS
SERVING THE METAL CUTTING INDUSTRY SINCE 1973
1400 MILL LANE • WACONIA• MN 55387
TEL: 952.442.6455 • FAX: 952.442.6457
www.milltronics.net
Startup Checklist For MB / VK / RH / RW15-20 Series Milling Machines
(Mail to the above address to activate the machine warranty)

Company
Address
City State Zip
Contact Phone
Email Fax

Model Serial Number

Distributor Phone
Salesman

Customer Responsibility
(See site preparation guidelines for details)
Remove machine from skid Checked By
Place machine on leveling pads Checked By
Power ran to machine Checked By
Air ran to machine (90 to 120 psi), 10 CFM Checked By

Milltronics Representative Responsibility

(Initial or write n/a if does not apply)
1. Check for missing parts
2. Visually check for damage outside of machine and inside.

Mag Panel

Inside Mag Panel Check the Tightness Of All Connections

1. Terminal block connectors
2. All relays and contactors
3. Transformer taps
4. Main disconnect - both sides
5. Any AC distribution blocks
6. Make sure that all plug in components are well seated
7. Check all spindle and axis drive connectors

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 WARRANTY INITIATION DOCUMENTS
SERVING THE METAL CUTTING INDUSTRY SINCE 1973
1400 MILL LANE • WACONIA• MN 55387
TEL: 952.442.6455 • FAX: 952.442.6457
www.milltronics.net

Arc flash and shock hazard. Follow ALL requirements in NFPA 70E for safe work practices
and for Personal Protective Equipment before opening electrical cabinet or performing
adjustments or diagnostic measurements while energized.
Only qualified personnel should attempt to take current and voltage readings or perform service.
See the safety checklist on page 2 for qualifications.

Check the Power

Check incoming power at line side of disconnect switch
1. Gnd - L1 L1 – L2 !! CAUTION !!
Gnd - L2 L1 – L3 HIGH VOLTAGE
Gnd - L3 L2 – L3 EXISTS HERE.
ENSURE THAT THE "WILD LEG" IS WIRED TO L2 IF APPLICABLE.
2. Check to be sure the machine power is sourced directly from the power breaker
box, and that the breaker and wire size are appropriate.
3. Make sure the machine is wired to the GND line from the plant AC distribution
system by a copper wire equal to or greater in size than the power feed wires. Milltronics
does not allow the use of a separate ground rod, conduit, or wire raceways to be used as
a ground source. In terms of machine operation and reliability, nothing may be more
important than the machine being bonded to a good ground source.
Without a transformer, this wire must connect from our “G” ground directly to the electrical
service box ground. Never can the ground be derived from conduit or an unproven ground
source. If using a transformer, refer to the transformer grounding information attached.
POWER THE MACHINE DOWN!
4. Replace the shield on the disconnect switch after checking incoming Voltage.
5. Check internal transformer for proper wiring to accept incoming power based
upon the readings above. Change tapping to match.

CAUTION DANGEROUS VOLTAGES EXIST FOR NEXT 4 STEPS!

Turn on the main power at the disconnect switch but DO NOT ENABLE THE DRIVES!

1. Check +24 VDC. Measure between terminal blocks 12 & 22

2. Check +5 VDC. Measure between + and – V pins on the 5 VDC power supply.
3. Check 110v AC on the secondary side of the 110 transformer, or between
terminal blocks 1 & 2.
VAC (The secondary AC voltage must be between 110 and 125 VAC )
4. Check parameters against the list shipped with the machine
To access parameters, enter PARAMS-SETUP-LEVEL at the front panel, then type "PROTO3"
ENTER "3" ENTER.

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 WARRANTY INITIATION DOCUMENTS
SERVING THE METAL CUTTING INDUSTRY SINCE 1973
1400 MILL LANE • WACONIA• MN 55387
TEL: 952.442.6455 • FAX: 952.442.6457
www.milltronics.net
ENABLE MACHINE AND BE READY TO E-STOP IN CASE OF AXIS RUNAWAY.
NOTE: TO PERFORM #1 THE PARAMETERS MUST BE OPEN IN SETUP LEVEL 3.
1. Press HOME then HERE then Cycle start. Use HDW Z
to relieve the weight from the counterweight support. Remove the
counterweight support (MB & RH 19-30 models) located towards the
top of the column though the holes in the side.
2. Home machine (machine must be ENABLED). Check
for smooth motion.
3. Run all axes over full travel.
4. Check the operation of each feedrate and spindle
override position while observing the percentage of change on the display.
5. Jog Mode full travel, all directions.
6. Handwheel, full travel, all directions, all override positions.
7. MDI
8. Check software limits. Move each axis toward each end of the travel to make
sure that that it hits the soft limit before it hits the e-stop switch or stop bumper. The axis should
stop moving before an E-stop limit is reached or a drive fault occurs from hitting a stop bumper.
If an E-stop is reached or a drive fault occurs, check the soft limit parameter.
9. Check Following Error. While in JOG mode move each axis at 100 ipm (rapid
JOG mode at 50% override). In DISP-ERROR (in setup level 3) the following error should
display an equal amount for each axis while being moved individually. Make no adjustments
without first consulting the factory.
10. Check the operation of all cooling fans on the enclosure, axis and spindle drives.
11. Check spindle motor fan rotation direction against label on side of fan housing.
12. Check flood pump rotation and verify lubricator function. Visually inspect flood
pump to make sure it is in an upright position (RH20&30 models).
Spindle – Observe spindle warm-up procedure on page 33
1. Run the spindle through all of the speed ranges. (MDI S1000 M3)
2. Try all spindle override positions (0%-175%)
3. Try both directions CW and CCW using M3/M4 commands in MDI-misc.
4. Try both directions using the CW and CCW front panel switches.
5. Check the draw bar function by inserting and removing tools.
Chip Auger and/or Side Mount Arm Style Tool Changer (if equipped)
1. Check for proper operation and direction of chip auger and tool magazine, reverse
two legs of input power (L1 & L3) if necessary for proper direction.
3. If the machine is equipped with an auger, verify the operation of the door switch. When the
door switch is held actuated the auger should be enabled, When the door switch is released
the auger should stop, then be disabled.
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 WARRANTY INITIATION DOCUMENTS
SERVING THE METAL CUTTING INDUSTRY SINCE 1973
1400 MILL LANE • WACONIA• MN 55387
TEL: 952.442.6455 • FAX: 952.442.6457
www.milltronics.net
Tool Changer (side mount arm style)
First default all of the tool pocket settings, UTIL-TLCNG-SLOTS-DEFAULT.
1. Remove any tool from the spindle and program a tool change without any tools in
the magazine. Observe the operation and make sure everything looks good. Make sure the
magazine rotates in the proper direction.
2. Load some tools into the magazine through the spindle and perform several tool
changes. Change to tool #1 (T1M6), then manually insert a tool into the spindle. Change to tool
#2 (T2M6) then manually insert a second tool into the spindle. Tool #1 should now be in pocket
#2. Change to tool #3 (T3M6), now tool #2 should be in pocket #3 and the spindle is ready to
accept tool #3.
3. Run several tool changes. Make sure that the air line lubricator dispenses a drop
of oil per every 1 to 2 tool changes. Adjust the drip rate if necessary with the adjustment knob
on the top of the lubricator.

Tool Changer (carousel style)

1. Check the tool change height. Enter MDI and use a G32 to send Z to tool change
position and use M19 to orient the spindle. Use the tool out button to place an empty tool holder
into spindle. Go to the back of the machine and remove the air supply.
Note: The machine will E-stop when the air supply is removed because of the low air switch,
you can override this by having someone hold the ENABLE button in, or by changing the
“check air pressure” parameter in PARAMS-SETUP-POWER.

Now you can manually pull the tool changer into position and check the alignment with the tool
holder. If it is good, push the tool changer back to its parked position and reconnect the air
supply. If it does not line up use the handwheel to determine the correct position the tool change
parameter needs to be adjusted and is found under PARAMS-SETUP-AXIS.
2. Remove the tool in the spindle and execute a tool change without any tools in the
carousel.
3. Load some tools into the carousel and perform several tool changes.
4. Run several tool changes. Make sure that the air line lubricator dispenses a drop
of oil per every 1 to 2 tool changes. Adjust the drip rate if necessary with the adjustment knob
on the top of the lubricator.
4th and 5th axis if applicable
1. Connect and test any rotary/tilt tables included with the machine. Move each axis
to ensure it is operating correctly. Verify that the indicated position agrees with the position on
the table, and that motion is smooth and continuous.

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 WARRANTY INITIATION DOCUMENTS
SERVING THE METAL CUTTING INDUSTRY SINCE 1973
1400 MILL LANE • WACONIA• MN 55387
TEL: 952.442.6455 • FAX: 952.442.6457
www.milltronics.net
Level and Tram the Machine
(MB, RH, RW15-20 MODELS)
Note for RW15-20: The chip pan legs (if equipped) must be installed prior to leveling the
machine. The legs must support the weight of the enclosure or it may affect the tram.
9. Center the table in the travels of both the X and the Y-axes.
10. Adjust the center leveling pads so the machine is resting on only the 4 corner pads
11. Use a precision level placed on the center of the table and adjust the pads until the machine is
level side to side firmly setting on the 4 corner pads.
12. Rotate the level 90 degrees on the table and adjust the pads until the machine is level front to
back.
13. Re-check the side to side level again as it may have changed while adjusting front to back.
Repeat steps 6 & 7 until the machine is level in both directions.
14. Using a magnetic base with a dial indicator sweep the table to check tram. The tram should
sweep within .001” over a 10” diameter sweep. Adjust leveling pads if necessary. At this
stage it is more important to be level to tram and NOT level to the precision level.
15. Extend the center pads (if equipped) to the floor. The center pads should have light pressure
applied to them. Be careful not to affect the level or tram while adjusting them.
16. With the level placed lengthwise along the table checking the X-axis level, move the Y-axis
in and out. If there is any twist in the Y-axis, the bubble will move as Y travels in and out.
Ideally there is no twist and the bubble will not move. If it does move, go back through the
process and re-level the machine.
0

Note tram readings here when complete

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 WARRANTY INITIATION DOCUMENTS
SERVING THE METAL CUTTING INDUSTRY SINCE 1973
1400 MILL LANE • WACONIA• MN 55387
TEL: 952.442.6455 • FAX: 952.442.6457
www.milltronics.net
We invite you to include any comments that you may have here

Installation and training begun completed

Customer Acceptance
Installation complete - Warranty activated this date
Warranty period commences on the date of initial customer delivery.
I / we have reviewed the preceding pages and concur that all startup checks have been
satisfactorily performed. I / we accept this machine, its installation, and the terms of the
warranty.
Customer Signature Print Date

Milltronics Rep. Print Date

When this form is complete forward it to Milltronics for warranty activation

commencing on the date of initial delivery to the first customer.