Mafell FM 1000 Mode d'emploi

FM1000

170758.0822/b

IMPORTANT

Read Before Using

IMPORTANT

Lire avant usage

IMPORTANTE

Leer antes de usar

Operating/Safety Instructions

Consignes d’utilisation/de sécurité

Instrucciones de funcionamiento y seguridad

For English Version

See page 2

Version française

Voir page 21

Versión en español

Ver la página 40

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English

Table of contents

1 Signs and symbols ........................................................................................................... 3

1.1 Identification of the device ................................................................................................ 5

2 Product specifications ...................................................................................................... 6

2.1 Technical data .................................................................................................................. 6

2.2 Scope of delivery .............................................................................................................. 7

2.3 Adjustment elements ........................................................................................................ 7

3 General safety .................................................................................................................. 8

3.1 Intended use ..................................................................................................................... 8

3.2 Foreseeable misuse ......................................................................................................... 8

3.3 Safety instructions ............................................................................................................ 9

3.4 Specific safety rules ....................................................................................................... 10

3.5 Safety devices ................................................................................................................ 11

3.6 Residual risks ................................................................................................................. 12

4 Setup / adjustment ......................................................................................................... 12

4.1 Mains connection ........................................................................................................... 12

4.2 Tool selection ................................................................................................................. 12

4.3 Collet chucks .................................................................................................................. 13

4.4 Tool change .................................................................................................................... 15

5 Operation ........................................................................................................................ 16

5.1 Startup ............................................................................................................................ 16

5.2 Switching on / off ............................................................................................................ 16

5.3 Speed selection .............................................................................................................. 17

5.4 Overload protection ........................................................................................................ 17

6 Service and maintenance ............................................................................................... 18

6.1 Storage ........................................................................................................................... 18

7 Troubleshooting .............................................................................................................. 19

8 Optional accessories ...................................................................................................... 20

9 Exploded view and spare parts list ................................................................................. 20

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1 Signs and symbols

These operating instructions contain the following general information signs to guide you, the reader, through

the operating instructions and to provide you with important information.

Sign

Meaning

Important information

This sign highlights user tips and other useful information.

➢

Identifies an intermediate result in a sequence of actions.

✓

Identifies the final result of a sequence of actions.

Tab. 1: General signs and their meanings

Warning icons warn of dangerous points, risks and obstacles.

Icon

Meaning

Warning

This icon can be found at all locations where you can find information regarding your

safety. Non-observance can result in extremely serious injuries.

Warns of danger of electric shock.

Warns of danger caused by dust.

Warns of the danger of cutting.

Warns of the danger of cutting off or severing limbs.

Tab. 2: Warning icons and their meanings

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Mandatory icons are intended to prevent accidents.

Icon

Meaning

Wear eye protection.

Wear dust mask.

Wear hearing protection.

Wear protective gloves.

Tab. 3: Mandatory icons and their meanings

During the operation of the power tool there are always actions to be taken where hazards can occur. These

potentially dangerous actions are preceded by warnings which must be observed.

Classification of the danger level (signal words) of warnings

Warning

Meaning and consequences of non-observance

Imminent dangerous situation that will cause serious or

fatal injuries.

Potentially dangerous situation that can cause serious or

fatal injuries.

Potentially dangerous situation that can cause light

injuries.

Situation that can cause material damage on the machine

Tab. 4: Structure of warnings

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1.1 Identification of the device

The icons listed and explained below can be found on the rating plate or on the product.

Icon

Explanation

Icon

Explanation

V

Volt

1, 2, 3, ...

I, II, III, ...

Rotational speed setting

A

Ampere

rpm

Revolutions per minute

Hz

Hertz

ø

Tool diameter

W

Watt

~

Alternating current

kg

Kilogram (weight)

Protection class II

min

Minutes (time)

Read operating instructions

s

Seconds (time)

Protective goggles

n0

Rated speed at no load

Hearing protection

n

Rated speed at normal load

Dust mask

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2 Product specifications

for machines with item number 9M0023

The article number and machine number are listed on the type plate of the machine.

By entering the article number and machine number on the MAFELL homepage, you can

call up the spare parts lists, exploded drawings, and other product information belonging

to your machine (see also Chapter 9 Exploded view and spare parts list).

2.1 Technical data

Operating voltage

120 V~, 60 Hz

Current at normal load

8.3 A

Tool speed at no load

10000 to 25000 rpm

Tool shaft

3 - 8 mm [0.12 - 0.32 in]

Diameter of tool holding fixture with collet chuck

6.35 mm [0.25 in]

Grinding tool diameter

40 mm [1.57 in]

Milling cutter diameter

36 mm [1.42 in]

Weight without power cord

1,6 kg [3.53 lbs]

Length of the connecting cable

4 m [13.12 ft]

Dimensions (width x length x height)

73 x 254 x 79 mm [2.87 x 10 x 3.11 in]

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2.2 Scope of delivery

Fig. 1: Scope of delivery

Components

A

Milling motor FM1000

B

Union nut

C

Collet chuck OZ ø 8 mm [0.31 in]

D

17-mm [0.67 in] single open-end wrench

2.3 Adjustment elements

Fig. 2: Adjustment elements

Adjustment elements on the machine

1

Locking button

2

Power switch

3

Setting wheel

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3 General safety

Please read all safety instructions and directions. Failure to comply with the safety instructions and

directions can cause electric shock, fire and/or serious injuries. Please retain all safety instructions and

directions for future reference.

3.1 Intended use

The milling motor is intended for stationary installation in a guiding gantry system with a collar size of ø 43 mm

[1.69 in].

Intended use also requires the guiding gantry system to be included.

The milling motor can be operated with cutter diameters that are compatible with the collet chucks listed in the

special accessories. Wood, plastic and non-ferrous metals can be machined. The cutting data must be

selected such that the motor is not overloaded.

3.2 Foreseeable misuse

The machine is not intended for any other use than the intended use listed above.

The manufacturer is not liable for any damage resulting from such other use.

To use the machine as intended, comply with the operating, maintenance and repair conditions specified by

MAFELL.

Foreseeable misuse also includes:

- Tampering with, removing and/or bypassing safety devices of any kind.

- Operating the machine without safety devices.

- Non-observance of safety and warning instructions in the operating instructions.

- Removing the safety and warning labels from the machine.

- Operating the machine by unauthorized persons.

- Failure to follow prescribed maintenance and care instructions.

- Machining with excessive cutting depth or feed rate due to excessive motor load.

- Using the machine in continuous industrial operation.

- Using the machine as a hand-guided milling motor.

Never use:

- Damaged and/or deformed tools.

- Blunt drill bits as they impose an excessive load on the motor.

- Tools that are not suitable for the no-load speed of the milling motor.

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3.3 Safety instructions

READ ALL INSTRUCTIONS!

Non-observance of the instructions listed below can cause electric shock, fire and/or serious injuries

.

Work area

- Children and adolescents are not allowed to operate this machine.

- Replace damaged cables or plugs immediately. To avoid safety hazards, only MAFELL or an authorized

MAFELL service workshop is allowed to replace parts.

- Prevent sharp kinks of the cable. Do not wrap the cable around the machine, especially when transporting

and storing the machine.

- Do not use this machine when you are tired, or under the influence of drugs, alcohol or medicaments. Be

aware of what you are doing. Stay alert and use common sense.

- Keep children and bystanders at a distance while you are operating the machine. Distractions can cause

you to lose control of the machine.

- Use eye protection, dust mask and hearing protection. Appropriate safety equipment, used

under proper conditions, will reduce the risk of injuries.

Instructions for service and maintenance:

- Cleaning the machine regularly, especially the adjustment elements and the guiding devices, is an important

safety factor.

- Ensure that only genuine MAFELL spare parts and accessories are used. Failure to do so will make

warranty claims and the liability of the manufacturer null and void.

- Prepare a periodic maintenance schedule for your machine. When you clean the machine, be careful

not to disassemble any part of the machine. Reassembling the machine bears the risk that internal

wires are routed incorrectly or pinched, or that return springs of the safety device are mounted

incorrectly. Certain cleaning agents, such as gasoline, carbon tetrachloride, ammonia, etc. can damage

plastic parts.

- Some of the dust produced by sawing, sanding, drilling and other building work contains chemicals

known to cause cancer, birth defects or other reproductive harm. Some examples of these

chemicals are:

- Lead from lead-based paints,

- Crystalline silica from bricks and cement and other masonry products,

- Arsenic and chromium from chemically treated wood.

Your risk from this hazard varies with the frequency at which you perform this type of work. To reduce your

exposure to these chemicals: Work in a well-ventilated area. Work only with approved safety equipment,

such as dust masks that are specially designed to filter out particles of microscopic size.

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3.4 Specific safety rules

Operation information:

- Never work without the protection devices of the gantry system in which the milling motor is inserted, which

are required for the respective operation.

- Do not change anything on the gantry system or the milling motor that could affect the safety.

- Using the unit in conjunction with water or conductive liquids is prohibited.

- Keep the milling motor away from rain or wetness. The ingress of water into the milling motor increases the

risk of an electric shock.

- Keep your hands away from the danger zone of the tool.

- Check the workpiece for foreign bodies.

- Watch the rotational speed. Switch off the power supply immediately if the rotational speed rises

uncontrollably or suddenly.

RETAIN THESE INSTRUCTIONS!

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3.5 Safety devices

Danger

Risk of injury from missing safety devices

These devices are necessary for the safe operation of the machine. They must

not be removed or rendered ineffective.

➢ Check the proper functioning of the safety devices before you start

operating the machine.

➢ Never use the machine with missing or ineffective safety devices.

The machine is equipped with the following safety devices:

Safety device

Type of check

Stable collar for installation in stationary machines

Visual check for damage

Plastic housing to protect against electric shock

Visual check for damage

Stable connecting cable to protect against electric

shock

Visual check for kinks and incisions

Switching device

Functional check (coasting time must not exceed

5 seconds)

Warning lamp for rotating tool

Visual check for damage

If the safety devices are damaged or not functioning properly, follow the instructions in the chapter

Troubleshooting. For other malfunctions, please contact your dealer or MAFELL Customer Service directly.

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3.6 Residual risks

Warning

Risk of injury when working with the machine

Even when the machine is used as intended and in compliance with the safety

regulations, there are still residual risks caused by the intended use, which can

have consequences for your health.

➢ Observe the safety instructions and information in these instructions.

➢ Always be extremely careful and cautious when you work with the machine.

The existing residual risks include:

- Breakage and ejection of the tool or parts of the tool.

- Impaired hearing when working without hearing protection for long periods of time.

- Emission of harmful wood dusts during longer operation without extraction.

4 Setup / adjustment

4.1 Mains connection

Prior to starting up the machine, check to ensure that the mains voltage corresponds to the operating voltage

specified on the rating plate of the machine.

4.2 Tool selection

Use only the collet chucks listed in the chapter "Special accessories". The tools are selected as a function of

the materials to be machined, taking into account the performance of the feed drives. Take into account the

performance of the milling motor when you select the maximum tool diameter and the intended machining

depth.

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4.3 Collet chucks

Notice

Tightening the union nut excessively without an inserted tool can compress and thus damage the collet

chuck.

➢ Tighten the union nut only when a tool is inserted.

➢ To protect the thread, screw the union nut only lightly onto the milling spindle when there is no tool

inserted.

Information for using the collet chucks:

- Ensure that you use the correct cutter size for the collet chucks.

- To prevent the collet chucks from binding, oil them a little at the beginning and after prolonged use.

- To improve the concentricity, lightly grease the collet chucks or use a solid lubricant (for example Molykote

P-40).

- Using a square piece of wood or a rubber mallet (never a metal tool!), tap lightly from behind on the collet

chuck to loosen it if it is jammed.

Use the following procedure to mount a collet

chuck:

1. Click the collet chuck into the union nut.

2. Screw the union nut onto the milling spindle.

✓ Collet chuck mounted.

Fig. 3: Mounting the collet chuck

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4.3.1 Recommended tightening torques (consider overall system)

- Tightening torque for union nut / collet chuck = 10 - 11 Nm

- Tightening torque for collar = 7 Nm

The collar (4) has a diameter of 43 mm [1.69 in] and

is 25.5 mm [1 in] wide.

The clamping unit in which the milling motor is

installed must be at least 20 mm [0.79 in] thick.

If possible, clamp the milling motor over the entire

mounting diameter of the clamping neck (4).

If possible, avoid spot clamping (e.g. via a threaded

pin) in the clamping neck (4). Excessive clamping

force can damage the internal ball bearings.

Fig. 4: Collar on the milling motor

4.3.2 Maximum speed when using a collet chuck adapter

The recommended maximum rotational speed for using the collet chuck adapter OZ and the collet chuck

adapter ER, is 16000 rpm.

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4.4 Tool change

Caution

Risk of burns/cutting

The inserted tool can heat up considerably during longer work processes.

Furthermore, the cutting edges of the insert tool are sharp.

➢ Wear protective gloves when changing tools.

The milling spindle is equipped with a precision collet chuck to hold the tools. The locking button controls the

spindle lock, which makes it easier to tighten and loosen the union nut.

Use the following procedure to change the tool:

1. Pull out the power plug of the machine.

2. Put down the cable where you can see it.

3. Press and hold the locking button (1) to lock

the milling spindle.

4. Loosen the union nut with the 17-mm single

open-end wrench [0.67 in] or the ER 16 M

chuck key.

5. Pull off the old tool from the front.

Fig. 5: Removing the tool

6. Insert the new too into the tool holding fixture

until it hits the stop.

7. Press and hold the locking button (1) to lock

the milling spindle.

8. Tighten the union nut with the 17-mm single

open-end wrench [0.67 in] or the ER 16 M

chuck key.

9. Check to ensure that the tool is seated

properly.

✓ Tool changed.

Fig. 6: Inserting the tool

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5 Operation

5.1 Startup

These operating instructions must be brought to the attention of all persons entrusted with the operation of the

machine, with particular emphasis on the chapter "Safety instructions".

These operating instructions describe only the milling motor. They do not take the installation situation into

account. Please take any other operating instructions into account, too.

5.2 Switching on / off

Use the following procedure to switch on the

machine:

1. Push the power switch (2) forward until it

engages.

➢ After 0.2 s, the milling motor accelerates

with a soft start to the previously selected

rotational speed. The duration of the soft

start depends on the selected rotational

speed. At maximum rotational speed, it is

approx. 1.2 s.

➢ The light at the setting wheel (3) shines

blue.

✓ The machine is switched on.

Fig. 7: Switching the machine on

Use the following procedure to switch off the

machine:

1. Press on the rear end of the power switch (2).

➢ The power switch jumps to the OFF

position.

➢ The light at the setting wheel (3) goes

out and the motor coasts to a standstill.

✓ The machine is switched off.

Fig. 8: Switching the machine off

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5.3 Speed selection

The setting wheel 3 permits a stepless change of the rotational speed. The concrete values of the rotational

speed of the individual steps can be found in the table below or on the rotational speed sticker on the housing.

The integrated electronics corrects to the selected rotational speed until the motor characteristic curve is

reached.

Fig. 9: Changing the rotational speed

Step

rpm

1

10000

2

13000

3

16000

4

19000

5

22000

6

25000

5.4 Overload protection

Overload during operation causes the milling tool to break, the workpiece to be damaged or even the milling

motor or gantry system to be damaged.

To protect the milling motor, the operating

parameters current, rotational speed and

temperature are monitored dynamically, and the

milling motor is switched off if necessary.

A short moment before the overload protection is

activated, the light at the setting wheel 3 changes to

permanent red.

To be able to restart the milling motor, switch the

circuit breaker (2) off and back on. The milling motor

becomes operational and the light at the setting

wheel (3) changes to blue.

Fig. 10: Overload protection

Prior to carrying out any work on the work spindle after the overload protection has been

activated, ensure that the mains plug is pulled out.

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5.4.1 Visual output of the remaining running time

The visual output signals on the setting wheel (3) show the operating status. The lamp at the setting wheel

shines permanently blue as long as there is no overload on the milling motor.

If the milling motor is overloaded, the calculated remaining time is displayed as a red blinking code. The table

below shows the relationship between the blinking code and the related remaining runtime.

Operating mode

Remaining runtime in

seconds

Setting wheel - light

Continuous operation

Unlimited

Blue, permanent

Overload operation

(motor running)

< 160

1 x red pulse

< 80

< 40

2 x red pulse

< 20

< 10

3 x red pulse

< 5

Red, permanent

Shutdown

0

Table 5: Relationship between remaining running time and the related visual output signal at the setting wheel

If the remaining run time is not sufficient for your application, reduce the load or the feed rate to be able to

switch back to continuous operation.

6 Service and maintenance

MAFELL machines are of a low-maintenance design.

Have the carbon brushes replaced after a maximum of 125 to 150 operating hours.

The installed ball bearings are lubricated for life. After a longer period of operation, MAFELL recommends that

the machine be handed over to an authorized MAFELL service workshop for inspection.

6.1 Storage

Clean the machine thoroughly if you will not use it for quite some time. Spray bare metal parts with a rust

inhibitor.

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7 Troubleshooting

Warning

Risk of injury from a sudden start of the machine.

There is a risk that the machine starts suddenly due to carelessness when

working with the machine or during troubleshooting. The rotating tool can cause

serious injuries.

➢ Determining the causes of existing malfunctions and their elimination

always require increased attention and caution!

➢ Pull out the mains plug before you start troubleshooting!

Some of the most common malfunctions and their causes are listed below. For other malfunctions, please

contact your dealer or MAFELL Customer Service directly.

Malfunction

Cause

Elimination

The milling motor cannot be

switched on. The lamp at the

setting wheel does not shine

Mains voltage missing or too low

Have the power supply checked

by an electrician

Mains fuse defective

Have the fuse replaced by an

electrician

The milling motor cannot be

switched on. The lamp at the

setting wheel shines blue

Carbon brushes worn out

Take the milling motor to the

MAFELL customer service

workshop

The milling motor stops during

operation. The lamp at the

setting wheel does not shine

Mains failure

Have the mains back-up fuses

checked by an electrician

The milling motor stops during

operation. The lamp at the

setting wheel shines red

Machine overload

Switch off the circuit-breaker.

Clear the work spindle before

starting up the machine. Switch

on the circuit breaker and

continue operation with less

load/feed rate

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8 Optional accessories

- Collet chuck OZ8 ø 2 mm [0.08 in]

Order no. 093819

- Collet chuck OZ8 ø 3 mm [0.11 in]

Order no. 093812

- Collet chuck OZ8 ø 3.175 mm [0.125 in]

Order no. 093810

- Collet chuck OZ8 ø 4 mm [0.16 in]

Order no. 093813

- Collet chuck OZ8 ø 5 mm [0.20 in]

Order no. 093820

- Collet chuck OZ8 ø 6 mm [0.24 in]

Order no. 093814

- Collet chuck OZ8 ø 6.35 mm [0.25 in]

Order no. 093811

- Collet chuck OZ8 ø 8 mm [0.32 in]

Order no. 093815

- Collet chuck OZ8 ø 10 mm [0.40 in]

Order no. 093822

- Collet chuck OZ8 ø 3 mm [0.11 in] + union nut

Order no. 093816

- Collet chuck OZ8 ø 3.175 mm [0.125 in] + union nut

Order no. 093817

- Collet chuck ER 16 ø 3 mm [0.11 in]

Order no. 093753

- Collet chuck ER 16 ø 3.175 mm [0.125 in]

Order no. 093757

- Collet chuck ER 16 ø 4 mm [0.16 in]

Order no. 093754

- Collet chuck ER 16 ø 6 mm [0.24 in]

Order no. 093755

- Collet chuck ER 16 ø 6,35 mm [0.25 in]

Order no. 093760

- Collet chuck ER 16 ø 8 mm [0.32 in]

Order no. 093756

- Collet chuck ER 16 ø 10 mm [0.40 in]

Order no. 093759

- Union nut OZ

Order no. 093729

- Union nut ER 16 M

Order no. 093758

- Reducing sleeve ø 3 mm [0.11 in]

Order no. 207944

- Reducing sleeve ø 3,175 mm [0.125 in]

Order no. 207945

- Reducing sleeve ø 4 mm [0.16 in]

Order no. 207949

- Reducing sleeve ø 6 mm [0.24 in]

Order no. 207946

- Reducing sleeve ø 6,35 mm [0,25 in]

Order no. 207947

- Collet chuck adapter OZ incl. union nut OZ

Order no. 207943

- Collet chuck adapter ER 16 incl. union nut ER 16

Order no. 208109

- PV control cable M8 / 4-pol, 5 m [16.40 ft]

Order no. 208311

9 Exploded view and spare parts list

The corresponding information on the spare parts can be found on our homepage: www.mafell.com

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