Skip to content
  • There are no suggestions because the search field is empty.

25 Installation (Clone)

NOTE: An Installation Checklist is available in Chapter 15.

The installation and commissioning procedure is summarised in the following steps. Keep a record of your installation for warranty purposes if you are self-installing the SYIL.

25.1 Steps Overview

  1. Check and record the state of the crate as delivered
  2. De-crate the machine
  3. Visually check the machine and accessories, photograph as needed
  4. Remove the loose accessories from the pallet
  5. Lift the machine off the pallet
  6. Seat the machine
  7. Check the coolant tank for watertightness and fill with coolant
  8. Connect the air
  9. Connect power cable
  10. Power on for first time
  11. Check the correct phase rotation and correct if needed
  12. Lift the Z axis off the table and clean the spindle
  13. Clean all greased or coated surface including the inside of the coolant tank
  14. Remove the shipping straps on the axes and the ATC
  15. Clean and install the armour on the X and Y axes
  16. Fill the oilers
  17. Level the machine
  18. Test functionality

25.2 Consumables Required during Installation and Commissioning

  • Slideway oil
  • WD-40 or similar
  • Grease
  • Air line/tool oil
  • Soluble coolant oil
  • Water

25.3 Disassembly of the Crate

Complete this task with the machine on solid ground with sufficient space around it.

NOTE: It is not advisable to remove the plywood panels in locations such as the bed of a lorry. Required tools for this task are:

  • a set of metric Allen Keys to remove the retaining screws
  • a crowbar to lift and pry the panels

25.3.1 How to disassemble the crate

  1. Using the crowbar, lift the lid portion of the crate such as to disengage the nails holding it in Lift the perimeter in total before attempting to move the lid
  2. Pull the free lid over side of the crate using the crowbar to dislodge it and to lift the lid as needed
  3. Once on the ground make the nails safe
  4. Select the first panel you will be removing and unscrew the self-drilling screws holding it in position on the base. (The hexagon head is 12 mm) Do not remove the screws holding the other panels yet
  5. Pry the panel free and lay Make any nails present safe
  6. Repeat until the crate is removed in its entirety

NOTICE
  • Moving the machine from a cold environment to a warm indoor location may cause moisture to condense on the machine
  • Moisture may affect the electronics and electrics of the machine or cause damage
  • Keep the machine covered for at least 24 hours for its temperature to equalise

25.4 Inspect the Machine for Damage

SYIL recommends that the machine equipment be inspected for shipping damage before unloading and placing machine onto foundation.

  • Remove all wrapping around machine
  • Examine the machine for structural damage
  • Note any shipping damage to the machine on the shipper’s bill of It is the customer’s responsibility to file a damage claim
  • Photograph any equipment damage for your records

25.5 Removing Machine from the Steel Pallet

SYIL recommends that the customer review this section to determine if there is proper capacity and ability to lift and place the machine into the location. If not, then a rigging agency should be contacted.

25.5.1 Preparation

Remove any loose items that may have been supplied with the machine. These may include some or all:

  • Coolant tray – now coolant tray is a single piece
  • Coolant washdown and air hose
  • Slide way armour panels
  • Toolkit
  • Manuals and paperwork

25.5.2 Releasing the machine from the pallet

The machine is held on to the base using 3 threaded studs. These pass through the jacking/levelling studs that in turn thread into the base of the machine.

Remove the nuts on the threaded studs.

25.6 Safe Lifting of the Machine off the Pallet

25.6.1 Lifting with a crane

  • Pay special attention to machine balance while lifting
  • Beware that the machine might be overturned because of an improper lifting Otherwise injury to people or machine damage may occur
  • Always assign a person to guide the way to ensure safety

When transporting the machine by crane, be sure to take the following precautions:

  • Position the base of the crane and the horizontal support plate so that the machine can be loaded with the fulcrum of the overhanging steel cable directly above its centre
  • Ensure the angle of the steel cable’s fulcrum does NOT exceed 90°. If possible, adjust the angle to 60°
  • Ensure that the steel cable is secured on both sides of the pedestal or with a fixing device designed for transporting heavy equipment

 

 

 

 

 

 

CAUTION
  • Lifting work should be performed only by qualified personnel
  • Lift the machine slowly while ensuring it is balanced on all sides and that the lifting cables are positioned against its external casing or outermost components
  • If two or more people are lifting the machine, they should communicate to ensure they exert force on it simultaneously and in the same direction
  • Do not use cables of inadequate length or that have sustained rust or other damage to lift the machine
  • Lift the machine slowly. When one of the steel cables has reached maximum tension, temporarily halt lifting and check that the machine is balanced before continuing to lift it to the designated height
  • The machine should be lowered slowly. When lowered almost to the ground, temporarily halt lowering and check that the machine’s base is level and aligned with the intended position, then resume lowering to set it down completely 

 

X7

25.6.2 Lifting with a Forklift

When transporting the machine by forklift, be sure to take the following precautions:

  • Ensure you have read and understood the manual’s safety instructions before installing the machine
  • Ensure the ground is free of lubricant oil, grease, or water to prevent slipping and falling during installation
  • Before beginning installation, check and confirm that the machine has been placed in the correct position

CAUTION
  • Only qualified personnel to operate a forklift should attempt to transport the machine
  • In order to avoid damaging the machine or its surroundings, a minimum of two people should be present while operating the forklift
  • Lower the machine slowly to prevent impact with the ground
  • A wooden pallet can be used to support the machine during the lifting process

This machine should be lifted and moved by a forklift. Attention should be paid to the machine balance during lifting and moving. This machine should be lifted under the following conditions:

  • The weight of the machine is approximately 2,000 Kg. It is the responsibility of the operator to ensure that the rating of the forklift and the load capacity of the forks at the load distance are suitable for the task.
  • Beware that the lifting truck might overturn because of an improper lifting This might cause people injury and damage the machine
  • Always assign a person to guide the way to ensure safety

NOTE: Extended forks are required for this operation to be completed with ease.

NOTE: Having a selection of timber to hand will help with any potential mismatch in level of the front and rear of the machine.

NOTE: Do not lift the machine higher than it needs to be lifted. Adjust the levelling screws to get enough clearance, if necessary.

The Centre of gravity of the machine is estimated to be 800 mm from the back of the electrical cabinet

 X5 

 Place the forks of the forklift as shown in Figure 74 

 X7

The Centre of gravity of the machine is estimated to be 800 mm from the back of the electrical cabinet Place the forks of the forklift as shown in Figure 98 and Figure 99.

25.6.3 Moving with a pallet truck

Place 2 strips of wood of 10 mm in thickness between the pallet truck and casting so that the forks can be inserted all the way in. See Figure 100 and Figure 101

25.7 Installing the feet

The studs that secure the machine to the shipping pallet must be retained when the machine is lifted. The studs are then used to hold the cast iron feet to the machine for easy relocation of the machine.

Reuse the shipping nuts on the studs.

NOTE: Do NOT place the thick steel washer on the stud under the foot. This will result in the hexagon head of the stud protruding from the foot and result in the machine being unstable.

25.8 Fitting Through Low Doors

The SYIL X5 has two cable chains extending past the head of the machine. It may become necessary to unscrew these to allow the machine to pass through doors with an opening height of less than 2.1 m. See Figure 76

To loosen the cable chains, unscrew the 4 cap head screws, 2x each side, holding them to the column.

NOTE: The minimum height of the SYIL X5 is 1.95 m with the feet removed.

25.9 Test the Coolant Tray for Water Tightness

While the machine is not yet connected to the coolant hoses and the power, test the seal of the plug by doing these steps:

  1. Wipe down the coolant tank to remove excess oils
  2. Fill with water
  3. Let the tray sit for a few hours to identify if there are any small leaks

  4. If the tray is leaking from:

    • the plug, remove the plug and reapply the PTFE tape

    • any other location, contact the customer service



25.10 Connect the Coolant Hoses and Pump

  1. Move the coolant tank into position behind the machine
  2. Align the chip trays with the spouts on the machine casting
  3. Screw and tighten the rubber coolant hose on to the pump outlet
  4. Insert the second return line into the smaller hole of the coolant tank
  5. Connect the power connector of the pump to the socket on the right hand side of the electrical enclosure
X5

X7

25.11 Connecting the Air Supply

NOTE: The factory supplied air inlet fitting receives a 10 mm pneumatic hose.

Push the hose into the inlet until it is fully seated. Test the grip of the connection by pulling the hose.

X5

X7


X11

T5/T7

25.11.1 Air and consumables required

Compressed air is required for:

  • Clearing swarf and cuttings – Air blast (activate with macro M07)
  • Ensuring tool holder tapers are clean during tool change
  • Air curtain of the Keeps coolant and debris out of the high speed elements of the cartridge while also offering cooling to the cartridge

The Air Curtain of the spindle has a parameterised time delay. Contact customer service for instructions.

A 90 psi with capacity more than 50 litre compressor is necessary for normal use if it is rated for extended duty cycles.

25.12 Connecting Power

NOTE: See Chapter 5 before connecting the machine to the power supply. Open the electrical cabinet using the keys provided in the toolbox.

Under the safety isolator switch, a terminal block can be seen as shown in Figure 79.

NOTE: Use crimp terminals with a 6 mm hole.

At this stage, also connect the MPG to the controller panel

25.12.1 Pre-Power ON Checks

Before powering on, check the following:

  1. Power cable is secure
  2. Using a multimeter check that the PE (Earth) cables are all connected to the PE connection of the input terminal
  3. Check that all DIN rail mounted electrical components are held well in place and have not come loose during shipping
  4. Gently pull each of the cables in terminal block in the electrical panel to ensure they are tight
  5. Take the panel off the rear of the controller and inspect the cables in that enclosure

25.12.2  First Power ON

NOTE: Keep the electrical cabinet doors always closed before powering on. The isolator will not rotate unless the door is closed.

  1. Ensure that the Emergency Stop on the front panel is also pressed in

  2. After the isolator switch is turned on, the following elements are audible:

    • Lubrication pump

    • Electrical cabinet fans and chiller

    • Spindle fan

  3. Press the Green illuminated button to start the controller
    NOTE: The Controller on button for the LNC 6800 based machines is shown in Figure 81. Other controllers have similar buttons on the user panels.

    The machine will then boot up.

    NOTE: When the machine is fully booted, the controller may give the E-stop warning as well as the air pressure low warning.

    NOTE: It is preferable to use the MPG for this operation. Do not attempt to move the X or Y axes yet.

  4. Release the E-stop button and press the relevant Reset button to clear any
  5. Move the machine Move the Z axis up so that the supporting block or tube can be removed.

25.12.3 Checking phase rotation

NOTE: It is very important that the 3 phases of the power cable are installed in the correct sequence. The effect of incorrect phase sequence is to make 3 phase synchronous motors rotate in the opposite direction they are intended.

To check the correct sequence, the easiest test is to check the rotation of the coolant pump. The pump must rotate in the counter clockwise direction. See Figure 82

Remove the cover of the pump’s fan to be able to see the rotation easier, if needed. Remember to replace the

cover to avoid injury or damage to the pump.

NOTE: Rotation of the pump is the best indicator of the phases of the 3-phase supply being installed correctly. If the pump rotates in the incorrect direction:

  1. Power off the machine and isolate the power
  2. Swap any two of the power cables on the power inlet terminal

25.12.4 Clean the machine

NOTE: The machine will be shipped with some surfaces covered in a protective wax, while others are covered in grease

  1. Clean the machine using WD-40 and rags
  2. Clean the spindle taper
  3. Clean the coolant Remnants of oil from the testing of the machine may be found

25.12.5 Check Lubrication Circuit

The lubrication pump can be activated manually by pressing the FEED button on it.

  1. Hold for 2-5 seconds and observe the pressure dial
  2. Look in the machine to ensure that oil has come through into the ways and ballscrews

 25.13 Removing the Shipping Straps

NOTE: The 16 tool version does not have the straps. Shipping straps are now painted red for easy identification.

Straps are placed:

  • On the 12 tool umbrella type tool changer
  • Between the table saddle and the table to restrain the X axis
  • Between the table saddle and the Y axis ballscrew bearing housing

Ensure that power is switched OFF and the air system is NOT pressurised. Remove the ATC retaining strap

Before removing the axis retention straps:

  1. Power to the machine
  2. Press the Emergency STOP button to ensure that the axes do not lose reference accidentally
  3. Remove the shipping straps and store them for future

25.14 Fitting the Axis Armour

The axis covers are shipped removed. A total of 3 loose elements are to install:

  • The front cover of the X axis
  • 2 angle See Figure 113

Assemble the armour as follow:

  1. Using the supplied button head screws and washers, attach the front Y axis cover to the table saddle
  2. Using the two angle brackets (See Figure 113), connect the front and rear Y axis See Figure 114 for correct installation of the angles
  3. Assemble the front X axis cover

25.15 Check lubrication circuit

The lubrication pump can be activated manually by pressing the FEED button on it.

  1. Hold for 2-5 seconds and observe the pressure dial
  2. Look in the machine to ensure that oil has come through into the ways and ballscrews

25.16 Levelling after Seating

Use a precision level to level the machine with a sensitivity of 0.02 mm/m, example shown in Figure 84

Connect power and air to have access to the bed. This allows to move the Z axis up and out of the way.

The machine is levelled through the 3 jacking screws that that locate on the conical machine feet. Applying grease to the threads makes the process easier, as does the use of a ratchet socket wrench. For optimum performance of the machine, it is advisable to achieve a level in the X and Y axes of 0.04 mm/m or better.

The procedure is as follows:

  1. Using all three of the jack bolts, lift the machine such that the coolant tray slides under it with Depending
  2. on the floor’s flatness, this may Typically, an extension of 30 mm is required
  3. Place the spirit level along the X axis of the machine and adjust the lowest foot
  4. It is easier to do with two people, one adjusting, the other advising of the level
  5. Once the bubble of the spirit level is centred in the sight glass, the right-to-left level is good
  6. Place the spirit level parallel to the Y axis of the machine and adjust the front foot
  7. When the front to back is level, check that the coolant tray is still able to be installed and removed easily
  8. If the coolant tray fowls the enclosure, increase the height of the whole machine but equal amounts on all three feet, then repeat the levelling process

25.17 First Spindle Run : Run-In

Before commencing production runs on the machine, it is important that the spindle has properly been run-in. This ensures that the spindle as a whole system is operating correctly. Write the following program and allow the machine to run while supervised.

 

Unit

Speed

Unit

Duration

1

 

 

 

 

 

RPM

2,000

 

 

 

 

 

minutes

20

2

4,000

20

3

8,000

20

4

1,000

5

5

12,000

20

6

15,000

20

7

1,000

5

8

18,000

20

9

20,000

2

10

10,000

5

11

1,000

5

During the run-in process measure the spindle temperature at regular intervals. Contact customer service if the temperature exceeds 55 oC.

25.18 Take a Controller Back up

25.18.1 Siemens 828 D controller back up

NOTE: Access level "User" is required to create an archive.

  1. Select the Startup operating
  2. Press the menu forward key and then the Startup archive The Startup window opens.
  3. Select the Create startup archive option and confirm with OK. The Create startup archive window opens



  4. Use the SELECT button to choose which data classes are to be archived:
    • Select All to archive all data belonging to the control component
    • Select Selection to create an archive containing only data from the selected data classes
  5. Select the control components for the archive
  6. Use the option to enter a comment and the creator of the archive
  7. Press the OK softkey to create the The Create archive: Select archive window opens
  8. Select the directory User or Manufacturer. Alternative: Select the New directory softkey to create a new
  9. Enter a name and confirm with OK. The directory is created below the selected The Create archive: Name window opens
  10. Enter a name and confirm with OK
  11. In the selected directory an archive file of the type *.ard is created

25.18.2  SYNTEC 22MA controller back up

  1. Press the Maintain softkey
  2. Press the SYS softkey
  3. Follow the prompts to create a backup archive on a USB stick
 

25.18.3 FANUC

 

25.18.4 LNC M6800

NOTE: Press the E-Stop button to be able to proceed with the back up Take a backup of the LNC controller by doing these steps:

  1. Press the E-stop button
  2. Plug a USB flash drive into the USB port
  3. Press the MAINTE key on the keyboard
  4. Type 7 in the User level and press INPUT
  5. Type in the password 168888


    NOTE: Take the backup with the IP addresses set correctly. This will allow you to restore from a PC if needed later

  6. Press the MAINTE key on the keyboard
  7. Go to CONTROLS NETWORKS SETTINGS – NET
  8. Check the IP address, and subnet mask are correct



  9. Press the MAINTE key on the keyboard
  10. Press the BACKUP softkey
  11. Select Export to USB and check the ticks on Backup All and Output to USB. This will export a small archive with the most important elements.



  12. Press the TRANSFER button
  13. Press the right-hand key on the keypad
  14. Press INPUT to create a new folder
  15. Press INPUT to save the back up file



  16. Repeat the process but this time select all lines using the ALL soft key