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5 Planning ,Transport and Placement

5.1 Planning

5.1.1 Basic theory

This information is for the supervisor in charge of the installation of the machine tool and his employees.

Prepare the installation site so that the power line can be placed and connected immediately when the machine tool arrives.

Get all the necessary information about:

  1. The machine tool place and its surrounding environment.
  2. Place data and equipment electrical power.

5.1.1.1 Initial Installation

Only personnel authorized by the machine manufacturer are allowed to install the machine tool for the first time.

Otherwise, the company will not be responsible for possible damage or functional failure.

5.1.1.2 Customer obligations

The customer is responsible for the following preparation measures:

  1. Prepare the location of the lathe.
  2. Ensure that:
    1. Power supply, lighting, industrial water, compressed air, telephone.
  1. Transportation within the enterprise to the location.
  2. Place the lathe.
  3. Connect the required energy.
  4. Lathe cleaning and degreasing.
  5. Provide required cooling lubricants.

5.1.2 Requirements for placement site

The user is responsible for the correct location of the machine tool.

In the future, if there are problems due to the failure to comply with these conditions, the company will not bear any responsibility.

The user must check, confirm and implement the following conditions before supplying the machine tool.

5.1.2.1 Environmental requirements

  1. The installation of machine tools must meet the requirements of local environmental protection regulations.
  2. The machine is placed in a receiving box, or its floor structure must be able to seal the oil.

5.1.2.2 Ground

A continuous, B25 quality reinforced concrete floor is required.

The placement surface must be reviewed and approved by a person.

  1. There shall be no expansion joints, cracks, cable trench or other fractures on the floor surface where the complete equipment is located.
  2. The flatness of the mounting surface must be within ± 2mm.
  3. Under the action of machine load or external image, the placement surface shall not sink.

5.1.2.2.1 Ground bearing capacity

The center of gravity is moved by the weight and stroke of the workpiece.

The bearing capacity of the ground must be reviewed by a load-bearing structural Planner (statical architect).

The following weights must be taken into account:

  1. The maximum installed weight of the machine tool.
  2. Maximum weight:
    1. Tools and accessories cabinet and objects therein.
    2. Workpiece and tooling.
    3.  Personnel 
    4. Transport equipment.
    5. Other devices directly close to the machine tool.

5.1.2.2.2 Basement slab, Floor cover

If the machine tool is placed on the basement cover plate, floor cover plate or other bearing structure, the following points must be paid attention to:

A load-bearing structural Planner (statical architect) experienced in building dynamics must examine:

  1. The supporting structure should be able to bear the inertia force of the machine tool.
  2. If it is not possible to confirm whether the layout measures taken can adequately cushion the vibration.

5.1.2.2.3 Ground shaking

The ground vibration or violent shaking is not allowed to affect the function and accuracy of the machine tool.

5.1.2.2.4 Imported

In order to transport the machine tool to your site, it must be large enough. Please refer to the installation data of the machine tool for the details of the overall dimensions of the machine tool.

5.1.2.2.5 Workshop size

The interior must be of sufficient height and width.

  1. There must be a site for placing operations.
  2. There must be access and space for the operator.
  3. There must be access and space for maintenance work.
  4. The necessary air flow for cooling the unit must be met.
    1. Minimum separation from walls and roofs is 1.5 m.

    5.1.2.2.6 Machine Area

    Attention shall be paid that there shall be no column or other obstacles that hinder the installation and maintenance work in the machine tool area.

    5.1.3 Environment condition

    The machine is not allowed to operate in the flammable and explosive dangerous area.

    5.1.3.1  Indoor temperature

    The temperature in the workshop must be regulated uniformly. Only a few temperature fluctuations are allowed.

    Ensure the function of the machine tool under the following conditions：

    Name

    unit，unit

    number

    ambient temperature

    ℃

    +15 to +35

    Under the following conditions to ensure the accuracy of the machine tool：

    Name

    unit，Element value

    numerical value

    ambient temperature

    ℃

    +20 to+23

    Temperature fluctuation (at the same time)

    °C/h

    <0,4

    Temperature fluctuation

    °C/24h

    <±1,5

    Prevent direct heat radiation from sunlight, hot objects or other nearby machine tools.

    When the temperature is lower or higher than the allowable indoor temperature, special measures must be taken.

    5.1.3.2 Air humidity

    Name

    Unit

    Numerical Value

    Relative air humidity at 20 ° C

    %

    20 to 75

    5.1.3.3 Location and height of installation site

     

    Unit

    Numerical Value

    The maximum installation height is based on IEC204

    m

    Altitude 1000 meters
    1. If the physical environment or operating conditions deviate from this regulation, it is required to make an agreement between the supplier and the user.
    2. When the installation height is > 1000 m, the load current will be reduced according to the following chart.

    The current must be reduced in the same way for In, Is6 and Imax.

    1. In = XH In 1 000 m / 100 %
    2. Is6 = XH Is6 1 000 m / 100 %
    3. Imax = XH Imaxmax 1 000 m / 100 %

    For example: LT 50 A with HSA-analog adjustment: the selected inverter pulse repetition frequency is 6.3 kHz; the installation height is 2,000 m.

    5.1.3.4 Noise emission

    Name

    Unit

    Value

    The measured surface sound pressure complies with DIN 45635-16 level 2 standard during idling

    dB(A)

    < 78

    5.1.3.5 Dust and sand contaminants

    In order to reduce machine wear and reduce property damage in machining seals, the following environmental conditions must be maintained:

    1. No sand, grinding or wire cutting dust on the site
    2. No machining which can generate or roll up sand grinding or wire cutting dust in the environment.

    5.1.3.6 Aerosol pollutants

    In order to prevent corrosion on the workpiece and machining, it must be ensured that the site is dry and free of corrosive steam.

    Brazing, welding, painting, pickling or electroplating equipment are not allowed in the same workshop.

    5.1.4 Floor Plans

    5.1.4.1 Symbolic interpretation

    Attention symbol

    The following symbols appear on the previous page and appear as precautions!

    Site require  ments
    Operation side 

    Control cabinet 

    E Electrical control cabinet interface

    P Pneumatic connection interface

    Additional safety evacuation routes and safe areas must comply with local regulations.  

    5.1.4.2 Foundation plans

    1. Machining support (4x);       2. Foundation size;

    Appropriate floors requiring approval by load-bearing structural designers (statics).

    5.1.4.3 Layout drawing of machine

    5.1.4.3.1 Lie and chained type tool magazine with 40T (Standard)

    Top view ：

    Front view ：

    5.1.4.3.2 Disc type tool magazine with 24Tand Vertical chained type tool magazine with 40/60T (Option)

    Top view ：

    Front view ：

    5.1.4.3.3 Vertical chained type tool Magazine with 60T (Option)

    Top view ：

    Front view ：

    5.1.4.3.4 Requirements for electrical and pneumatic

    1. The back of the machine;          2. The right side wall of the machine;

    3. Adjust the screw position; 

    5.1.4.4 Lay feet

    5.1.4.4.1 Description

    Standard

    Components

     

    Num.

    4

    Model Specification

    GS41+TK8

    Manufacturer

    Nivell

    5.1.4.4.2  ATC

    Components

     

    Num.

    1

    Model Specification

    HSK 63 ATC

    Manufacturer

    Wbuna CNC Equipment (Shanghai) Co., Ltd.

    5.1.4.4.3 The load on the machine tool setting element

    Show the location of the placement components on the foundation map

    Place the largest total load on component A

     

    Unit

    Numerical Value

    Static

    kg

    1600

    dynamic

    kg

    1770

    Place the largest total load on component B

     

    Unit

    Numerical Value

    Static

    kg

    920

    dynamic

    kg

    1570

    Place the largest total load on component C

     

    Unit

    Numerical Value

    Static

    kg

    2030

    dynamic

    kg

    1330

    Place the largest total load on component D

     

    Unit

    Numerical Value

    Static

    kg

    1480

    dynamic

    kg

    1650

    5.1.5 Electric

    5.1.5.1 Safeguard

    When working on electrical equipment, incorrect connections or defective connections can cause damage to electronic components.

    The instructions in the circuit diagram must be observed.

    This machine tool is designed for the protective measures of the safety lead system (protective ground).

    The machine tool is strictly prohibited to operate on the power grid with fault current protection.

    These protective measures are limited by the drive technology used by the AC motor. These protective measures are permitted according to item 5.2.11 of the DIN EN 50 178 standard of the April 1998 edition (VDE 0160).

    If the installation site specifies the installation of a fault current protection device, a special agreement must be reached with the competent power supply company (EVU) regarding the mentioned regulations. If unforeseen problems occur, please consult with Shanghai Aerospace iGen Intelligent Technology Co., Ltd.。

    If a leakage protection switch is necessary, it must be connected to the machine tool through a pre-isolation transformer.

    Machining connection

    1 Direct connection; 2 Connect with front isolation transformer

    Under the following conditions, the machining can be directly connected（1）：

    TN-S grid, TN-C grid.

    Operating voltage 400V AC ± 10%.

    Front isolation is required under the following conditions:

    transformer（2）：

    1. Equipped with TN-S, TN-C power grid, but the working voltage is not 400 VAC ± 10%
    2. TT grid
    3. IT grid

    5.1.5.2 Main safety device

    The overload current protection device (general fuse) of the power cable must be installed outside the scope of the machine and is not included in the scope of supply of Shanghai Aerospace One Intelligent Technology Co., Ltd.。

    5.1.5.3 Electrical data

    The power supply connected to the machine tool or equipment must be a TN-S-power supply with three-phase live wire (L1, L2, L3), neutral wire (N) and protective wire (PE).

    Connection

    Features

    Power connection terminal

    3-phase live wire (L1, L2, L3), neutral wire and protection wire, 50/60

    Hz400/230 VAC with tolerance ±10%

    power voltage

    Value

    Grid voltage tolerance

    400 V +/- 10%

    The actual voltage value under load must not exceed the allowable tolerance fluctuation range of the rated voltage.

    The cross-sectional specifications of the connecting cables are in accordance with the German standard DIN 57100/VDE 0100 or other local standards！

    5.1.5.3.1 Power cord, fuse

    Follow the instructions on the nameplate of the electrical control cabinet to configure the power cord and the fuse of the power distribution cabinet in the workshop.

    5.1.5.4 Equipment power

    5.1.5.4.1 Spindle 14 000 r/min

    Model

    Power consumption at 100% ED on time

    A

    Power consumption at 100% ED on time

    kVA

    Maximum operating current of the isolation switch

           A

    Standard

    40

    23

    80

    With the paper tape fitter

    47

    28

    80

    5.1.5.4.2 Spindle20 000 r/min

    Model

    Power consumption at 100% ED on time

    A

    Power consumption at 100% ED on time

    kVA

    Maximum operating current of the isolation switch       A

    Standard

    60

    40

    80

    With the paper tape fitter

    68

    45

    80

    5.1.5.5 45 kVA front isolation transformer

    Name

    Unit

    Value

    The output voltage

    V, Hz

    3/400, 50/60

    Front isolation transformer DIN in

    V

    200, 220, 400, 420, 440, 500

    Front isolation transformer CSA/UL in

    V

    208, 230, 460, 575

    rated power

    kVA

    45

    In Maximum secondary voltage (400 V)

    A

    65

    fuse

    A

    3 x 80 Non-rapid fuse

    Primary voltage

    Model

    Unit

    Value

    200V

    A

    130

    220V

    A

    118

    400V

    A

    65

    420V

    A

    62

    440V

    A

    59

    500V

    A

    52

    Name

    Unit

    Value

    Cable length above the channel

    m

    0.8

    Cross-sectional area of connecting cable

    Complies with German standard DINN

    5710/VDE 0100

    5.1.5.6 External data transmission

    If external data transmission is planned, the corresponding hollow metal tube used for the data cable must be installed

    The data cable is not allowed to be laid directly beside the power cable or cross-laid with the power cable.

    5.1.6 Pneumatic device

    1. Pneumatic connection；

    5.1.6.1 Claim

    Compressed air at intake point

    1. It must be free of condensate.
      1. Air cooling to 2-5 °C is the recommended value (eg by air dryer).
    1. It must be dry and dust-free.
      1. Recommendation: Air filter (user side) located in front of the machine.
      2. Filtration accuracy = 40 μm, please ensure that the filter specifications correspond to the compressed air consumption of the machine tool.

    5.1.6.2 Technical data

    Prepared by the user：

    Name

    Unit

    Value

    Pneumatic connection

    AVENTICS

    1 823 376 010

    Compressed air connection

    ∅ mm

    10,1

    Minimum rated broadband

    mm

    7,2

    The machine is ready:

    Name

    Unit

    Value

    Pneumatic connection

    AVENTICS

    1 823 351 017

    Air volume:

    Name

    Unit

    Value

    Machine tool without tool air cooling

    m3/h

    10

    Tool cooling blow (continuous operation)

    m3/h

    20

    Minimum air pressure

    bar

    6,0

    Maximum air pressure

    bar

    8,0

    Setting value of pressure gauge

    bar

    6,0

    Pressure interface

    ∅ mm

    9 (3/8“)

    Minimum rated broadband

    mm

    7,2

    The compressed air intake pipe (user side) should be kept as short as possible.

    If the peripheral equipment used requires compressed air, please confirm that the working pressure is 4-8 bar (59-117psi) and the air quality complies with the international standard ISO 8573-1.

    Component

    Unit

    Value

    Solid matter/granularity

    Quality level 5

    μg

    < 40

    Water/pressure dew point

    Quality level 4

    ℃

    < +3

    Oil/residual oil content

    Quality level 2

    mg/m3

    < 0,1

    Èuc1Ýu187 ?\u253 y (V)

    m3/h

    3

    5.2 Transport

    5.2.1 Overview

    The reader of this material is responsible persons and employees responsible for the lathe transport, placement and installation.

    Installation site can be prepared in advance so that placement and connection can be conducted immediately after the lathe is delivered.

    Transportation equipment shall be stored in a clean and dry place so as to be used for transporting in the future.

    Tips on the annular sling shall be noted before reusing.

    5.2.2 Safety

    Machine tools can be handled by personnel with appropriate qualifications or authorized personnel.

    Danger!Good that can be overturned!

    Use the truck to transport machine tools.

    Falling and tipping of the transport base or packing case may cause serious injuries or even death.

    1. Safe fixation measures shall be taken to the transport base or packing case according to regulations.
    2. Please pay attention to abide by handling notes, safety considerations, precautions regulations and local regulations.
    3. Only suitable, perfect and functioning transportation with enough bearing capacity is allowed to use.
    4. Pay attention to abide by regulations on handling weight and transport dimensions (refer to “Transport Information”).
    5. Pay attention to abide by regulations on suspension point and gravitational center mark 

    Heavy and huge goods

    Extrusion may cause serious injuries or even death.

    1. Please develop an unimpeded transportation road that is wide enough.

    Danger! Suspended weight

    Falling of the machine tool or peripheral devices caused by denormalized use or installation of handling equipment may result in serious injuries or even death.

    1. People shall not stay under the suspended weight.
    2. The machine tool and accessories shall be handled carefully.
    3. Supporting or traction on sensitive spare parts such as the workbench, lever, protective cover or processing room cannot be allowed.
    4. If required, only lever can be plugged in the opening of machine tool footstand.

    5.2.2.1 Fixation of transport base/packing case

    Damp proof protection must be conducted for the machine tool, controller, electric set, accessories and plug.

    1. The packing case shall be stand up.
    2. Because center of gravity of the transport base or packing case is high, the large angle of slope generated when the forklift is raised shall be avoided.
    3. Pay attention to the identification of sling suspended point on the packing materials.
    4. Please pay attention to the notes on the packing materials.

    Danger! Good that can be overturned!

    Transport on the ground with steep slope

    Slipping and tipping of the transport base or packing case may cause serious injuries or even death.

    1. Transport vehicles shall not go downhill or uphill on steep slope.

    5.2.3 Required transport equipment

    5.2.3.1 Machine tool with the magazine of 40 tools

    Preparations of users

    1. The bearing capacity of hoisting of forklift, hoist or truck shall be 7 tons at least.
      1. The clearance height of hoist hook shall be 8 meters at least.
      2. This height has the following components:

    Tray                                                     Case

    Load height of truck                            1.30 m                                    1.30 m

    Height of packing case                                   2.55 m                                                3.10 m

    Height of transport chassis                 0.20 m                                   0.20 m

     

    Machine tool/rope of packing case

     

    Length                                                             1 m                                          1 m

    Clearance height                                      5.05 m                               5.40 m

    1. Two annular slings (1) with bearing capacity of greater than 5 tons (length is 2 meters)
    2. Threeshackles (2) with bearing capacity of greater than 6.5 tons

    1 Minimum height

    Provided by machine tool manufacturers

    1.annular sling；         2.shackle；     3.eye bolt；

    For transporting the machine tool without packaging, the following means of transportation or stopper is required:

    1. Two M30 set screws (3) with the bearing capacity of 5 tons
    2. 1 x transporter (4)  

    5.2.3.2 Chip conveyor

    Preparations of users

    1.annular sling；         2.hook；         3.eye bolt；

    For transporting the chip conveyor without packaging, the following means of transportation or stopper is required:

    1. 2 x annular sling
    2. 3 x openable rings (2)
    3. 3 x eye bolt M12 (3)

    5.2.4 Transport data

    5.2.4.1 Machine tool

    Transport weight of the magazine with 40 tools

    Unit

    Numeric value

    Machine tool with synchronizing workbench

    about kg

    5 530

    Machine tool with synchronizing workbench and transport base

    about kg

    5 780

    Machine tool with synchronizing workbench and transport packing case

    about kg

    6 380

    Adopt the dimension when transporting the base (B x H)

    Unit

    Numeric value

    Machine tool with the magazine of 40 tools

    about m

    2.30 x 2.60

    Adopt the dimension when transporting the chassis (B x H)

    Unit

    Numeric value

    Machine tool with the magazine of 40 tools

    about m

    2.50 x 2.80

    Transport dimension (L x B x H)

    Unit

    Numeric value

    Machine tool with the magazine of 40 tools

    m

    2.89 x 2.20 x 2.50

    Machine tool with transport base and the magazine of 40 tools

    m

    3.07 x 2.40 x 2.70

    Machine tool with transport packing case and the magazine of 40 tools

    m

    3.07 x 2.40 x 3.10

    L=length，B=breadth，H=height

    Container transport dimension (L x B x H)

    Unit

    Numeric value

    Machine tool with the magazine of 40 tools

    m

    2.89 x 2.20 x 2.50

    With transport base

    m

    3.07 x 2.30 x 2.70

    5.2.4.2 Chip conveyor

    Transport weight

    Unit

    Numeric value

    Chip conveyor

    about KG

    300

    Transport dimension (L x B x H)

    Unit

    Numeric value

    Chip conveyor

    m

    3,12 x 0,92 x 1,54

    L = length，B = breadth，H = height

    5.2.4.3 Band type filter 600l

    Name

    Unit

    Numeric value

    Height

    mm

    1 856

    Breadth

    mm

    1 347

    Length

    mm

    1 775

    Weight

    kg

    530

    5.2.4.4 Transport planning of the magazine with 40 tools

    Front view

    1.approx center of gravity;     2.transport height exclusive of machine tool bracket;

    Top view

    1.approx center of gravity;               2.bottom profile of slide plate;
    3.cooled lubricant box;               4.slide plate device；

    The extension-level requires additional fees for dismantling and conversion.

    Enquire about the ex-factory price.

    Center of gravity

    1.approx center of gravity;     2.bottom profile of slide plate;             3.transport height exclusive of machine tool bracket;           4.cooled lubricant box；                     5.slide plate device;

    Release bellows of Y- axis slipway, and compress it into a whole, then fix its left and right sides.

    Approx rotation point

    X                                                                      Y                                                          Z

    108                                                                  175                                          150

    5.2.4.5 Transport planning of magazine (with 40 tools) container

    Front view

    1.approx center of gravity;     2.lowered machine tool height;

    3.maximum transport height with slide plate;

    Top view

    1.approx center of gravity;     2.slide plate device;   

    3.cooled lubricant box;            4.bottom profile of slide plate

    The extension-level requires additional fees for dismantling and conversion.

    Enquire about the ex-factory price.

    Center of gravity

    1.approx center of gravity;          2.bottom profile of slide plate;
    3.lowered machine tool height;           4.maximum transport height with slide plate;
    5.cooled lubricant box;           6.slide plate device;

    Release bellows of Y- axis slipway, and compress it into a whole, then fix its left and right sides.

    Approx rotation point

    X                                              Y                                              Z

    108                                             175                                       150

    5.2.5 Arrival of machine tool

    5.2.5.1 Input check

    • Transport damage and packaging integrity shall be checked immediately on delivery:
      • - Machine tool
      • - Accessories
      • - Peripherals

    5.2.5.2 Damage condition

    • Transport damage condition shall be specified in writing on shipping order/delivery order by the transport company。
    • Damage condition shall be photographed.
    • The damage conditions of machine tools shall be reported to our company. and transport company directly.

    5.2.6 Use forklift to unload machine tool

    • Damp proof protection measures shall be taken to all transport goods.
    • Please pay attention to abiding by regulations on transport weight, refer to the Chapter “Transport weight”.
    • Suspension point and gravitational center mark shall be noted.

    Necessary tools/materials

    • Forklift

    Procedures

    • Center of gravity may not lie in the core of the packing case, so the forklift claw shall be placed outward whenever possible!

    Heavy and huge goods

    Accidents is likely to happen because the machine tool is easy to slip, overturn or fall.

    • Please use specified transport security protection materials.
    • Please use forklift with adequate specification.
      • Lift the machine tool carefully.

    Danger!Suspended weight

    Life risk, people are forbidden to stay under the suspended weight.

    • Place the machine tool smoothly free of vibration.
    • Unloading of machine tool has been finished.

    5.2.7 Use hoist to unload machine tool

    • Damp proof protection measures shall be taken to all transport goods.
    • Please pay attention to abiding by regulations on transport weight, refer to the Chapter “Transport weight”.
    • Suspension point and gravitational center mark shall be noted.

    Necessary tools/materials

    • Hoist
    • Transport rope

    Procedures

    • Center of gravity may not lie in the core of the packing case, so the hoisting rope shall be wrapped up in a position as wide as possible!

    Heavy and huge goods

    Accidents is likely to happen because the machine tool is easy to slip, overturn or fall.

    • Please use hoist with adequate specification and dimension.
    • Please use transport rope with enough bearing capacity.
    • Lift the machine tool carefully, and see if the machine tool is lifted vertically.

    Danger! Suspended weight

    Life risk, People are forbidden to stay under the lifting object.

    • Place the machine tool smoothly free of vibration.
    • Unloading of machine tool has been finished.

    5.2.8 Use forklift to handle machine tool

    Prerequisites

    • Use bolt to tighten the machine tool and fix it on the transport base.

    Necessary tools/materials

    • Forklift

    Procedures

    • Stretch forklift fork into the packing case or under the transport base.

    Heavy and huge goods

    Accidents is likely to happen because the machine tool is easy to slip, overturn or fall.

    • Please use specified transport security protection materials.
    • Please use forklift with adequate specification and dimension.

    Danger! Suspended weight

    Life risk-people are forbidden to stay under the suspended weight.

    • Lift the packing case or transport base with machine tool carefully, and transport it to placement site.
    • Place the packing case or transport base with machine tool smoothly free of vibration.
    • Remove the packing materials, recycle and dispose them in accordance with environmental regulations.
    • The machine tool has been carried to the placement site.

    Machine tool installation

    If all the safety devices of machine tool haven’t been installed or operated normally, there may be risk of accident to personnel.

    • The placement site shall be sealed up. No admittance.

    5.2.9 Use hoist to handle machine tool

    Prerequisites

    • Remove retaining bolt of the machine tool from the transport base.
    • Transport square timbers have been dismantled.
    • Transport rack has been installed.

    Necessary tools/materials

    • Hoist

    Procedures

    • Tension annular sling slightly.

    Heavy and huge goods

    Accidents is likely to happen because the machine tool is easy to slip, overturn or fall.

    • Please use hoist with adequate specification and dimension.
    • Please use annular sling with adequate specification and dimension.

    Danger! Suspended weight

    Life risk, people are forbidden to stay under the suspended weight.

    • Lift the machine tool carefully, and see if the machine tool is lifted vertically.
    • If required, put the machine tool down and balance its weight.
    • Use hoist to transport the machine tool to the placement site.
    • The machine tool has been carried to the placement site.

    Machine tool installation

    If all the safety devices of machine tool haven’t been installed or operated normally, there may be risk of accident to personnel.

    • The placement site shall be sealed up. No admittance.

    5.2.10 Dismantle magazine transport device with 40 tools

    These transport devices may be used when there is handling within the enterprise in the future. Our company will not recycle these transport devices. When not in use, these transport devices shall be stored properly.

    1.annular sling;            2.shackle;        3.eye bolt;       4.measuringsystem;

    It is important to note that measuring system (4) shall not be damaged when disassembling the bolted swivel hoist (3). 

    Prerequisites

    • Machine tool is placed on the estimated site.

    Procedures

    • The annular sling (1) shall be picked from the handling hook and placed properly.
    • Remove two annular slings (1) and hook (2).
    • Dismantle bolted swivel hoist (3).
    • Fix X-axis bellows on the processing room again.
    • Machine tool components disassembled because of transport shall be assembled again.
    • Transport devices have been dismantled.

    5.2.11 Unload peripherals and transport

    5.2.11.1 hip conveyor

    Use hoist to handle

    Chip conveyor is in a state of operational readiness upon arrival.

    1.annular sling;           2.hook;            3.eye bolt

    Hoisting rope shall not be bended or twisted. Non-contact trend of hoisting rope and annular sling shall be noted when they don’t intervene each other.

    No responsibility for property damage and personnel injury

    our company does not take responsibility for consequence caused by not using the specified hoisting and auxiliary appliance.

    • Use the pre-specified transport appliance.

    Prerequisites

    • Removepacking materials of chip conveyor.

    Necessary tools/materials

    • Hoist
    • 2 x annular sling
    • 3 x shackle
    • 3 x eye bolt M12

    Operation

    • Release the fixation device for chip conveyor on the transport base.
    • Screw on three eye bolt (3).
    • Hang the annular sling (1) on the hoist hook.
    • Fix annular sling (1) on eye bolt (3) of upper gantry by hook (2).

    Heavy and huge goods

    Slipping, tipping or falling of devices may cause injuries, even death or serious personnel injuries.

    • Use hoist with enough bearing capacity.
    • Use transport rope with enough bearing capacity.
    • Close the transport route in order to keep unauthorized personnel out.
    • Keep a safe distance from the heavy objects being transported in all directions.

    Danger! Suspended weight

    Heavy and huge goods

    Suspended weight may cause injuries, even death or serious personnel injuries.

    • People are not allowed to stay under the suspended weight.
    • Use hoist to lift the chip conveyor and transport it to the placement site of machine tool.
    • Chip conveyor shall be placed next to the placement site of machine tool.

    Use forklift to handle

    Chip conveyor is in a state of operational readiness upon arrival.

    Prerequisites

    • Remove packing materials of chip conveyor.

    Necessary tools/materials

    • Forklift

    Procedures

    • Drive the forklift to the underside of transport base of chip conveyor.

    Heavy and huge goods

    Slipping, tipping or falling of devices may cause injuries, even death or serious personnel injuries.

    • Keep a safe distance from the heavy objects being handled in all directions.
    • Lift the transport base with the chip conveyor by forklift, run to the placement site and put it down there.
    • Chip conveyor shall be placed next to the placement site of machine tool.

    5.2.11.2 Belt filter (Optional)

    Use hoist to transport

    Make sure that the load lifting device only be suspended from the hoisting ring of the coolant lubricant equipment specifically installed for transport purpose.

    Do not violate transport regulations.

    Non-standard transport can inflict economic loss.

    • Collision and damage shall be avoided.
    • Do not use brutal force in transport.
    • Make sure that the water tank of the coolant lubricant is evacuated before the transport of the belt filter.

    No responsibility for property damage or personal injury

    our company does not take responsibility for consequence caused by not using the designated hoisting or auxiliary appliance.

    • The designated transport appliance shall be used.

    Heavy and huge cargo

    Slipping, tipping or falling of devices may cause injuries, even death or serious personnel injuries.

    • Hoist with adequate bearing capacity shall be used.
    • Close the transport route to keep off unauthorized entry.
    • Keep a safe distance with the transported weight in all directions.

    Prerequisites

    • Having removed packing materials of the belt filter.

    Necessary tools/materials

    • Hoist
    • Hook

    Operation

    • Fix the hoisting device to the hosting ring of the belt filter steadily.

    Transported by beam

    Transport damage may occur.

    • When using the hoist to transport, make sure that the hoisting ropes on all suspension points shall be pulled upwards vertically.

    Danger! Heavy cargo

    Heavy and huge cargo

    Hoisted weight may cause dangerous accident.

    • It is absolutely forbidden to enter into the area under the hoisted weight.
    • Transport the belted filter to the placement site.
    • The belted filter shall be placed next to the machine tool.

    Use forklift to transport

    When using the forklift to transport, make sure that the barycenter of the equipment is right in the middle between the two folks.

    Differentiated by specification, the barycenter of the equipment may be not in the middle of the coolant lubricant container.

    Transport belted filter by forklift.

    Transport against rules may cause accident and damage.

    • Collision and damage shall be avoided.
    • Do not operate by brutal force.
    • Make sure that the water tank of the coolant lubricant is evacuated before the transport of the belt filter.

    Prerequisites

    • Having removed the package of the belt filter.

    Necessary tools/materials   

    • Forklift

    Procedures

    • Move the forklift beneath the belted filter carefully.

    Heavy load.

    Possible injury: Slipping, tipping or falling of the machine may cause body injury or death.

    • Keep a safe distance with the transported weight in all directions.
    • Lift the belted filter equipment cautiously, and move it to the installation site and put it down.
    • The belted filter shall be placed on the installation site next to the lathe.

    5.2.11.3 Numerical control indexing system

    Prerequisites

    • Having removed the packing materials of the numerical control index head.

    Necessary tools/materials

    • Hoist
    • 2 x eye bolt
    • Transporting rope

    Procedures

    • Screw the eyebolts into the transporting hole.
    • Thread the transporting rope through the eyebolts.
    • Hang the transporting rope on the hook of the hoist.

    Heavy and huge cargo

    Slipping, tipping or falling of devices may cause injuries, even death or serious personnel injuries.

    • Ensure to use hoist of adequate specification and dimension.
    • Ensure to use transporting rope with adequate bearing capacity.
    • Close the transport route to keep off unauthorized entry.
    • Keep a safe distance with the transported weight in all directions

    Danger! Suspended weight!

    Heavy and huge cargo.

    Suspended weight may cause injuries, even death or serious personnel injuries.

    • It is absolutely forbidden to enter into the area under the hoisted weight.
    • Hoist the numerical control indexing equipment and transport it carefully.
    • Put numerical control indexing equipment on the proper backer plate。
    • The transport of numerical control indexing equipment has been finished.

    5.2.12 Transport machine tool

    5.2.12.1 Preparation of transport

    To transport an installed machine tool to another place, you shall dismantle it and prepare carefully for the transport.

    Dismantlement and transport preparations service can be provided by the after-sales department of our company.

    5.2.12.2 Transport position of the spindle

    The peripheral devices and the power pipeline can only be dismantled by qualified and authorized personnel.

    Prerequisites

    • Machine tool is power on.

    Procedures

    • Dismantle the tool from the machine spindle.
    • For cleaning the machine tool, please refer to Chapter “Maintenance”.
    • Operate the machine tool spindle to the following position：
    • The spindle shall be on the transport position.

    X-axis

    108

    Y- axis

    175

    Z- axis

    150

    5.2.12.3 Cut off electrical connection

    Dismantle the power line of pre-isolation transformer when the transformer is connected.

    Prerequisites

    • The axis is on the transport position.
    • The processing room door is open.

    Procedures

    • Cut off the power separate equipment.

    Warning! Dangerous voltage！

    High voltage still exists even the power separate equipment is cut off.

    Electric shock may cause injuries, even death or serious personnel injuries.

    • Only qualified and authorized personnel can operate these procedures.
    • Preferentially abide by local rules and regulations.
    • Separate the power line and connecting line to the electrical control cabinet with the workshop power.
    • The electrical wiring has been dismantled.

    5.2.12.4 Apply rust-proof protective layer

    • Apply appropriate rust-proof protective layer above all the bare part of the machine tool.

    5.2.12.5 Dismantle control console

    Rotating arm

    Prerequisites

    • The transport base has been covered with bubbled plastic film.

    Necessary tools/materials

    • Installing

    Procedures

    • Dismantle the protective cover of the white cable on the rotating arm (1).

    No extra cable wiring.

    Break or other damage of the cable is dangerous.

    • The cable shall not be in a tight condition with enough length when carrying the control console from the rotating arm.
    • Loosen the cable from the fixed clamp of the rotating arm.
    • Carry the operation control panel upright from rotating arm (1).
    • Settle the control console on the transport base and fix it with proper bandage.
    • Lean the rotating arm (1) against the door of the processing area and fix it with proper bandage.
    • The control console has been dismantled.

    5.2.12.6 Install transporting protective equipment

    Front door of the processing area

    safety fixing angle iron

    The protective angle iron on the above front fender apron fixes the opened processing area door onto the fender apron.

    Prerequisites

    • The processing area door has been closed.

    Necessary tools/materials

    • Safety fixing angle iron
    • Safety screw

    Procedures

    • Install the safety fixing angle iron (1).
    • Press the safety fixing angle iron (1), and tighten the clamping screw.
    • Install the transporting protective equipment of the processing area front door. 

    Side front door of the processing area

    Safety fender apron

    The protective steel plate on the above front fender apron fixes the opened processing area door onto the fender apron.

    Prerequisites

    • The processing area door has been closed.

    Necessary tools/materials

    • Safety fender apron
    • Clamping screw

    Procedures

    • Install the safety fender apron (1).
    • Press the fender apron (1), and tighten the clamping screw.
    • Install the transporting protective equipment of the processing area side front door. 

    Side back door of the processing area

    1.Safety fixing angle iron

    The protective angle iron on the above front fender apron fixes the opened processing area door onto the fender apron.

    Prerequisites

    • The processing area door has been closed.

    Necessary tools/materials

    • Safety fixing angle iron
    • Clamping screw

    Procedures

    • Install the safety fixing angle iron (1).
    • Press the safety fixing angle iron (1), and tighten the clamping screw.
    • Install the transporting protective equipment of the processing area back door. 

    Door inside of the processing area

    Fixing angle iron

    The protective angle iron inside the machine tool fixes the opened processing area door.

    Prerequisites

    • The processing area door has been closed.

    Necessary tools/materials

    • Safety fixing angle iron
    • Clamping screw

    Procedures

    • Install the safety fixing angle iron (1).
    • Press the safety fixing angle iron (1), and tighten the clamping screw.
    • Install the transporting protective equipment of the processing area inside door. 

    X-axis

    Safety fixing angle iron

    The two protective angle iron on the back of the machine tool fix the X-axis on the machine tool bed.

    Necessary tools/materials

    • Safety fixing angle iron
    • Clamping screw

    Procedures

    • Install the safety fixing angle iron (1).
    • Press the safety fixing angle iron (1), and tighten the clamping screw.
    • Transporting protective equipment has been equipped with X-axis.

     Y-axis

    The safety fixing angle iron on the left of the Y-axis slide base fixes Y-axis and X-axis together.

    Necessary tools/materials

    • Safety fixing angle iron
    • Clamping screw

    Procedures

    • Install the safety fixing angle iron (1).
    • Press the safety fixing angle iron (1), and tighten the clamping screw.
    • Transporting protective equipment has been equipped with Y-axis.

    Z-axis

     Z-axis will move entirely backwards. 

    Prerequisites

    • The axis is on the transporting position.

    Procedures

    • Z-axis is fixed by motor.
    • Z-axis is on the transporting position.

    X-axis armour protection 

    Protective materials

    Safety elements fix the armour to protect its moving.

    Necessary tools/materials

    • Protective material
    • Guide bar

    Procedures

    • Install the guide bar that is used with bellows.
    • Protect the armour and apply protective materials.
    • Please keep the protective material in proper storage.
    • Install the protective material that is used with bellows.

    5.2.12.7  Dismantle the peripheral device

    Dismantle the coolant lubricant water tank

    The peripheral device and all power pipelines can only be dismantled by qualified and authorized personnel.

    Recycle and dispose wasted coolant lubricant in accordance with the local environmental regulations.

    Prerequisites

    • The power line and connection to the electric control cabinet have been cut off.

    Necessary tools/materials

    • Cleaning cloth
    • Installation tools

    Operations

    • Cut off the electrical wiring with the machine tool.
    • Pump out the coolant lubricant.
    • Dismantle conveying hose.
    • Screw the adjusting screw to the parallel position.
    • Pull the coolant lubricant water tank forward from the machine tool.
    • Clean the coolant lubricant water tank.
    • The coolant lubricant water tank has been dismantled.

    Dismantle chip conveyor

    The peripheral device and all power pipelines can only be dismantled by qualified and authorized personnel.

    Recycle and dispose wasted coolant lubricant in accordance with the local environmental regulations.

    Prerequisites

    • Cut off the power line and mechanical connection to the electric control cabinet.

    Necessary tools/materials

    • Cleaning cloth
    • Installation tools

    Operation

    • Cut off the electrical wiring with the machine tool.
    • Pump out the coolant lubricant.
    • Dismantle conveying hose.
    • Screw the adjusting screw to the parallel position.
    • Pull the chip conveyor forward from the machine tool.
    • Clean the chip conveyor.
    • The chip conveyor has been dismantled.

    Dismantle the belt filter

    All the power pipeline, wiring and peripheral device of the machine tool can only be dismantled by qualified and authorized personnel.

    Recycle and dispose wasted coolant lubricant in accordance with the local environmental regulations.

    Prerequisites

    • The power line and the connecting wiring of the control cabinet have been cut off.

    Necessary tools/materials

    • Cleaning cloth

    Procedures

    • Turn the power-separate device on the belt filter to “0”.
    • Cut off the electrical connection between the machine tool and the belt filter.
    • Pump out the coolant lubricant.
    • Transport connecting wiring and accessories.
    • Identify and dismantle conveying hose that connects the machine tool.
    • Clean the belt filter.
    • The belt filter has been dismantled.

    Dismantle the numerical control index head

    The peripheral device and the power pipeline can only be dismantled by qualified and authorized personnel.

    The oil gas pipeline and Pneumatic pipeline is only allowed to be dismantled when no pressure presents in the pipeline.

    Prerequisites

    • The power line and connection to the electrical control cabinet have been cut off.
    • The power of machine tool has been cut off and the machine tool been locked with a padlock.

    Necessary tools/materials

    • Cleaning cloth
    • Installation tools

    Operation

    • Pull up the control signal and feeding motor plug from the workbench.
    • Dismantle the compressed air and hydraulic pipe connector.
    • Dismantle the four T-bolts on the workbench.
    • Clean the numerical control index head
    • The numerical control index head has been dismantled and can be lifted from the workbench with a hoist.

    5.2.12.8 The transporting equipment of tool magazine installed with 40 tools

    1.annular sling；2.shackle；3.eye bolt；4. measuring system

    Do not damage the measuring system (4) when installing the annular sling (3).

    Prerequisites

    • Transport preparation has been finished.
    • Transporting safety protection has been equipped.

    Procedures

    • Screw the eye bolt (3) on the machine tool pillar.
    • Fix the annular sling (1) and shackle (2) on the eye bolt (3).

    Danger! Suspended weight!

    Non-standard use of transport suspension devices.

    Falling of the machine tool may cause serious personal injury or death.

    • Suspend the suspension device correctly and check its firmness.
    • Twist or knot is not allowed on the annular sling.
    • Hang the annular sling (1) on the hoist hook, drooping the two rope rings.
    • Use the annular sling (1) to put the hoist above the machine tool.
    • Use the shackle (2) to fix the annular sling (1) on the eye bolt(3).
    • Transporting suspension devices have been equipped.

    5.2.12.9 Transport and shipments

    Safety

    Use proper packing materials for the machine tool transport by road or sea.

    • Please comply with transport precautions, safety precautions, accident preventive regulations and other local regulations!
    • Entrust a proper transport company.
    • Pay attention to the transport weight and size (See Chapter “Transport Weight” and “Transport Size”).
    • Apart from the net weight of the machine tool, make allowance for the weight of random accessories and package.

    Prepare well for transport

    Heavy and huge cargo.

    Slipping, tipping and falling may cause accidents.

    • Adopt transporting protective measures as mentioned above.

    Prerequisites

    • Prepare for the transport of machine tool.

    Operation

    • Settle the machine tool on a large enough and firm transport base.
    • Fix machine tool bed and transport base with bolts.
    • Support and fix the processing room, machine tool protective cover, electrical control cabinet and control console with planks.
    • Take anti-slip measures with accessories in loose packing.
    • If required, pack the transport base into a box.
    • Pack according to the transport precautions.
    • The machine tool is ready for transport.

    Danger! Suspended weight！

    Machine tool may tip or fall during transport.

    Life risk

    • Use hoisting equipment with adequate bearing capacity, such as hoist, hoisting rope and forklift, etc.
    • It is absolutely forbidden to stay under the suspended weight.
    • Close the transport route to keep off unauthorized entry.

    5.3 Placement

    5.3.1 Basics

    5.3.1.1 First installation

    First installation only can be carried out by the authorized personnel of the machine tool manufacturer. Otherwise, our company take no responsible for any possible damage or functional fault.

    5.3.1.2Customer’s obligation

    Customer is responsible for the following preparations:

    • Prepare for the site to place the lathe.
    • Ensure to provide：
      • Power, light, industrial water, compressed air and telephone.
    • Transport from the area of our company to the site of placement.
    • Place the lathe.
    • Connect necessary power source.
    • Clean and degrease the lathe.
    • Provide required coolant lubricant.

    5.3.2 Place the machine tool

    Our company will put the individually packed placement components of machine tool on the machine tool transport base when delivering it.

    Ensure to locate the placement components correctly. See Chapter “Set Statistics”

    Reminder!

    Only placement components can be used to place the machine tool on the site of placement.

     Only hoist can be used to put the machine tool on the oil sump 

    1. nut            2.shim            3. spherical gasket            4. subulate backer plate
    5. machine tool footstand            6. Screw            7. spherical gasket
    8.subulate backer plate            9. placement components

    5.3.2.1 Option 1

    Please follow the order of the placement components as illustrated.

    Prerequisites

    • The machine tool is set near the site of placement.
    • Placement components are uninstalled.

    Necessary tools/materials

    • Hoist
    • Two battens (Thickness: about 200mm)
    • Placement components

    Procedures

    • Hoist the machine tool.
    • Put down the battens and then the machine tool for the second time.
    • Insert the placement components (9), the screw (6), the subulate backer plate (8) and the spherical gasket (7) through the bottom of the machine tool footstand (5).
    • Insert the subulate backer plate (4) and the spherical gasket (3) on the machine tool footstand by screw (6).
    • Sheathe the shim (2) and fix it with nut (1).
    • Hoist the machine tool and place it on the workshop floor carefully.
    • Loosen the nut (1).
    • The machine tool has been placed.

    5.3.2.2 Option 2

    Please follow the order of the placement components as illustrated.

    Prerequisites

    • The machine tool is set near the site of placement.
    • Placement components are uninstalled.

    Necessary tools/materials

    • Hoist
    • Placement components

    Procedures

    • Lift the machine tool with a hoist.
    • Align placement components (9), screw (6), subulate backer plate (8) and spherical gasket (7) according to the placement components layout.
    • Place the machine tool on the placement components.
    • Screw the subulate backer plate (4), spherical gasket (3), shim (2) and nut (1),but not in a tighten condition.
    • The machine tool has been placed.

    5.3.3  Set the machine tool with mechanical arm system

    Our company will put the individually packed machine tool set device on the machine tool transport base when delivering.

    Ensure to locate the set device correctly. See Chapter “Place Statistics”

    Only placement components can be used to place the machine tool on the site of placement.

    1. machine tool            2. placement components          3. Base          
    4. anchor bolt connecting pipe          5. anchor bolt pole          6. subulate backer plate
    7.spherical gasket          8. shim          9.nut

    5.3.3.1 Fix the machine tool on the ground

    Install the anchor bolt

    Find anchor bolt drill diagram on the groundwork drawing.

    Avoid the damage of rebar when drilling on the reinforced concrete floor. Drill perpendicular to the anchor bolt basic surface with a percussion drill.

    Necessary tools/materials

    • Percussion drill
    • Electric hammer drill with a diameter of Ø18
    • Anchor bolt connecting pipe HVU
    • Anchor bolt pole with external thread
    • Vacuum cleaner or blower

    Procedures

    • Draw the position of anchor bolt pole by groundwork drawing
    • The dill depth is 180mm. 
    • Use vacuum cleaner or blower to clean the hole.
    • Push the anchor bolt connecting pipe point into the hole.
    • Use percussion drill to push anchor bolt in to the hole
    • Leave the anchor bolt pole harden for 1 hour
    • The anchor bolt pole has been placed.
    • Put the machine tool on the placement components.

    Please follow the order of the placement components as illustrated.

    Prerequisites

    • The machine tool is set near the site of placement.
    • Placement components are uninstalled on the ground.

    Necessary tools/materials

    • Hoist
    • Set device

    Procedures

    • Lift the machine tool with a hoist.
    • Align the placement components on the ground by using a fixed anchor bolt pole (5) according to the placement components position draw.
    • The machine tool is placed on the placement components.
    • Screw the subulate backer plate (6), spherical gasket (7), shim (8) and nut (9), but not in a tight condition.
    • The machine tool is fixed on the ground. Please follow the order of the placement components as illustrated.

    5.3.4 The machine tool alignment

    5.3.4.1 Preparation

    Keep the measuring surface of the levelling instrument clean.

    Loosen the clamp nut before alignment.

    Ensure the machine tool has been placed for 24 hours in a constant temperature before alignment.

    Prerequisites

    • The machine tool has been placed.
    • The machine tool has reached a balance with the environment in temperature.

    Necessary tools/materials

    • Leveling instrument, with reading accuracy of 0.02/1 mm/m.
    • Gradiograph, with reading accuracy of 0.005/1 mm/m.

    Operation

    • Clean the surface of levelling instrument.
    • Lay the leveling instrument parallel with the longitudinal axis and lateral axis on the workbench or lean it on the spindle box.
    • After putting the leveling instrument on the surface for measurement, give it a little push back and forth.
    • Check if there is abrupt change in number, keep parallel with the longitudinal axis and lateral axis and take an average number.
    • Preparation for the placement of the machine tool has been finished.

    5.3.5 Dismantle transporting protective materials

    The operational move can get stuck by the transporting safety protective materials.

    Possible damage of the machine tool.

    • Dismantle all the transporting safety protective materials before adjustment and production.

    Please refer to Chapter “Install Transporting Safety Protective materials” on dismantling transporting safety protective materials.

    Dismantle by the inversed steps of the installation.

    5.3.6 Clean the rust-proof protective layer

    All the bare metal parts of the machine tool and peripheral equipment is applied with rust-proof protective materials to avoid rust during transport.

    Please use oil or grease as centralization lubrication.

    Necessary tools/materials

    • Cleaning cloth
    • Kerosene
    • Oil or Grease

    Operation

    Corrosive cleaner

    Damage the guide rail and vanished surface.

    • Clean the machine tool with kerosene and cleaning clothe shed no fiber only.
    • Clean up the rust-proof agent of the brake disc, the brake piston and the bare component of the machine tool, such as guide rail, stop dog, bolt and clamping surface.
    • Apply proper lubricant on the bare part of the machine tool.
    • The rust-proof protective layer has been cleaned up.

    5.3.7 Electrical connection

    5.3.7.1 Power supply requirement

    The power supply of the machine tool shall follow each requirement of the European Standard EN 50160 on “Voltage Characteristics of Electricity Supplied by Public Distribution Networks”. In electrical installations, please follow the European Standard EN 60 204, Part 1, Chapter 6.3.3 “Protection on Automatic Disconnection of Supply” and also see IEC 364-4-41 (DIN 57 100, VDE 0100, Part 410).

    • The machine tool is not allowed to connect to the power supply with FI- Leakage-Current Interrupters. Please refer to the European Standard EN50178, Chapter 5.3.2.3.
    • Connecting wire must be fixed, because the leakage current on EMV (Electromagnetic Volume) measure is greater than 3.5 mA AC.
    • Copper conductor with cross section of at least 10 mm2 Cu shall be used as Protective wiring, which is also suitable for the special equipment of direct connection with customer’s power instead of through machine tool.

    Or

    • Monitor the protective wiring by equipment with automatic disconnection of supply function of electronic components in malfunction.

    or

    • Keep the electrical paralleled with the protective wire and layout the second wire through the separate block terminal. And the second wire shall accord with material of (HD) 384.5.54 S1 (German Standard DIN VDE, Part 0100540) Chapter 543 on “Protective Requirement of Protective Wiring”.

    5.3.7.2 The whole set of equipment with a pre-posed isolation transformer

    Warning! Dangerous Voltage!

    Electric shock may cause accidents and result in serious personal injury or death.

    • Only qualified (with electrician license) and authorized personnel is allowed to conduct electrical connection.
    • Please comply with the local regulation and rules preferentially.
    • Isolate power wire and adopt safety measures to prevent power-on.

    Prerequisites

    • Cut off the customer’s on-the-spot power.
    • The power isolation equipment of the electrical control cabinet has been cut off.

    Procedures

    Turn on the pre-posed isolation transformer. 

    Do not damage earthing wire.

    • Fix the power cable of the machine tool with inlet thread and pull the cable to the pre-posed isolation transformer.
    • Connect the earthing protective wire PE with the yellow green terminal, and connect three-phase firing wire L1, L2 and L3 to the connecting terminal strip of the pre-posed isolation transformer.
    • Pull the wire from the output terminal (secondary) of the pre-posed isolation transformer to the machine tool.
    • Connect the three-phase firing wire L1, L2, L3, null line(N) and earthing protective wire to the terminal of the pre-posed isolation transformer.
    • The earthing protective wire shall be connected with the customer’s benchmark earthing (PE).

    It applies to any form of electric power.

    • Fix the power cable of the machine tool with inlet thread and pull the cable to the pre-posed isolation transformer.
    • Fix the power cable with inlet thread and pull the cable to the pre-posed isolation transformer by tension reductive equipment.
    • Connect the three-phase firing wire L1, L2, L3 to the connecting terminal strip of the electrical control cabinet of the machine tool.

    • Please refer to the electrical connection diagram.
    • Null line and grounding protective wire are not connected.
    • Power isolation equipment is not on.
    • Turn on the customer’s on-the-spot power.
    • Check the costumer’s power voltage of the power firing wire L1, L2, L3, L3 and the corresponding null line and earthing protective wire. The voltage of L1-N, L2-N, L3-N, L1-PE, L2-PE and L3-PE must be 230V±10%.

    If no voltage is detected, the installation of customer’s power shall be checked.

    • Cut off the customer’s on-the-spot power.
    • Connect the null line N to the blue connecting terminal on the terminal strip, and connect the protective wire (PE) to the green connecting terminal.
    • Turn on the main switch of the customer’s power distribution cabinet and turn on the power of the machine tool.
    • Start a numerical control program and double check the inlet terminal voltage of the power.
    • The machine tool has been connected correctly.

    5.3.7.3 The machine tool with the pre-posed isolation transformer

    The wiring connection between the over-current protective device (main fuse) and the discrete pre-posed transformer cable depend on the customer’s operating voltage. Set relevant short circuit protection by the customer on the input side of the pre-posed isolation transformer.

    Cable used to connect the pre-posed transformer with the machine tool is in the scope of supply of our company.

    Please conduct the electrical wiring of the machine tool in accordance with our pre-regulation. Make sure that there is fuse on the input and output side of the transformer.

    5.3.7.4 Overall wiring without the pre-posed isolation transformer

    Warning! Dangerous voltage！

    Electric shock may cause life risk.

    • Only authorized professional electrician personnel can operate electrical wiring.
    • Isolate power wire the adopt safety measures to prevent power on.

    Prerequisites

    • Cut off the customer’s on-the-spot power.
    • Power isolation equipment of the electrical control cabinet has been cut off.

    Wiring

    • Fix the power cable with inlet thread and pull the cable to the pre-posed isolation transformer by the tension reductive equipment.
    • Connect the three-phase firing wire L1, L2, L3 to the connecting terminal strip of the electrical control cabinet of the machine tool.

    • Please refer to the electrical wiring diagram.
    • Null line and grounding protective wire are not connected.
    • Power isolation equipment is not on.
      • Turn on the customer’s on-the-spot power.
      • Check the costumer’s power voltage of the power firing wire L1, L2, L3, L3 and the corresponding null line and grounding protective wire.
      • The voltage of L1-N, L2-N, L3-N, L1-PE, L2-PE and L3-PE must be 230V±10%.

    If no voltage is detected, the installation of customer’s power shall be checked.

    The machine tool is possible to be damaged in an incorrect installation.

    Otherwise, it may damage components and come up with dangerous touch voltage when connecting the machine tool.

    • Comply with the professional requirement in installation.
    • Company conducting the connection shall take responsibility for the damage caused by incorrect installation.
      • Cut off the customer’s on-the-spot power.
      • Connect the null line N to the blue connecting terminal on the terminal strip, and connect the protective wire (PE) to the green connecting terminal.
      • Turn on the main switch of the customer’s power distribution cabinet and turn on the power of the machine tool.
      • Start a numerical control program and double check the inlet terminal voltage of the power.

    The voltage of L1-N, L2-N, L3-N, L1-PE, L2-PE and L3-PE must be 230V±10%.

    • The machine tool has been connected correctly.

    5.3.7.5 Data interface

    • When connecting data interface (such as the ethernet), please lead the data cable to the numerical control system interface in the shortest route (similar to the layout of data cable of the measuring system cable). The cable going by the NC-axis actuator in the electrical control cabinet is forbidden. (EMV-electromagnetic interference problem).
    • Please keep the electric potential balance between the machine tool and PC, or there might be multifunction in data transfer.

    5.3.7.6 Checklist

    Electrical connection checklist

    Please check if the connection is correct before turning on the lathe.

     

    Check all the items on the list and sign on it.

    • In the required reactive power, keep the network voltage stable in the range of 360VAC to 440VAC.
    • Make sure that there is correct network voltage or relevant voltage regulation on the pre-posed isolation transformer.
    • Make sure that the power wire and fuse have correct design according to the power consumption and the effective regulation.
    • The wire has been laid according to effective regulations and damage-proof measures have been taken on it.
    • Power wire (connecting cable) and earthing wire have been correctly connected to pre-posed isolation transformer and the wiring board X1 in the electrical control cabinet as required.
    • All the connecting plug and cable are plugged in and locked in equipment such as the chip conveyor and belt filter.
    • Cable sleeving and retainer ring have been installed.
    • Keep all the cable (even moving on the spindle saddle) from abrasion, bending, squeezing and avulsion damage.
    • There is correct voltage, frequency and right-handed magnet field on the wiring board X1.
    • The rotation direction of the equipment such as the coolant lubricant pump and blower is in conformity with the arrows on each surface.
    • The null line has been connected to the customer’s power correctly.
    • If pre-posed isolation transformer is required, has it been connected correctly?

    5.3.8 Pneumatic connection

     Partial enlarged picture A

    1. Connection of pneumatic system

    Compressed air is forbidden to connect at this stage.

    High atmospheric pressure

    Possible danger for personal injury.

    • Only authorized professionals can conduct pneumatic connection.。
    • Adjust compressed air pressure to zero before connecting pneumatic circuit.

    Procedures

    • Insert the hosepipe into the connecting sleeving.
    • The pneumatic system has been connected.

    5.3.9 Placement, connection and operation of peripheral equipment

    5.3.9.1 Chip conveyor

    1 . Power isolation device 

    Installation

    The chip conveyor is allowed to be fixed on the machine tool after the adjustment of the machine tool.

    Restore the transporting equipment in a clean and dry room for later use. Before reuse, please follow the illustrations on the circular ring.

    Prerequisites

    • The machine tool has been aligned.
    • The pallet storage device is at the site of placement.
    • Open the package of the chip conveyor and clean it.

    Necessary tools/materials

    • Solid wrench
    • Hex wrench

    Procedures

    • Remove the circular ring and transport-used ring.
    • Push the chip conveyor from front into the prescribed hole.
    • Loosen the clamping nut of the adjusting bolt.
    • Use the adjusting screw to adjust the chip conveyor, that is to seal the machine tool base with a sealing strip.
    • Use locknut to lock when adjust the bolt.
    • Connect the conveying hose to the coolant lubricant pump.
    • The chip conveyor is closed.

    Electrical wiring

    Prerequisites

    • The chip conveyor is turned off.
    • Power separate device is off the locked with a padlock.

    Procedures

    • Turn the switch of chip conveyor power separate device (1) to “0”.
    • Plug the connecting wire into the machine tool socket. Please refer to Chapter “Medium Supply”.
    • Electrical wiring has been finished.

    Debugging and putting into production

    Reminder！

    Fill the chip conveyor with the coolant lubricant, please refer to “Chip Conveyor” in the Chapter of Maintenance.

    For other attentions on the coolant lubricant, please refer to the Chapter “Coolant Lubricant”.

    Prerequisites

    • Electrical wiring of chip conveyor has been finished.

    Procedures

    • Turn the switch of chip conveyor power separate device (1) to “ I”.
    • Check if all the hose coupler is sealed and tighten the hose rand if necessary.
    • Debugging and putting into production has been finished.

    Debugging and putting into production of 600 Liter/980 Liter Belt Filter

    Fill the chip conveyor with coolant lubricant, please refer to “Chip Conveyor” in the Chapter of Maintenance.

    For other attentions on coolant lubricant, please refer to the Chapter “Coolant Lubricant”.

    Prerequisites

    • Electrical wiring of chip conveyor has been finished.

    Procedures

    • Turn the switch of chip conveyor power separate device (1) to “I”.
    • Fill the chip conveyor with the coolant lubricant in the processing room.
    • Check if all the hose coupler is sealed and tighten the hose rand if necessary.
    • Check the setting of level switch and correct if necessary, please refer to “Chip Conveyor” in the Chapter of Maintenance.
    • The chip conveyor is ready for operation.

    5.3.9.2 Belt filter

    Belt filter of 600 Liter

    1. main switch； 2.socket

    Wiring and block terminal have the same identification number (BMK). Please ensure the integral layout while connecting.

    Placement

    Prerequisites

    • The machine tool has been aligned and connected to power.
    • Remove all the package of belt filter with the accessories and check if there is transport damage.
    • Cleaned the belt filter.
    • Turn off the power separate device and lock it with a padlock in case of accident power-on.

    Necessary tools/materials

    • Installation tools

    Operation

    • Place the belt filter next to the machine tool and align it, please refer to Chapter“Placement Plan”.
    • Connect the hosepipe of the machine tool to the belt filter.
    • The belt filter has been installed.

    Electrical connection

    Prerequisites

    • The belt filter has been installed.
    • Cut off the power of the machine tool on the power separate device, and lock the power separation device with a padlock.

    Necessary tools/materials

    • Installation tool
    • Turn the range switch of the coolant lubricant to “0” position.
    • Plug the connecting cable into the socket (2) of the belt filter.
    • Plug the connecting cable into the socket of the machine tool. Please refer to the Chapter “Medium Supply”.
    • The electrical wiring has been finished.

    Debugging and putting into production

    Fill the belt filter with tehcoolant lubricant, and please refer to “Chip Conveyor” and “Belt Filter” in the Chapter of Maintenance.

    For other attentions on the coolant lubricant, please refer to the Chapter of “Coolant Lubricant”.

    Prerequisites

    • Electrical connection of belt filter is finished.

    Procedures

    • Turn the switch of chip conveyor power separation device (1) to “I”.
    • Fill the chip conveyor with coolant lubricant in the processing room.
    • Check if all the hose coupler is sealed and tighten the hose rand if necessary.
    • Debugging and putting into production have been conducted.

    5.3.9.3 Numerical control indexing Device

    Placement

    Prerequisites

    • The machine tool has been aligned and connected the power of the workshop.
    • The connecting surface of the numerical control index head bolt has been cleaned up.
    • The power of the machine tool has been cut off and the machine tool has been locked with a padlock.

    Necessary tools/materials

    • Installation tool
    • Four T-groove bolts

    Procedures

    • Lay the numerical control index head carefully on the workbench.
    • The flat key of the numerical control index head shall engage in the clamping groove of the workbench.
    • Screw the numerical control index head on the workbench tightly with the four T-groove bolts.
    • Remove the ring bolt for transport use.
    • If necessary, put tailstock on the workbench and fix it with the four T-groove bolts.
    • The numerical control index head has been installed.

    Connection

    The oil gas pipeline and pneumatic pipeline are only allowed to be connected when there is no pressure in the pipeline. 

    Prerequisites

    • The numerical control index head has been installed.
    • The power of the machine tool has been cut off and the machine tool has been locked with a padlock.

    Procedures

    Non-standard connecting wire layout.

    Malfunction. Damage on the connecting wire.

    • Twisting of the connecting wire and cross arrangement of wire is forbidden.
    • Plug controlling signal and feed motor into the back of the workbench.
    • Plug compressed air and hydraulic pressure connection into the back of the workbench.
    • The numerical control index head has been connected.

    5.3.10 Final check

    After the machine tool is installed, a final check shall be conducted.

    Pay attention to and mark all the items.

    Check all the liquid level of all the operational materials. Necessary illustration can be found in the section “First filling” (Please refer to “Maintenance and Lubricant”).

    Final checklist

    • Sufficient bearing capacity of the ground.
    • Keep all the required safety distance and working area according to the current rules.
    • Place and install the machine tool reliably according to the current laws and regulations.
    • Check the completeness of the electrical connecting wire, notice and mark all the items on the electrical connection checklist.
    • Dismantle and take away all the transport safety protection, equipment, installation tools and accessories.
    • All the protective device, water-splashing proof device have been installed.
    • The coolant lubricant tank has been installed and the coolant lubricant pipe has been connected.
    • Keep all the monitoring control switch, protective switch and safety switch function well.
    • Ensure there is sufficient liquid level in the centralized lubricant pump station, oil hydraulic pump, electric principal axis cooling and coolant lubricant device.
    • Ensure there is reliable protection against cutting, bending, squeezing, and tearing of all the cables, even when moving on the axis sliding board or on the sliding boarding.
    • The water-splashing proof device and coolant lubricant tank shall be sealed.
    • Screw up the connecting terminal screw, fixing screw and connecting screw tight.
    • Technical material is complete. (Safety precautions, Machine tool, Numerical control system Manual, circuit diagram etc.)

    Read technical materials (Safety precautions, Machine tool, and Numerical control system manual) carefully.