Pre Delivery & Installation Guide GX 480 GX 480 DT GX 480 APC GX 480 DT APC GX 600 GX 800 GX 1000 Document number 1902494 Issue B November 2006 Page 1
CONTENTS Page INTRODUCTION 3 MACHINE DELIVERY 4 INSTALLATION 5 MACHINE FOOTPRINT 6 MACHINE GROSS WEIGHT 9 LIFTING & MOVING THE MACHINE 10 GROUNDING THE MACHINE 12 POWER SUPPLY REQUIREMENTS 13 ELECTRICAL POWER CONNECTION 14 ELECTRICAL CABINET 14 PNEUMATIC CONNECTION 14 REMOVING THE SHIPPING BRACKETS 15 PREPARING THE COOLANT SYSTEM 18 COOLANT TANK CAPACITY 19 INSTALLING THE CHIP CONVEYOR (OPTION) 20 MACHINE DIMENSIONS 20 APC PALLET DIMENSIONS 31 TOOLING SYSTEM 32 TRAINING 32 Page 2
INTRODUCTION The contents of this document have been prepared to help you ensure the best possible installation. IMPORTANT :- Nothing in this document or in accompanying literature, drawings, charts or letters, implies the existence of a contract between yourself and Hardinge. The information given is believed to be accurate but you are reminded that no claim for damage, delay or cost incurred from the use of this information will be accepted by Hardinge. If there are items upon which you are unsure, or questions you may have which are not covered within the document, please do not hesitate to contact us. The telephone number is (0116) 286 9900. Ask for the Machine Order Department or contact your local distributor. Your co-operation in making two telephone calls is sought immediately after installation is completed, so that commissioning of the machine can be concluded without delay, and to arrange for your training. The telephone numbers and contacts are:- For commissioning: ask for the Service Department (0116) 286 9900 For training: ask for the Application Department (0116) 286 9900 You may of course have made alternative arrangements for all or part of the delivery, installation, commissioning and training. If so, we hope that you will still find the information in this document of value. To assist your planning for the future maintenance of your machine, we have included a chart indicating oils and greases required, together with the coolant system capacity. Thank you for choosing Bridgeport by Hardinge. Should you require additional clarification to ensure the successful installation of your Bridgeport Vertical Machining Centre, please contact:- Hardinge Machine Tools Ltd, Whiteacres, Cambridge Road Whetstone Leicester, LE8 6BD England. Tel: +44 116 286 9900 Fax: +44 116 286 9902 Hardinge Inc. One Hardinge Drive Elmira, New York 14902-1507 USA Tel: +1 607 734 2281 Fax: +1 607 734 6193 Hardinge Taiwan 4 Tzu Chiang 3rd Rd, Nan Tou City, 540 Taiwan Tel: +886-49-2260-536, Ext 104 & 108 or Your Local Distributor. Page 3
MACHINE DELIVERY If you have selected to have your machine delivered by Hardinge there are a number of points upon which we need information. NOTE :- If access is difficult, please advise us whereupon you will be contacted in order that arrangements for a visit from a representative of our haulers can be made. They will decide the most appropriate method of accessing your plant. Please use the following information to assess the suitability of our transport. Do not hesitate to call if in doubt. Telephone number (0116) 286 9900. Ask for the Machine Order Department. The machine will be delivered on a crane lorry by our haulers who are contracted to deliver and off-load at the nearest point of access at your premises, and then install the machine inside your premises. The vehicle specification is as follows:- Overall length including cab (36ft) 11.0m Length of deck (24ft) 7.3m Width of deck (8ft) 2.4m Height of deck (4.5ft) 1.4m Overall height of crane (MIN) 4.1m NOTE :- When operating the vehicle crane, its hydraulic legs will be extended to steady the lift. This will increase the width by an additional (4ft) 1.2m. To determine the total loaded height of the vehicle, check the above information together with the overall dimensions of your machine illustrated in this document. It is in everyone s interest to ensure that the off-loading is completely possible. We do urge you to check carefully and to discuss with us areas of doubt. If on arrival our vehicle is unable to off-load the machine, delays and additional charges could arise. Lifting Equipment As the machine is to be lifted by Fork Truck it is recommended that the minimum capacity be 10,000kg with a minimum tine length of 1,200mm. Page 4
INSTALLATION To assist you the following points should be carefully considered. Check the packing list as soon as you are able to ensure that all items have been delivered. If there are shortages call us on (0116) 286 9900. Ask for the Machine Order Department. The following information is provided for your guidance. 1. Foundation Requirements A solid foundation is required to bear the machine weight. Any friable areas should be made good using recognized building construction techniques. If doubt exists, consult your building architect. Do not locate the machine near equipment that causes vibration. Poor cutting or damage to the control may result from vibration transmitted to the machine. 2. Uncrating (where necessary) Carefully remove the outer casing, internal braces and skids so that the machine is not damaged in any way. Should damage have occurred in transit inform: i) the haulage contractor ii) iii) the railways and/or shippers, or local agent and state the full extent of the damage. Retain all the packing materials until the Insurance Company s assessor has inspected the machine. 3. Leveling Procedure a) Make sure the location of the machine is exactly where you need it to be. Ensure allowance for access for operation, cleaning and maintenance is provided. See the installation dimensional drawing for minimum clearances. See pages 19 ~ 29 for machine outline drawings b) Locate the floor pads which are packed with the associate kit and position them on the floor under each jack bolt. When satisfied lower the machine gently onto the pre-located pads. Ensure jack bolts are screwed down to provide a 15 to 20mm gap from the underside of the base casting to the floor. c) If you use skates then employ the jack bolts with suitable support packing to raise the machine enough to remove the skates and finally set onto the floor pads. Page 5
MACHINE FOOTPRINT GX 600, 800 & 1000 Page 6
GX 480, GX 480 DT Page 7
GX 480 APC, GX 480 DT APC 5 6 3 4 1 2 7 8 NOTE: Dimensions are shown in inches (millimeters) Page 8
Jacking screws (all machines) M30 thread, with 32mm (1.1/4 ) A/F hexagon, and 41mm (1.5/8 ) A/F locknut Machine Number of jacking screws GX 600, 800 & 1000 7 GX 480 & GX 480 DT 6 GX 480 APC & GX480 DT APC 8 MACHINE GROSS WEIGHT (PACKED) (SHIPPING WEIGHT) Machine Model GX 480, GX 480 DT GX 480 APC, GX480 DT APC Standard and High Speed Machines 6,622 lb [3,010 Kg] 8,096 lb [3,680 kg] High Torque Machines GX 600 12,254 lb [5,570 Kg] 12,474 lb [5,670 Kg] GX 800 12,694 lb [5,770 Kg] 12,914 lb [5,870 Kg] GX 1000 13,024 lb [5,920 Kg] 13,244 lb [6,020 Kg] Page 9
LIFTING AND MOVING THE MACHINE (For GX 480 or GX 480 DT) (For GX 600/800/1000) Page 10
Machine Legs Under Table (GX 1000 Machine Shown) Tower Support Legs at Rear of Machine (GX1000 Machine Shown) Tower Support Legs at Rear of Machine (GX 480 Machines Shown) Page 11
GROUNDING THE MACHINE If an earth ground is to be installed, the customer must supply and install the ground rod, ground rod clamp, and ground conductor according to all applicable electrical codes. a) All VMC machines must be grounded in order to protect personel and the machine from electrical hazards. Grounding must be in accordance with the standards for electrical equipment. b) Ideally, the grounding point should be as close as possible to the machine. c) A qualified electrician must carry out the grounding work, otherwise serious injury, death, or accidents involving machine damage could result. d) The machine must be grounded in one of the following ways: 1) Independent grounding 2) Common grounding Regardless of the type of grounding system used, the earth loop impedance of the supply, which connects the machine to ground/earth, must not exceed 1 ohm. Page 12
e) Never ground the machine in the manner shown in the illustration below. No more than one grounding conductor wire can be connected to a single terminal. If the grounding conductors are connected in the manner shown in the illustration above, a faulty connection at one of the terminals could cause grounding current to be fed back to the machine, resulting in serious accidents. NOTE:- We are unable to assist with electrical cable selection as this depends upon your particular site. Your qualified electrical engineer will be able to calculate the correct needs from the power supply requirement chart. Once the electrical and air supplies are provided make the connection to the machine. The delivery dimensional drawing gives details of input locations. POWER SUPPLY REQUIREMENTS Heidenhain Fanuc Siemens Voltage 220V 400V 220V 400V 220V 400V Full load Full load Full load kw kw kw current (amps) current (amps) current (amps) 480 --- --- --- 20 64 36 --- --- --- 480 APC --- --- --- 20 64 36 --- --- --- 600 28 98 53 25 74 43 25 64 43 800 28 98 53 25 74 43 25 64 43 1000 28 98 53 25 74 43 25 64 43 Page 13
ELECTRICAL POWER CONNECTION Consult the local utility supply company to determine exact service and wiring requirements for your area. A qualified electrician must carry out the connection of the mains electrical supply to the machine. ELECTRICAL CABINET Earth (ground) wire connections 3 Phase supply (no neutral required) PNEUMATIC CONNECTION Unit Value Pressure bar > 5.0 Flow rate ( STANDARD m/c) Litres / Min > 453 Flow rate ( high speed spindle) Litres / Min >650 Dew point (at ATM. Pressure) C -17 or lower Note: The air supply must be clean (40micron particulate size) and dry. Do not connect direct to a compressor with a short pipe as water/oil may condense out and cause a potential seizure of the spindle bearings through the air purge circuit. An air drier unit is recommended. The minimum recommended bore size for the air supply pipe is 10mm Page 14
REMOVING THE SHIPPING BRACKETS X and Y Axes Some machines have a separate shipping bracket for the X and Y axes. Both brackets (M & N) are located near the front of the table. Other machines have one shipping bracket, O, centered on the tower at the rear of the table. DO NOT thread any of the screws back into their holes after removing the shipping brackets. Separate X Axis and Y Axis Shipping Brackets One X and Y Axes Shipping Bracket Page 15
Tool Changer Carousel (Tool Magazine) Shipping Bracket Operator Control Panel Operator Control Panel Shipping Bracket and Pendant Thread the screws back into the pendant support and tighten them. Page 16
Pallet Changer (GX 480 APC & GX 480 DT APC) DO NOT thread any of the screws back into their holes after removing the shipping brackets. D Secondary table F APC hinge arm Loosen the clamping bolts (F) and remove the wooden clamp APC hinge arm shipping bracket (D) Page 17
PREPARING THE COOLANT SYSTEM 1. Roll coolant tank S, into the opening under the front of the machining center. 2. Install the coolant hose and tighten the clamps. 3. Pour the coolant directly into the chip pan of the coolant tank. Fill the tank with the approved coolant to the FULL line of the sight gauge. Coolant Tank (For GX 480 or GX 480 DT) s Coolant Tank (For GX 600/800/1000) Page 18
COOLANT TANK CAPACITY Coolant tank capacity GX 480, 100 liters (27 gallons) GX 480 DT GX 600 230 liters (62 gallons) GX 800/1000 360 liters (97 gallons) INSTALLING THE CHIP CONVEYOR (OPTION) 1. Roll the coolant tank out. 2. Lift out the chip trays, chip pan and filters (screens) from the coolant tank. 3. Set the chip conveyor into the coolant tank. 4. Plug one end of the cable into the connector on the chip conveyor. 5. Replace the coolant tank with chip conveyor into the opening. 6. Attach the coolant hose to the coolant tank. 7. Plug the other end of the chip conveyor cable into the connector located on the bottom of the power case. Page 19
7 2 3 6 8 4 5 9 1 AIR MANUALMODEODEHARDINgE AUTOMPUSH MACHINE DIMENSIONS GX 480 and GX 480 DT Machining Center Dimensional Drawings Size GX 480 GX 480 DT A 1575 1575 B 2168 2168 C 2542 2542 D 2047 2071 E 2136 2310 F 1681 ~ 2111 1692 ~ 2122 1893 ~2323(CTS) G 1767 1767 H 488 488 Page 20
GX 600 Machining Center HARDINgE GX 600 Machining Center Front View Page 21
GX 600 Machining Center Top View Page 22
GX 600 Machining Center Right Side View Page 23
GX 800 and GX 1000 Machining Centers HARDINgE GX 800 Machining Centers Front View Page 24
HARDINgE GX 1000 Machining Center Front View Page 25
GX 800 /1000 Machining Centers Top View Page 26
GX 800 /1000 Machining Centers Right Side View Page 27
MANUALMODEAUTOMODEGX 480 APC and GX 480 DT APC Machining Centers GX 480 APC and GX 480 DT APC Machining Center Front View Dimensional drawing Dimension A B C D E F G H GX 480 APC 1645 2644 3003 2197 2286 1831 ~ 2261 2043 ~ 2473 1767 488 (CTS) GX 480 DT APC 1645 2644 3003 2221 2460 1842 ~ 2272 1767 488 Page 28
GX 480 APC and GX 480 DT APC Machining Center Top View Dimensional drawing Dimension A B C D E F G H GX 480 APC 1645 2644 3003 2197 2286 1831 ~ 2261 2043 ~ 2473 1767 488 (CTS) GX 480 DT APC 1645 2644 3003 2221 2460 1842 ~ 2272 1767 488 Page 29
PUSH GX 480 APC and GX 480 DT APC Machining Center Right Side View Dimensional drawing Dimension A B C D E F G H GX 480 APC 1645 2644 3003 2197 2286 1831 ~ 2261 2043 ~ 2473 1767 488 (CTS) GX 480 DT APC 1645 2644 3003 2221 2460 1842 ~ 2272 1767 488 Page 30
APC PALLET DIMENSIONS Page 31
TOOLING SYSTEM Spindle Collet Toolholder Pullstud Dimension, E 40 taper MAS 403 BT-40 MAS 403 BT-40 NV000253606A ISO 7388/1 NV000253604A ANSI B5.50 NV000253604A CAT (5/8 UNC) NV000253607A DIN 69871 DIN 69871-B NV000253610A 34 mm 30 taper MAS 403 BT-30 MAS 403 BT-30 ANSI B5.50 CAT (1/2 UNC) DIN 69871 NV000253606J NV000253604J NV000253607J NV000253610J 28 mm TRAINING Please telephone the Application Department (0116) 286 9900 for details of courses, delegates fees, hotel reservations etc. Your earliest attention to this matter is requested as places on our training courses are limited. Full joining instructions for delegates will be forwarded prior to the course date. Page 32