INSTALLATION MANUAL

The manuals for maintenance are comprised of the following three manuals including this manual: MAINTENANCE MANUAL, MAINTENANCE INFORMATION, and INSTALLATION MANUAL.

Applicable Model
CL-25

Applicable NC Unit
MSC-521

Before starting operation, maintenance, or programming, carefully read the manuals supplied by Mori Seiki, the NC unit manufacturer, and equipment manufacturers so that you fully understand the information they contain. Keep the manuals carefully so that they will not be lost.

IMCECL25B2E

The contents of this manual are subject to change without notice due to improvements to the machine or in order to improve the manual. Consequently, please bear in mind that there may be slight discrepancies between the contents of the manual and the actual machine. Changes to the instruction manual are made in revised editions which are distinguished from each other by updating the instruction manual number. Should you discover any discrepancies between the contents of the manual and the actual machine, or if any part of the manual is unclear, please contact Mori Seiki and clarify these points before using the machine. Mori Seiki will not be liable for any damages occurring as a direct or indirect consequence of using the machine without clarifying these points. All rights reserved: reproduction of this instruction manual in any form, in whole or in part, is not permitted without the written consent of Mori Seiki.

The product shipped to you (the machine and accessory equipment) has been manufactured in accordance with the laws and standards that prevail in the relevant country or region. Consequently it cannot be exported, sold, or relocated, to a destination in a country with different laws or standards. The export of this product is subject to an authorization from the government of the exporting country. Check with the government agency for authorization.

990730

Machine Information
Description of machine : CNC lathe

Model name :

Machine serial No. :

Manufacturing date :

Representative :

Business hours : 8 : 30 17 : 30

SIGNAL WORD DEFINITION

A variety of symbols are used to indicate different types of warning information and advice. Learn the meanings of these symbols and carefully read the explanation to ensure safe operation while using this manual. <Symbols related with warning> The warning information is classified into three categories, DANGER, WARNING, and CAUTION. The following symbols are used to indicate the level of danger.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. The information described in the DANGER frame must be strictly observed.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. The information described in the WARNING frame must be strictly observed. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury damages to the machine. The information described following the caution symbol must be strictly observed. <Other symbols> Indicates the items that must be taken into consideration. Indicates useful guidance relating to operations.

Indicates the page number or manual to be referred to. The number in ( ) indicates the section number.

FOREWORD
This manual describes items to be understood and prepared before the machine is installed. Therefore, users are urged to read this manual before the machine is installed. When the machine is delivered, MORI SEIKIs servicemen install the machine at the specified place. The information in this manual should be referred to when the machine is moved by the user to make sure the necessary procedures and items to be checked are executed.

CONTENTS

1.

ENVIRONMENTAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . P1 1.1 1.2 1.3 1.4 1.5 Ambient Temperature and Humidity . . . . . . . . . . . . . . . . . . . . . . . . P1 Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P1 Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P1 Installation Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P1 Maintenance Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P1

2. 3.

FOUNDATION WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2 PREPARATION FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P6 3.1 3.2 3.3 3.4 3.5 3.6 3.7 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P6 Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P7 Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P8 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P9 Breaker for Shop Power Distribution Board . . . . . . . . . . . . . . . . . P9 Compressed Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P9 Hoses for Supplying Compressed Air . . . . . . . . . . . . . . . . . . . . . . P9

4. 5.

AFTER RECEIVING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P10 CARRYING THE MACHINE TO CHANGE FLOOR LAYOUT . . . . . . . . . P11 5.1 5.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P11 Carrying the Machine by Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . P11

6. 7. 8. 9.

CONNECTING THE POWER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P13 CONNECTION OF COMPRESSED AIR SUPPLY HOSE . . . . . . . . . . . . P14 REMOVING TRANSIT CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P14 LEVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P15

APPENDIX 1 1.1 1.2

INSTALLATION DATA . . . . . . . . . . . . . . . . . . . . . . APPENDIX P1

Transit Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX P1 Hoisting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX P2 POWER CAPACITY TABLE . . . . . . . . . . . . . . . . . APPENDIX P4

APPENDIX 2 2.1 2.2

CL-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX P4 CL-25 with Gantry Type Loader . . . . . . . . . . . . . . . . . . APPENDIX P5 MACHINE NOISE DATA . . . . . . . . . . . . . . . . . . . . APPENDIX P6

APPENDIX 3 3.1 3.2

CL-25A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX P6 CL-25B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX P7

P1

1.

ENVIRONMENTAL REQUIREMENTS
Consider the following requirements when installing the machine.

1.1

Ambient Temperature and Humidity

Install the machine at a site where the ambient temperature remains within the range 10 to 35_C and the humidity does not exceed 75% RH (with no condensation). Failure to comply with these conditions could cause trouble in the electrical systems of the NC unit and peripheral devices and lead to machine faults. Install the machine at a site where neither it nor the NC unit is subject to direct sunlight. Direct sunlight will raise the temperature and cause thermal displacement, adversely affecting machining accuracy.

1.2

Vibration
The machine must not be installed at a site subject to excessive vibration (greater than 4.9 m/s2). Excessive vibration could lead to machine faults and will adversely affect machining accuracy.

1.3

Dust
1

Choose an installation site that is as free as possible from dirt, dust, and mist. If dirt and dust adhere to the cooling fan fitted inside the machine its cooling capability will be impaired and this could lead to machine faults. Install the machine at a site where it will not be reached by chips, water, and oil scattered from other machines. These could cause machine faults.

1.4

Installation Ground
Make sure the floor is strong enough to support the machine. The floor must not be sloped or irregular in any way. Twisting or other distortion of the machine will adversely affect machining accuracy.

1.5

Maintenance Area
When installing the machine, refer to the installation drawing and other instructions and provide sufficient maintenance area to allow the chip conveyor (if featured) and coolant tank to be removed, and the electrical cabinet door to be opened and closed, without difficulty. Also ensure that the doors of the machine and NC unit will be able to be opened without interference. If you do not provide sufficient maintenance area it will not be possible to carry out maintenance work properly and the life of the machine will be shortened. Refer to the INSTALLATION DRAWING in the DRAWINGS published separately.

P2

2.

FOUNDATION WORK
Carry out foundation work in the manner as described below to maintain machine accuracy and its life for a prolonged period. If the ground at the machine installation site does not have sufficient strength, the ground must be reinforced with piles, field piles, etc. Consult a civil engineer to determine the size and the number of piles or field piles needed.

<Materials required for foundation work>

1 Machine

Concrete Strength (28 days after placing concrete): 20.6 MPa Slump value: 8 Ballast: Approx. 25 mm The slump value represents fluidity of concrete: the larger the value, the softer the concrete. Rubble Pieces of hard stone broken into a size of 50 to 150 mm

Chamfer

Reinforcing bar Foundation bolt box 2 Concrete

Concrete subslab 3

Filling ballast Approximately 20% of rubble in weight and approximately 25 mm in diameter.

Ground 5 (0.20) 200 (7.87) dia. 4 20 (0.79) Paper or sponge-like material

Filling ballast

Rubble

Foundation bolt box The foundation box is a hard cardboard tube (made by Fuji Void) called a void on which paper or sponge-like material is fastened with wire or gummed cloth tape to prevent the void from being extracted.

500 (19.69)

110 (4.33)

5 Void 6

Styrofoam (for anti-vibration purpose) Reinforcing bars (13 to 19 mm dia.) (for fixing foundation bolt boxes)

P3

<Procedure>
Styrofoam 100 (3.94) Outline of the foundation

1)

Because 100 mm of styrofoam must adhere to the inside surface of ditch, dig the foundation 100 mm outside of the outline of the foundation. Refer to the FOUNDATION DIAGRAM in the separately supplied DRAWINGS.

Filling ballast

Rubble

2)

Ground Concrete subslab

Place the rubble and compact it with filling ballast (approximately 20% of the rubble weight). The thickness of this layer should be approximately 200 mm.

3)

Pour approximately 100 mm concrete on the layer and cure the concrete for two days in winter and for one day in summer. Mark the foundation outline and the center positions of the foundation bolts on the concrete subslab surface. Line the ditch with 100 mm of styrofoam.

4)
Rubble

Approx. 100 (3.94)

5)

Approx. 200 (7.87)

100 (3.94)

Approx. 200 (7.87)

6)

Place the foundation bolt box at the marked foundation bolt center position and arrange the 13 to 19 mm dia. reinforcing bars in two steps at intervals of approximately 200 mm as illustrated left. Fix the foundation bolt box with the reinforcing bars.

Approx. 200 (7.87)

Foundation bolt box is fixed with reinforcing bars

P4

7)
First concrete

Before pouring the first concrete, clean the concrete subslab surface and then wet the surface. Make sure that there is no water sump on the surface. Pour the first concrete gradually. Compact it with a tamping rod or vibrator so that first concrete can be applied to each corners of the styrofoam.

8)

To be chamfered

9)

Before the first concrete is completely dry, chamfer the area facing the outside of the machine by approximately 100 mm. This allows the secondary concrete layer to be poured easily. The illustrated left shows the foundation base before pouring the secondary concrete layer.

10) Wait for two or three days, then remove the foundation bolt boxes (void and extraction prevention). 11) Cure the first concrete for more than two weeks. Before pouring the secondary concrete, wet the concrete surface for at least 12 hours and remove any puddles of water just before pouring the secondary concrete. This step is very important. It provides better flowing conditions for the secondary concrete layer and allows it to adhere to the concrete surface. In addition, it prevents the concrete from drying too quickly. <Foundation work after machine installation>
Jack bolt Temporary jack bolt

1)

Place the machine on the temporary jack bolts and adjust the level. Clamp the jack bolt plate with the washer and the jack bolt so that the plate is parallel to the ground.

Washer

Jack bolt plate Foundation bolt

P5

2)
Protrusion of secondary concrete

Pour the secondary concrete until the surface is flush with the ground surface. The secondary concrete should protrude a little around the jack bolt plate. Compact secondary concrete well so that it will stick to the back face of the jack bolt plate satisfactorily. Secondary concrete: Use a mixture of concrete and non-shrink agent. A gap may form between the jack bolt plate and the secondary concrete as it begins to cure. If it occurs, rotate the jack bolt until the jack bolt plate and washer contact the secondary concrete.

Jack bolt Nut and washer Lock nut Jack bolt plate

3)

After the secondary concrete has been cured, remove the temporary jack bolts and adjust the machine level again. The curing period will vary based on a variety of conditions.

First concrete

The machine can now be installed as shown left.

500 (19.69)

Foundation bolt Reinforcing bar Secondary concrete

100 (3.94)

Concrete subslab

Ground

200 (7.87)

Rubble

P6

3.

PREPARATION FOR INSTALLATION

For the installation of the machine at customers plant, service technicians of Mori Seiki will visit the customer. To carry out installation smoothly, the following items should be prepared by the customer. The items to be prepared must meet the local regulations and the specifications of the machine to be installed. Preparation Power source Power cable Transformer Grounding cable Breaker for the shop power distribution board Air source* Air connection hoses* *: Refer to 3.1 3.2 3.3 3.4 3.5 3.6 3.7 Check

Depending on the machine specifications, some models do not use pneumatic actuators. For such models, it is not necessary to prepare these items. If it is not known whether or not your machine requires the air source and connection hoses, please consult Mori Seiki.

3.1

Power Requirements
The power source must satisfy the requirements indicated below. Do not install the machine close to major sources of electrical noise, such as electric welders and electrical discharge machines. If the voltage supply is not stable, the machine may malfunction, leading to accidents involving serious injuries or damage to the machine.

Item Voltage (200/220 VAC) Voltage drop Frequency Momentary power failure Voltage impulse

Range +10% and 15% of nominal supply voltage Within 15% of normal voltage for 0.5 seconds. 50/60 Hz "1 Hz Less than 10 msec. Peak value is 200% or less of the effective value (rms value) of the line voltage with pulse duration of 1.5 msec. 7% or less 5% or less

Waveform distortion of AC voltage Imbalance in line voltages

P7

3.2

Power Cables
For power cable, prepare the one which can supply the total power capacity required by the machine. For the power capacity required by the machine, refer to APPENDIX 2, POWER CAPACITY TABLE in this manual. Cable type, wire thickness, and other cable specifications vary according to the insulation class, ambient temperature, temperature correction coefficient, and wire laying conditions. For the selection of the cable, consult the dealer of cables. Examples of cable selection are given below. Conditions: Insulation class . . . . . . . NR/SR Ambient temperature . . 55_C Temperature correction coefficient . . . . . . . . . . . . 0.41 Laying conditions . . . . . . 3 phase wires + grounding wire inside the flexible conduit Wire thickness (mm2) 6 10 16 25 35 50 70 95 120 150 185 240 300 Total electric capacity at 200 V 6.2 8.6 11.6 15.3 19.1 23.8 29.3 35.5 41.4 47.5 54.2 64.3 74.2 Total electric capacity at 380 V 11.8 16.4 22.1 29.0 36.3 45.2 55.8 67.4 78.7 90.3 103.0 122.2 141.1 Conditions: Insulation class . . . . . . . PVC/TPE Ambient temperature . . 55_C Temperature correction coefficient . . . . . . . . . . . . 0.61 Laying conditions . . . . . . 3 phase wires + grounding wire inside the flexible conduit Wire thickness (mm2) 6 10 16 25 35 50 70 95 120 150 185 Total electric capacity at 200 V 9.2 12.8 17.3 22.7 28.5 35.4 43.7 52.8 61.6 70.7 80.7 Total electric capacity at 380 V 17.6 24.4 32.9 43.3 54.1 67.3 83.0 100.3 117.2 134.4 153.3

P8

3.3

Transformer
For the operation of the machine, 200 VAC, 50 Hz power source is required. If available power source differs from this specification, install a transformer between the shop power source and the machine. The adequate transformer is available from Mori Seiki. If the customer selects the necessary transformer, consult the transformer manufacturer and select the one which conforms to the related local regulations. An example of transformer selection is indicated below. Select the transformer according to the available voltage and the total capacity of the machine. For the total capacity of the individual models, refer to APPENDIX 2, POWER CAPACITY TABLE in this manual. <Selection example> Manufacturer: Klckner Moeller
Type No. of phases Allowable electric capacity Input voltage Input current Output voltage Output current Frequency Allowable ambient temperature Protection Insulation Mass Compliance standard Type No. of phases Allowable electric capacity Input voltage Input current Output voltage Output current Frequency Allowable ambient temperature Protection Insulation Mass Compliance standard kg (lb.) 375 (825) kVA V A V A Hz _C 187 65.0 3 3UI 550/470/90/150 kg (lb.) 185 (407) kVA V A V A Hz _C 70.7 39.7/37.6/35.7/34.4/ 32.8 24.5 3 3UI 440/424/80/80 3UI 440/420/80/137 3-phase 34.64 360/380/400/415/436 57/54/51.4/49.6/47.2 3 200 100 50/60 40 IP33 E 250 (550) IEC742, IEC76 3UI 550/470/90/180 3-phase 90.0 360/380/400/415/436 146.5/138.7/131.8/ 127/120.9 3 200 260 50/60 40 IP33 E 450 (990) IEC742, IEC76 520 (1144) 347 3 120 360/380/400/415/ 436/525 3UI 580/620/100/170 320 (704) 156 88.4/83.7/79.6/76.7/ 73 54.0 3UI 550/470/90/120

106/100.6/95.6/92.1/ 87.7

196.4/186/176.7/170/ 162/134.7

P9

3.4

Grounding
For the grounding cable, consult the cable manufacturer to select the one which is sufficient to take earth for the machine to be installed. When selecting the grounding cable, observe the local regulations applied to the area where the machine is installed.

3.5

Breaker for Shop Power Distribution Board

Use a breaker for the AC inverter. If another type of breaker is used for the AC inverter, it will be actuated by the high-frequency leak current specific to AC inverters. Leak current will not affect to operators. Obtain the current consumption of the machine with the following formula: A = P/1.732 V where, A: Input current (A) P: Power capacity (kVA V: Input voltage (V)

1000)

Select the proper circuit breaker by consulting the electric part manufacturer based on the current consumption calculated above. For the total capacity of the individual models, refer to APPENDIX 2, POWER CAPACITY TABLE in this manual.

3.6

Compressed Air Supply

For the compressed air source, select the one which can supply necessary volume of the compressed air at the necessary pressure. For the selection, consult the compressor manufacturer.
1

Use only clean and dry air, 0.7 MPa, 10_C or less. If you use air that is moist or has a high concentration of dust, the pneumatic devices could malfunction, causing damage to the machine. If the compressed air quality is not within the specified range, use line filter, dryer, etc. between the machine and the air source.

Pressure setting of the compressor should be in the range from 0.5 to 1.0 MPa. If the setting is higher than 1.0 MPa, pneumatic actuators used in the machine might be damaged.

3.7

Hoses for Supplying Compressed Air

For the hose used to supply the compressed air, select the one which can withstand the compressed air pressure. For the selection, consult the hose manufacturer. Compressed air supply port size: Rc 3/8

P10

4.

AFTER RECEIVING THE MACHINE

When transporting the machine or if the machine is not installed immediately after its delivery, store it in a place where the ambient temperature remains within the range 20 to 60_C and the humidity does not exceed 75% RH (with no condensation). Failure to comply with these conditions could cause troubles in the electrical systems of the NC unit and peripheral devices and lead to machine faults. When the machine is delivered, pay attention to the following items. 1) If the machine is delivered in package, check the external frame of the package and if the machine is delivered without package, check the external appearance of the machine. If the package frame is damaged, contact Mori Seiki before unpacking. If the machine appearance shows damages, also contact Mori Seiki leaving the machine damages as they are. 2) If the machine is not moved to the installation site just after its delivery, keep the machine at a place not exposed to the weather or a place not subject to dust, dirt, and mist. If the machine is left in such places, it will cause rusting or corrosion.

P11

5.

CARRYING THE MACHINE TO CHANGE FLOOR LAYOUT

When the machine is delivered to your shop, Mori Seikis service technicians will install the machine at the designated place. The information described below should be used when the machine is moved after initial installation due to such as floor layout change. If it becomes necessary to carry the machine due to relocation of the plant or selling of the machine, contact Mori Seiki.

5.1

Preparation
1) 2) 3) 4) 5) 6) Before turning off the power, move each axis to the position where it should be fixed. Turn off the main switch on the electrical cabinet. Turn off the breaker of the transformer. Turn off the main breaker on the shop power distribution board. Disconnect the power cable and the ground cable. Fix the machine units with transit clamps. Refer to APPENDIX 1.1, Transit Clamps in this manual. 7) 8) 9) Turn off the compressed air. Remove the compressed air supply hose. Disconnect the cables of coolant motor and chip conveyor motor.

10) Disconnect the cables and pipes for the peripherals such as oil cooler and fan cooler. 11) Remove the coolant tank and the chip conveyor from the machine. 12) Drain the coolant from coolant tank. 13) Remove the jack bolts.

5.2

Carrying the Machine by Hoisting

1

Only a qualified technician should perform machine hoisting work. Operation of the crane or forklift by a person unfamiliar with safe operation practices could lead to accidents involving serious injuries or damage to the machine. Use only wires, shackles and jigs of the dimensions specified in the manual. They must be strong enough to support the mass of the machine. If the machine is hoisted using equipment that cannot bear its mass it will fall, causing serious injuries or damage to the machine. Before lifting the machine, grasp the machines center of gravity, and make sure that the machine is well balanced in both the crosswise and lengthwise directions after hoisting it a little above the floor. If you continue to hoist the machine although it is not properly balanced, it will fall, causing serious injuries or damage to the machine.

P12

Before hoisting the machine, check that no tools, rags, etc., have been left inside it. When the machine is lifted, these articles could fall out and injure plant personnel or damage the machine. If a crane is used to hoist the machine, do not carry the machine while it is lifted to an excessive height. Lifting the machine excessively high when carrying it will create more potential hazards than when carrying it at a lower height. When moving the machine with a forklift, do not lift it high above the ground. If it is moved in this condition, it may become unbalanced and fall, or the forklift may topple over, causing serious injuries or damage to the machine. Take the mass of the machine into consideration when determining the appropriate forklift capacity. If a forklift without sufficient capacity to lift the machine is used, the machine will fall, causing serious injuries or damage to the machine.

If a rust-preventive coating is applied to the slideway surfaces, it must be removed completely. If any rust-preventive coating remains on the slideways when the axis feed is attempted, the machine could cause damage to the machine. The saddle and cross slide are fixed in place with transit clamps when the machine is shipped. Also, eyebolts are used to hoist the machine. All clamps and eyebolts must be removed before switching the power ON. If a clamp cannot be removed without switching the power ON first, remove it immediately after switching the power ON. If axis feed is attempted while a clamp is still in place, the machine will be damaged. Before hoisting the machine, check that all of its parts are clamped. Lifting the machine while any of the parts is not clamped adequately could damage the machine. When installing the machine, mount the coolant tank and the chip bucket by pushing them into an appropriate position. Otherwise, coolant may be splashed around the machine causing the operator or persons around the machine to topple down and get injured.

When moving the machine with rollers, determine the number of rollers, and the material that they are made of, so as to ensure that they can support the mass of the machine. Also use skid and leading boards that can support the mass of the machine. If they cannot support the mass of the machine the rollers, skid, or leading board may be distorted, making it impossible to move the machine. After the machine has been installed, it must be leveled. Adjust the machines crown and distortion values according to the Accuracy Test Results Chart delivered with the machine. If this adjustment is not carried out properly, machining accuracy will be adversely affected.

P13

6.

CONNECTING THE POWER CABLE

This section explains the connection of power cable from the shop power distribution board to the transformer and then to the machine. Power cable connection indicated below assumes that the transformer which Mori Seiki specifies as applicable one is used. If the transformer selected by the customer is used, carefully follow the instructions given in the manual supplied with the transformer to connect the power cables.
1

Only a qualified electrical technician should perform work involving the power cable connections. If the work is done by a person unfamiliar with the necessary safety precautions when performing electrical work, he/she may receive an electric shock.
Grounding work is essential. If grounding work is not performed, the machine operator could receive an electric shock.

The machine must be grounded independently of other machines. If electric welders or electric discharge machines are grounded to the frame of the plant building, do not connect the ground wire of the machine to the plant frame. If the ground wire is not connected independently, the machine could malfunction due to electrical noise from other machines, leading to accidents involving serious injuries or damage to the machine. <Cable connection procedure> Shop power source (360 436 VAC)
L1 L2 L3 N PE

1)

Turn off the breaker at the shop power distribution board.

2)

Turn off the breaker of the transformer.

3)

L001

L002

L003 436 V 415 V 400 V 380 V 360 V

Connect the power cable from the terminal blocks in the electrical cabinet L01, L02, L03 and to the terminal blocks (secondary) L01, L02, L03 of the transformer. and Connect the power cable from the terminal blocks (primary) L1, L2 and L3 of the transformer to the breaker at the shop power distribution board.

4)

200 V N To the machine (200 VAC) N L01 L02 L03

P14

Terminal blocks L1, L2, and L3 are for 400 VAC system (360 436 VAC) and those L01, L02, and L03 are for 200 VAC system. Never connect the cable to wrong terminal blocks, otherwise the machine will be damaged. If the cable is run through the punched hole in the transformer circuit breaker box, take proper cable protection means conforming to IP54.

For the transformer of 24.5 kVA or 34.64 kVA, connect the power cable from L1, L2, and L3 to the primary side of the breaker. The transformers with larger capacity have terminal blocks, therefore, connection should be made to the terminal blocks. 5) Connect the ground cable to the terminal block PE in the transformer for grounding the machine. Check the grounding resistance of the grounding cable. Turn on the breaker at the shop power distribution board. Turn on the breaker of the transformer. Check the input voltage.

6) 7) 8) 9)

10) Check the phase order. If a phase rotation indicator is not available, check it from the rotation direction of the hydraulic pump motor.

7.

CONNECTION OF COMPRESSED AIR SUPPLY HOSE

1) Connect the compressed air supply hose from the air source to the air supply port (Rc 3/8) in the air panel of the machine. Start the compressor to supply the compressed air to the machine. Make sure that there is no air leak at hose joints and pneumatic actuators. Adjust the compressed air pressure to the specified value with the regulator in the air panel. Refer to the MACHINE SPECIFICATIONS in the MAINTENANCE INFORMATION published separately.

2) 3) 4)

8.

REMOVING TRANSIT CLAMPS

After carrying the machine to the required place, remove all transit clamps before turning on the power. The transit clamps that cannot be removed before turning on the power should be removed immediately after turning on the power. Refer to APPENDIX 1.1, Transit Clamps in this manual. Keep the removed transit clamps so that they will not be lost.

P15

9.

LEVEL ADJUSTMENT
If the machine level is not adjusted correctly, the machine will be tilted or twisted after installation. This will result in uneven wear of the slideway surfaces and deteriorate machining accuracy. After installing the machine, always check the machine level. <Adjusting procedure> 1) 2) Mount the leveling base to the turret head. Place a level on the leveling base. At this procedure, do not rotate the turret head.

Jack bolt

Adjust the machine level by turning the jack bolts while observing the level on the leveling base. 3) Adjust the jack bolts so that the height between floor and machine will be the setting value. For the setting value, refer to GENERAL VIEW in the DRAWINGS published separately. Make sure that all jack bolts hold the machine uniformly.

4)

If a jack bolt is extending excessively, it will cause machine vibration.

Check machine level. The illustration left shows the machine after level adjustment.

5)

After checking the machine level, read the level to check and adjust twisting and crowning of the machine.

APPENDIX P1

APPENDIX 1
1.1

INSTALLATION DATA

Transit Clamps
Fix the transit clamps at the locations indicated below before carrying the machine. <Standard> <With gantry type loader>

C A

B A

Front door

Turret

Turret and saddle

Loader

P2 APPENDIX

1.2

Hoisting the Machine

<Standard> <With gantry type loader>

C B

C B

Left rear side

Front side

Right rear side

After the installation of the machine, remove and keep the hoisting hooks.

APPENDIX P3

<Wire rope dimensions>

3 2 1

No.
1 2 3

Diameter 14 14 14

mm Length 2820 2520 2620 kg 4000

mm

Mass of machine

P4 APPENDIX

APPENDIX 2
1

POWER CAPACITY TABLE

Breaker and power distribution board capacities are determined using the current calculated by the following formula. Current (A) = Total capacity (kVA) 3 200 (V) 1000 1.2 *

*: Allowance for selection

2

When a 6-slot NC is used to add optional specifications and functions, the power capacity of the NC is 0.6 kVA.

2.1

CL-25
(I91890 A01) Machine Model NC Standard CL-25 MSC-521 Option FANUC PSM-30 A06B-6087-H130 Motor model X a6/3000 A06B-0128-B075 Inverter model Spindle Manufacturer di drive Motor model motor Output (30 min/continuous rating) kW Inverter model 1 Inverter capacity (continuous rating) FANUC aP40 A06B-0831-B901#0240 15/11 SPM-26 A06B-6088-H326#H500 kVA kVA kVA 23 0.24 1.0 ) 0.24 ) 0.34 + 1.58 0.52 1.5 0.055 0.2 kVA kVA kVA 28 5 3 35 18.5/15 SPM-30 A06B-6088-H330#H500 30 Z a22/2000 A06B-0147-B075

Power S Supply l Module

Manufacturer Model Servo motor

SVM2-80/80 A06B-6079-H208

2 3 Other U i Unit Motor kW 4

NC Electrical cabinet Coolant pump Hydraulic pump Machine fan motor Chip conveyor Total of unit [ Power factor 0.8 ] (Standard)

Total capacity (Standard, continuous rating) 1+2+3+4 220 V 50 Hz transformer

APPENDIX P5

2.2

CL-25 with Gantry Type Loader

(I91890 A01) Machine Model NC Standard CL-25 with gantry type loader MSC-521 Option FANUC PSM-30 A06B-6087-H130 Motor model X a6/3000 A06B-0128-B075 Inverter model Spindle Manufacturer di drive Motor model motor Output (30 min/continuous rating) kW Inverter model 1 Inverter capacity (continuous rating) FANUC aP40 A06B-0831-B901#0240 15/11 SPM-26 A06B-6088-H326#H500 kVA kVA kVA 23 0.24 1.0 ) 0.24 ) 0.34 + 1.58 0.52 1.5 0.055 0.2 kVA kVA kVA kVA 36 5 3 8 43 18.5/15 SPM-30 A06B-6088-H330#H500 30 Z a22/2000 A06B-0147-B075

Power S Supply l Module

Manufacturer Model Servo motor

SVM2-80/80 A06B-6079-H208

2 3 Other U i Unit Motor kW 4 5

NC Electrical cabinet Coolant pump Hydraulic pump Machine fan motor Chip conveyor Total of unit [ Power factor 0.8 ] (Standard) Gantry type loader [LG-10]

Total capacity (Standard, continuous rating) 1+2+3+4+5 220 V 50 Hz transformer

P6 APPENDIX

APPENDIX 3
3.1 CL-25A

MACHINE NOISE DATA

Unit: mm

B
Model Person Place Meas. Instrument Level CL-25A

A
Serial No. 364

F
Date 12. 2. 1994

Department: Manufacturing Dept. Name: Kazutada Hashimoto

Section: Quality Assurance Sec. Iga No.2 Plant

Brueel & Kjaer Type 2230, Brueel & Kjaer Type 4155 Active Character of Indicator Character of Frequency Fast A 57 dB 69 dB (dB) Measuring Point* A B 63 64 65 69 72 75 78 C 65 66 67 71 75 78 79 D 69 70 71 72 75 77 78 E 63 65 66 68 70 73 76 F 63 64 65 67 69 71 74 G H I

Default Value

Background Noise Machine Power ON

Machine Noise Data Spindle Speed (min1) Machine Power ON 500 1000 1500 2000 2500 3000 62 64 65 67 70 72 75

*: Measuring point is 1 m from machine, and 1.6 m from floor.

APPENDIX P7

3.2

CL-25B
Unit: mm

B
Model Person Place Meas. Instrument Level CL-25B

A
Serial No. 351

F
Date 12. 2. 1994

Department: Manufacturing Dept. Name: Kazutada Hashimoto

Section: Quality Assurance Sec. Iga No.2 Plant

Brueel & Kjaer Type 2230, Brueel & Kjaer Type 4155 Active Character of Indicator Character of Frequency Fast A 55 dB 70 dB (dB) Measuring Point* A B 64 66 70 74 76 76 78 C 65 67 68 73 76 77 79 D 70 70 71 73 75 76 78 E 63 64 67 71 72 74 75 F 62 63 66 69 71 73 74 G H I

Default Value

Background Noise Machine Power ON

Machine Noise Data Spindle Speed (min1) Machine Power ON 500 1000 1500 2000 2500 2800 64 65 68 73 75 76 76

*: Measuring point is 1 m from machine, and 1.6 m from floor.

INDEX

INDEX
Page

A
AFTER RECEIVING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P10 Ambient Temperature and Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P1

B
Breaker for Shop Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P9

C
Carrying the Machine by Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P11 CARRYING THE MACHINE TO CHANGE FLOOR LAYOUT . . . . . . . . . . . . . P11 CL-25A, MACHINE NOISE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APP. P6 CL-25B, MACHINE NOISE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APP. P7 CL-25, POWER CAPACITY TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APP. P4 CL-25 with Gantry Type Loader, POWER CAPACITY TABLE . . . . . . . . . . . . . APP. P5 Compressed Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P9 CONNECTING THE POWER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P13 CONNECTION OF COMPRESSED AIR SUPPLY HOSE . . . . . . . . . . . . . . . . . P14

D
Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P1

E
ENVIRONMENTAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P1

F
FOUNDATION WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2

G
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P9

H
Hoisting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APP. P2 Hoses for Supplying Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P9

I
INSTALLATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APP. P1 Installation Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P1

L
LEVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P15

INDEX

Page

M
Maintenance Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P1 MACHINE NOISE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APP. P6

P
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P7 POWER CAPACITY TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APP. P4 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P6 Preparation, CARRYING THE MACHINE TO CHANGE FLOOR LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P11 PREPARATION FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P6

R
REMOVING TRANSIT CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P14

T
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P8 Transit Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APP. P1

V
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P1

ii

Comment Form

Date:

To improve this manual, we invite you to make comments on any insufficient description or errors in this manual. We want to know how you think we can make this manual better. Please restrict your comments to those concerning this manual only. Name of manual Number of revisions Name Department Address Chapter Page Line Comments / Requests INSTALLATION MANUAL IM-CECL25-B2E (1998.2) Company Telephone

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APPENDIX

CONVERSION TABLE OF UNITS

This manual uses SI unit system and metric system. If inch system is required, please convert the values to inch system by referring to the following table.
Quantity Length Velocity Area Volume Volumetric flow rate Mass Force Torque Pressure Metric 1 mm 1m 1 mm/min 1 m/min 1 1 m2 mm2 SI 1 mm 1m 1 mm/min (0.017 mm/s) 1 m/min (0.017 m/s) 1 1 m2 103 m3) mm2 Yard/Pound 0.0394 in. 3.281 ft 0.0394 in./min 3.281 ft/min 10.764 ft2 0.0016 in.2 0.264 gal. 0.264 gpm 2.2 lb. 2.2 lbf 7.233 ft@lbf 14.22 psi (14.22 lbf/in.2) 204.4 lb./ft2 1.34 HP 33.8_F _F = (1.8 _C) + 32 1.076 105 ft2/s 1 rpm 1_ (deg) 1 kcal 7.233 ft@lbf 1 kcal/h 1G Different from torque Degrees, minutes, and seconds may also be used. Temperature difference: 1_C = 1 K 1 St = 100 cSt 1 MPa = 1000 kPa 1 kPa = 1000 Pa ton: metric ton gal.: US gallon gal.: US gallon Remarks

1 L (liter) 1 L/min 1 kg 1 kgf 1 kgf@m 1 kgf/cm2 1 ton/m2

1 L (liter) (1

1 L/min (1.66666 105 m3/s) 1 kg 9.80665 N 9.80665 N@m 9.80665 9.80665 102 MPa 103 Pa

Output Temperature Kinematic viscosity Rotational speed Angle Work Power Acceleration 1

1 kW 1_C 1 cSt min1 1_ 1 kcal 1 kgf@m 1 kcal/h 1G (rpm) 1

1 kW 1_C (274.16 K) 1 106 m2/s (1/60 s1)

min1

1_ (/180 rad) 4.186 103 J

9.80665 J 1.16 W 9.80665 m/s2

In the texts and drawings in this manual, there are dimensions and other values specific to inch specification machines. In the case of these specific dimensions and values, converting the corresponding values for the metric specification machines into inch system dimensions or values using the conversion table will not give the correct dimensions or values. <Example> The dimensions and values specific to the inch system machines include cutting feedrate per spindle revolution, manual jog feed rate, tool dimensions, zero point (NC lathe only), and T-slot and pallet dimensions (machining center only). For these values, refer to the values specified in the machine specification table. If the required value is not found in the table, contact Mori Seiki. Units and numerical values in ( unit system. ) in the SI column indicate the formal expression of the SI

However, they are not used usually and the units described above the expression in ( ) are used instead of the formal SI unit expression. These units are also approved as SI unit system expression.

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000517