Part 2 Installation 1. Installation considerations 1-1. Environmental conditions 1-2. Shop power source. 1-3. Things to be ued by customer. 2. Installation 2-4. Location... 2-2. Carrying... 41. Using crane. 2. Using rollers, Foundation. 2-4. Cleaning ... 2-5. Supplying hydraulic oil 2-6, Removing shipping brackets 4, Ram... cs Backgauge, stoppers, and stopper fingers 2-6-3. Pendant control box. 2-7. Pulling out rear guard (for machine with eight or ten axes) 2419 ‘Supplying electric power. nee 2-20 -1. Connecting power cable ceed -2. Checking electrical connections 2-22 . Leveling 2-10. Paralleling ram and bed. 2-11. Checking machine origin 2-12. Checking movement of each axis 227 2-13. Making final Checks ....--..-e-eo- 2-28 241-3. Things to be supplied by customer Primary power cable (four-conductor cabtyre type) and ground-fault circuit breaker NOTICE @ Install a ground-fault circuit breaker in the shop power source. It must have a residual operating current of 30 mA and be compatible with inverters. @ This table gives the specifications required when the shop power source voltage is 400 or 460 v, Model Minimum conductor size Full-load current Hs5020 5.5 mm? {0.009 in.”} 21a HS8025, 5.5 mm? {0.009 in.} 21A HS1303, 8 mm? {0.012 in.2} 30A HS1703 14 mm? {0.022 in?} 38A HS2204 14 mm? {0.022 in.} 45A Transformer (when required) Unless the shop power source voltage is 400 or 460 V, prepare a 400/460 V step-up or step-down transformer. 23Dimensions of machine 6 Unit: mm {in.} Standard machine Model A 5 oc he E F 85020 _| 3725 (146.7) | 2585 (101.8) | 775 (305) | 3075(%23.1) | 465(18.3) | 675 (266) Hse025 | 4180 (164.6) | 2585 (101.8) | 775 (905) | 3535 (1382) | 465 (183) | 675 (258) 51303 | 4780 (188.2) | 2585 (101.8) | 775,305) | 4135 (1628) | 465 (183) | 675 (266) 1703 _| 4925 (193.9) | 2945 (115.9) | 775 (905) | 4175 (1644) | 465 (183) | 675 (256) is2204 | 6040 (297.8) | 2970116.) | 775 (30.5) | 5295 (2085) | 465 (18.3) | 675 (256) Machine with eight or ten axes Model A 8 < D E F wssozo_| 3725 (146.7) | 2610 (1106) | 75 (905) | 3075 (121.1) | 4651163) | 675 (266) tse025 | 4180 (164.6) | 2810(110.6) | 775 (05) | 3695 (730.2) | 465(183) | 675266) HS1303__| 4780 (188.2) | 2820(111.0) | 775(305) | 4195 (7628) | 465(16.3) | 675 (266) HS1703_| 4925 (1939) | 3005(118.3) | 775 (305) | 4175 (164.4) | 465(183) | 675 (266) 482204 | 6040 (237.6) | 3025 (119.1) | 775 (30.5) | 5295 (2085) | 4654183) | 6754266) 252-2-2, Using rollers a center of gravity at its front. If the rear bottom of the machine is jacked up without paying attention to its balance, the machine may tip over, resulting in a very dangerous situation. When jacking up the machine, insert the claw of a jack below the left or right side-plate bottom of the machine frame. ROLLERS 27$5020 foun Unit: mm {in.} )« 200) (150 * 300 * 450H) Bend line, tun and connect the primary power cable (composed of four 2 ar (0.009 in} conductors, Including a ground) to the electrical closure, {Rjuat te depth of concrete cover and the number of renforsng ‘Sis to suit the conditions of the location. Vearing capacty of foundation: 50 kNim® (1044 psf) Wrength of concrete: FC = 16 Nimmé {2611 psi) jhass of machine: 4600 kg (10140 Ib} tase othe foundation construction drawing by referring to this ‘rawing. (AES3273-A.HS1303 founda Unit: mm fin.} of ; Electicalencios | lle. 5 i Uk £ “Leo ngaNe” \aneborbtt mao x 450. I {10.2}) g 300 {11.8} Blocked-out hole: 150 x 300 x 450H Rb x 200 x 200) dle: (150 x 300 * 450H) Bend tine of works O™ SOO * SO ‘and connect the primary power cable (composed of four sm? {0.012 in.?} conductors, including a ground) tothe electrical ‘sure. \st the depth of concrete cover and the number of reinforcing ‘to suit the conditions of the location. sh the bottom of the machine level to within errors of 5 mm {0.2 in}. ring capacity of foundation: 50 kN/m? {1044 psf) gth of concrete: FC = 18 Nimm: {2611 psip 's of machine: 8200 kg {18080 Ib) ate the foundation construction drawing by referring to this ving, base plates are shipped attached to the machine. ply the J-shaped anchor bolt. = conerete into the blocked-out holes after instaling the hine and setting the anchor bolts. AES3276-A 2-11HS2204 foundatio 550 Unit: mm {in} 120 (4.7) 450 (17.7) | iS «” \ Anchor bott: M20 » 450 260 (10.2) 300 11.8) Biocked-out hole: 150 * 300 x 450H | Run and connect the primary power cable (composed of four 14 mm? {0.022 in} conductors, including @ ground) to the electrical enclosure. 2. Adjust the depth of concrete cover and the number of reinforcing bars to suit the conditions of the location. 3. Finish the bottom of the machine level to within errors of S mm {0.2 in.}. |. Bearing capacity of foundation: 50 kN/m? (1044 psf) 5. Strength of concrete: FC = 18 Nimm* (2611 psi. 5. Mass of machine: 18000 kg {39690 Ib) 7- Create the foundation construction drawing by referring to this drawing, 5. The base plates are shipped attached to the machine. 3. Supply the J-shaped anchor bolts. 9. Pour concrete into the blocked-out holes after installing the ‘machine and setting the anchor bolts. int al (450 (17.7) 150 ‘AE53279-A 2-132-4, Cleaning After the machine is installed on the foundation, clean it. Particularly, remove the ‘ust inhibitor from the punch holders, the die holders, and the top surface of the bed, using cleaning oil NOTICE ‘© Do not use a solvent or scraper that removes the paint of the machine. 2.5. Supplying hydraulic oil Pour the recommended hydraulic oil into the hydraulic oil tank to the upper red line on the oil gauge when the ram is at the maximum ‘opening limit. (Refer to “2. Maintaining hydraulic system” in Part 7.) Recommended hydraulic oil: Amada AS-56, Shell Tellus Oil 56, or ISO VG56 equivalent NOTE @ The hydraulic oil, Amada AS-56, is delivered with the machine. Model Hs5020 | HS8025 | HS1303 | HS1703 | HS2204 Tank capacity, L {US gal}| 55 {14.5} | 90 {23.8} | 150 {39.6} | 235 {62.1} 295 {77.9} 245Machine with optional Y-axis (Machine with eight or ten axes) There are two shipping brackets for the backgauge, one left and one right. 1. Loosen the bolts A on the stretch bar and then the bolts B on the machine frame. 2. Remove the shipping brackets for the backgauge. 3. Keep the removed shipping brackets and their bolts. Machine with optional LS-axis (Machine ten axes) There are two shipping brackets for the stoppers, one left and one right. cover ‘SHIPPING BRACKET \ BOLTB (YELLOW) COVER 1. Loosen the bolts A and B shown above. Remove the shipping brackets for the stoppers. Tighten the bolts A and B to secure the covers. Pen Keep the removed shipping brackets. 24172-7, Pulling out rear guard (for machine with eight or ten axes) ‘When your machine is equipped with the eight or ten axes, the rear guard is secured in six places inside its frame. Pull out the rear guard as described below. NOTICE @ If the backgauge is operated without pulling out the rear guard, it may be broken. Never do so. 1. Loosen the six bolts A. 2. Pull the rear guard out of the frame, 3. Tighten the bolts A to secure the rear guard on the side plates of the machine frame. 4. Secure the accessory covers A and B with the bolts B. 5. Do the same on the other side. COVER A *2-8-1. Connecting power cable Connect the four-conductor power cable to the machine as described below. 1. Turn to OFF the machine circuit breaker on the electrical enclosure, and turn off the shop circuit breaker. 2. Loosen the screws securing the door of the electrical enclosure, and open the door. 3. Pull the power cable from the shop circuit breaker through the power inlet into the electrical enclosure. 4. Connect the three power cable conductors to the primary terminals L1 (R), L2 (S), and L3 (T) of the machine circuit breaker in the electrical enclosure, 5. Connect the ground conductor to the ground terminal at the right side of the machine circuit breaker. 6. Secure the power cable to the breaker base with a cable tie. 7. Turn on the shop circuit breaker. 8. To check that a current is flowing to the primary terminals of the machine circuit breaker in the electrical enclosure, check the voltage with a tester. PRIMARY TERMINALS _ 1), 28), Bm BREAKER™ BASE POWER INLET. 9. Close the door of the electrical enclosure, and secure it with the screws. 2-21After completing the connection of the four-conductor power cable, check the rotational direction of the hydraulic pump ‘motor to see that the electrical connections are made properly. The correct rotational direction of the hydraulic pump motor is the arrow direction shown right. 1. Tum on the shop circuit breaker, and turn the machine circuit breaker to ON. 2. Turn the MOTOR keyswitch to ON. The light above the keyswitch illuminates, and the hydraulic pump motor starts. 3. Check the rotational direction of the hydraulic pump motor, and immediately turn the MOTOR keyswitch to OFF. The hydraulic pump motor stops, and the light above the keyswitch ‘extinguishes. NOTICE @ The hydraulic pump may fail if its motor is run in the reverse direction for a long time. 4. Tum the machine circuit breaker to OFF, and turn off the shop circuit breaker. 5. When the hydraulic pump motor runs in the arrow direction, this means that the electrical connections are made properiy. ‘When the hydraulic pump motor runs in the reverse direction, interchange two of the three power cable conductors connected to the primary terminals L1 (R), L2 (S), and L3 (T) by referring to “2-8-1. Connecting power cable” in this Part. 2-232-10. Paralleling ram and bed ‘Check that the ram and bed are parallel at the left edge D1 and right edge D2 as shown below. If not, parallel them as described below. 1. Remove the punch holders at the left and right edges. 2. Close the ram to 190 mm {7.48 in.}, and measure the dimensions D1 and D2 with the CLOSING foot pedal pressed and held. 3. If the dimension D2 is greater than the dimension D1 (0), add the difference to the Ref D1 If the dimension D2 is smaller than the dimension D1, add the difference to the Ref D2, NOTE @ The Ref D1 and Ref D2 are adjusted by changing the value of a soft Parameter. For details, refer to the “1-3. Soft parameters” in Part 5. 4. Tum off the power, tum it on again, and repeat steps 1 and 2. 5. Repeat steps 1 to 4 so that the difference between the dimensions D1 and D2 becomes 0.01 mm {0.0004 in.}. EDGE D1 DIAL INDICATORS, 2-252-12 Checking movement of each axis Be sure to check the movement of each axis by referring to "5. Composition of axes” in Part 1. Manually move each axis, and check that it moves free of trouble. NOTE @ If the ram tits or stops midway, open it as described below. 1. Turn on the shop cirouit breaker. 2. Turn the machine circuit breaker to ON. © NOTICE, @ Do not use the touch screen during the startup of the NC. 3. After the NC starts up, a message appears as shown right. Wait until the message disappears 4. Press and hold the OPENING foot pedal until the ram reaches the maximum opening limit. ‘OPENING FOOT PEDAL 2-272-13. Making final checks Oil leakage and air removal Check for any oil leak. After installing the tools, close the ram to apply force to the tools for a few seconds. This forces air out of the ram hydraulic unit. In case of existing air in the hydraulic circuit, the ram moves unsmoothly, and an alarm message is displayed. 2-282-11, Checking machine origin Check the machine origin as described below. 2-26 ‘Check that all axes of the machine are zero-returned and the parallelism ‘adjustment of the ram and bed is completed. (For how to zero-return the axes, refer to “5. Zero-returning all axes” in Part 4.) Set a dial indicator in the machine origin setting jig, and zero the dial indicator. The origin setting distance of the machine origin setting jig is 240+0.02 mm {9.44940.001 in}. . Set the dial indicator at the center of the bed, and press and hold the CLOSING foot pedal to close the ram by 110 mm {4.33 in}. . Read an error from the zero of the dial indicator. ‘Substitute the read error into the grid shift, and zero the dial indicator. 24020.02 mm {9.44920.001 in.)2-9. Leveling Level the machine as described below. Leveling in left-to-right direction 1. Place a spirit level at the center of the bed. 2. Turn the two leveling bolts on the lef or right side of the machine to level the machine to 0.05 mm/m {0.00060 in./t} or less. Leveling in front-to-back direction 3. Clean the traveling surface of the lower guide roller behind the ram. 4. Attach a square spirit level with a magnet to the traveling surface. 5. Tum the two leveling bolts on the front or back side of the machine to level the machine to 0.05 mm/m {0.00060 in./f} or less. Anchoring 6. When the leveling of the machine is completed, tighten the nuts of all leveling bolts. GUIDE ROLLER PLATE LEVELING BOLT fa NUT SQUARE SPIRIT LEVEL fet WITH MAGNET BASE PLATE 2:242-8-2. Checking electrical connections @ Checking of the electrical connections must be performed at a height of 2 m {6.6 ft} or more. As a rule, do not step onto the machine to perform this check. Given the risk of falling from height, ask AMADA to do the check for a fee. When working at height, wear a safety belt and take any other compulsory measures according to the safety laws, regulations, and standards in your country or region to prevent falling from height. For the work at height, prepare a stepladder. Attaching hook of safety belt (for work at height) Attach the hook of the safety belt to a specified hole on the ram hydraulic unit as shown below. WARNING @When checking the rotational direction of the hydraulic pump motor, do not get any part of your body or clothing too close to any rotating parts (like the coupling of the motor to the pump). If you have any part of your body or clothing caught in a rotating part, you may get hurt. 2-222-8. Supplying electric power WARNING @ Have a qualified electrician make the necessary electrical connections. ©@ Before opening the door of the electrical enclosure, turn off the shop circuit breaker. @ Before connecting the power cable to the machine, turn off the shop circuit breaker. @ Install a ground-fault circuit breaker in the shop power source. © Ground the machine independently of other equipment. NOTICE © Supply the machine with three phase, 400/460 VAC, 50/60 Hz electric power with voltage variations of within +10%. @ For the apparent power of the machine, refer to “1-2. Shop power source” in this Part. © For the minimum conductor size and type of the power cable to be used and the capacity of the ground-fault circuit breaker to be installed in the shop power source, refer to “1-3. Things to be supplied by customer’ in this Part. © Supply and ground the machine independently of other equipment. If the machine is supplied and grounded together with other equipment, it may not only be damaged, but also stop suddenly or operate improperly, resulting in an accident. 2-202-6-3. Pendant control box The shipping brackets for the pendant control box are attached to the bed. PENDANT CONTROL 80x BOLT B ~ SHIPPING BRACKET A (4 PLACES) (YELLOW) SHIPPING BRACKET 8) (YELLOW) BOLTS C 1, Remove the bolts A from the bottom of the pendant control box. Also remove the urethane washer inserted between the shipping bracket A and the pendant control box bottom. 2. Loosen the bolts B. While supporting the shipping bracket A, remove the bolts B. 3. Loosen the bolts C of the bed, and remove the shipping bracket B. 2482-6. Removing shipping brackets Remove the shipping brackets securing the machine parts as described below. NOTE @ Take care not to lose the removed shipping brackets and their bolts. They are required when moving the machine to another location. 2-6-1. Ram The shipping brackets securing the ram are positioned near the upper left and right guide rollers. 1. Loosen the nut and bolt A of each shipping bracket. stock _\ seit 2. Remove the bolts B, and remove the blocks. BOLT A 3. Keep the removed blocks and BOLTS 8 their bolts. 2-6-2. Backgauge, stoppers, and stopper fingers ‘Standard machine There are two shipping brackets for the backgauge, one left and one right. There are also two shipping brackets for the stopper fingers, one left and one right. BOLTS ‘SHIPPING BRACKET A SHIPPING BRACKET 8. BOLTS ¢’ STOPPER 1. Loosen the bolts A on the stretch bar and then the bolts 8 on the machine frame. Loosen the bolts C on the stoppers. Remove the shipping brackets for the backgauge and stopper fingers. Keep the removed shipping brackets and their bolts. eB eN 2-16HS Unit: mm {in} 120 (4.7) | Base plate: (T25 x 275 x 275) Je reinforcement, Blocked-out hole: (150 x 300 x 450H) Run and connect the primary power cable (composed of four +14 mm? {0.022 in.3} conductors, including a ground) to the electrical enclosure. ‘Adjust the depth of concrete cover and the number of reinforcing bars to suit the conditions of the location. Finish the bottom of the machine level to within errors of 5 mm {0.2 in.) Bearing capacity of foundation: 50 kN/m? (1044 psf) Strength of concrete: FC = 18 Nimm: (2611 psi) Mass of machine: 11000 kg {24260 Ib} Create the foundation construction drawing by referring to this drawing. ‘The base plates are shipped attached to the machine. Supply the J-shaped anchor bott. Pour concrete into the blocked-out holes after installing the machine and setting the anchor bolts. ital and vertical AES3277-AHs8¢ a h 5] 0 SN. anchor bot M20 x 4501 260 (10.2) 300 (11.8), Blocked-out hole: 150 * 300 x 450H fe: (T12 « 150 x 150) +ked-out hole: (150 x 300 * 450H) +. Run and connect the primary power cable (composed of four Unit: mm {in.} 55.5 mmr {0.009 in} conductors, including a ground) to the electrical ‘enclosure. 2. Adjust the depth of concrete cover and the number of reinforcing ‘oars to sult the conditions of the location. 43, Finish the bottom of the machine level to within errors of S mm {0:2 in.) 44. Bearing capacity of foundation: 50 kNim® (1044 psf) 5, Strength of concrete: FC = 18 Nimm? (2611 psi) &. Mass of machine: 5600 kg {12350 Ib} 5 Create the foundation construction drawing by referring to this drawing £8. The base plates are shipped attached to the machine ‘9, Supply the J-shaped anchor bolts. +10, Pour concrete into the blocked-out holes after installing the ‘machine and setting the anchor bolts 4 double reinforcement, horizontal and vertical sinforcing 2-10 AgS3274—2-3. Foundation To maintain bending accuracy, install the machine on a flat concrete floor that is Strong enough to carry the mass of the machine and is not likely to subside. Before carrying the machine into the location, execute the foundation work by referring to the foundation drawing on the following pages. If the ground is soft with a bearing capacity of 50 kN/m? {1044 psf} or less, reinforce the foundation with steel bars or the like. 282-2. Carrying © Carrying the machine is very dangerous. Have a qualified contractor perform the carrying work. @ Use a crane and wire rope slings strong enough to carry the mass ofthe machine. (For the mass of the machine, see the serial number plate attached to the machine.) There are two lifting holes at the top of the machine frame, one left and one right. Attach the wire rope slings to the two lifting holes. Slowly lift and carry the machine to the location, and slowly lower the machine at the location. 2-62. Installation 2-1. Location Select a place where an ample space can be secured for the machine by paying full attention to the required floor area and the following items: * There must be no pillars and other obstacles where the tools are installed and Femoved. (At least 835-mm {32.87-in.} long tools must be able to be horizontally installed and removed by opening the left or right side guard of the machine.) * The ceiling must be at least 1 m {3.3 ft} from the top of the machine. (Take the height of the base plates into account.) * There must be an additional space to locate a tool ‘storage case and any other necessary items, + Space must be available for workpiece loading and unloading, machine maintenance, and other tasks. A space of 1 m {3.3 ft} or more must be available at the rear of the machine. An enough space must be available for the door of the electrical enclosure to be opened. An enough space must be available for the side covers of the bed to be removed. NOTICE, @ Do not install the machine in a place where it is exposed to dust from such operations as sandblasting and to direct sunlight, rain, and wind. 241. Installation considerations 1-1. Environmental conditions * Keep the machine at least 10 m {33 ft} away from a welder or any other equipment that may produce electrical noise and magnetic fields. + Where the ambient temperature is not higher than 5°C {41°F}, keep the machine energized during the day's work. * The higher the humidity in the place where the machine is installed becomes, the ‘ower the insulation performance of its electric parts becomes. The machine does ot require any special dehumidification measures, but do not install it in such a humid place. ‘+ Do not use the machine in a place where it is subjected to dust, dirt, and organic or corrosive gases. 1-2. Shop power source Power requirements: Three phases, 400/460 VAC#10%, 50/60 Hz+1 Hz, and apparent power given in the table below. Model Hs5020 | HS8025 | HS1303 | HS1703 | HS2204 ‘Apparent power 14.5 kVA | 14.5 kVA | 20.8 kVA | 26.3 kVA | 31.2 kVA NOTICE ‘© Supply the machine from a power source independent of a welder or any other ‘equipment that may produce line voltage variations. Otherwise the machine may Not operate properly. @ The machine only for North America requires 460 VAC. In other areas, supply 400 VAC to the machine. Use the machine with the specified voltage 22