11.

2004

Contents

1 Technical data........................................................3

2 Packing and handling ............................................4

2.1Packing .............................................................4

2.2Transport and handling .....................................5

2.3Unpacking and handling....................................6

3 Installation of the machine .....................................7

4 Unblocking the machine.........................................8

5 Commissioning ....................................................10

5.1 Hardware layout .............................................10

5.2Connections .................................................... 11

XENON 5.3Switching on for the first time ..........................16

5.4 Switching off...................................................17

C2. Installation
5.5Operations after abnormal main power

failure..............................................................17

6 Unblocking of Z axis ............................................18

7 Leveling of the machine .......................................18

8 Filling of Deionizing resin and clean water...........19

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1. Technical data

Main machine
Overall size 1780x1350x2015 mm
Total weight 2100 Kg
Work tank size 1190x832x470 mm
Max. work-piece size 800x500x200 mm
Bed bottom to floor 130mm

Work table
Size 740x400mm
Max. work-piece weight 350 Kg
Table to floor 985mm

Coordinate axes
X、Y、Z travel 350/250/220mm
U、V travel 90mm
Max. taper angle ±15o/150mm
X、Y、U、V minimum resolution 0.5µm
Z minimum resolution 0.0020mm
Position accuracy ISO230-2
Bidirectional accuracy A 0.010mm
Unidirectional accuracy R↑or R↓ 0.005mm
Reversal value 0.003mm

Dielectric unit
Overall size 1190x690x1270mm
Volume 150L
Power of circulating pump 0.9KW
Power of flushing pump 1.5KW
Accuracy of filter cartridge 0.005mm
Number of filter cartridges 4
Cartridge size Φ144.5xΦ32x375mm (from outside to inside)
Deionizing resin 10L

Cabinet
Overall size 1040x650x1780mm
Weight 310Kg
Maximum output power 5KVA
Maximum machining current 25A
Standard power supply voltage 3×380V/3×400 V 5 KVA
Full load current 7.6A
Power supply frequency 50/60Hz
Memory 20G hard disk
Input mode MDI，3.5" floppy disk, DNC
CRT 15" color display
Number of controlled axes 5，four simultaneous
Command mode Incremental / absolute
Measure unit Metric / inch

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2. Packing and handling

2.1 Packing

The complete machine tool is packed in 3 crates:

LxWxH Gross Weight

Main
machine 2180x1800x2230mm 2700kg
crate
Cabinet
1300x1050x2150mm 540kg
crate
Dielectric
1400x1350x1630mm 500kg
crate

Comply with the direction arrows shown

on the crate

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2.2 Transport and handling

The crates are to be loaded using either:

• A crane, with a rated capacity higher than

the weight of the package.

• A forklift, with a minimum fork length of 3/4 of

crate dimension, so that the crate remains
stable.

Important:
During handling and transportation of
machine:
• The crate must be kept upright, according
to the arrow on the crate side
• Shock and vibration should be avoided.

3/4 of crate dimension at least.

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2.3 Unpacking and handling

Note: After unpacking, if those

problems are found out such as the
damage, quality problems, imperfect 1
problems of the XENON machine and
5
so on, you should first take photos 2
for them please, and then inform the
Agie Charmills‘s agent to let the
persons, who were authorized by the
agent or the company, confirm and
then repair. Repaired the machine
without authorization, Beijing 4 3
Charmills would disclaim all
responsibility.

Unpacking consists of removing the

machine as a whole from the wooden
pallet on which it was transported.

• If the package is a crate, first remove

the top of the crate, then the side
panels.

Or first remove the screws that fix the

crate to the pallet, and then lift the
crate to expose the machine, as
shown in the figure.

• Remove the accessory packages.

• Position the machine at the desired

place.

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3. Installation of the machine

• Environmental requirements
[1] The air must be clean and dust-free and no direct sunlight.
[2] Avoid premises in which the air is contaminated with abrasive particles (grinding machine room)
and which is far from vibration source.
[3] Avoid high humidity areas (relative humidity should be between 40% and 80%).
[4] Permissible ambient temperature range:
for guaranteed accuracy: 20 °C ± 3°C
for operation of the equipment: 15°C to 30°C.
[5] Air source for semi-automatic threading (As shown picture on the right side) :
Pressure: about 0.5 MPa
Flow rate:≥100 L/min， 1-Coupling 2. Plastic Pipe: Ø6
• Power supply requirements:
– Voltage: must be conform to that printed on the machine nameplate.
– Frequency, phase: 50Hz/60Hz 3 phases with an earth wire, every wire
cross-section: 2.5mm2
– Voltage fluctuation allowance: ±10%

Note: The local related requirements to power supply connection must be observed. Good
earthing must be secured with earth resistance no more than 1 Ω.
BAC has configured the generator for standard voltages: 380V/400V. If the user’s power supply is
380V/400V, please confirm the transformer connection way respectively and check the voltage
fluctuation, which should be less than 10%. If the user’s supply is not of standard voltages, an external
transformer (option) will be needed. For the connection way of the transformer, refer to labels on it.
• Machine installation plan

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Note: 1. Dimensions around the machine in this figure are the minimum.
2.“▲’s in this figure are the locations of feet of machine.
3.The height of room for the machine should be more than 2.2m。

4. Unblocking the machine

Those parts of the machine that are
subjected to movement during
transportation are locked in place with the
red appropriate locking devices. All the
locking devices with their related screws
must be removed and kept in safe place
for any possible removal of the machine.

• Unlocking of X axis

[1] Unscrew and remove 8(M5 screws (1)

which fix the side cover (2) on the left
of the table, remove the cover (2) to
expose the red locking block (3),

[2] Unscrew 4(M8 screws (4) and remove

the red locking block (3),

[3] Replace the cover sheet（2）.

• Unblocking of Y axis

[1] Unscrew 4 ( M8 screws (2）fixing the

red locking block (1) near Y motor, and
remove the red block (1),

[2] Fix the bellows（3）correctly.

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• Unblocking of U, V-axes
[1] Unscrew 15 M5 screws (3) fixing the
upper and middle cover (1 and 2) and
remove the two covers to expose U
locking block (5) and V locking block (4),

[2] Unscrew 8-M8 screws (6) fixing the two

locking blocks and remove the two red
blocks,

[3] Replace the two covers（1）and（2）.

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5. Commissioning
5.1 Hardware layout

Legends:
KM1-Main contactor for TM1
KM2-Circulation Pump
FC1-Inverter

Main machine
Legends:
(1) Sheath for polarity cables
(2) Sheath for dielectric unit cables
(3) Sheath for main machine cables

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5.2 Connections
• Connection of main machine and
generator

[1] Open the cabinet front door (1), and the

right side door (2),

[2] Open the left side cover（3）and the

back cover（4）,

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[3] Fix the three sheaths as shown in the

attached figure,

Legends:
(1) Sheath for polarity cables
(2) Sheath for dielectric unit cables
(3) Sheath for machine cables

[4] Connect machine grounding wire to the

grounding bar (1), and also fix the
naked shield onto the grounding bar
(1).

[5] Cables going to BAB-B33main board,

SUS-B02board, KM1 contactor and
transducer pass through the left side of
the cabinet while others go through the
right side.

[6] Connect the cables between main machine and the generator according to the following drawing.

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• Connection of main machine with

dielectric unit

Insert the dielectric unit cable plugs (1) into

the main machine sockets (2). And then fix
the sheath (3) to the fixing hole (4).
(1)

(3)

(2)

(4)

Connection of circulating pump

Connect PE to terminal block first, then the U6, V6 and W6 to KM2 orderly.

• Connection of main power supply cable

[1] Open the cabinet front door,

[2] Pass the power supply cable through the cabinet

bottom to the inside of the cabinet,

[3] Connect power supply cords to the terminal block (1).

Terminal block (1)

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•Connection of inverter
[1] Open the cabinet front door;

[2] Find the cable of U/T1, V/T2, W/T3, PE on the machine

for the high pressure pump

[3] Open the cover of the inverter FC1;

Note: first to connect PE, second phase leads!

[4] Connect the cables of U/T1, V/T2, W/T3 as follows:

please refer to the maintenance drawing on the page of Pump FC1: Inverter
and level switch control

- +1 +2
R/L1 S/L2 T/L3 B1 B2 U/T1 V/T2 W/T2

Input Pump1: High pressure pump

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After finished connection, take away the fix

lawyer from the cabinet （the fix lawyer only is
used for transportation）.

fix lawyer

5.3 Switching on for the first time

Caution: before switching on, it is necessary to confirm correct cables connection and
good boards installation.

[1] Connect the power supply cord to the

mains network;
[2] Place the main switch (1) in the ON (2)
position;
[3] Press starting switch (2) to power on
the generator and after a few seconds
the default screen displays. The
switching on ends.

(1)

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5.4 Switching off

• Normally switching off

By normally switching off we mean that
upon receiving switching-off signals, the
system first saves system data and then
shuts off automatically.

[1] Press OFF button (3). The system

executes automatic-off program.
[2] After switching off, place main switch (1)
in the Off- position to cut off mains
supply.

Caution: before automatic-off program ends, don’t place the main switch in the OFF
position, otherwise the system will not be able to save system data that exist in the system
before power-off.
• Abnormally switching off
By abnormally switching off we mean switching off under urgent conditions. In that case, the system will
not save system data and exits from the current program directly to shut off.

[1] Press emergency stop button (5), the system will shut off.
[2] After shut-off, place the main switch (1) in the OFF position to cut off the mains supply.

Caution: Under special conditions, if the main switch (1) is directly placed in the OFF
position to switch the system off instead of pressing off button (3) or emergency stop button (5),
the data of the current program will lose completely and UPS power supply will not shut off
automatically with the indicator (4) on all the time. To shut off UPS power supply, manually
press B1 button (6) on SUS-B02 board.

5.5 Operations after abnormal main power failure

When power failure occurs in the mains network and if you hope the system will automatically recover
the operation before power failure when power returns normal, please keep the current status of the
machine. In that case, the UPS power supply indicator (4) will be lit all the time, which means the
system is in the waiting state for power recovery. Upon power recovery the system will start
automatically and continue the interrupted operation by the power failure (under “No Man” is opened).

If you don’t hope to go on with the interrupted operation after power recovery, proceed as follows:
[1] Place main switch (1) in the OFF position,

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[2] Press B1 button (6) on SUS-B02 to

turn off UPS power supply, and UPS
indicator goes out.
[3] After power recovery, to restart the
system you must press the starting button
(2).

Note: The automatic recovery of the prior-to-power-failure program cannot be achieved

at present.
You must shut off the Generator and then restart it by pressing the starting button (2),
otherwise it is still in the waiting state, although the mains network work normally, when
voltage pulsation occurs greatly for a moment causes power supply failure.

6. Unblocking of Z axis
[1] Open the work tank door

[2] Lift Z-axis by pressing “+Z” key in the

hand-box or by selecting “+Z” in
Manual Operation dialogue box or say
the page and remove the wooden
block that supports Z- axis.

Wooden block

7. Leveling of the machine

[1] Grease the screws of machine feet,
[2] Move table to the middle of X axis and positive limit,
[3] Adjust the screws to make the bed bottom 130mm away from the floor,
[4] Make a front screw hang in the air and level the machine by using the other three screws:
Requirements: level indicator, less than 80µm/m in X, 40µm/m in Y.
[5] Appropriately adjust the screw hanging in the air，
[6] Check if X level indicator changes while Y axis is moving. If changes occur, readjust the screw
hanging in the air till the machine stands stable.

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8. Filling of Deionizing resin and clean water

Preparing 180 liters of clean water or distilled water in advance.
8.1 Fill the deionising bottle with 10 liters of resin, Proceed as follows:
• Remove the bottle cover
• Open the 10L-bag of resin and pour it into the deionising bottle quickly.
• Put the cover back on again immediately.
Important: Deionising resin oxidizes in the air.
8.2 Fill the pure water or distilled water into the clean tank until it overflows into the dirty tank,
then fill the other water into the dirty tank up to exceeding the “working water” level.
Check that there are no extraneous material such as packing material, left in the clean tank and the
dirty tank.
Make sure that drain pipe of deionising is directed to the clean tank.
It is forbidden that Use Top water or Industrial water, etc., as a substitute for the clean water or
distilled water. Because the qualified machining fluid must be less than 5µm, and less than 10 µ
s/cm.
More information can be seen on the Chapter7.2 Replace deionising resin.

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