CTV200 250 Pu V1.0 en

P lanning documentation
covering preparatory
measures
1 WHAT IS THE PURPOSE OF THIS DOCUMENTATION? .... 3

1.1 Symbol and information explanation .............................. 3
2 PREPARATORY MEASURES NECESSARY ........................ 4

2.1 Services to be provided by the customer ....................... 4
2.2 Foundation properties .................................................... 4
2.3 Environmental protection measures ............................... 5
2.4 Planning information....................................................... 5
2.5 Foundation plan CTV 200/250 ....................................... 6
2.5.1 Machine anchoring CTV 200/250....................... 7
2.5.2 Oil bath anchoring (option) ................................. 7
2.6 Installation plan CTV 200/250 ........................................ 8
2.7 Space requirement CTV 200/250 ................................. 10
2.8 Foundation plan transport belt with prism
shaped mountings ........................................................ 12
2.8.1 Fitting the transport belt with prism shaped
mountings......................................................... 13
2.9 Installation plan EWAB transport belts ......................... 14
2.9.1 Mounting EWAB transport belts ....................... 15
3 ELECTRIC............................................................................. 16
3.1 Protective measures..................................................... 16
3.2 Main fuse, machine without pre-transformer ................ 16
3.3 Electrical data ............................................................... 17
3.4 Info concerning machines with pre-transformer ........... 18
3.5 Empty conduits for external data transmission............. 18
4 AMBIENT CONDITIONS FOR THE MACHINE .................... 19

4.1 Hydraulic ...................................................................... 19
4.2 Chip disposal ................................................................ 20
4.3 Pneumatics (option) ..................................................... 20
Planning documentation V 1.0 page 1

CTV 200/250 Doc. no.: DEP001G0
5 MATERIALS REQUIRED FOR A START UP....................... 21
5.1 Lubricants and coolants ............................................... 21
5.1.1 Lubricant filling levels ....................................... 21
5.1.2 Coolant filling quantity ...................................... 21
5.1.3 Lubricant table .................................................. 22
5.1.4 Coolant filling quantities ................................... 23
5.1.5 Handling lubricants and coolants ..................... 24
5.1.6 Pump and container for changing hydraulic
oil and coolants ................................................ 25
6 FIXING MATERIAL ............................................................... 26

6.1 Fixing the machine ....................................................... 26
6.2 Fixing the transport belt ............................................... 26
6.3 Pre-transformer fixing ................................................... 27
6.4 Tools............................................................................. 27
6.5 Electrical tools .............................................................. 27
6.6 Fitting instructions for Hilti composite anchors ............. 28
The publisher reserves all rights, including reprinting and copying of parts of this handbook and its translation.
Reproduction or copying with an electronic copying system of any part of this manual is forbidden unless approved in writing, this also inclu-
des for learning and training purposes.
The original (German) language version of the manufacturer is binding for technical contents.
Issue: V 1.0
Ident No.: 7004203
© 2000 GILDEMEISTER Drehmaschinen GmbH
page 2 V 1.0 Planning documentation

Doc. no.: DEP001G0 CTV 200/250
1.1 Symbol and information explanation
1 What is the purpose of this documentation?
1 What is the purpose of this documentation?

This documentation is intended for those responsible for the machine
installation and their employees, permitting the preparation of the place
of installation and its surroundings, so that the machine can be imme-
diately set up and connected when delivered.
• Content
- Foundation details
- Space requirement
- Connected values for the necessary utilities
- List of materials to be made available
As a service GILDEMEISTER offers the further training and education

of qualified personnel. The utilisation of the possibilities which the ma-
chine offers is dependent upon the qualification level of the user. For
this reason we recommend to clarify in advance whether your staff
have the necessary knowledge. Plan your schedule so that all training
measures are completed prior to the delivery of the machine.
If necessary, please contact our training department in advance

under the telephone number 05205-74-0.
1.1 Symbol and information explanation
Warning, Caution!
This symbol is used to give a warning of possible danger of injury or to
health irrespective of the severity of the danger.
This symbol is used to highlight special instructions or warning where

material damage could result.
This symbol indicates advantageous and economical applications.

CTV 200/250 Doc.no.: DEP001G0
2.1 Services to be provided by the customer
2 Preparatory measures necessary
2.1 Services to be provided by the customer
The final customer must prepare the machine installation place (foun-
dations, required energy etc.), the on-house transport of the machine
to the place of installation, the installation of the machine, the connec-
tion of the required utilities and the cleaning and degreasing of the ma-
chine, respectively provision of the required lubricants and coolants
The first start up (alignment and function test) of the machine is made
by authorised personnel of the machine manufacturer!
2.2 Foundation properties
• In order to work in accordance with the intended purposes, the ma-

chine must be permanently level and horizontal.
For this reason ensure that the foundations are sufficiently rigid with
a flatness of ± 2 mm(0.078“).
Ensure that the complete installation surface area (including the pe-
riphery units) has a flatness of ± 2 mm (0.078“).
The machine requires a full length reinforced concrete floor or a ma-

chine foundation of at least 300 mm (11.811“) deep.
• Ensure that there is no expansion joint in the foundations beneath

the machine bed. When using a bar feeding unit ensure that the
foundations are one piece (without expansion joint).
Have the foundation size determined in accordance with the ground

properties by a structural engineer in accordance with DIN 4024,
part 1. Refer to the enclosed foundation and loading diagrams for
the foundation minimum dimensions.

Doc.no.: DEP001G0 CTV 200/250
2.3 Environmental protection measures
• The pressure resistance of the foundation concrete (minimum con-

crete strength class B25 - 25 N/mm2 as per DIN 1045) must be at
least 8.3 N/mm2 with reinforced concrete and 7.0 N/mm2 for non-re-
inforced concrete.
The machine (and peripheral equipment) must be dowelled to the foun-

dations.
2.3 Environmental protection measures
Install the machine in accordance with the individual local environmen-

tal protection measures.
Take this into consideration when planning the foundations.
Position the machine in an oil bath, otherwise ensure that the

foundations are oil tight.
When designing the oil bath ensure that free space is provided for ex-
changing or dismantling the chip conveyor.
2.4 Planning information
The surface dimensions stated in this documentation are only valid for
the machines with the shown peripheral equipment. If other peripheral
equipment is used, an order based plan will be handed over to you after
completion for approval.
Normally the machine is delivered by lorry having a total height of 4 m

(157.480“).

2.5 Foundation plan CTV 200/250
Scale 1:50
Machine zero point
Operating side
Switch cabinet
1 Steel reinforced
ceiling
2 Chip conveyor
3 Oil mist separator

(Option)
4 Workpiece feeding
Point loading lb.

M1 M2 M3 M4 M5 M6
static 674.157 4943.202 674.157 5393.258 2696.629 2696.629
dynamic 4494.382 5393.258 898.876 7640.449 4494.382 5393.258

2.5.1 Machine anchoring CTV 200/250
1 threaded bolts DIN 976 M12x120* HILTI

Detail X1 Ident.-No. 2252051
2 nut DIN 934 M12

Ident.-No. 0001346
3 washer 37x13x3
Ident-No. 2292317
4 pressure screw SW17 M24x1.5x60
5 pressure plate 30x70x100

Ident-No. 0933618
6 internally threaded sleeve HIS-N M12x125 HILTI

Ident-No. 2252048
7 composite (adhesive) anchor system HVU

M16x125 HILTI Ident-No. 2252050
2.5.2 Oil bath anchoring (option)
1 threaded bolts DIN 976 M8x70 HILTI

Ident-No. 2270469
2 nut DIN 934 M8

Ident-No. 0001341
3 washer 40x8,4x3
Ident-No. 2292321
6 internally threaded sleeve HVU M8x90 HILTI

Ident-No. 2270464
7 mortar cartridge HVU M10x90 HILTI

Ident-No. 2270465
* With oil bath threaded bolts DIN 976 M12x170 HILTI Ident. No. 2285279

2.6 Installation plan CTV 200/250
Scale 1:50

Machine zero point
Operating side
Switch cabinet connection
Switch cabinet
1 Hydraulic unit
2 Chip conveyor
3 Oil mist separator (Option)
4 Pre-Transformer (Option)
5 Hood opened
6 Workpiece feeding (design as per individual installation plans)
7 Slide traverse area
8 Coolant tank 500 l (110 gal UK) (Option)
P Pneumatic connection

2.7 Space requirement CTV 200/250
Not only does the machine require space but also sufficient space must
be provided in its immediate proximity.
• Space for operator movement

• Lay-up areas
• Open doors
• Space for free access around the machine
• Other equipment, e.g. chip containers
• Space for maintenance and repair work, e.g. changing worn parts

Scale 1:50
Machine zero point 1 Chip conveyor 3 Workpiece feeding

(*) dimensions A, B
Operating side 2 Options coolant container, pre-trans- dependent upon
former (as per installation plan) design
Turning centre (**) with optional coolant units the
dimension ( ) increases

2.8 Foundation plan transport belt with prism shaped mountings
Scale 1:50
Machine zero point
Operating side

2.8.1 Fitting the transport belt with prism shaped mountings

2.9 Installation plan EWAB transport belts
Scale 1:50
Machine zero point
Operating side
Values in brackets only apply to the 500 mm (19.68’’) long EWAB belts version.

2.9.1 Mounting EWAB transport belts
Detail Y1
1 threaded bolts DIN 976 M12x80 HILTI

Ident. No. 2270428
2 nut DIN 934 M12

Ident. No. 0001346
3 washer 35x13
Ident-No. 0463539
4 internally threaded sleeve HIS-N M12x125 HILTI

Ident-No.2252050
5 composite (adhesive) anchor system HVU M16x125 HILTI

Ident-No. 2252050

3.1 Protective measures
3 Electric
3 Electric
3.1 Protective measures
This machine has been designed for grounding wire protection

measures (protective earth). Do not operate on networks with leakage
current protection systems.
This is due to the drive technology used with AC motors and is permis-
sible in accordance with DIN VDE 0160/5.88 (Pos. 6.5.2)
or pr En 50 178/11.94 (Pos. 5.2.11).
If a leakage current protection device is prescribed at the place of in-

stallation, a special agreement must be reached with your local electri-
cal supply company with reference to the stated regulation. Please
contact GILDEMEISTER Drehmaschinen GmbH should unexpected
problems be encountered.
If an FI-protective switch is absolutely necessary ensure that the ma-

chine is connected with a disconnect pre-transformer.
3.2 Main fuse, machine without pre-transformer
Ensure that the overcurrent protection device (main fuse) for the main
cable is installed outside the machine. This is not included in our scope
of delivery.

3.3 Electrical data
3 Electric
3.3 Electrical data
Five terminals are provided in the switch cabinet or in the pre-trans-

former for the electrical connection of the machine.
Operating voltage (U) 400 V ± 10% 460/ 480/ 500 V ± 10%* 230 V ± 10 %*
Phases L1, L2, L3 L1, L2, L3 L1, L2, L3
Protective earth PE PE PE
Neutral conductor (Only N N N

required for service outlet)
Main fuse (slow blow) 80 A 80 A 160 A
Nominal current (I) 72 A 72 A 148 A
Frequency (f)** 50 Hz ± 1% 50 Hz ± 1% 50 Hz ± 1%
Nominal apparent power (S) 50 kVA 50 kVA 50 kVA
Conductor cross section (A) 25 mm2 25 mm2 70 mm2

(Supply line) (0.98 sq.in.) (0.98 sq.in.) (2.75 sq.in.)
* Pre-transformer required 400 V ± 10%

** Frequency 60 Hz: Option 60 Hz necessary
The stated nominal apparent power (S in kVA) refers to the maximum

equipping stage of the machine. The use of regulated drives may briefly
result in an approx. 50% higher rating in the operating mode S6 (=
40%).
The machine is designed for connection to the four conductor system

(three phases and a PE conductor). A loadable neutral conductor is not
required.
The socket in the switch cabinet (for service purposes 230 V,

fuse 6.3 A) can only be used with an existing N conductor.

3.4 Info concerning machines with pre-transformer
3 Electric
3.4 Info concerning machines with pre-transformer
The cable connection between overcurrent protection device (main

fuse) and the separate pre-transformer is dependent upon the custom-
er's operating voltage. The customer must supply a corresponding
short circuit protection.
The connection cable between the pre-transformer and the machine

forms part of our scope of delivery (in accordance with the installation
location in the installation plan).
3.5 Empty conduits for external data transmission
Fit the corresponding metal conduits for the data lines if external data
transmission is planned.
Do not route data lines directly beside or crossing power lines.

4.1 Hydraulic
4 Ambient conditions for the machine

• Permissible ambient temperature: +15° to + 35 °C
(+59 deg.F to +95 deg.F)
• Maximum relative humidity: 75%
• Maximum installation height: 1000 m (3280 ft.) above
sea level
Special operating conditions are applicable if one of these values is ex-

ceeded at the place of installation, e.g.
• Installation in rooms with a high level or dust or a corrosive atmos-

phere
• Effects of strong electrical or magnetic fields
• Effects of extreme temperatures, e.g. sun radiation
• Installation in explosion or explosion endangered areas
• If strong vibrations, shocks or impacts occur,
contact your GILDEMEISTER representative.
4.1 Hydraulic
Only use clean oil (minimum degree of purity 25 µm)

4.2 Chip disposal
4.2 Chip disposal
A chip bath is required in order to remove chips from the chip conveyor.
This must be designed so that it is not possible to reach into the ejection
shaft of the chip conveyor with the chip carriage positioned below.
The chip carriage should have a device for coolant return flow in the
coolant holder or the machine chip conveyor. This saves costs and pro-
tects the environment.
4.3 Pneumatics (option)
If the use of handling system and peripheral units requires compressed

air, ensure that an operating pressure of 4-8 bar (59-117 psi), air quality
in accordance with ISO 8573.1 is available.
• Solid matter/particle size <40 my, quality class 5

• Water/pressure dew point <+3°C, quality class 4
• Oil/residual oil content < 0.1 mg/m³=°C, quality class 2

5.1 Lubricants and coolants
5 Materials required for a start up
Ensure that coolants and lubricants do not react in a way adversely af-
fecting their function. The coolant must react neutrally with regard to
the lubricant. Based on experience we recommend to have the compat-
ibility of the lubricants and coolants confirmed in writing from the sup-
pliers when obtaining lubricants and coolants from various sources
5.1.1 Lubricant filling levels
• 14 l (3.03 gal UK) hydraulic oil for the tank and pipe system
• 1,8 l (0.39 gal UK) liquid grease (capacity of the fresh oil container)
• 1 kg (2.205 lb.) heavy duty grease paste for lubricating the chuck
5.1.2 Coolant filling quantity
Tyfocor or a similar coolant quality is harmful. Be cautious when han-

dling such material, observe the manufacturer’s instructions.
• 19 l (4.11 gal UK) coolant for the cooling unit

Mix ratio:
- Water H2O 70 %
- Tyfocor 30 %

5.1.3 Lubricant table
The following are several brand names as a guide for the selection of
lubricants.
(Selection and sequence of the makes does not represent a corre-
sponding quality evaluation.)
Manu- Lubricating grease Hydraulic oil Lubricating

facturer ISO L-XABHA00/000 ISO HM32 grease*
DIN KP00/000 G-10 DIN HLP32 ISO XM2
DIN K2K
ARAL Vitamin GF 32 ARALUB HI2

Vitamin GE 32
BP Energol HLP-D 32 Energrease LS 2

Energol HLP 32
Castrol HYSPIN AWS 32 LZV-EP

VARIO HDX
DEA Aastron HLP 32 Glissando 20

Actis HLPD 32
elf ELFOLNA 32
ELFOLNA DS 32
ELFOLNA HMD 32
Esso NUTO H32 BEACON 2
Fuchs RENOLIN MR 10 RENOLIT FWA 160

RENOLIN B 10
Klüber Microglube GB00
Mobil Mobil DTE 24 Mobilux 2
Shell Tellus oil 32 Alvania grease G 2

Hydrol DO 32
Zeller + Gmelin Divinol

Lithogrease 00
No warranty can be accepted for machine damage resulting from the

use of unsuitable lubricants.
* Lubrication grease for clamping means (chuck):

Please note the clamping means manufacturer’s information!

5.1.4 Coolant filling quantities
• 190 l (41.21 gal UK) coolant lubricant

(Capacity of the chip conveyor)
The following companies offer specially matched selections of lubricat-
ing oils and coolants:
(The manufacturer sequence does not represent a corresponding
quality evaluation).
Manufacturer Coolant
Aral Sarol range
Castrol Hysol RD
Fuchs Ratak-Resist 68 CF
Mobil Mobilmet 151/221 range
Adhere to the mixing ratio recommended by the manufacturers:
• e.g. too thin: oxidisation of working space and workpieces

• e.g. too thick: insufficient cooling effect
• Ensure that the ph value of the coolant used is within the range
8.5 - 9.5.
Contact your coolant manufacturer for more information.

5.1.5 Handling lubricants and coolants
Oils, lubricants and coolants

These products imply a possible danger to health and environment due
to their contents (additives).
Selection and application are exclusively in the hands of the user. For
handling these materials the operating instructions prepared by the
user should include:
• Material designation
• Notification of dangers to persons and the environment
• Protection measures and behaviour rules, e.g.
- Wear protective gloves made of a resistant plastic
- Avoid contact with skin and eyes
- Do not breath in fumes and vapours
- Fire, naked flame and smoking are forbidden
Please clarify in advance how you can dispose of lubricants and cool-
ants in an environmentally sound manner.
Lubricant vapours can be produced during turning. GILDEMEISTER of-

fers oil mist separators for extraction purposes.
Danger of fire and explosion

exists when using coolants having 15% or more oil content or when us-
ing flammable coolant lubricants in conjunction with an air tight, en-
closed working space.
Please contact the manufacturer with reference to preventive meas-

ures.

5.1.6 Pump and container for changing hydraulic oil and coolants
Regular maintenance measures include the changing of lubricants and

coolant lubricants. The following is required for this purpose:
• a simple pump to draw off the liquid

• a container to hold the drawn off liquid (up to 250 l*) (54.22 gal UK).
* 250 l (54.22 gal UK) may be exceeded with machines having a special coolant
system

6.1 Fixing the machine
6 Fixing material
6 Fixing material
Fit the adhesive anchors in accordance with the HILTI instructions (re-
fer to the adhesive anchor accompanying instructions).
6.1 Fixing the machine
The machine scope of delivery includes the following fixing elements:
- 6 pressure screws SW17 M24x1.5x60

Wn 90103 Id. No. 004535
- 6 washers 35x13 Id.No. 0463539
- 6 nuts DIN934 M12, Id.No. 0001346
- 6 threaded bolts DIN976 M12x125, Hilti
- 6 internally threaded sleeves HIS-N M12x125, Hilti
- 6 adhesive capsules HVU M16x125, Hilti
- 6 pressure plates 90x70x30
6.2 Fixing the transport belt
The fixing elements are part of the scope of delivery and are make de-
pendent:
- threaded bolts
- internally threaded sleeves
- adhesive capsules
- pressure discs

6.3 Pre-transformer fixing
6 Fixing material
6.3 Pre-transformer fixing
The scope of delivery includes the following fixing elements:
- 2 internally threaded sleeves

- 2 composite (adhesive) anchors
- 2 threaded bolts
- 2 nuts
6.4 Tools
No special tools are required.
- Standard width across flats 7 to 36 mm (0.28’’ to 1.42’’)

- Standard Allan keys 2 to 14 mm (0.08’’ to 0.55’’)
- Crowbar for removing the transport securing system on the lorry
- 7 mm (0.28’’) square spanner
6.5 Electrical tools
- Standard screwdrivers
- 3 mm (0.12’’) two-way key
- Rotating field measuring instrument

6.6 Fitting instructions for Hilti composite anchors
6 Fixing material
6.6 Fitting instructions for Hilti composite anchors

Mortar cartridge HVU M16*125 and internal threaded collar HIS-N M12*125
1. Producing the drilled hole

Match the position of the drilled hole with the armouring so that damage to the
armouring is avoided. Drill the hole at right angles to the surface of the anchoring
ground using a hammer drill.
Drilled hole depth: 125 mm (4.92’’)
Drilled hole diameter: 22 mm (0.86’’)
2. Cleaning the drilled hole

Remove the drill residue from the drilled hole using a blow out pump or a vacu-
um cleaner.
3. Fitting the mortar cartridge HVU

Push the mortar cartridge down to the bottom of the drilled hole with the pointed
end first.
4. Fitting the internal threaded collar HIS-N

Drive in the internally threaded collar using setting tools (Allan screw M16) and
a boring machine at a speed between 250 and 750 r.p.m. Switch off the boring
machine immediately the drilled hole depth (threaded collar is flush with the bot-
tom) is reached, in order to avoid pulling out the mortar.
5. Curing time
Do not touch the internal thread during the curing time.
6. Curing time
Do not unscrew the setting tools (Allan screw) from the internal threaded collar
until the curing is completed.
Drill hole temperature > 20 °C > 10 °C > 0 °C

>68 deg.F >50 deg.F >32 deg.F
Waiting period setting 20 Min. 30 Min. 1 hour

and loading prior to applying
the tightening torque
7. Fixing the component

Secure the machine using a threaded bolt AM 12*120 (4.6), nut and washer.
Tightening torque: 30 Nm (2.22 ft.Ib)
34720065 Screwing in depth in HIS-N:12 - 30 mm (0.47’’-1.18’’)


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P lanning documentation

1 WHAT IS THE PURPOSE OF THIS DOCUMENTATION? .... 3

2 PREPARATORY MEASURES NECESSARY ........................ 4

4 AMBIENT CONDITIONS FOR THE MACHINE .................... 19

Planning documentation V 1.0 page 1

6 FIXING MATERIAL ............................................................... 26

page 2 V 1.0 Planning documentation

1 What is the purpose of this documentation?

As a service GILDEMEISTER offers the further training and education

If necessary, please contact our training department in advance

1.1 Symbol and information explanation

This symbol is used to highlight special instructions or warning where

This symbol indicates advantageous and economical applications.

Planning documentation V 1.0 page 3

2 Preparatory measures necessary

2.1 Services to be provided by the customer

2.2 Foundation properties

• In order to work in accordance with the intended purposes, the ma-

The machine requires a full length reinforced concrete floor or a ma-

• Ensure that there is no expansion joint in the foundations beneath

Have the foundation size determined in accordance with the ground

page 4 V 1.0 Planning documentation

• The pressure resistance of the foundation concrete (minimum con-

The machine (and peripheral equipment) must be dowelled to the foun-

2.3 Environmental protection measures

Install the machine in accordance with the individual local environmen-

Position the machine in an oil bath, otherwise ensure that the

2.4 Planning information

Normally the machine is delivered by lorry having a total height of 4 m

Planning documentation V 1.0 page 5

2.5 Foundation plan CTV 200/250

Machine zero point

3 Oil mist separator

Point loading lb.

page 6 V 1.0 Planning documentation

2.5.1 Machine anchoring CTV 200/250

1 threaded bolts DIN 976 M12x120* HILTI

2 nut DIN 934 M12

4 pressure screw SW17 M24x1.5x60

5 pressure plate 30x70x100

6 internally threaded sleeve HIS-N M12x125 HILTI

7 composite (adhesive) anchor system HVU

2.5.2 Oil bath anchoring (option)

1 threaded bolts DIN 976 M8x70 HILTI

2 nut DIN 934 M8

6 internally threaded sleeve HVU M8x90 HILTI

7 mortar cartridge HVU M10x90 HILTI

Planning documentation V 1.0 page 7

2.6 Installation plan CTV 200/250

page 8 V 1.0 Planning documentation

Machine zero point

Switch cabinet connection

3 Oil mist separator (Option)

6 Workpiece feeding (design as per individual installation plans)

7 Slide traverse area

8 Coolant tank 500 l (110 gal UK) (Option)

Planning documentation V 1.0 page 9

2.7 Space requirement CTV 200/250

• Space for operator movement

page 10 V 1.0 Planning documentation

Machine zero point 1 Chip conveyor 3 Workpiece feeding

Planning documentation V 1.0 page 11

2.8 Foundation plan transport belt with prism shaped mountings