03.

2005
 Contents

1 Technical Data............................................. 3
2 Dimensions and weights of packages ......... 4

3 Transport means ......................................... 4

4 Transport..................................................... 4

5 Unpacking the System Units ....................... 5

5.1 Main machine ........................................ 5

5.2 Generator .............................................. 7

5.3 Dielectric Unit ........................................ 9

6 Remove transportation securing devices .... 9

SP Series 6.1 Remove the work table

C2. Installation
securing device ...................................... 9

6.2 Remove the saddle securing catches.... 9

6.3 Remove the spindle shipping brace .... 10

7 Installation of the machine ........................ 10

7.1 Instructions for installing

the machine ......................................... 10

7.2 Auxiliary Equipment............................. 10

7.3 Installation of the machine................... 11

8 Level the machine ..................................... 15

9 Make the connections ............................... 15

9.1 Connect work tank to dielectric unit..... 15

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9.2 Electrical connections.......................... 15

10 Start-up ...................................................... 17

10.1 Checks before start-up ...................... 17

10.2 Start up .............................................. 17

10.3 Setup of system................................. 17

11 Fill the dielectric unit .................................. 18

12 Functional checks ...................................... 18

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1 Technical Data

Main machine Unit SP 1 SP 3

Machine external mm 1200×1500×2200 1700×2360×2480
dimension(L×W×H)
Net weight of kg 2080 3680
main machine
Nominal work-piece mm 790×480×260 1040×700×420
dimensions(L×W×H)
Work tank dimensions mm 1000×550×360 1330×820×500
(L×W×H)
Work table dimensions mm 500×320 800×500
(L×W)
Worktank capacity L 178 460
X travel mm 320 500
Y travel mm 250 400
Z travel mm 250 400
Maximum table kg 400 1000
workload
Maximum ram workload kg 60 100
Dielectric unit

Reservoir capacity liters 290 700

Dielectric pump’s flow L/min 20~120 20~120
rate (single pump)
Dielectric filter medium paper cartridge
External dimension mm 1200×720×700 1700×1200×900
Weight kg 300 500
Generator

Model SP50/SP100 (optional) SP50/ SP100 (optional)

External dimension mm 623×533×1714 623×533×1714
Weight kg 380 380
Display unit color CRT color CRT
Power consumption KVA 10/18 10/18
Max. machining current A 50/100 50/100
Dielectric pump

1 pump 1.1 KVA

Environmental requirements

Room temperature
For guaranteed precision 20℃ ±3℃
For operation of machine 15℃ ~ 30℃

Humidity 40% ~ 80%

Sound emission < 80dB

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Performance
Max. machining current 50A/100A
Best surface roughness Ra≤0.4µm
o
Lowest electrode wear ≤0.3 /oo

2 Dimensions and weights of packages

System SP1 SP3

1.Main machine net weight(kg) 1400 2800
gross weight(kg) 2100 3600
dimension(mm) 2100×1700×2230 2100×2140×2460
2.Cabinet net weight(kg) 380 380
gross weight(kg) 540 540
dimension(mm) 1140×1000×2160 1140×1000×2160
3.Dielectric unit net weight(kg) 230 500
gross weight(kg) 400 700
dimension(mm) xx 2040×1500×1260

3 Transport means

●Fork lift truck

●Crane

4 Transport

Move the single part of the system to the installation site according to the instructions for
each one.

Caution: Move or lift the packed unit(s) or unpacked system elements only as described or
illustrated!

[1] Unload the packed system (components) from the road or rail vehicle with a fork lift truck or
elevator truck. If the crates are visibly damaged, do not unpack the system before notifying
our company and the insurance company.

Fork lift truck or elevator truck:

● lifting capacity
main machine ≥3000kg

generator ≥1200kg
● fork length ≥1830mm

● fork width <100mm

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[2] Do not drop or tip the packages.
[3] Open crates only under cover.
Warning: Airtight packing--please do not open!
- The parts of the system packed in the moisture barrier bag must remain at their place of
installation for 24 hours before opening the bag. This reduces the risk of corrosion due to
condensation.

- If there is visible damage to the system, inform our company or agents and the insurance
company. Photograph the damaged parts.

[4] Transport the system units to the place of installation. Let stand for the acclimatization
period (24 hours) before opening the bag.

5 Unpacking the System Units

The cartons of accessories delivered with the system are to be kept under lock and key
together with the dispatch documents to await check after the arrival of the commissioning
engineer.

Caution: The transport or lifting of system elements is only to take place as described or
illustrated below!

Read the following instructions carefully before unpacking and assembly.

5.1 Main machine

[1] Open the protective aluminum bag and pull it down to expose the machine.

[2] Remove the fixing

screws with a socket
spanner or an
adjustable spanner.

[3] Remove the angle braces.

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[4] Insert two steel tubes (Φ70mm, wall thinkness >10mm, length : one>1500mm, one > 2500
mm ) into lifting holes, and lift as shown in the following figure.

1. Ø70x L2 steel tube

2. Ø70xL1 steel tube

3. Soft materials

4. Brace L3

For SP1:
L1=1000mm
L2=2000mm
L3=1300mm

For SP3
L1=1500mm
L2=2500mm
L3=1800mm

Note: Soft materials should be padded where lift rope contacts the machine tool’s surface.

[5] Fit the attached machine seats, then place machine down (see Chapter 2 “installation
plan”).

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5.2 Generator

M10 screws (B) anchor

the generator to two
beams. The braces are
fixed to the pallet floor
with fixing screws (A).

[1] Pull down the

protective aluminum
shroud to expose the
generator.
[2] Remove the four fixing
screws (A).
[3] Move the generator
with a fork lift truck or a
crane with lifting
capacity: 1000kg

●Fork lift truck:

Place forks completely

underneath the cabinet from the
front or back. Carefully lift the
cabinet from its pallet. The
spacing between the forks
should be wide enough to
provide stability when lifting and
lowering the generator.

● Crane

The generator has four 25mm inner diameter eyebolts (lifting rings) to allow you to move the
unit. We recommend that you use two 610mm braces.

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CAUTION:
If you wish to lift the
generator without a brace,
it is imperative that you
proceed as shown in the
right diagram. Otherwise
you could damage the
cabinet.

[4] After lifting the generator, remove the four M10 screws (B) and the wooden beams. Screw
the four leveling screws into the base of the generator.

[5] Place the generator down.

Screw

Air deflector
[6] Install the air deflector (foe 100A
generator), packed in the packing case.
See the right figure:

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5.3 Dielectric Unit

[1] Pull down the protective aluminum shroud to expose the dielectric unit.
[2] Remove the screws securing the dielectric unit.
[3] Move the unit with a fork lift truck or crane.

● Crane

Note: Soft materials should be

padded where lift rope contacts the
unit’s surface.

● Fork lift truck

Note: Place fork completely

underneath the unit. Carefully lift
the unit from its pallet.

Screw

6 Remove transportation securing devices

6.1 Remove the work table securing device

Facing the system, remove the bellows to expose the work table securing device in red.
Remove it, then replace the bellows.

6.2 Remove the saddle securing catches

Facing SP3 machine, remove the left protection cover to expose the red securing block for
the saddle. Remove it and replace the cover. For SP1, remove the lower left plate of the
protection cover to expose the red securing block. Remove it and replace the plate.

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6.3 Remove the spindle shipping brace

[1] Keep Z+ key on the

hand-box pressed to
move the spindle upward
at middle speed.

Note: During the process,

hold the wooden support
between the platen and table
to protect worktable against
damage.

[2] Remove the wooden

support.

7 Installation of the machine

7.1 Instructions for installing the machine

Remember that the system subassemblies are extremely reliable, high precision units. So
exercise great care when installing and moving this system. Make sure that you do not subject
the subassemblies to violent impacts, or damage electric cables.

7.2 Auxiliary Equipment

The following auxiliary equipment will be needed for the installation and start-up:
• level with indication of 0.02mm/m
• mains cable (see section “Mains connection”)
• pump or siphon (for dielectric)
• grease solvent
• brush
• cleaning cloth
• scissors or knife
• general purpose tool set:
-set of Allen keys -
screwdriver -
adjustable spanner -
15 mm hex. socket -
24mm hex. Socket

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7.3 Installation of the machine

Caution: Moving or lifting system units must take place only as described or illustrated above.

Transport the system components to the final installation location and assemble according to
the installation plan.

Sequence: first the machine and then the generator.

7.3.1 Requirements of the place of installation

The choice of the place of installation is very important for a precision machine tool. The
accuracy of the work-piece depends on it.

●Vibrations
If possible, do not install this system near machines that transmit vibrations through the
foundations (loss of the precision of alignment of the machine). If sources of disturbance are
unavoidable, mount the machine on vibration-damping elements. Fixing with anchor bolts is not
necessary.

● Dust
Install the system in a room as free dust as possible. Locate your machine away from
equipment used to machine graphite. Graphite dust is highly conductive and can cause short
circuits in electronic components. Locate your machine away from grinders, sand blasters and
chip producing equipment. Dust particles from grinders, for example, are highly abrasive and
can cause abnormal wear on ball screws, rails and table.

7.3.2 Main power supply

● Power supply requirements:

Voltage: must agree with that printed on the machine name plate
Frequency, phase: 50Hz/60Hz 3 phases
Permissible variation ±10%
The cross area of the leads of the cable from input and the value of overcurrent protection
setting of supply side：
50A generator 100A generator
2 2
The cross area of the leads of the cable from input >=4mm >=4mm
Overcurrent protection setting of supply side 20A 30A
● Good earthing must be secured with earth resistance no more than 1 Ω.
● Our company has configured the generator for the customer’s voltage according to the
purchase specification. However, before turning on the system, check whether the
connections agree with the local voltage according to the connection labels on the three
transformers; and check the voltage for variations:
[1] Measure the voltage during working hours,
[2] Measure the voltage after work has ceased (lunch break or evening),
[3] If there is a greater voltage variation, a stabilizer will be needed.

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7.3.3 Installation layout

[1] Installation plan

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[2] Foundation drawings

X Y Z A B C
SP1 3000 mm 2700 mm 300 mm 1500mm 1200mm 500mm
SP3 3800 mm 4200 mm 300 mm 2360mm 1700mm 700mm

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[3] Machine feet schematics

CG

460

SP1 machine feet schematic

CG

700

SP3 machine feet schematic

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8 Level the machine

Level the machine with a precision level by

adjusting the machine feet. Place the level
(0.02/1000) at the middle of worktable top,
adjust No. 1, 2 and 3 foot (see “Installation
plans”). The inclination (from side to side and
from front to back) should be less than or
equal to 0.04/1000. Other feet are auxiliary.
foot
foot

9 Make the connections

9.1 Connect work tank to dielectric unit

Transport the dielectric unit to the final

installation location and position it in place. Level
the dielectric unit by adjusting four fixing
bolts（there have five fixing bolts for SP3
machine）. Connect oil filling hose to work tank (as
shown right).

Fix the oil return bellows to the outlet of oil

return channel and fasten it with a throat hoop.

9.2 Electrical connections

Connect control, work leads

and pump cables to machine
control enclosure. Pass pump
cables through the right side
holes and work leads cables
through the bottom hole as
shown right. The control
cables pass through the inlet in
the top. Upon completion of
connections, screw the nuts
fast.
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[1] Work leads cables connection
Connect the work leads from
generator to the terminals of
machine control enclosure,
with FS to red terminal and
FS- to the black.

[2] Pump motor connection

Connect the pump motor
cable to the KM6 contacters
in the machine control
enclosure, and the ground
wire to terminal PE on the
XT6 terminal block. See the
figure right.

[3] Control cable connection

Connect the control cable
from the machine tool to the
terminals J4, J5, J6, J7 on
the mother board BAB-7A,
terminal J4 on the IMC-B05-
01board at P15 position,
terminal J3 on the BSE-12 B
board at P1 position, and
terminals FL-10, FL-12 at
the lower left of the
generator.

[4] Power supply connection

See “Mains power supply”.

Note: 1) On the XT6 To fume extractor

terminals block, the
terminals 4 (24VAC1) and 5
(24VAC2) are left for the
user to connect work lamp,
terminals 2 (3) and 1 (16-)
for connection of a fire
extinguisher and terminals
12 (OV) and 13(SMS) for a To work lamp
fume extractor.

2) All shielded cables To fire extinguisher

(unshielded part) should connect

to ground bar securely.
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[5] Ground wire connection
Good connection of the PE terminal of generator with the input terminal of protective ground
wire must be made and the ground wire must be copper wire with cross-section large
enough.

Windscreen

Note: User need take out the windscreen from accessory box and
install it on the cabinet for 100A cabinet.

10 Start-up

10.1 Checks before start-up

[1] Check if the setting of main transformer is correct,

[2] Check if all PC boards are properly seated and secure,
[3] Check if all the connectors are plugged fast, with no loose connection.

Note: ALL the above work should be carried out exclusively by our service technicians.

10.2 Start up
After the above checks and
confirmation, perform as
follows:

[1] Turn on master switch,

[2] Release the two emergency
stop switches (one is on the
generator and the other
under the work tank),
[3] Press the green switch,
[4] Wait till the system enters
normal state and Page 1
appears on the screen.

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 upon completion of setting.

[4] Return to Page 1 and press

the PUMP button on the hand-
box to check whether the Starting / stopping
pump is rotating in the
Pump button
direction of the arrow. If not,
exchange any two phases of
the power input.
11 Fill the dielectric unit

[1] Check that there is no dielectric in the work tank or circuit.

[2] Clean the dielectric unit, then fill it.

12 Functional checks

Check the functions of the following:

[1] System software,
[2] Movement of X, Y and Z axes,
[3] limit and float switch,
[4] dielectric pump motor,
[5] all fans

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