1. The requirements for foundation and installation position of machine.
The precision of each part of machine is very high, so you have to be very careful to move and install. Make sure that each part of machine should not be impacted and the cable should not be damaged.
Installation steps: mechanical installation, electrical connection, and debugging.
Note: please refer to the mechanical part of instruction manual for specific requirements of the foundation, and look at the plane layout and installation of foundation of the machine in chapter 9.4.1 for details.
2.The requirements for work environment and electrical requirements.
*Environmental requirements*
EDM is a high precision machine, in order to utilize its performance, please give full consideration to its environment setting. The environment temperature in which the machine can be used is from 10℃ to 35℃, and the humidity is less than or equal to 80% (not condensation).
(1)In order to ensure the machining precision, especially the mirror processing function of PIKA, the machine should be installed in constant temperature workshop, and the constant temperature should be controlled in the range of 20+22（℃）.
(2)Each part of the machine should be installed in the relative position with ground foundation as shown in Figure 9-2.
(3)There should not be strong electromagnetic interference around the machine, shielding should be added when necessary.
(4)There should not be electric welding tool, grinder, and equipments with fire and dust. The work site should be kept clean.
(5)Don not blow machine with hair dryer directly.
(6)When touch-screen device is selected, the humidity of environment must meet the environment for the use of electronic equipment. Otherwise, the condensation phenomenon will lead to failure of electronic equipment.
*Electrical requirements*
(1)Electrical installations within the workshop must comply with the requirements of the safety law, there must be an over current protection device in the power supply circuit. Specifications of over current protection device are as follows: A1-40:25A/ A1-80:30A/ phase.
(2)Power grid voltage
- Power grid voltage, frequency, phase, 50 (60): 380V Hz, three-phase four wire or three-phase five wire power supply.
- Allowable fluctuation range: 10%. If the power grid instability, it is recommended to install the three-phase AC voltage regulator at the input end.
- Power factor: 0.87.
- Required input power (kVA): A1-40:13kVA; A1-80:18kVA.
Note: The power fluctuations have great effects on the PIKA mirror finishing, it is strongly recommended to install power supply regulator!
3.Moving the machine.
Transportation and hoisting.
- Forklift: the shortest fork arm shall not be less than the length of wooden case to maintain the smooth operation of fork. A35:tonnage≥3tons; A50:tonnage≥5tons; A30:tonnage≥3tons.
- Crane: hoisting capacity must be greater than the weight of the machine together with the packing box. tonnage≥5tons.
- During hoisting, centre of gravity of hoisting should be consistent with the sign outside the package box. Pay attention to the stability of the package box..
- The center of gravity of the machine is in the rear. Insert the machine from the side with forklift, and the fork arm must exceed the length of machine.
- Absolutely avoid rush and shock.
- When the machine is transported without the packing bracket at the bottom, the forklift should insert into the bottom of the steel pipe from the column direction, and place the non slip goods between the steel pipe and the fork arm. Use crane or forklift truck to move the machine.
*Crane*
Shown as figure. Insert each of two steel pipes through the lifting hole respectively, and lift the machine gently. When hoisting, the front and two sides of machine should be isolated and supported against the steel wrie rope with soft materials, so as not to damage the machine cover and other parts. The touch points between the steel wire rope and the machine should also be placed with soft pad materials, so as to protect the paint surface and the exterior surface of machine.
*Forklift truck*
When shoveling with forklift, the load of forklift must be more than 5 tons. Pay attention to the center of gravity of machine. There should be paid more special attention to the situation when shoveling the machine that the column of machine is very heavy and the back area behind the machine is small. When moving th emachine using other methods (such as: rollers, wheel...), the machine should be kept forward steadily , should not be bumped up and down.
4.Moving the storage tank transport.
The oil storage tank can moved with forklift: insert the fork at the bottom of the tank, lift and move it carefully.
5.Moving the power supply cabinet.
The power supply cabinet can be omved with forklift or crane: Hoisting ability: 1000kg.
Forklift: insert the fork tooth into the bottom of the cabinet from the side deeply and fully, lift the cabinet up from its bottom careffully. The space of fork tooth should be wide enough to ensure the stability of hoisting the electrical cabinet up and down.
(Note: the center of gravity of electric cabinet is high, please be sure to pay attention to its stability, and avoid the phenomnon that electric cabinet falls over.)
Crane: there are four rings on electric cabinet, the inner diameter is 16mm. Users can use them to move the electric cabinet.
6.Releasing the locking device of machine.
After installation of machine, the mechanical locking device must be released first.
(1)Remove the support frame under the spindle.
(2)Release the locking device of spindle counterweight.
The locking device of spindle counterweight is behind the column as figure below. Please disassemble according to the following steps:
Unscrew the two compression screws (M6 * 50), remove the pressing block（M12×70）, and remove the nylon pad, gasket etc.
(3)Release workbench locking device. Remove the link screw, the fixed block and the rubber pad between the column and the workbench. The workbench can move in the direction X and Y.
Note: After releasing the locking device, keep the locking screw, the clamping block, the nylon pad, the rubber pad, the fixed block and other parts for reuse in future!
7.Connection between machine and power supply cabinet
Remove the front cover plate, the left side plate and the right side plate of the power supply cabinet, you can see the installing position of each component inside the power supply cabinet.
Note: please refer to the mechanical part of instruction manual.and look at the connection between machine and power supply cabinet in chapter 9.5 for details.
8.Connection of the power supply cabinet
Three phase AC voltage regulator (capacity not less than 15kVA) must be used when inputing the current into the power supply cabinet（A1-40、A1-80）. It can ensure that the AC voltage of power supply input is in the range of 380V(+ 10%) and can also guarantee the overall system works stabily. The connection method is shown as below!
9.Connection between working liquid tank and oil storage tank.
Hoisting the storage tank to the specified installation position, The oil return port of working oil tank must correspond to the internal of storage tank port.The oil return pipe is connected to oil return port at the lower left of the working oil tank, and all these compose the circulation system of working fluid. During installation, make sure that oil resistant rubber pad (provided with the machine) must be put between the oil return pipe and oil return hole. Tighten and fix the screws, then connect the oil storage tank to the working liquid tank with the sucker.
The overall system runs steady, the connection method is shown as below!
（Note: users must place the storage tank in the position shown in the chart, otherwise, there is interference phenomenon possibly between the oil return pipe and the side of storage tank during the moving of machine.)
Please refer to the mechanical part of instruction manual and look at the plane layout chart of the machine in chapter 9.4.1.1 for details.
10.Injection of processing liquid
The processing liquid can be injected into the storage tank after finishing the installation of the machine and the storage tank.
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