Hurco i Series User manual

Pre-Installation Manual for i-Series Machines v387 February 2015
PRE-INSTALLATION MANUAL
FOR i-SERIES MACHINES
February 2015

ii - Pre-Installation Manual for i-Series Machines Pre-Installation Manual for i-Series Machines v387
The information in this document is subject to change without notice and does not
represent a commitment on the part of Hurco Companies, Inc. (Hurco). The software
described in this document is furnished under the License Agreement to customers. It is
against the law to copy the software on any medium except as specifically allowed in the
license agreement. The purchaser may make copies of the software for backup purposes.
Hurco Manufacturing Company reserves the right to incorporate any modification or
improvements in machines and machine specifications which it considers necessary, and
does not assume any obligation to make any said changes in machines or equipment
previously sold.
Hurco products and services are subject to Hurco’s then current prices, terms, and
conditions, which are subject to change without notice.
© 2015 Hurco Companies, Inc. All rights reserved.
Patents:U.S. Patents B14,477,754; 5,453,933; Canadian Patent 1,102,434; Japanese
Patents 1,649,006 and 1,375,124; other Patents pending.
Hurco, Max, Ultimax, and WinMax are Registered Trademarks of Hurco Companies, Inc.
AutoCAD, Autodesk, and DXF are registered trademarks of Autodesk, Inc.
MS-DOS, Microsoft, and Windows are registered trademarks of Microsoft Corporation.
Many of the designations used by manufacturers and sellers to distinguish their products
are claimed as trademarks. Hurco has listed here all trademarks of which it is aware. For
more information about Hurco products and services, contact:
Hurco Companies, Inc.
One Technology Way
P.O. Box 68180
Indianapolis, IN 46268-0180
For Hurco subsidiary contact information, go to Hurco’s Web site:
www.hurco.com

Pre-Installation Manual for i-Series Machines v387 Installation Checklist — iii
INSTALLATION CHECKLIST
Prepare the site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
Ensure the foundation and floor are capable of supporting the machine’s weight. 1 - 3
Ensure there is a clear route from the loading dock to the machine location. . 1 - 4
Ensure there is adequate space for machine door clearances. . . . . . . . . . . . 1 - 4
Ensure there is appropriate power availability and the
voltage requirements are met. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Ensure adequate service fusing is available. . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Ensure transformer requirements are met. . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
Ensure proper grounding of machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
Ensure compressed air is available. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Ensure operating temperature requirements are met. . . . . . . . . . . . . . . . . . 1 - 8
Inspect the machine for damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
Ensure an appropriate forklift or crane is available to lift the machine. . . . . . 2 - 3
Review the pre-installation requirements. . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Schedule an appointment for a Hurco-certified Service Engineer
to prepare the machine for start-up after power is connected
by a Certified Electrician. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
Attend a Hurco programming training class for machine operators. . . . . . . . 3 - 3

iv - Installation Checklist Pre-Installation Manual for i-Series Machines v387

Pre-Installation Manual for i-Series Machines v387 Documentation Conventions — v
DOCUMENTATION CONVENTIONS
This documentation uses several conventions to explain the safety features and
emphasize key concepts. These conventions are described in this section.
Icons
This manual may contain the following icons:
Caution/Warning
Important
Troubleshooting
Hints and Tricks
Where can we go from here?
The operator may be injured and the machine severely damaged if the
described procedure is not followed.
Ensures proper operation of the machine and control.
?Steps that can be taken to solve potential problems.
Useful suggestions that show creative uses of the WinMax features.
Lists several possible options the operator can take.

vi - Documentation Conventions Pre-Installation Manual for i-Series Machines v387

Pre-Installation Manual for i-Series Machines v387 Table of Contents -vii
TABLE OF CONTENTS
Pre-Installation Manual for i-Series Machines
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Documentation Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1
Preparing the Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 -2
Foundation Supporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 3
Foundation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 3
Anchoring Machine to Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 3
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 4
Electrical Service Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 4
Calculating Service Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 6
Recommended Isolation Transformer Configuration . . . . . . . . . . . . . . . .1 - 7
Grounding Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 7
Compressed Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 8
Recommended Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 8
Tool Retention Knobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 9
Machine Arrival . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Inspecting for Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2
Moving the Machine into Final Position . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Machine Lifting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Removing Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Lowering the Machine onto its Foundation . . . . . . . . . . . . . . . . . . . . . .2 - 6
Start-up Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1
Pre-Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1
Other Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2
Service Visit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2
Programming Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3
Release Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I

viii - Table of Contents Pre-Installation Manual for i-Series Machines v387

Pre-Installation Manual for i-Series Machines v387 Site Preparation 1-1
SITE PREPARATION
This manual provides instructions for tasks that should be completed prior to the machine
installation.
Machine Overview
The pictures below identify some of the easily recognized components of machines. The
location of some components may differ on other models.
Figure 1–1. Turning Center with Max Console
Figure 1–2. Machining Center with dual-screen console
1. Max Console
2. Turret
3. Conveyor option
4. Coolant Drip Tray
5. Enclosure Door
6. Spindle
7. Tailstock/Chuck Gauge
options
8. Tailstock/Chuck
Footswitch options
1. Dual-screen Console
2. Machining Table
3. Chip Conveyor
4. Enclosure Doors
5. Spindle
6. Automatic Tool Changer
7. Coolant Gun
8. Air Gun

1 - 2 Site Preparation Pre-Installation Manual for i-Series Machines v387
Preparing the Site
Prepare the site.
To avoid problems when the equipment arrives for installation, Hurco recommends that
the following items be reviewed to ensure that the machine will be ready for the Hurco
Service Engineer to install the machine.
Please refer to the model-specific Specification Sheets for weight and dimension
specifications for each model.
Review the following:
• Capacity of the floor to support machine weight.
• Capacity of forklift or crane to lift the machine and accessory skids.
• Overhead and door clearances to allow the machine to enter building and
machine location.
• Plant obstructions on the way to machine location.
• Code requirements for utility services.
• Proximity of compressed air and proper electrical service.
• Space to allow efficient operation, considering full axes travel and future
servicing access requirements.
• Use of internal personnel for management of installation.

Pre-Installation Manual for i-Series Machines v387 Site Preparation 1-3
Foundation Supporting the Machine
Ensure the foundation and floor are capable of supporting the machine’s weight.
The foundation must be able to support the weight of the machine and should be
constructed of continuous concrete (reinforced is best). The thickness and consistency of
the concrete must be compatible with industry standards for supporting machine weight.
Actual requirements will depend upon the physical properties of underlying soil. A local
civil engineer must be consulted if soil conditions are questionable.
All Hurco machining and turning centers sit on leveling pads that allow the machine to be
leveled.
Foundation Guidelines
The following guidelines are listed on the Foundation/Floor Plan Assembly drawing for
each machine:
1. Flatness allowance of the floor level should be within +10 mm (0.39 in).
2. Take precautions so that there are no cracks in the concrete.
3. Leveling bolts are supplied in the shipping box with the machine.
4. Based on the soil conditions, the stiffness of the foundation shall be
determined, so that the machine base does not deflect more than 0.013 mm
(0.0005) inches to maintain the machine accuracy and performance.
5. The drawing located in the Model-specific Specifications document shows the
general arrangement required for the machine foundation. Local masonry
contractor and/or civil engineers must be consulted for additional
recommendations (e.g. depth, reinforcing steel based on the load bearing
characteristics of the soil) to achieve specified performance of the machine.
6. Foundation contractor must paint foundation with a liquid proof paint prior to
the installation of the machine to prevent the foundation from absorbing
moisture.
Anchoring Machine to Foundation
For improved performance, accuracy, and reliability, Hurco recommends that machines be
anchored to the foundation. If a machine is to be anchored, failure to follow the
recommended foundation guidelines may void guarantees of quoted machine accuracy.
If a machine is to be anchored, the following requirements must be met:
1. Core drilled hole must be prepared to ensure proper adhesion of grout to the
Please refer to the model-specific specifications document for the
machine foundation drawing to provide to the Civil Engineer for
location and placement of the leveling pads for the machine, and for
machine weight.

1 - 4 Site Preparation Pre-Installation Manual for i-Series Machines v387
foundation concrete.
2. The grout and anchor bolt manufacturers’ recommendations must be followed
to ensure full strength of the foundation.
3. After proper cure time, the anchor bolt must be capable of allowing a
minimum torque transmission of 271 Nm (200 ft-lb).
Machine Dimensions
Ensure there is a clear route from the loading dock to the machine location.
When moving a machine, be sure to allow adequate space for maneuvering. If door and
ceiling clearances appear to be close to approximate machine dimensions, measure the
machine first before attempting to move it.
Ensure there is adequate space for machine door clearances.
Allow additional space around the machine for servicing and safe operation. Leave room
for removing the coolant tank and the chip conveyor (if equipped).
The Model-specific Specifications document provides these machine dimensions:
•Shipping Dimensions—height, width, length, and weight configuration of
the machine and auxiliary equipment as mounted to the skid. Shipping
dimensions are measured with the machine on its shipping pallet.
•Operating Dimensions—width and length measurements that must be
considered for maintenance and service of the machine, such as opening all
enclosure and electrical power cabinet doors and location of auxiliary
equipment.

Pre-Installation Manual for i-Series Machines v387 Site Preparation 1-5
Electrical Service Requirements
The customer is responsible for providing incoming electrical power to the Hurco
machining center or turning center.
Ensure there is appropriate power availability and the voltage requirements are met.
The machine’s full load KVA power rating can be found on the serial number
identification tag that is affixed to the electrical power cabinet.
A certified electrician should ensure the following electrical service requirements:
• On-site wiring must comply with all applicable electrical codes.
• Dedicated, grounded 3-phase AC power is required to prevent high/low
voltages, spikes, surges, and noise.
• The AC power source shall be balanced and must match the voltage
specifications on the machine electrical cabinet.
• Wiring to the machine must be capable of supplying continuous specified
amperage.
• Failure to provide the required power parameters may affect safety, machine
performance, and the warranty.
• A Hurco-certified Service Engineer must supervise final electrical connections
to the machining center.
Run an electrical power line of adequate length and gauge to the
machine’s location to reach the connections in the power cabinet.
Final connections must be supervised by a Hurco-certified Service
Engineer.
See the Model-specific Specifications document for Full Load KVA and
Full Load Amp ratings to ensure proper wire gauge.
Always disconnect machine power before working with electrical
connections.

1 - 6 Site Preparation Pre-Installation Manual for i-Series Machines v387
Calculating Service Fusing
Ensure adequate service fusing is available.
First, determine your incoming AC Voltage, 3 Phase service. Use the Service KVA
Requirements to calculate the service fusing for your machine.
For 3-phase power, the equation is .
For example, to calculate the fuse current where incoming service KVA ( ) is 50 KVA
and Input Voltage (Ε) is 400 VAC:
See the Model-specific Specifications document for Incoming Voltage
and Full Load KVA.
P3Φ
I
3xE
--------------
=
ΡΦ3
IP3Φ
E3×
-----------------50 000VA,
400Vx1.732
-----------------------------
==
I50 000VA,
693V
--------------------------73A==

Pre-Installation Manual for i-Series Machines v387 Site Preparation 1-7
Recommended Isolation Transformer Configuration
Ensure transformer requirements are met.
If a transformer is required and the machine was not equipped with one, the customer is
responsible for providing a transformer. The transformer must meet Hurco machine-
operating voltage requirements. Hurco recommends the Wye configuration (4) on the
transformer secondary that feeds power to the machine. It is the customer’s
responsibility to have a qualified electrician connect the transformer to the power source.
Figure 1–3. Wye Transformer Configuration
Figure 1–4. Delta Transformer Configuration
Grounding Equipment
Ensure proper grounding of machine.
The electrical and electronic control systems of the machining center are interconnected
internally and terminate at a single point ground (SPG) terminal. The SPG provides only
one conducting path between the machine and external ground, preventing an unwanted
ground loop (ground differential voltage). The SPG is located inside the machine power
cabinet.
The SPG must be properly connected to the ground circuit of the AC power source.
The grounding conductor must be sized to conform to all applicable electrical codes.
However, Hurco recommends that the size of the neutral conductor (when applicable) be
at least the size of the phase (current carrying) conductors.

1 - 8 Site Preparation Pre-Installation Manual for i-Series Machines v387
Compressed Air Requirements
Ensure compressed air is available.
A continuous supply of clean and dry compressed air is required for proper machine
operation. Compressed air will connect to the machine’s filter, regulator, lubricator (FRL)
unit. Use these specifications:
• Air humidity dew point: 2º C (35º F).
• Use a minimum 13 mm (0.5 in) diameter (trade size) pipe supply line to the
machine.
• Install a drip leg in the line before the connection to the FRL unit. The drip leg
will help remove the moisture in the air supply and improve operation of the
FRL unit.
• Do not use quick-coupler type fittings at the connection to the FRL unit or in
the supply line to the machine because these fittings restrict the air supply.
Recommended Operating Temperature
Ensure operating temperature requirements are met.
Hurco machines may be operated in a facility with ambient temperatures ranging from
0º C to 35º C (32º F to 95º F) and in non-condensing relative humidity up to 95%. The
electrical cabinet has a heat exchanger to regulate the temperature inside the cabinet to
ensure that the electronics operate within their temperature limits. Some high-duty cycle
applications may require that the heat exchanger be replaced with an optional air
conditioner.
Set up the machine away from external heat sources, such as direct sunlight and heating
vents.
See the Model-specific Specifications document for Air Supply
specifications.
For ambient shop temperatures higher than 35ºC (95ºF), an optional
air conditioner is recommended in place of the heat exchanger to
ensure the electronics operate within their rated limits.

Pre-Installation Manual for i-Series Machines v387 Site Preparation 1-9
Tool Retention Knobs
Tool retention knobs are required for all Hurco machining centers. The knobs are attached
to the top of tool holders and are used by the spindle's clamp mechanism to hold the tool
in the spindle. Please refer to the Model-specific Specifications document for more
information.

1 - 10 Site Preparation Pre-Installation Manual for i-Series Machines v387

Pre-Installation Manual for i-Series Machines v387 Machine Arrival 2-1
MACHINE ARRIVAL
Upon machine arrival, please complete the following instructions to place the machine at
the installation site (see the appropriate section for detailed information):
1. Inspect the machine upon arrival.
2. Lift machine off the truck or transporter.
3. Move machine near permanent location.
4. Remove auxiliary equipment from pallet.
5. Lift the machine from the pallet.
6. Place the machine on the pads.
7. Rough level the machine.
Follow all local regulations for safe handling of machinery.
• Do not remove any bracing on the machine.
• Do not remove equipment from inside the machine.
• Do not remove auxiliary equipment from a second pallet, if
equipped.
• Do not remove or install the console.

2 - 2 Machine Arrival Pre-Installation Manual for i-Series Machines v387
Inspecting for Damage
Inspect the machine for damage.
Hurco recommends that the machine equipment be inspected for shipping damage before
unloading and placing machine onto foundation.
• Remove all wrapping around machine to inspect the shock sensor.
• Before unloading the machine from the shipping carrier, check to see if the
shock meter sensor is tripped. This sensor is located on the casting in the
rear of the machine. The shock meter sensor is a spring-loaded device that
will dislodge the springs if the machine experiences a shock that exceeds 2g.
Figure 2–1. Shock Meter Sensor—intact (photo on left) and dislodged (photo on right)
• Examine the machine for structural damage.
• Note any shipping damage to the machine on the shipper’s bill of lading. It is
the customer’s responsibility to file a damage claim.
• Photograph any equipment damage for your records.
Any damage that occurs during lifting machine off of shipping
pallet or placing into position is the responsibility of the customer
or the customer’s rigging agent.
If the sensor springs are dislodged, inspect the machine carefully
for damage, including all castings.
Hurco-certified Service personnel can help determine the cost of
repairing any damages that occurred during shipment, or during or
after placement of machine onto its foundation.