Index R300 User manual

Transport,
Installation,
Start-up
R300
Valid from the machine No. 485024
OPERATING INSTRUCTIONS
Transport
LR1802.10081 - 06.11.2014
1114/SP (Transport, Aufstellung, Inbetriebnahme)

Note on applicability
Illustrations in this publication may deviate from the product supplied. Errors and omissions due to technical
progress excepted.
A word on copyright
This document is protected by copyright and was originally compiled in German.
The duplication and distribution of this document or parts thereof is prohibited without prior consent of
the copyright owner, and any violators will be prosecuted. All rights, including the right to translate, are
reserved.
©Copyright by INDEX-Werke GmbH & Co. KG, TRAUB Drehmaschinen GmbH & Co. KG 2014
Englisch

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TABLE OF CONTENTS
Table of Contents
Table of Contents ............................................................................................................................................................ 3
Safety Instructions .......................................................................................................................................................... 5
Notes on Transport, Installation, Start-up ....................................................................................................................... 5
General sources of danger during in-house transportation...................................................................................... 5
Dimensions and Masses.............................................................................................................................................. 6
Transporting and Lifting Aids....................................................................................................................................... 6
Transport equipment, ropes......................................................................................................................................... 6
Preparations ...................................................................................................................................................................... 7
Appropriate Transporting and Lifting Means .................................................................................................................. 7
Space Requirements ......................................................................................................................................................... 8
Subsoil, Foundation ........................................................................................................................................................... 8
Environmental Conditions ................................................................................................................................................. 8
Power Supply..................................................................................................................................................................... 9
Main Circuit Breaker.......................................................................................................................................................... 9
External Data Transfer....................................................................................................................................................... 9
Compressed-Air Supply .................................................................................................................................................... 10
Pressure Accumulator ....................................................................................................................................................... 10
Operating Fluids to be Provided ...................................................................................................................................... 10
Pumps and Tanks .............................................................................................................................................................. 11
Chip Removal..................................................................................................................................................................... 11
Disposal of Used Operating Materials ............................................................................................................................ 11
Observing the Ground and Waste Water Regulations.................................................................................................. 11
Transpor t............................................................................................................................................................................ 12
Transport and Installation Charts R300........................................................................................................................... 12
Transport Chart (Without Transport Means) .............................................................................................................. 12
Installation Chart............................................................................................................................................................ 13
Delivery............................................................................................................................................................................... 14
Machine ......................................................................................................................................................................... 14
Pressure Accumulator................................................................................................................................................... 14
Other Separate Units.................................................................................................................................................... 14
Transporting with Transport Casters................................................................................................................................ 15
Suspension and lashing points .................................................................................................................................... 16
Locations of the Transport Locks on the Machine ....................................................................................................... 19
Unloading the machine with a crane .............................................................................................................................. 20
Unloading and Transporting of Separate Units............................................................................................................... 23
Unpack the Accessories and Check them for Completeness ..................................................................................... 23

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TABLE OF CONTENTS
Installation......................................................................................................................................................................... 24
Electrical Connection ......................................................................................................................................................... 24
Important Notes ............................................................................................................................................................ 24
Installing the Machine....................................................................................................................................................... 25
Level the Machine............................................................................................................................................................. 26
Leveling the Z-Axis ....................................................................................................................................................... 26
Leveling the Y-Axis ....................................................................................................................................................... 27
Adjusting Machine Feet 4 and 5 ................................................................................................................................ 28
Running Machines on an External Cooling Water System .................................................................................................... 29
Technical Data of the Cooling Water Supply............................................................................................................. 29
Installation and Leveling of Options and Accessories................................................................................................... 30
Start-up .............................................................................................................................................................................. 31
Cleaning the Machine ....................................................................................................................................................... 31
Check the Operating Fluid Levels and Replenish, if Necessary. ................................................................................. 31
Pressure Accumulator ....................................................................................................................................................... 32
Removing the Transport Locks........................................................................................................................................ 32
Attaching Filling and Venting Filters................................................................................................................................. 33
Data Loss Due to Prolonged Downtime ........................................................................................................................ 34
Switching on the Machine ............................................................................................................................................... 34
Relocation .......................................................................................................................................................................... 35
Only for Machines Equipped With Chip Conveyor........................................................................................................ 35
Only for Machines Equipped With Blank Feeder .......................................................................................................... 35

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SAFETY INSTRUCTIONS
Notes on Transport, Installation, Start-up
Safety Instructions
Notes on Transport, Installation, Start-up
Use only suitable hydraulic jacks to lift the machine and ad-
equate transport casters or armored rollers with appropriate
carrying capacity for transport.
If the door to the work area is open, the door safety interlock
will remain open after disconnecting the power supply line.
Transport locks can be identified by their red color.
Failure to follow proper procedures for transport, installation and start-up is prone
to cause accidents and may induce damages to or malfunctions of the machine for
which INDEX rejects any liability or warranty.
Prior to delivery of the machine, the procedures for unloading, transporting to the
installation site, installation, and start-up must be carefully planned while absolutely
observing the cautions below in this document.
Associated transport instructions and/or manufacturer documentations exist for
separate units such as chip conveyor, bar feeder, bar loading magazine and similar
devices. These documentations must also be followed without fail.
General sources of danger during in-house transportation
Danger to life!
Do not stand under suspended loads.
Machines must be transported by authorized and qualified personnel only.
Act responsibly when transporting the machine and always consider the conse-
quences. Avoid dangerous and risky actions.
Slopes and gradients (driveways, ramps, etc.) are particularly dangerous. Use extra
care if such passage-ways cannot be avoided.
Ensure secure and proper seating of the cargo. If necessary, use additional fixtures
to ensure that the cargo is not able to slip.
The transport vehicles must be able to produce sufficient traction and braking
forces for safe transport.

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SAFETY INSTRUCTIONS
Notes on Transport, Installation, Start-up
Dimensions and Masses
The machine and control cabinet masses are indicated on the respective machine
installation chart in Chapter “Working Documents”.
The masses of optional separate units, such as chip conveyor, bar feeder, bar
loading magazine and similar devices, can be found either in the specific transport
instructions/manufacturer documentation for these options or accessories, or in the
corresponding machine installation chart in Chapter “Working Documents”.
Transporting and Lifting Aids
For lifting and transporting the individual units, only lifting and transporting aids hav-
ing sufficient capacity and loading space must be used.
Transport equipment, ropes
For lifting the machine with a crane use only the provided transportation gear. This
also applies to certain separate units such as bar feeder and the bar loading maga-
zine.
For lifting all other separate units with a crane no special transportation equipment
will be provided.
When selecting your own transportation equipment and ropes make sure that they
have the recommended capacity and length.
When selecting and applying the transportation equipment and ropes/round slings
respectively, consider the following instructions in this document, e. g.:
– Unloading the machine with a crane or a mobile crane.
– Unloading and transporting of separate units.

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PREPARATIONS
Preparations
This section is addressed to the persons responsible for the installation and their
staff.
The information provided here allows you to prepare the installation site and its
surroundings such that the machine, when delivered, can be installed and put into
operation immediately.
Be sure to carefully plan the delivery, unloading, and transporting of the machine
from the unloading site to the installation site.
Take the size (dimensions) and masses of each unit into consideration.
Suitable transporting and lifting means must be available when the machine is deliv-
ered.
Any obstacles along the transport route from the unloading site to the installation
site must be eliminated before the machine is delivered.
Check the transport route for load capacity, levelness, damaged pavement, traverse
grooves, slopes, gradients, etc.
Is the width and height of entrances and gates sufficient?
If elevators are to be used, do they have sufficient capacities?
Proper planning will pay off!
Appropriate Transporting and Lifting Means
– Crane
– Mobile crane
– Forklift (only for separate units; not suitable for the machine)
– Transport trolley
– Transport casters
– Armored rollers
– Hydraulic jack
– Forklift truck (only for separate units).

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PREPARATIONS
Space Requirements
The following must be ensured:
– Sufficient free space around the machine.
– Sufficient movement space for the operator.
– Sufficient space for maintenance and repair.
– It must be possible to open all doors of the machine completely.
– Space for placing blank and workpiece pallets, workpiece containers, chip trol-
leys, tool trolleys, etc.
Use the machine installation chart in Chapter “Working Documents” to determine
the required space.
Chapter “Working Documents” also includes specific installation charts for addi-
tional equipment such as bar feeders, bar loading magazines, etc.
Subsoil, Foundation
A special foundation is not necessary. Only the bearing capacity and strength of the
floor must be suitable for the machine weight based on constructional aspects.
There must be no expansion joints in the area of the machine footprint.
The machine can be anchored in the foundation. For the distances between the an-
choring holes, see the machine installation chart in Chapter “Working Documents”.
Bar guides, bar feeders, and bar loading magazines must generally be anchored in
the foundation (for information, see the associated operating instructions and the
machine installation chart in Chapter “Working Documents”).
If a bar feeder or bar loading magazine is used, INDEX also recommends anchor-
ing the machine in the foundation.
Environmental Conditions
See Environmental Conditions in the document “Safety instructions”
If the actual conditions at the installation site differ from these
specifications, be sure to contact INDEX or an INDEX represen-
tative.

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PREPARATIONS
Power Supply
The power supply cord to the machine should be as short as
possible. Use a sufficient wire size.
The power supplies for the programmable logic controller (PLC) and the numerical
control (NC) require stable mains conditions, i.e., the max. allowed operating voltage
fluctuations are +10% or -10%.
The mains line must comply with the regulations of the local electricity supplier and
the IEEE directives. For further information, see the machine installation chart in
Chapter “Working Documents”.
Main Circuit Breaker
Check that the building connection has sufficient capacity to
cover the additional load to be protected.
Discuss any unclear conditions with your local electricity sup-
plier.
The main circuit breaker is not included in the delivery of the machine. It must be
installed outside the machine according to DIN EN 60204-1.
If a pre-transformer is required, the main circuit breaker must be installed before
the pre-transformer, i.e., on the primary side.
The loads to be protected depend on the existing operating voltage.
The values for:
– Machine connection,
– operating voltage,
– main circuit breaker
are indicated on the name plate or the wiring diagram.
External Data Transfer
Data lines must not be routed directly next to power lines.
For data transfer to/from external computers or storage devices, suitable metal
conduits must be installed for the data lines.
The locally valid guide lines and regulations must be taken into con-
sideration.
Les différentes directives et prescriptions en vigueur dans le pays
d’utilisation devront être prises en compte.
Devono essere rispettate di volta in volta le direttive e le prescrizioni
vigenti nel paese di utilizzo.
De gällande riktlinjerna och föreskrifterna i användningslandet måste
följas.
Deben observarse las prescripciones y las directivas vigentes en el
país de utilización.
Devem ser consideradas as recomendações e regulamentos do res-
pectivo país.
Käyttömaassa voimassa olevia direktiivejä ja määräyksiä on noudatet-
tava
Je nutno dodržovat také aktuální směrnice a předpisy platné v zemi
použití.
Należy uwzględnić też obowiązujące dyrektywy i przepisy kraju użyt-
kownika.
Se vor respecta normele şi directivele în vigoare în ţara de destinaţie.
Figyelembe kell venni a felhasználó ország mindenkor érvényes irány-
elveit és előírásait.
Met de geldende richtlijnen en voorschriften van het gebruiksland
moet rekening gehouden worden.
Der skal tages hensyn til de pågældende gældende direktiver og
forskrifter i brugslandet.
必须对所在国家各现行指令和规定加以考虑。
Es müssen die jeweils geltenden Richtlinien und Vorschriften des
Verwendungslandes berücksichtigt werden.
Необходимо учитывать соответствующие действующие директи-
вы и предписания страны, в которой применяется ресивер.
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PREPARATIONS
Compressed-Air Supply
Observe the max. allowed connection pressure for the machine.
See the pneumatic diagram in Chapter “Working Documents”.
Machines equipped with pneumatically actuated components require a compressed-
air supply with the following capacity:
Operating pressure ..................................6-10 bar
Air demand...............................................depending on the machine equipment
For the air supply on the machine, see the machine installation chart in Chapter
“Working Documents”.
Pressure Accumulator
If the machine was shipped by plane, all accumulators attached to the machine are
depressurized.
Before start-up of the machine, all accumulators must be filled with nitrogen (N2) by
a specialist. The prescribed pressures must be observed.
For the prescribed pressures, see the hydraulic diagrams in Chapter “Working
Documents”.
Operating Fluids to be Provided
– Hydraulic fluid 1)
– Lubricating oil 1)
– Approx. 1 kg of high-performance grease for chuck
– Cooling lubricant
For the appropriate types of lubricating oil, hydraulic fluid, grease, and cooling lubri-
cant, see the Chapter “Notes on Operating Materials” and "Hydraulic Diagrams and
Machine Installation Chart" in Chapter “Working Documents”.
Caution:
For the cooling of the spindle only a lubricating oil in accordance with
ISO VG5 is used.
1) The machine is delivered with a full tank.
The locally valid guide lines and regulations must be taken into con-
sideration.
Les différentes directives et prescriptions en vigueur dans le pays
d’utilisation devront être prises en compte.
Devono essere rispettate di volta in volta le direttive e le prescrizioni
vigenti nel paese di utilizzo.
De gällande riktlinjerna och föreskrifterna i användningslandet måste
följas.
Deben observarse las prescripciones y las directivas vigentes en el
país de utilización.
Devem ser consideradas as recomendações e regulamentos do res-
pectivo país.
Käyttömaassa voimassa olevia direktiivejä ja määräyksiä on noudatet-
tava
Je nutno dodržovat také aktuální směrnice a předpisy platné v zemi
použití.
Należy uwzględnić też obowiązujące dyrektywy i przepisy kraju użyt-
kownika.
Se vor respecta normele şi directivele în vigoare în ţara de destinaţie.
Figyelembe kell venni a felhasználó ország mindenkor érvényes irány-
elveit és előírásait.
Met de geldende richtlijnen en voorschriften van het gebruiksland
moet rekening gehouden worden.
Der skal tages hensyn til de pågældende gældende direktiver og
forskrifter i brugslandet.
必须对所在国家各现行指令和规定加以考虑。
Es müssen die jeweils geltenden Richtlinien und Vorschriften des
Verwendungslandes berücksichtigt werden.
Необходимо учитывать соответствующие действующие директи-
вы и предписания страны, в которой применяется ресивер.
02
03
04
05
06
07
09
10
12
13
15
16
19
20
21
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