Index ABC User manual

LL1602.10043 - 04.08.2014
0814/Pr/Sp (Transport, Aufstellung, Inbetriebnahme)
Transportation,
Installation,
Commissioning
ABC
OPERATING INSTRUCTIONS
Refer to additional sheet: Important information before commissioning

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ABC
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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Transportation, Installation, Commissioning
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ABC
CONTENTS
Contents............................................................................................................................................................................. 3
Safety Instructions .......................................................................................................................................................... 5
Instructions for shipment, installation, commissioning .................................................................................................. 5
General sources of danger during in-house transportation...................................................................................... 5
Dimensions and masses.............................................................................................................................................. 6
Shipping- and lifting equipment................................................................................................................................... 6
Transport equipment, ropes......................................................................................................................................... 6
Preparations ...................................................................................................................................................................... 7
Suitable transport- and lifting equipment........................................................................................................................ 7
Space requirements .......................................................................................................................................................... 8
Foundations ........................................................................................................................................................................ 8
Environmental Conditions ................................................................................................................................................. 8
Power supply ..................................................................................................................................................................... 9
Compressed Air Supply .................................................................................................................................................... 9
Main fuse ........................................................................................................................................................................... 9
External data transfer........................................................................................................................................................ 10
Media to be provided ....................................................................................................................................................... 10
Pumps and Tanks.............................................................................................................................................................. 11
Chip disposal...................................................................................................................................................................... 11
Disposal of used media.................................................................................................................................................... 11
Compliance with waterbalance regulations .................................................................................................................... 11
Transport ............................................................................................................................................................................ 12
Delivery............................................................................................................................................................................... 12
Machine ......................................................................................................................................................................... 12
Pressure accumulator ................................................................................................................................................... 12
Other separate units..................................................................................................................................................... 12
Transportation equipment............................................................................................................................................. 12
Unloading the machine with a crane .............................................................................................................................. 14
Quick start manual for Transport ABC ...................................................................................................................... 15
Preparations ...................................................................................................................................................................... 17
Transportation with a fork lift ........................................................................................................................................... 17
Transportation with casters .............................................................................................................................................. 18
Placing the machine.......................................................................................................................................................... 20
...with a crane or a mobile crane .......................................................................................................................... 20
...with hydraulic jacks (Fig.)..................................................................................................................................... 20
Unloading and transporting separate units ..................................................................................................................... 22
Unpacking the accessories and checking them for completeness ............................................................................. 22

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CONTENTS
Installation......................................................................................................................................................................... 23
Electrical connection ........................................................................................................................................................ 23
Important notes............................................................................................................................................................. 23
Putting-up and Levelling the Machine ............................................................................................................................ 24
Putting-up and alignment of attachments ...................................................................................................................... 25
Anchoring the Machine................................................................................................................................................ 25
Commissioning................................................................................................................................................................. 26
Cleaning the Machine ....................................................................................................................................................... 26
Checking supplies, restocking .......................................................................................................................................... 26
Pressure accumulator ...................................................................................................................................................... 26
Removing the shipping brackets...................................................................................................................................... 27
Attaching the filler/breather filter ..................................................................................................................................... 28
Bleeding the Hydraulic System........................................................................................................................................ 28
Loss of data after a longer idle period ........................................................................................................................... 28
Switching-on the Machine................................................................................................................................................ 28
Changing the location .................................................................................................................................................... 29
Applicable only for machines with a chip conveyor...................................................................................................... 29
Applicable only for machines with a bar feeder or a bar loading magazine.............................................................. 29
Mounting the shipping braces ......................................................................................................................................... 30

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SAFETY INSTRUCTIONS
Instructions for shipment, installation, commissioning
Safety Instructions
Instructions for shipment, installation, commissioning
When the working area door is open, the interlocking switch
remains open after disconnecting the mains supply.
Shipping brackets are identified by their red color.
Improper shipment, installation or commissioning often leads to accidents, damage
or malfunction of the machine which INDEX will accept no liability for and which
will not be covered by the warranty.
Before the delivery, you should carefully plan the shipment to the installation site,
the unloading, the installation and the commissioning of the machine. Please pay
attention to the following instructions in this document.
For separate units e.g. chip conveyor, bar feeder, bar loading magazine etc., please
see the corresponding shipping instructions.
General sources of danger during in-house transportation
Machines may be shipped only by authorized and qualified personnel.
Act consciously during shipping. Please omit hazardous and risky actions. Consider
the consequences before acting.
Slopes and pitches can be particularly dangerous (e.g. ramps etc.). If passage is
unavoidable extra precautions must be taken.
Make sure that the load will not slide off and that vehicle's traction and brake force
are sufficient. Provide the load with additional securing devices, if necessary.

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SAFETY INSTRUCTIONS
Instructions for shipment, installation, commissioning
Dimensions and masses
For the masses of the machine and the control cabinet see the appropriate ma-
chine installation diagram in the chapter "Working data."
For the masses of separate units e.g. chip conveyor, bar feed, bar loading magazine
etc. see the additional transportation instructions for these attachments or the ap-
propriate machine installation diagram in the chapter "Working data".
Shipping- and lifting equipment
For lifting and moving individual units use only lifting and moving equipment with
adequate load bearing capacity and loading area.
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 chapter is addressed to all personnel in charge of the installation.
On the basis of the following instructions, the installation site can be prepared for
immediate installation and commissioning of the machine.
Make sure that the delivery, the unloading and the placement of the machine from
the unloading location to the installation site are planned carefully.
Take into account the size (dimensions) and the masses of the individual units.
Suitable transport and lifting equipment must be provided on delivery of the ma-
chine.
Remove potential obstacles along the way from the unloading location to the instal-
lation site.
Inspect the route for load bearing capacity, evenness, damage to surface, ridges,
gradients and slopes etc.
Is there sufficient clearance through gates and door ways?
Do elevators have sufficient load bearing capacity?
Good preparation pays off!
Suitable transport- and lifting equipment
– Crane
– Mobile crane
– Fork lifter
– Trolley
– Conveyor rolls
– Hydraulic jacks
– Pallet truck (only for separate units; not suitable for machines).

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PREPARATIONS
Space requirements
Make sure to provide for the following:
– Sufficient clear space around the machine.
– Sufficient moving space for the operator.
– Sufficient space for maintenance and repair works.
– It must be possible to open all machine doors completely.
– Floor area must be provided for blanks- and workpiece palettes, workpiece con-
tainer, chip pan, tool trolley etc.
See the machine installation diagram in the chapter "Working Data" for determining
the space requirements.
For attachments such as bar feeders, bar loading magazines etc., see separate
installation diagrams in the chapter "Working Data".
Foundations
Special foundations are not necessary as long as the floor quality complies with the
usual building regulations according to the weight of the machine.
Within the machine standing area there must not be expansion joints.
The machine may be anchored. For anchoring holes refer to the machine installa-
tion diagram in the chapter "Working Data".
Bar supports, bar feeders and bar loading magazines must always be anchored.
(For instructions see the appropriate operating instructions and the machine installa-
tion diagram in the chapter "Working Data").
When using a bar feed or a bar loading magazine INDEX recommends anchoring
the machine as well.
Environmental Conditions
See Environmental Conditions in the document “Safety instructions”
If the data at the installation site deviate from the values
above, please, contact INDEX or an INDEX agency.

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PREPARATIONS
Power supply
Keep the cables for mains supply to the machine as short as
possible. Cable cross section must be adequate.
Power supply for the PLC and for the NC must be stable, i.e. the voltage fluctua-
tion must not exceed +10% - 10%.
The cables must comply with the regulations of the local electricity suppliers and
the locally valid regulations.
For additional data see chapter "Working Data".
Compressed Air Supply
Be aware of the max. permissible pressure for the machine.
See pneumatic diagram in the chapter "Working Data".
Machines with elements operating with compressed air require compressed air sup-
ply with the following capacity:
Working pressure.....................................6 to 10 bar
Consumption ............................................according to machine equipment
For compressed air feed into the machine, see machine installation diagram in the
chapter "Working Data".
Main fuse
Check if the service line can be loaded with an extra value that
requires fusing.
In case of doubt have the situation clarified by the local elec-
tricity provider.
The main fuse is not provided with the machine delivery. According to the regula-
tions DIN EN 60204-1 this must be installed externally i.e. outside of the machine.
If a pre-transformer is required, the main fuse must be installed ahead of the pre-
transformer i.e. in the primary circuit.
The fusing depends on the operating voltage.
For the values for
– mains connection,
– operating voltage,
– main fuse
see machine installation diagram in the chapter "Working Data".

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PREPARATIONS
External data transfer
Data lines must not run directly next to power lines.
When you intend to transmit data from/to an external computer or memory, appro-
priate metal ducts for the data lines must be installed.
Media to be provided
– Hydraulic oil 1)
– Lubricating oil 1)
– Appr. 1 kg heavy duty grease for chucks
– Coolant
For types of lubricating oil, hydraulic oil, grease and coolant as well as filling
amounts see chapter "Maintenance Instructions" and the "machine installation dia-
gram" in chapter "Working Data".
Attention!
Only hydraulic oil according to ISO 4406 with a purity 15/12 (10 µm
absolute) may be filled. Hydraulic oil: HLP 32; HLPD 32; VG 32.
Lubrication oil CG 68; G68
1) Machine supplied with tank filled.