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Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 1 of 37
Type II Vipros 368 King with Fanuc 18PCUser Pre-installation Guide
Amada America Inc.7025 Firestone Blvd.
Buena Park CA. 90621Phone: (714) 739 2111
Fax.: (714) 739 4099Email [email protected]
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 2 of 37
Warning! Qualified personnel must complete all work.
! Do not apply power to the Type II Vipros 368 King until an A.E.S.I. (AmadaEngineering and Service Incorporated) Engineer is present and has instructed youto do so.
! Considerable effort has been made to ensure that this manual is free ofinaccuracies and omissions. However, as we are constantly improving our product,some of the data contained herein may not exactly reflect the latest revisions to theType II Vipros 368 King. If in doubt concerning a specific item, please contact yourlocal Amada America sales person for clarification, or check our Internet site,http://www.amada.com for the latest release of this document.
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 3 of 37
Contents
Introduction ......................................................................................................................................................................................5
Specifications - Motion Package ......................................................................................................................................................6
Specifications - Punching System....................................................................................................................................................7Turret Configuration - 58 Station - 4 Auto-Index ..........................................................................................................................8
Specifications - Fanuc 18PC Controller ...........................................................................................................................................9
Specifications - Hydraulic Systems ..................................................................................................................................................9Power Hydraulic Numerical Control .............................................................................................................................................9Hydraulic Power Unit ...................................................................................................................................................................9
Supply Requirements - Electrical ...................................................................................................................................................10Optional Equipment ...................................................................................................................................................................10Installing the Electrical Power Supply ........................................................................................................................................11
Supply Requirements - Pneumatic.................................................................................................................................................12Optional Equipment ...................................................................................................................................................................12Installing the Pneumatic Supply.................................................................................................................................................12
Planning the Location of the Type II Vipros 368 King ....................................................................................................................13Moving the Vipros Type II Vipros 368 King................................................................................................................................13Plan View - Type II Vipros 368 King ..........................................................................................................................................14Plan View - Type II Vipros 368 King with standard conveyors ...................................................................................................15Plan View - Type II Vipros 368 King with standard conveyors and MP1530 loader...................................................................16End View – Type II Vipros 368 King ..........................................................................................................................................17Elevation View – Type II Vipros 368 King ..................................................................................................................................18
SBC EX 5.5 Chiller.........................................................................................................................................................................19SBC EX 5.5 Chiller Placement...................................................................................................................................................19Chiller Connections....................................................................................................................................................................20
Foundation Requirements..............................................................................................................................................................21
Foundation Anchoring Procedure ..................................................................................................................................................22Foundation J-bolt Detail .............................................................................................................................................................22Plan View - Foundation Type II Vipros 368 King........................................................................................................................23Elevation - Foundation Type II Vipros 368 King.........................................................................................................................23
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 4 of 37
Machine Anchoring Requirements .................................................................................................................................................24Saw Cut J-bolt Mounting Holes..................................................................................................................................................24Core Drill J-bolt Mounting Holes ................................................................................................................................................25Foundation / Floor J-bolt Mounting Procedure...........................................................................................................................26Drilled Hole with Anchor Rod and Adhesive Mounting Holes.....................................................................................................28Drilled Hole with Anchor Rod and Adhesive Mounting Procedure .............................................................................................29
Removing the Protective Coating...................................................................................................................................................31
Machine Leveling ...........................................................................................................................................................................32Rocking Test ..............................................................................................................................................................................32Floor Condition: Crowned ..........................................................................................................................................................33Floor Condition: Sloped .............................................................................................................................................................34Leveling Procedure ....................................................................................................................................................................35
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 5 of 37
Introduction
This manual describes the tasks that the purchaser of a Type II Vipros 368 King must complete before calling A.E.S.I. (AmadaEngineering and Service Incorporated) to complete the installation and operator training.
An overview of the preparations is as follows:
! Plan the location of the Type II Vipros 368 King taking into account the Safety and Maintenance areas indicated on the planview. See page 13, Planning the Location of the Type II Vipros 368 King.
! Prepare the Type II Vipros 368 King floor or foundation as required. See page 21, Foundation Requirements, for details.
! Uncrate the Type II Vipros 368 King and place on the foundation, but do not fill the anchor-bolt holes (if used) until afterA.E.S.I. completes the initial installation.
! Install the electrical supply. See page 10, Supply Requirements - Electrical , for details.
! Install the pneumatic supply. See page 12, Supply Requirements - Pneumatic, for details.
! Remove the protective coating from the surface of the Type II Vipros 368 King See page 31, Removing the ProtectiveCoating, for details.
! If additional equipment is to be installed, repeat the previous steps for each piece of additional equipment.
Note: It is the purchaser’s responsibility to install any safety devices to ensure the safety area.
Note: Considerable effort has been made to ensue that this manual is free of inaccuracies and omissions. However, asAmada America strives to continually improve our products, some data contained herein may not exactly reflect thelatest revisions to the Type II Vipros 368 King. If in doubt concerning a specific item, please contact your local AmadaAmerica sales engineer for clarification.
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 6 of 37
Specifications - Motion Package
Travel Method X and Y axes work piece movement
Control Method X, Y, T & C
Drive Motors Fanuc AC Servo (X, Y, T, C)
Maximum Sheet Size 60" (Y) x 158" (X) with one repositioning cycle. (Additional material supporttables required)
Maximum Sheet Thickness 0.135"
Maximum Material Weight 110 lb.
Maximum Axis Travel 78.74" (X) by 60" (Y)
Max. Linear Table Speed ( X / Y / Combined ) 3,149 ipm / 3,149 ipm / 4454 ipm
Punching Accuracy ±0.004"
Positioning Accuracy ±0.001"
Repeatability ±0.001"
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 7 of 37
Specifications - Punching System
Press Capacity 33 Tons
Press Stroke 1.575"
Stroke Rate (X/Y) Pitch Stroke StrokeRate
0.079" 0.118" 860/690
0.079” 0.236” 520/510
0.315” 0.315” 400/370
1.000" 0.315" 340/290
Maximum Hole Diameter 4.500"
Tool Type Amada Thick Turret
Turret Rotation Speed 30 RPM
Feed Clearance 0.787"
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 8 of 37
Turret Configuration - 58 Station - 4 Auto-Index
201 A/I
202103
204
305
106
307 108
309110
311
112
213
314115
216
117218
319
120
321
122
323
124
325
126
227
328
229
230A/I
231
132
233
334
135
336137
338139
340
141
242
343
144
A/I245
146
247
348
149
350
151
352
153
354
155
256
357
258
A/I
1200mm disk
58 STATION4 AUTO INDEX
MaximumSize Round
Number ofStations(Keyed)
24 (16)
24 (24)
4 (4)
2 (2)
2 (2)
2 (2)
A
B
C
D
B
E
½" (12.7mm)
1¼" (31.7mm)
2" (50.8mm)
3½" (88.9mm)
1¼" (31.7mm)
4½" (114.3mm)Auto Index
VIPROS 358 KING VIPROS 368 KINGVIPROS 558 VIPROS 568
PEGA 358S
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 9 of 37
Specifications - Fanuc 18PC Controller
Model Fanuc 18PC (with PHNC)
Control Function X, Y, T & C
Input Method MDI, Paper Tape, DNC
Minimum Command Unit 0.001" (X, Y) .010 (C)
Minimum Travel Unit 0.001" (X, Y) .010 (C)
Operating Modes Automatic, MDI & Manual
Display Modes Program Contents, Position Information, Program Check, Parameters, Tool Hit Counter, SelfDiagnostics
Interlock Displays Oil Temperature, Oil Pressure, Door Open
Specifications - Hydraulic Systems
Power Hydraulic Numerical ControlRam Cycle Patterns 277 Total
Punching 2Nibbling 1Forming 250Marking 10Knockouts 10Slitting 4
Minimum Increment 0.01mm
Hydraulic Power UnitModel Yuken
Dual Operating Pressure 100 kgf cm² & 195 kgf cm²
Oil Type Mobil DTE® Excel 46 (formerly called Mobil Hydraulic Oil NZ 46)
Oil Capacity 40 Gallons
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 10 of 37
Supply Requirements - Electrical
Type II Vipros 368 King 230 / 460 / 3 / 60 ±10%, 28 kVA 63 amps @ 230 / 3 / 60 VAC* 32 amps @ 460 / 3 / 60 VAC*
SBC EX 5.5 Chiller
Chiller voltage must be specifiedwhen machine is ordered.
230 or 460 / 3 / 60 ±10%, 15 kVA38 amps @ 230 / 3 / 60 VAC*19 amps @ 460 / 3 / 60 VAC*
Optional EquipmentStandard Conveyors (2) 208 / 230 / 460 3ph ±10%, kVA
2.1 amps @ 208 / 3/ 60 VAC*2.0 amps @ 230 / 3 / 60 VAC*1.0 amps @ 460 / 3 / 60 VAC*
MP1530 Loader 200 / 3 / 60 ±10%, 10 Kva29 amps @ 200 / 3 / 60 VAC*
To operate at 230 / 460 VAC a step up transformer with the following service isrequired
26 amps @ 230 / 3 / 60 VAC*13 amps @ 460 / 3 / 60 VAC*
* The actual supplied electrical service must be sized to allow for starting current of approximately 150% of this value.
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 11 of 37
Installing the Electrical Power Supply
The Type II Vipros 368 King requires two separate electrical power sources. The first power source is supplied to the Fanuc18PC. The other supply source goes to the SBC EX 5.5 Chiller. The Type II Vipros 368 King should be supplied from apower line separate from those for welding machines or other machines that produce electrical noise.
! The Type II Vipros 368 King electrical inlet is 64" above floor level at the rear of the Fanuc 18PC control.
! The SBC EX 5.5 Chiller electrical inlet is approximately 53" above floor level.
! For the location of required electrical supplies for optional equipment, please see the installation guides for the specificequipment.
Type II Vipros 368 King electrical enclosure SBC EX 5.5 Chiller electrical enclosure
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 12 of 37
Supply Requirements - Pneumatic
Type II Vipros 368 King 80 psi @ 8.8 ft³/min.
Optional EquipmentMP1225 Loader 75 psi @ 31.8 ft3/min.
Installing the Pneumatic SupplyThe Type II Vipros 368 King requires connection to a compressed air system by hose or pipe. The compressed air must beclean and dry.
Please note the following:
! The minimum pipe inside diameter is ½".
! The air pressure required is 80 psi.
! The air volume required is 8.8 ft³/min..
! The air inlet is approximately 16" above the floor level atthe front of the Type II Vipros 368 King
For the location of required air supplies for optional equipment,please see the installation guides for the specific equipment
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 13 of 37
Planning the Location of the Type II Vipros 368 King
The following diagrams provide the details for positioning the Type II Vipros 368 King.
! No obstacles are allowed in the worksheet travel area and the ceiling must be at least 40" above the top of the Type II Vipros368 King.
! All of the recommended Safety / Maintenance areas should be used, but at a minimum, the doors of the Fanuc 18PC controlmust be able to be opened. Any reduction of the listed Safety / Maintenance areas may decrease personnel safety andincrease time and expense of installation and maintenance.
! The Type II Vipros 368 King and Fanuc 18PC control must be protected from direct sunlight or other heat sources. Exposureto direct heating sources such as infrared heaters have been shown to affect punch and die alignment.
! The positioning of the SBC EX 5.5 Chiller is very flexible. See page 19, SBC EX 5.5 Chiller, for details.
Moving the Vipros Type II Vipros 368 KingLifting or moving of the Type II Vipros 368 King should bedone only by professional rigging companies well versed inthe moving of large and heavy industrial machinery.Acceptable moving methods include, lifting by overheadcrane as shown, wheeled dollies beneath the machine feet,or adequately sized forklift forks beneath the machineframe.
The Type II Vipros 368 King has a relatively high center ofgravity and narrow footprint. Care must be taken to preventinadvertent tipping of the machine while in motion.
139"This cover
may need tobe removed
This covermay need tobe removed
Machine Weight 20 tons.Lifting lugs front and rear ofMachine Frame.
CAUTION: TOP HEAVY LOAD
39,600 lb. @ 75.8"
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 14 of 37
Plan View - Type II Vipros 368 King
351.
2" R
ecom
men
ded
Saf
ety
/ Mai
nten
ance
Are
a 40
" Fr
om A
ll C
ompo
nent
s
410.9" Recommended Safety / Maintenance Area 40" From All Components
Track 200 Centerline
Chiller Unit(position variable)
37"
57"
Hydraulic Power Unit
59"
30"
11"
17"
Y-Axis Zero
60."
Wor
k Z
one
222.
7" M
achi
ne L
engt
h
108.
9"
81.1" to edge of table 81.1" to edge of table
162.2" Machine WidthV
IPR
OS
368
Kin
g C
ente
rline
VIPROS 368 King
120"
Tra
vel A
rea
60"
Mat
eria
l
314.96" Travel Area 157.48" Material
Additional Support Tables Required
Additional Support Tables Required
Electrical Requirements
Vipros 368 King Type II230 / 460 / 3 / 60 ±10% 28 kVA
SBC EX5.5 Chiller230 or 460 / 3 / 60 ±10% 15 kVA
70 amps @ 230 / 3 / 60 VAC35 amps @ 460 / 3 / 60 VAC
37 amps @ 230 / 3 / 60 VAC19 amps @ 460 / 3 / 60 VAC
Vipros 368 King Type II
Compressed Air Requirements
80 psi @ 8.8 ft³/min.
E1
E1
E2
E2
E3
A1
A1
Operator Control Station
12" 12"12"
scale
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 15 of 37
Plan View - Type II Vipros 368 King with standard conveyors
351.
2" R
ecom
men
ded
Saf
ety
/ Mai
nten
ance
Are
a 40
" Fr
om A
ll C
ompo
nent
s
410.9" Recommended Safety / Maintenance Area 40" From All Components
Conveyor 1
Access Required for Scrap / Slug Removal
Con
veyo
r 2
Track 200 Centerline
Chiller Unit(position variable)
37"
57"
Hydraulic Power Unit
59"
30"
11"
17"
Y-Axis Zero
60."
Wor
k Z
one
222.
7" M
achi
ne L
engt
h
108.
9"
81.1" to edge of table 81.1" to edge of table
162.2" Machine WidthV
IPR
OS
368
Kin
g C
ente
rline
VIPROS 368 King
120"
Tra
vel A
rea
60"
Mat
eria
l
314.96" Travel Area 157.48" Material
Additional Support Tables Required
Additional Support Tables Required
Electrical Requirements
Vipros 368 King Type II
V368 Standard Conveyor 2
230 / 460 / 3 / 60 ±10% 28 kVA
SBC EX5.5 Chiller230 or 460 / 3 / 60 ±10% 15 kVA
208 - 230 / 460 / 3 / 60 ±10% .8 kVA
70 amps @ 230 / 3 / 60 VAC35 amps @ 460 / 3 / 60 VAC
37 amps @ 230 / 3 / 60 VAC19 amps @ 460 / 3 / 60 VAC
2.1 amps @ 208 / 3/ 60 VAC2.0 amps @ 230 / 3 / 60 VAC
V368 Standard Conveyor 1208 - 230 / 460 / 3 / 60 ±10% .8 kVA2.1 amps @ 208 / 3/ 60 VAC2.0 amps @ 230 / 3 / 60 VAC1.0 amps @ 460 / 3 / 60 VAC
Vipros 368 King Type II
Compressed Air Requirements
80 psi @ 8.8 ft³/min.
E1
E1
E2
E2E3
E3
E4
E4
A1
A1
Operator Control Station
12" 12"12"
scale
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 16 of 37
Plan View - Type II Vipros 368 King with standard conveyors and MP1530 loader
351.
2" R
ecom
men
ded
Saf
ety
/ Mai
nten
ance
Are
a 40
" Fr
om A
ll C
ompo
nent
s
498.2" Recommended Safety / Maintenance Area 40" From All Components
145.
8"78
.0"
223.
8" M
P15
30 L
oade
r Le
ngth
MP1530Xformer
82.1" to edge of loader 162.7" MP1530 Loader Width
Access Required For Material / Parts Removal
MP1530
Conveyor 1
Access Required for Scrap / Slug Removal
Con
veyo
r 2
Track 200 Centerline
Chiller Unit(position variable)
37"
57"
Hydraulic Power Unit
59"
30"
11"
17"
Y-Axis Zero
60."
Wor
k Z
one
222.
7" M
achi
ne L
engt
h
108.
9"
81.1" to edge of table 81.1" to edge of table
162.2" Machine WidthV
IPR
OS
368
Kin
g C
ente
rline
VIPROS 368 King
120"
Tra
vel A
rea
60"
Mat
eria
l
314.96" Travel Area 157.48" Material
Additional Support Tables Required
Additional Support Tables Required
Electrical Requirements
Vipros 368 King Type II
V368 Standard Conveyor 2
230 / 460 / 3 / 60 ±10% 28 kVA
SBC EX5.5 Chiller230 or 460 / 3 / 60 ±10% 15 kVA
208 - 230 / 460 / 3 / 60 ±10% .8 kVA
70 amps @ 230 / 3 / 60 VAC35 amps @ 460 / 3 / 60 VAC
37 amps @ 230 / 3 / 60 VAC19 amps @ 460 / 3 / 60 VAC
2.1 amps @ 208 / 3/ 60 VAC2.0 amps @ 230 / 3 / 60 VAC1.0 amps @ 460 / 3 / 60 VAC
V368 Standard Conveyor 1208 - 230 / 460 / 3 / 60 ±10% .8 kVA2.1 amps @ 208 / 3/ 60 VAC2.0 amps @ 230 / 3 / 60 VAC1.0 amps @ 460 / 3 / 60 VAC
Vipros 368 King Type II
MP1530 Loader
MP1530 Loader
Compressed Air Requirements
80 psi @ 8.8 ft³/min.
75 psi @ 31.8 ft³/min.
29 amps @ 200 / 3 / 60 VAC
200 / 3 / 60 ±10%, 10 KvaTo operate at 230 / 460 VAC a step up transformer is required with the following service is required
26 amps @ 230 / 3 / 60 VAC13 amps @ 460 / 3 / 60 VAC
E1
E1
E2
E2E3
E3
E4
E4
A1
A1
A2
A2
E5
E5
Operator Control Station
12" 12"12"
scale
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 17 of 37
End View – Type II Vipros 368 King
162.2"
Floor Line
104.38"
56.06" 43.31"*Material Pass
Line7.44"
131.89" Shipping Width w/o Crate
35.43"29.53"
14.76"
78.74" X axis Load Position
*Material Pass Line will vary with installed optional equipment
12" 12" 12"
scale
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 18 of 37
Elevation View – Type II Vipros 368 King
Y Axis 0"
Center of Turret
Center Track 200 Tool
43.31"*Material Pass Line
222.76"
7.1"
14."
24.41" 1.64"
196.65"
41.63"62.30"41.63" 41.24"9.84"
113.39"
69.68" 19.70" 1.18"47.25"60.0"
29.5"
47.2"
HydralicPower Unit
*Material Pass Line will vary with installed options
11"
12"12"12"
scale
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 19 of 37
SBC EX 5.5 Chiller
Model SBC EX 5.5
Cooling Capacity 78,000 BTU/hour at 650 ambient air temperature
Water Volume 10-15 GPM at 35 p.s.i.
Reservoir Capacity 70 Gallons
Pump HP 1 hp single phase
SBC EX 5.5 Chiller PlacementThe SBC EX 5.5 Chiller is very important to the reliable operation of the Type II Vipros 368 King.
The SBC EX 5.5 Chiller must be placed so that an adequate flow of air is maintained.
The position of the SBC EX 5.5 Chiller is flexible. The SBC EX 5.5 Chiller is supplied with two (2) fifteen-foot lengths of hoseto connect the to the Type II Vipros 368 King Hydraulic Unit. The customer may supply a longer length of hose if required.
Under normal operating conditions the SBC EX 5.5 Chiller may be placed against walls as shown. However, for maintenancepurposes access to all sides of the SBC EX 5.5 Chiller may be required.
The SBC EX 5.5 Chiller must have a minimum 60" of clearance above the SBC EX 5.5 Chiller for proper airflow.
Two 15ft supplied water lines
6"
6"
Chiller Unit
Air Flow
Under normal operating conditions the Chiller may be placed against walls as shown. For maintenance purposes access to all sides may be required. 60" overhead clearence required. Chiller may be located up to 50ft from Hydraulic Unit. Chiller is not designed for outdoor placement.
Maximum Travel Areafor Material Size of(X)157.5" x (Y)60"
Hydraulic Unit(Location Fixed)
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
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Chiller Connections
Type II Vipros 368 King Hydraulic Unit SBC EX 5.5 Chiller
"Water Out
"Water In
Water Out#Water In# "(2) 15 ft. Water lines Supplied
(2) 15 ft. Water lines supplied#
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
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Foundation Requirements
The Type II Vipros 368 King does not require a special foundation to perform as expected, however there are minimumrequirements that an existing floor must meet in order to assure machine reliability and tool life. If the existing floor does notmeet the following minimum requirements, plans for a recommended foundation are given on page 23, Plan View - Foundation .
The minimum acceptable floor conditions to assure a successful installation are:
! The area of the floor where the machine frame is to be located must be a single, homogeneous slab in good condition. Theremust be no cracks or other signs of deterioration of the floor.
! The floor must be 4" to 6" thick.
! The floor must be capable of supporting 3.5 tons/ft².
! The floor must be level to 0.032"/ft.
If the existing floor meets the minimum requirement list above, it must still be inspected carefully when the anchor-bolt holes arecut. Voids under the floor, or wetness (not associated with the hole cutting procedure) should be considered signs of aninadequate floor and a new machine location or new foundation must be considered.
It is the customer’s responsibility to determine that the floor meets these minimum requirements. Placing the machine on aninadequate, cracked floor, or straddling seams in a floor may be grounds for voiding the machine warranty!
Amada America Inc. does not recommend the use of vibration isolating mounts under the machine feet, as these devices havebeen shown to increase the vibration within the machine frame, increasing the likelihood of vibration related problems. Solidleveling devices are acceptable provided they incorporate a means of anchoring the machine to the floor with the supplied J-bolts or alternative anchoring method.
Special Note: This document details several methods of anchoring the Type II Vipros 368 King to a new foundation or anexisting floor. These methods are designed to install the Type II Vipros 368 King as a stand-alone machineusing the supplied anchor bolts and base plates. Installation or use of additional options such as leveling padsor material handling systems may dictate other methods of anchoring or foundation design not shown in thisdocument. Before committing to a specific method of anchoring the Type II Vipros 368 King, confirm that thechosen method is compatible with all purchased optional items and planned expansion.
Type II Vipros 368 King with Fanuc 18PC User Pre-installation Guide ©Amada America, Inc.
Print Date 02/26/2001 Revision 4.0 This document available on the World Wide Web at http://www.amada.com Page 22 of 37
5"
10"15.8"
Base Plate
Hole in Foundation
Floor Line
Machine Foot
A
A
A
Machine Frame
Machine Foot
Base Plate
Supplied J-Bolt
4.4"8.0"
24"
Foundation Anchoring Procedure
An ideal foundation is given on the page following pages. This foundation must be used if the existing floor cannot meet theminimum requirements to support the machine.
The foundation must consist of a single, homogeneous slab. The foundation must be level to within 0.032" / ft. Anchoring theType II Vipros 368 King to the floor using the anchor-bolts supplied is essential to ensure reliable performance. Amadagenerally recommends that the foundation have a minimumload bearing capacity of 3.5 ton/ft2. It is the purchaser’sresponsibility to determine that the foundation meets theserequirements.
Please note the following:
! The base plates, shims, anchor bolts, nuts, and washers areshipped with the Type II Vipros 368 King.
! The concrete J-bolt pads should be filled after the machine isplaced on the foundation.
! See special note page 21
Foundation J-bolt DetailSee page 26, Foundation / Floor J-bolt Mounting Procedure,for proper method of mounting the Type II Vipros 368 King onthe foundation.
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Plan View - Foundation Type II Vipros 368 King
Existing Floor
Existing Floor
New Foundation
14.75" 29.5" Anchor Bolt Centerline
209"
48"
Machine Centerline
113.4" Anchor Bolt Centerline
120"
60"
24"24"
Elevation - Foundation Type II Vipros 368 King
Floorline
209.4"
48" 24" 24"113.4"
6"
6"24"
12"
12" 12"scale36"
Cement
Crushed Stone
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Machine Anchoring Requirements
Saw Cut J-bolt Mounting HolesTo maintain machine reliability, extend tool life, and remain level over an extended period the Type II Vipros 368 King mustbe anchored in place on an adequate floor or foundation.
At a minimum the floor must consist of a single, homogeneousslab, level to within 0.032"/ft², and capable of supporting 3.5tons/ft². It is the purchaser’s responsibility to determine thatthe floor meets these minimum requirements.
This machine mounting method should be used only if the flooris of such quality that it will support the weight of the machinewith the anchor J-bolts used only for maintaining the locationof the machine.
Please note the following:
! The base plates, shims, anchor bolts, nuts, and washersare shipped with the Type II Vipros 368 King.
! The concrete J-bolt pads should be filled after themachine is placed on the foundation.
! See special note page 21
5"
10"15.8"
Base Plate
Saw Cut Hole In Existing Floor
Existing Floor
Machine Foot
A
A
A
Machine Frame
Machine Foot
Base Plate
Supplied J-Bolt
4.4"8.0"
24"
Saw Cut Floor Hole (4)
14.75"29.5" J-bolt Centerline
113.4" J-bolt Centerline
Machine Centerline
Existing Floor
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10.0"
24.0"
Base Plate
10" Core Drill in existing floor
Floor Line
Machine Foot
A
A
A
Machine Frame
Machine Foot
Base Plate
Supplied J-Bolt
35.4" Core Drill Centerline
14.75"29.5" J-bolt Centerline
113.4" J-bolt/Core Drill Centerline
Machine Centerline
10" Core Drill Hole (4)
Existing Floor
Core Drill J-bolt Mounting Holes
To maintain machine reliability, extend tool life, and remain level over an extended period the Type II Vipros 368 King mustbe anchored in place on an adequate floor or foundation.
At a minimum the floor must consist of a single, homogeneous slab, level to within 0.032"/ft², and capable of supporting 3.5tons/ft². It is the purchaser’s responsibility to determine that the floor meets these minimum requirements.
This machine mounting method should be used only if the flooris of such quality that it will support the weight of the machinewith the anchor J-bolts used only for maintaining the locationof the machine.
Please note the following:
! The base plates, shims, anchor bolts, nuts, and washersare shipped with the Type II Vipros 368 King.
! The concrete J-bolt pads should be filled after themachine is placed on the foundation.
! See special note page 21
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Foundation / Floor J-bolt Mounting Procedure
Step 1. Saw cut or Core drill a hole in the existing floor andremove the underlying dirt to the required 24" depth.
See Floor J-bolt Mounting Hole Plan View (saw cut hole)or Alternative J-bolt Mounting Method Plan View (CoreDrill) for correct layout dimensions of the four anchorholes required.
Step 2. Set base plate over the hole.
Step 3. Set the machine on the base plate.
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Step 4. Set the J-bolt through the hole in machine foot, attachwasher and nut to hold J-bolt in place.
Step 5 Pour the Concrete.Ensure that the J-bolt remains correctly aligned to themachine frame during the pouring and hardening time ofthe concrete.Ensure that the concrete level is equal to the floor level
Step 6. To complete the mounting procedure, level the machineframe by inserting leveling shims between the machinefoot and base plate.
See Leveling the Machine section for correct procedure.
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14.75"29.5" Anchor Bolt Centerline
113.4" Anchor Bolt Centerline
Machine Centerline
1½" Core Drill Hole (4)
Existing Floor
Floor Line
Machine Foot
Machine Frame
Machine Foot
1" x 16" anchor bolt
6.00"
Existing Floor
Base Plate
Drilled Hole with Anchor Rod and Adhesive Mounting Holes
To maintain machine reliability, extend tool life, and remain level over an extended period the Type II Vipros 368 King mustbe anchored in place on an adequate floor or foundation.
At a minimum the floor must consist of a single, homogeneous slab, level to within 0.032"/ft², and capable of supporting 3.5tons/ft². It is the purchaser’s responsibility to determine that the floor meets these minimum requirements.
This machine mounting method should be used only if the floor is of such quality that it will support the weight of the machinewith the anchor J-bolts used only for maintaining the location of the machine.
Please note the following:
! The base plates, shims, anchor bolts, nuts, and washersare shipped with the Type II Vipros 368 King.
! The concrete J-bolt pads should be filled after themachine is placed on the foundation.
! See special note page 21
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Drilled Hole with Anchor Rod and Adhesive Mounting Procedure
Step 1. Drill the four Anchor Rod holes in the existing floor.
The holes should be drilled approximately 6” deep.
See Alternative Floor Bolt Mounting Method Plan View (Drilled Hole withAdhesive Anchor Rod) for correct layout dimensions.
Existing Floor
Step 2. Set the Amada Machine Leveling Plates over the drilled holes
Existing Floor
Step 3.
Step 4
Set the machine on the machine leveling plates.
Level the machine frame by adjusting the Amada machine leveling plates.
See Leveling the Machine section for correct procedure.
Existing Floor
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Step 5 Fill each of the Anchor Rod holes to within 2 inches of the floor surface withthe Adhesive compound. Do not overfill.
Existing Floor
Step 6 Attach the hex nut and flat washer on the Anchor Rod and place the AnchorRod into the drilled hole.
Using a twisting motion to move the Anchor Rod through the epoxycompound, seat the flat washer and hex nut against the top of the machinefoot.
Existing Floor
Step 7
Step 8.
Allow the Adhesive to harden for 24 hours.
Tighten the 4 hex nuts.
Existing Floor
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Y AXIS BALL SCREW
X AXIS BALL SCREW
Y AXIS LM GUIDES (1 EACH SIDE)
X AXIS LM GUIDES (TOP AND BOTTOM)
UPPER AND LOWER TURRETS
Removing the Protective Coating
The Type II Vipros 368 King must be thoroughly cleaned of protective coating. The sheet metal guards can be removed fromaround the turret to allow cleaning of the upper and lower turrets, tool bores and die holders.
Please note the following:
! Remove wrapping paper from the X and Y-axes ballscrews, then remove the protective coating.
! Remove the wrapping paper from the X and Y LMguides then remove the protective coating, make surethat you remove the paper from both sides of thecarriage.
! Clean die holders one at a time. Remove a die holder,clean and replace it before removing the next dieholder. If the die holders are mixed up, serious turretalignment problems may occur.
! A suitable solvent should be used to remove theprotective coating.
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Machine Leveling
Proper Machine leveling is critical to the Type II Vipros 368 King performing as designed.
Materials and tools required:
Supplied with the machine:
Assorted thickness machine leveling shim stock
Anchor bolts
Supplied by AESI service:
Spirit level capable of reading 0.0005"/ft
One (1) 12 ton hydraulic bottle jack
Not supplied:
Additional shim stock of 0.005" thickness may be required to achieve a properly leveled machine.
Rocking TestAfter the machine frame has been leveled the use of the following G-code is necessary to determine that the machine frameis properly leveled and balanced.
Should the machine frame vibrate or move excessively during the rocking test the machine frame must be re-leveled usingthe procedure in this manual.
Should the proper leveling technique not eliminate the excessive frame motion, consideration must be given to relocation ofthe machine or replacement of the existing floor with an adequate foundation.
Set M500 values to Top Position 0.080", Bottom Position, 0.080", Slow Position 0.000"Repeat test with X-axis movement values of 0.500", 1.000", and 4.000"
G92X78.740Y60.000G06A.100B0M500N1G91G70X-.25Tttt(Use any valid tool number)G70X.25M97P1G50
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Floor Condition: Crowned
The flatness of the floor plays an important step in the levelingprocedure of the machine. To properly level the machine theweight bearing points must be as far from the centerline of themachine frame as possible.
Should a condition known as crowning exist the weight bearingpoints of the machine may not be far enough from the machinecenterline to ensure a stable machine.
Under these conditions, a procedure known as Half-Shimmingshould be used.
CrownedFloor
WeightBearing Point
Machinecenterline
Base Plate Base Plate
Machine Foot
To move the weight bearing points further from the machinecenterline the use of half-shims of .125" thick on top of the baseplate as shown is recommended.
After the half-shims are installed and the machine frame isleveled, use the rocking test to determine that the machine frameis stable enough to allow production without damaging themachine.
Under extreme conditions the use of half-shims may not movethe machine weight bearing points far enough from the machinecenterline to ensure the machine frame is stable.
Under these conditions, a more suitable location must be foundfor the machine, or a new foundation for the machine will benecessary.
CrownedFloor
Weight Bearing Point
Machinecenterline
Half-shim
Base Plate Base Plate
Machine Foot
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Floor Condition: Sloped
The slope of the floor plays an important step in the levelingprocedure of the machine. To properly level the machine theweight bearing points must be as far from the centerline of themachine frame as possible.
Should the floor slope excessively the weight bearing points ofthe machine may not be far enough from the machine centerlineto ensure a stable machine.
Under these conditions, a procedure known as Half-Shimmingshould be used.
Sloped FloorWeight Bearing Point
Machinecenterline
Shim
Base PlateBase Plate
Machine Foot
To move the weight bearing points further from the machinecenterline the use of half-shims of .125" thick on top of the baseplate and leveling shims as shown is recommended.
After the half-shims are installed and the machine frame isleveled, use the rocking test to determine that the machine frameis stable enough to allow production without damaging themachine.
Under extreme conditions the use of half-shims may not movethe machine weight bearing points far enough from the machinecenterline to ensure the machine frame is stable.
Under these conditions a more suitable location must be foundfor the machine, or a new foundation for the machine will benecessary.
Sloped FloorWeight Bearing Point
Machinecenterline
Base PlateBase Plate
Machine Foot
Half-shim
Shim
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Leveling Procedure
1. Determine the high end of machine frame by placing the spirit levelon the turret to measure the level of the machine frame in the y-axis.
2. Use the bottle jack to lift the low end of the machine frame.
3. With the turret end of the machine frame slightly higher than thecarriage end. Shim beneath both machine feet and the base platesuntil the machine frame measures near level on the y-axis.
Shim Equaly Both Sides
BottleJack
4. Center the bottle jack under the carriage end of the machine frame.
5. Lift the machine frame until all weight is off the machine feet at thecarriage end of the machine frame. Lift the machine frame as littleas possible to take the weight off the base plates.
Remove weightof machine from
base platesBottleJack
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6. With the machine supported on the bottle jack at the carriage end ofthe machine frame and the machine feet at the turret end of themachine frame, place the spirit level on the turret.
7. Measure and record the level of the turret in the x-axis direction.
8. Lower the machine frame to place all machine feet in contact withthe leveling shims and base plates.
9. Lift the turret end of the machine frame to allow shimming betweenthe machine feet and base plates to level the machine frame in thex-axis direction.
10. Repeat steps 5 to 9 until the machine frame measures level to0.0005"/ft in step 7, then continue.
Shim tolevel X-axis
BottleJack
11. With the weight of the carriage end of the machine supported by thebottle jack. Monitor the level of the turret in the x-axis, as the bottlejack is slowly lowered to place the carriage end machine feet incontact with the base plates.
12. Any change in the level indicates that the carriage end of themachine needs to be leveled. Remove weight
of machine frombase plates
BottleJack
13. Lift the carriage end of the machine frame to allow shimmingbetween the machine feet and base plates to level the carriage endof the machine frame in the x-axis direction.
14. Repeat steps 11 and 13 until no difference in level is noted whenthe machine weight is on or off the base plates and shims, thencontinue.
Shim tolevel X-axis
BottleJack
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15. With all of the machine feet setting on the shims and base platesplace the spirit level on the turret to measure and note the level ofthe machine frame in the y-axis.
16. Using the bottle jack lift the low end of the machine frame and shimequally under both machine feet to level the machine frame in the y-axis.
17. Repeat steps 15 to 16 until the machine frame measures level to0.0005"/ft in the y-axis then continue.
Shim Equaly Both Sides
BottleJack
18. Run the machine using the rocking test G-code to determine thatthe machine frame is leveled adequately. Should excessivemovement of the machine frame be noticed check for the conditionsdiscussed in Floor Condition Crowned and Floor Condition Sloped
19. Tighten the anchor bolt nuts to prevent the machine frame frommoving when in use. Monitor the machine level while tightening theanchor bolts to assure the machine level is not changed.