P lanning documentation CTX 510 eco

N The first start up

The first start up (alignment and function test) of the machine is made
by authorised personnel of the machine manufacurer!.

1 PURPOSE OF THIS DOCUMENTATION ............................................................................... 3

1.1 Use of the instruction ...................................................................................................... 3
1.1.1 Explanation of symbols and warning signs......................................................... 3
1.1.2 Safety standards................................................................................................. 4

2 TO BE PREPARED ................................................................................................................. 5
2.1 To be prepared by the customer..................................................................................... 5
2.1.1 Quality of the foundation..................................................................................... 5
2.1.2 Warning notes on designing ............................................................................... 7
2.1.3 Planning data...................................................................................................... 8
2.1.3.1 Foundation plane ..................................................................................... 8
2.1.3.2 Load at support points .............................................................................. 9
2.1.3.3 Overall dimensions ................................................................................ 10
2.1.3.4 Occupied area ...................................................................................... 11

3 ELECTRICAL PART.............................................................................................................. 12
3.1 Connection to the mains ............................................................................................... 12
3.1.1 Protections........................................................................................................ 12
3.1.1.1 Electrical data for connecting the machine ............................................. 12
3.1.1.2 Tubing for external data transmission cable ........................................... 13

4 AMBIENT REQUIREMENTS FOR THE MACHINE .............................................................. 14

4.1 Hydraulics ..................................................................................................................... 14
4.2 Chip disposal ................................................................................................................ 14
4.3 Pneumatic part.............................................................................................................. 14

5 PRODUCTS NECESSARY FOR THE MACHINE OPERATION........................................... 15

CTX 510 eco_PU_EN-v1.0 Page 1

 5.1 Fluids ............................................................................................................................ 15
5.1.1 Recommendations............................................................................................ 15
5.1.2 Preparing lubricants and coolant-lubricants...................................................... 15
5.1.3 Recommendations concerning the removal of spent fluids .............................. 16
5.1.4 Table of filling.................................................................................................... 16
5.1.5 Smearing products available in the market....................................................... 17
5.1.6 Coolants-lubricants available in the market ..................................................... 18
5.1.7 Fluids for hermetic systems available in the market ........................................ 19

6 FIXING DEVICES .................................................................................................................. 21

6.1 Fastening of the machine ............................................................................................. 21
6.2 Tools ............................................................................................................................ 21
6.3 Electric tools ................................................................................................................. 21
6.4 Instructions relating to fastening of the machine .......................................................... 21

Copyright

All rights, including reprinting, reproduction of text contained in this manual and translations, are
reserved by FAMOT Pleszew S.A.

No part of this manual can be reproduced or copied in any form, including using electronic reproduction
means, not even teaching or training purposes, without written authorization by FAMOT Pleszew S.A.
Contents of this manual may undergo modification without any updating commitment towards users.
Some pictures, photographs and drawings in this manual may not accurately depict your lathe. This will
not affect the validity of the information herein contained.

Version : V1.0
© 2008 FAMOT Pleszew S.A

Page 2 CTX 510 eco_PU_EN-v1.0

Purpose of this documentation

1 Purpose of this documentation

1.1 Use of the instruction

This technical handbook contains the basic data necessary for proper prepa-
ration of the installation of the purchased numerically controlled CTX 510 eco
lathe.
This documentation is intended for managers and the cooperating employees
responsible for the choice and preparation of the installation place, so that the
machine can be installed and connected immediately after the delivery.
Some illustrations, photos or figures in this brochure may present your lathe in
an imprecise way; this, however, does not influence the validity of the informa-
tion therein included.
This brochure may be subject to modifications at any time, without the obliga-
tion to notify the customer.
The information, technical data and notes concerning the transportation and
installation of the external equipment (for example: a pressing bar device) are
presented in the manuals prepared by the manufacturers of such equipment.
In the scope of the Customers' Service program, FAMOT Pleszew S.A. offers
training to prepare the specialized personnel to make the best of your new ma-
chine.
The scope of training depends on the skills already acquired by your person-
nel. Therefore, a prior verification should be made of your employees' know-
ledge to ensure they are able to operate the machine you have purchased in
the best way.
In case of need, please contact our Service as soon as possible. Schedule all
the trainings to be completed before the machine is delivered.

1.1.1 Explanation of symbols and warning signs

The symbols presented below enable quicker understanding of the meaning
of some references..

To be checked in the specific handbook (for example: the turret, the air
conditioner, the chip conveyor).
 To be checked in next or previous chapters/paragraphs

© Information

; Contact the technical service

N Attention - Danger

b Qualified personnel

CTX 510 eco_PU_EN-v1.0 Page 3

 Purpose of this documentation

H Electric shock hazard

J Necessary recommendations

e Visual inspection

ƒ Clean up

’ Danger of crushing

M Magnetic field

0 No entry for persons with an electric pacemaker

À No entry for persons with metal prostheses

1.1.2 Safety standards

The first start-up of the CTX 510 eco lathe and the operating instructions are
delivered by the competent service of FAMOT Pleszew plant, which ensures
the efficiency and safety already from the first start-up.
FAMOT Pleszew S.A. reached a maximum level of technology and practice
currently attainable; however, the machine can not be operated by the person-
nel which is inexperienced, non-specialized or not mature enough.
The machine should be used in an appropriate way, in compliance with the in-
tended purpose.
The CTX 510 eco lathes meet the safety standards. Despite the above, the
lack of attention or experience can cause:
• the health hazard,
• the risk of damage for the machine and personal property of the user,
• the danger that affects the quality and efficiency of work
During transportation, installation and start-up operations, current safety stan-
dards should be met and all precautions made available by technology and
practice should be observed. In particular, the following should be respected:
• all valid safety standards relating to the work and operations of this type,
• the standards relating to connecting the electric system to the power supply,
• the standards valid in the country where the machine is used,
• the engineering standards covering hydraulic parts and parts under pressu-
re.

Page 4 CTX 510 eco_PU_EN-v1.0

To be prepared

2 To be prepared
Tabela 1: Standard dimensions
Pallet for lifting

Height (M.U. incl.) m 2,52

Width m 2,17

Length m 5,40

Pallet for sea transport

Height (final.) m 2,24

Width m 2,17

Length m 5,40

Approximate weight of the machine without package 7500 kg

Above dimensions can subject to changes

2.1 To be prepared by the customer

he customer at whose premises the final acceptance is to be carried out
should prepare the location for the machine installation i.e.:
• Perform the foundation.
• Perform necessary connections of power supply.
• Perform necessary connection of the pneumatic system.
• Commission a third party or perform on its own the internal transportation of
the machine in the place of installation, and clean up and degrease the
machine.
• Have a stock of necessary lubricating oils and coolant-lubricants at hand..

b The first start-up (the levelling and the shakedown test) of the machine are
carried out by the authorized personnel of the constructor.

2.1.1 Quality of the foundation

If the floor of the building guarantees a proper support, it is possible to set the
machine directly on the floor itself, and lay it on trimming plates.
In any case it is possible to anchor the machine with the foundation bolts with
the aid of HILTI chemical vials delivered in the accessory box.
The main function of the foundation plane is to guarantee the most solid pos-
sible support to the machine to prevent any deformations, as those could in-

CTX 510 eco_PU_EN-v1.0 Page 5

 To be prepared

fluence the precision and hence the production quality.

Should a new foundation be required, it is advisable to proceed as follows:
• Have the basement carrying capacity examined by an engineer qualified in
industrial building, considering that the machine and the foundation plane
transmit a max. pressure of 0.9daN/cm2 to the ground. Foundation
dimensions and characteristics should be modified if the ground carrying
capacity is below the value mentioned above.
• Make the foundation that ensures a rigid support for the machine (good
results are obtained by the reinforced concrete with the characteristic
resistance of approximately 250 daN / cm2).
• The foundation should be levelled with a maximum tolerance of 3 mm / m2.
Make the passage in the foundation for the electric cables, as presented in Fi-
gure "overall size"

N The foundation consisting of separate parts or made of different material is not

admissible. innego materiału.

When making the foundation, pay attention to some aspects (see:"Ambient

requirements for the machine").
Technical data
• 1.Foundation made of concrete having characteristic resistance R' ck = 250
daN/cm2 and depth about 400mm
• 2.Reinforcement grid (F8 / 200×200mm) over all the foundation surface,
made of electrically welded steel (Feb 44 k)
• Spacer washers (1 F8mm / 1 m2) made of steel (Feb 44 k)

Figure 1-1 Foundation

2.1.2 Warning notes on designing

The dimensions presented in this documentation relate exclusively to the ma-
chines with the standard equipment.
When other equipment is used (for example: a bar feeding device), prior to the
reception thereof contact the manufacturer to obtain technical data, the infor-
mation on the preparation and electrical connection.
In general, the machine is dispatched on a lorry of overall height of 4 m.

Page 6 CTX 510 eco_PU_EN-v1.0

To be prepared

2.1.3 Planning data

2.1.3.1 Foundation plane

Figure. 1-2 Foundation D43141

CTX 510 eco_PU_EN-v1.0 Page 7

 To be prepared

2.1.3.2 Load at support points

Figure 1-3 Support points D43137

Page 8 CTX 510 eco_PU_EN-v1.0

To be prepared

2.1.3.3 Overall dimensions

Figure. 1-4 Dimensions D43135

CTX 510 eco_PU_EN-v1.0 Page 9

 To be prepared

2.1.3.4 Occupied area

Figure. 1-6 Dimensions D43129

Page 10 CTX 510 eco_PU_EN-v1.0

Electrical part

3 Electrical part

3.1 Connection to the mains

3.1.1 Protections
As per their operational principle, modern digital drives with recovery of the
network voltage generate leakage current towards earth which is mainly of ca-
pacitive and impulsive type, and which is not a sign of any electrical failure, but
can cause unjustified interventions of differential switches.

Anyway, if you decide to apply a differential switch for additional protection, we

recommend using type B switches for continuous type failure currents with set-
ting not less than 300 mA and variable operating time.

3.1.1.1 Electrical data for connecting the machine

Tabela 2: Electric specifications

Values referring to the machine connection to the mains
400 V (+/ -
Power supply mains 3 phases
10%)
Frequency 50 Hz (+/- 1 %)
Apparent rated power 50 kVA
Active power 25 kW
Maximum current 72 A
Thermal protection 80 A
Fuse protection 100 A
Connecting cable 25 mm2
Control circuits
Control voltage CC 24 V

Frequency 60 Hz ( option )

CTX 510 eco_PU_EN-v1.0 Page 11

 Electrical part

The neutral wire is not necessary for installing the machine.

Figure. 1-7 Terminal block

The indicated apparent power (S in kVA) refers to the maximum stage of the
machine amplification. When using adequate motors in operational mode S6
(= 40%), the power may temporarily increase by about 50%.
The machine is designed for connection in the four-wire system (three phases
and PE wire).

3.1.1.2 Tubing for external data transmission cable

If the external data transmission is required/designed, the appropriate metal

tubing for the data cable should be installed.

: The data cables should not be run in the proximity of cables of high current
flows and should not cross them.

Page 12 CTX 510 eco_PU_EN-v1.0

Ambient requirements for the machine

4 Ambient requirements for the machine

Consider the following aspects when making foundations:
• the site must be vibration free,
• the site temperature should be uniform and not exposed to any heat sources
on the side, such as sun rays or exposed to cold air drafts,
• the site should be protected from noise generated by electric installations,
• air humidity shall not exceed 75%
• air temperature shall be kept as constant as possible and be within the
range from 15°C up to 35 °C (308°K),
• the site of installation should not be higher than 1000 m above sea level.
If any of these values is exceeded in the installation premises, or any special
conditions of use occur, for example dust is released in the installation premi-
ses,
• oxidating particles are present in atmosphere,
the installation is made in area where the explosion hazard occurs or the ex-
plosives are present,
please discuss these issues with your DMG representative.

4.1 Hydraulics
Only pure oil should be used (purity grade at least 25 µm).

4.2 Chip disposal

To collect the chips coming from the chip conveyor, the chip collecting carriage
is required. The carriage construction should prevent the hands from penetra-
ting into the conveyor ejector opening when the carriage is under the chip con-
veyor.

J The c chip collecting carriage should have the equipment for refilling the chip
conveyor with coolant.

This would reduce the coolant cost and would also contribute to improve envi-
ronmental protection.

4.3 Pneumatic part

Some assemblies of the machine operate with the pneumatic system, there-
fore it is essential to connect the machine to the central system equipped with
the air filtration system. The use of non-filtrated air can cause malfunction and
damage the machine.
The connection should be made to a line capable to withstand the pressure of
about 6 bar.

CTX 510 eco_PU_EN-v1.0 Page 13

 Products necessary for the machine operation

5 Products necessary for the machine operation

5.1 Fluids
The purpose of fluids and designation of lubricating points presented in this
handbook comply with DIN 51 502 Standard. The use of appropriate fluids is
necessary for safe machine operation and long life of the machine. In general,
the machine is delivered without fluids. It is recommended to continue using
the same fluids as these used for the first filling (see: instruction).

If this is not possible, use other fluids indicated in the table enclosed.
To avoid the incompatibility of the mixture, we recommend using the fluids of
the same brand, if possible.

5.1.1 Recommendations

J Only the usage of fluids of these types warrants the reliable functioning of the
machine.

The manufacturers of fluids have technical service which can pass to you the
detail information and recommendations regarding their application.

5.1.2 Preparing lubricants and coolant-lubricants

Due to some ingredients (additions), these products are the potential source
of risk to human health and may cause environmental pollution.
Their choice and usage depends exclusively on the user. The servicing in-
struction elaborated by the manufacturer should include the following informa-
tion to define the way of using the product:
• definition of the substance,
• presentation of the risk for human health/life and possible environmental
impact,
• protection means and rules of proceeding, for example
- recommendation to wear the protective shoes of the resistant material,
- caution to keep these substances away from skin and eyes,
- caution to avoid breathing vapours or sprayed substances in,
- no smoking during handling these fluids/oils.
The fumes of the lubricant can be generated during machining.
When the applied coolant- lubricant contains 15% of oil or more, and when the
easily flammable coolant- lubricant is used in a hermetic work place, there
exists the ignition and explosion danger.

Page 14 CTX 510 eco_PU_EN-v1.0

Products necessary for the machine operation

Contact the manufacturer for the means of protection..

5.1.3 Recommendations concerning the removal of spent flu1ids

The fluids used for machine operation are pollutants, so they may not be di-
scharged to the environment.
The ecological way of disposal of spent fluids should be defined before the
machine is installed. You can contact, for example, the hazardous waste dis-
posal depot.

5.1.4 Table of filling

Tabela 3: Table of applied fluids

Posi-
Fluid type DIN ISO-UNI
tion Q-ty
Symbol Symbol
Lubricators SUPER GREASE A

Self-centering
(1) See manufacturer's manual XBCEA
chuck. lubricators

A Hydraulic unit Hydraulic oil (TELLUS T32) HM32 l.40

C Cooling and lubri-

Emulsifiable oil l. 220
(2) cating unit

D Steady fluid for hermetic cooling

Turret cooling unit l.10
(3) circuits (ROL - ICE BLU)

1.

CTX 510 eco_PU_EN-v1.0 Page 15

 Products necessary for the machine operation

A C B

Figure 1-21 Fillings

J For compatibility, contact the manufacturer of such products or the authorized

agent dealing with such products.

• (1) Smear for fixing jigs; observe the constructor's indications.

• (2) Proportion of a mixture - observe the manufacturer's indications:
- if too liquid: the machine slideways and the parts being machined
undergo oxidation,
- if too dense: the action of the coolant is insufficient.
• (3) Use steady fluid for hermetic cooling systems, preferably in a ready-to-
use packages. If not accessible, prepare the 30% water solution of the
concentrate..

5.1.5 Smearing products available in the market

The COMPARISON TABLE presented below was derived from the COMPA-
RISON TABLE made available by S.T.A.N.I.M.U.C. UNI FEDERATED BODY
( issue 1996).
The manufacturers presented below offer specifically studied combinations of
lubricating oils; in case of using products different from those used by FAMOT,
contact the manufacturer for compatibility.
FAMOT Pleszew S.A. disclaims any liability for damages due to the use of
wrong products.

Page 16 CTX 510 eco_PU_EN-v1.0

Products necessary for the machine operation

Tabela 4: SMEARING PRODUCTS

Hydraulic oil Smear
Symbol ISO-UNI HM32 XBCEA

Manufacturer Type of oil Type of smear

AGIP OSO 32 GR MU EP 2
API CIS 32 PGX 2
ARAL ARAL VITAM GF 32 ARALUB HL 2
LITHOLINE H EP
ARCO DURO OIL AW 32
GR 2
RULTEN 900
BERGOLINE PARATER S 32
N2EP2
PARAVIS HLP 32 -
ENERGOL HLP-HM
BP GREASE LTX2
32
ENERGOL HLP-D
GREASE LTX2 EP
32
CASTROL HYSPIN AWS 32 SPHEEROL APT 2
- SPHEEROL EPL 2
ELF ELF OLNA DS 32 ROLEXA 2
- EPEXA 2
ESSO NUTO H 32 BEACON 2
FINA FINA HYDRAN 32 MARSON EPL 2
FUCHS REMOLIN B 32 RENOLIT FEP 2
IP IP HYDRUS OIL 32 ATHESIA GR 2
IP HYDRUS OIL X
ATHESIA GR EP 2
32
KLÜBER LAMORA 32 CENTOPLEX 2
- CENTOPLEX 2 EP
MOBIL MOBIL DTE 24 MOBILPLEX 47
- -
Q8 Q8 HAYDN 32 REMBRANDT EP 2
ALVANIA GREASE
SHELL TELLUS 32
R2
HYDRAULIC 32 SUPER GREASE A
TAMLITH GREASE
TAMOIL HYDRAULIC OIL 32
2

CTX 510 eco_PU_EN-v1.0 Page 17

 Products necessary for the machine operation

Tabela 4: SMEARING PRODUCTS

Hydraulic oil Smear
Symbol ISO-UNI HM32 XBCEA

Manufacturer Type of oil Type of smear

TAMLITH GREASE
TAMHYDRO OIL 32
2EP
TEXACO RANDO HD 32 MULTIFAK EP 2
- MULTIFAK MP 2
TOTAL AZOLLA ZS 32 MULTIS EP 2
- MULTIS 2
HYDRAULIC HLP
VALVOLINE L 2 EP GREASE
32
VANGUARD HYDRAULIC 32 LIKO EP2

5.1.6 Coolants-lubricants available in the market

The table below presents some series of products for the hermetic systems
available in the market.
If you use the product other than that used by FAMOT, we advise you to con-
tact the manufacturer of the coolant to settle the proper application.

Tabela 5: PACKAGES OF THE CONCENTRATED

PRODUCT
MANUFACTURER TYPE

ARAL Sarol 340

Sarol 445 EP
Sarol 460 EP
AVIA Avilub Metacon UV 18
Avilub Metacon 300 EP
Avilub Metacon Synt 100
BANTLEON Metacon BLU
Metacon BSB - F
CASTROL Alusol B
Syntilo R - HS
CINCINNATI Cimcool 603
CMT Acquasol 5 - 58

Page 18 CTX 510 eco_PU_EN-v1.0

Products necessary for the machine operation

Tabela 5: PACKAGES OF THE CONCENTRATED

PRODUCT
MANUFACTURER TYPE

ELF Sarelf ACS

Emulself FBB
Elf Solfuria SU
ESSO Bohröl BS EP 50
Kutwell 40
FIMITOL Avantin 550
Avantin 700
Avantin 800
FINA Vulsol BST
FUCHS Ratak Durant 20
MOBIL Mobilmet 151
OEMETA HD 52
PENNZOIL Boorolie EC
ROCOL Ultracut 390 H
Rotacut 80 EP
Rotacut 90 EP
SOLLNER Connexol WKS
TOTAL Lactuca LT 2
Rectimol Soluble 6
WELLCOR SR / 4
KB / S
WINTERS- HALL Wiolan KSU 2
WISURA WM 3052
VANGUARD Soloil 2911/B

5.1.7 Fluids for hermetic systems available in the market

The table below presents some series of products for the hermetic systems
available in the market.
If you use the product other than that used by FAMOT, we advise you to con-
tact the manufacturer of the coolant to settle the proper application.

CTX 510 eco_PU_EN-v1.0 Page 19

 Products necessary for the machine operation

Tabela 6: PACKAGES OF THE CONCENTRATED PRODUCT

PRODUCENT TYP

API Antigelo-Antyfryz
BP Antifreeze
ELF Glacelf
ESSO Antigelo Permanente-Antyfryz stay
FIAT Paraflu 11
FINA Termidor
MOBIL Anticongelante
MOTUL Antigel
ROL OIL ROL - ICE BLU
SHELL Antifreeze
TAMOIL Permanent Super Antifreeze
TEXACO Anti - freeze
TOTAL Antifreeze

Tabela 7: PACKAGES OF THE READY-TO-USE PRODUCT

(already diluted)
PRODUCENT TYP

AGIP Ecopermanent
API Permagel
BP New Sigil fluid - 20°
ELF L.C.R. - 20°
FINA Fluid PR
MOBIL Fluids for hermetic systems
ROL OIL Rolgel -20°
CHELL Fluid -38°
TAMOIL Ready Antifreeze -38°
TEXACO Fluids for hermetic systems
TOTAL Coolant

Page 20 CTX 510 eco_PU_EN-v1.0

Fixing devices

6 Fixing devices
Jointing pieces are mounted according to the HILTI assembly instructions
(see: the instruction enclosed to the jointing elements).

6.1 Fastening of the machine

Fixing elements are delivered together with machine:

Tabela 8: FASTENING OF THE MACHINE

Quan-
Description
tity

4 Pin HILTI M12 with washer and nut

4 Hexagon bolt M24x70
4 Pin HILTI with internal thread M12
4 Chemical vial HILTI
4 Trimming plate
4 Washer 21x40x6
4 Washer 13x28x5

6.2 Tools
• No special tools are required.
• Wrench, with opening from 7 to 36 mm
• Hexagon-socket wrench, from 2 to 14 mm
• Metal crowbar for removing the transport protections on the truck
• Wrench for square nuts 7 mm

6.3 Electric tools

• Flat-tip screwdriver
• Apparatus for measurements of the rotating field
• Hammer drill

6.4 Instructions relating to fastening of the machine

Anchoring with use of the chemical vial HILTI
Vial of chemical glueHVU M16x125

CTX 510 eco_PU_EN-v1.0 Page 21

 Fixing devices

Pins with external threadHAS M12x110/28

Pins with internal threadHIS-N M12x125

1. Making the holes

The position of the hole should be adapted to the reinforcement
rods to avoid any damage thereof. The hole should be drilled with
a hammer drill directed perpendicular to the anchorage foundati-
on surface.
• Depth of the hole: 125 mm
• Diameter of the hole: 22 mm

2. Cleaning the holes

Using the blowing pump or the aspirator, clean the hole of the
dust remaining after drilling..

3. Placing the cartridges with the mortar

HVU cartridges with the mortar should be inserted, with the tips
downwards, down to the bottom of the hole.

4. Placing the bushes with internal thread

With use of the setting tool (Allen screw M12) and the drill (ope-
rate within 250 -750 rev./min speed range), screw the tapped bu-
shing HIS-N in the hole. Switch out the drill immediately after
reaching the bottom of the hole (the tapped bushing is flush re-
garding the foundation surface), to avoid the mortar effluent.

5. Curing time
Do not touch the tapped bushing during the curing process.

6. Curing and loading time before the tightening torque is applied

Do not screw the setting tool (Allen screw) out of the tapped bu-
shing until the curing process is over.
Temperature of the hole >= 20°C . . . . . . . 20 min
Temperature of the hole = about 10°C . . 30 min
Temperature of the hole <= 0°C . . . . . . . 1 hour

7. Fastening of the subassembly

Fasten the machine with the threaded pins HAS M12x110/28,
with nut and washer.
Tightening torque . . . . . . . . . . . . . . 30 Nm
Depth of screwing (penetration) into HIS-N12 - 30 mm

Page 22 CTX 510 eco_PU_EN-v1.0