ELITE 42 M & ELITE 42 MS ELITE 51 M & ELITE 51 MS ELITE 27 MS

Transcription

1 INSTALLATION PROCEDURES FOR ELECTRICAL OPTIONS TP7489 ELITE 42 M & ELITE 42 MS ELITE 51 M & ELITE 51 MS ELITE 27 MS CNC Lathes Equipped with a GE Fanuc 18i-TB or 21i-TB Control - NOTE - This document is to be used with machines supplied with electrical schematic MLx Use LO with machines supplied with electrical schematic MLx Document Number: LO Revision Level: H

2 DATE DRAWN CHECKED APPROVED PART NUMBER HARDINGE 3/15/02 CTB KCD JPB LO BROTHERS INC. NAME FILE NUMBER ELMIRA, NY INSTALLATION INSTRUCTIONS, ML.CM LO DOC REVISIONS DATE INIT. ECN INITIAL RELEASE WAS REV. 1 5/14/02 CTB A Finalized mist collector. Added stack light, Spare M Codes, and 8/5/02 CTB Tool probe. B Add through spindle coolant and part probe 9/9/02 CTB C - Added bagged parts to mist collector 10/16/02 CTB D Added HP coolant 11/1/02 CTB E Add ML C1NO to mist collector 03/26/03 CTB F Deleted QC (relay cvr) from barfeed kit 05/20/03 JFM G Changes HP coolant and added CM machine. Added ML 10/2/03 CTB K100 to I/O block #3 installation G Add Air blast and turret coolant valve 3/13/06 CTB H Change HP coolant, add a relay end cover to the bar feed kits 3/28/06 CTB INSTRUCTIONS: This set of instruction cover the electrical installation of the following options on a ML/CM- GE/FANUC machine based on MLx schematics. Note LO instructions are for machines with MLx schematics.: Page CHIP CONVEYOR INTERFACE: ML/CM... 3 BARFEED INTERFACE: ML/CM... 7 I/O BLOCK #3 INSTALLATION: ML/CM MIST COLLECTOR INTERFACE: ML/CM STACK LIGHT: ML/CM SPARE M CODES: ML/CM TOOL PROBE: ML THROUGH SPINDLE COOLANT: ML PART PROBE: ML HP COOLANT: ML AIR BLAST LO doc Page 1 of 40 Print Date 4/18/2008

3 TURRET COOLANT Note: stack light information has not been finished or checked. To be finished at a later date. LO doc Page 2 of 40 Print Date 4/18/2008

4 Chip Conveyor Interface: ML/CM ML CHIP ELEC KIT, CHIP CONV INSTALLATI BOM QTY Part Number Description 1 ME LO INSTALLATION INSTRUCTIONS, ML 1 ML CHIP WIRE PKG, CHIP CONVEYOR 1 ML CHIP KIT, CHIP CONV. CABLE 3 SG FUSE, 5A CLASS CC 1 MC BASE, CONNECTOR 1 MC CONNECTOR, 15 POS FEMALE 3 TT PIN CODE PIN, GUIDE PIN 1 TT BUSH CODE PIN, BUSH 1 ML BUSBAR, 2 X 45MM 1 ML ADC CONTACTOR, 9A 24VDC 1 ML FUSE BLOCK, CLASS CC 1 ML CON CONNECTOR 1 LC RELAY, MINI 24VDC 1 LC CLIP, RETAINING Additional option needed on machine: None Installation Procedure 1. Put the machine in E-Stop. 2. Turn the machine s control off. 3. Turn off and lockout the main disconnect located on the left end of the machine. 4. Remove and lockout all incoming power to the machine. 5. Remove and lockout all utilities (air, water, etc.) from the machine. 6. Remove and lockout all power and utilities from any ancillary equipment mounted on or connected to the machine. 7. Remove the center cover plate located on the bottom of the power case. Save the mounting hardware to mount the new connector base. Discard the plate. See Figure #1 Chip conveyor connector mounting location Figure #1 LO doc Page 3 of 40 Print Date 4/18/2008

5 8. In the power case, mount the fuse block (ML ), connector (ML CON), contactor (ML ADC), busbar (ML ), and fuses (SG ). See Figure #2ML/2CM. Chip conveyor contactor mounting location Figure #2ML Chip conveyor contactor mounting location Figure #2CM LO doc Page 4 of 40 Print Date 4/18/2008

6 9. Label components with tags supplied with machine. 10. Mount relay (LC ) using clip (LC ) onto 1500I/O position 13CR. See Figure # I/O-13CR Figure #3 11. Mount connector (MC ) to base connector (MC ) (with hinge closest to C column). Use pin (TT PIN) at positions A1, C1, and A5. Use bushing (TT BUSH) at position C5. Note: Ground wire must be connected to connector before mounting, see Table # Using the wire package (ML CHIP) and Table #1ML/1CM, run wires and wire up components. Use machine schematics as added reference. Discard unused L1, L2, and L3 wires. MARKER WIRE P/N LENGTH END 1 TERM 1 END 2 TERM 2 400L B M-2 CK PL-A1 TT F 400L B M-4 CK PL-B1 TT F 400L B M-6 CK PL-C1 TT F G GY 39 G PL-G BU M-A1 CK I/O-2TB-38 CK DCCOM LTBU M-A2 CK I/O-2TB-37 CK Table #1ML MARKER WIRE P/N LENGTH END 1 TERM 1 END 2 TERM 2 408L B M-2 CK PL-A1 TT F 408L B M-4 CK PL-B1 TT F 408L B M-6 CK PL-C1 TT F G GY 39 G PL-G BU M-A1 CK I/O-2TB-38 CK DCCOM LTBU M-A2 CK I/O-2TB-37 CK Table #1CM 13. Mount 400PL/408PL to power case with row #1 closest to power case door. 14. Wire tie as needed 15. If chip conveyor is available at time of interface installation (i.e. field installation) wire up cable (ML CHIP) to conveyor per manufactures instructions; tightening cord grip when finished. If interface is being installed without conveyor being accessible (i.e. subassembly installation) pass cable along with case/machine. 16. Check for shorts and loose wires. 17. Reapply power and utilities to machine and any ancillary equipment. 18. Power up machine and bring out of E-Stop. LO doc Page 5 of 40 Print Date 4/18/2008

7 19. Check functionality of all safety equipment on machine (E-Stop buttons, Guard door switches, Etc.). 20. Check operation of interface. End Chip Conveyor Interface LO doc Page 6 of 40 Print Date 4/18/2008

8 Barfeed Interface: ML/CM ML BF MLA BF ELEC KIT, BARFEED INSTALLATION ELEC KIT, BARFEED INSTALLATION BOM QTY Part Number Description 1 ME LO INSTALLATION INSTRUCTIONS, ML 1 ML BUSBAR, 2 X 45MM 1 ML ADC CONTACTOR, 9A 24VDC 1 ML FUSE BLOCK, CLASS CC 1 ML CON CONNECTOR 1 ML BF WIRE PKG, BARFEED INTERFACE 1 ML BF CABLE PKG, BARFEED INTERFACE 1 MS SA SCREW, BH M5X.8X12 ASSY 3 SG FUSE, 10A, CLASS CC 2 MC BASE, CONNECTOR 2 MC CONNECTOR, 15 POS FEMALE 2 TT PIN CODE PIN, GUIDE PIN 5 TT BUSH CODE PIN, BUSH 8 LC RELAY, MINI 24VDC 8 LC CLIP, RETAINING 2 QC RELAY, 24VDC, 1NO 1 ML J2 RELAY JUMPER, 2 POS BU 1 QC RELAY END COVER Additional option needed on machine: None Installation Procedure 1. Put the machine in E-Stop. 2. Turn the machine s control off. 3. Turn off and lockout the main disconnect located on the left end of the machine. 4. Remove and lockout all incoming power to the machine. 5. Remove and lockout all utilities (air, water, etc.) from the machine. 6. Remove and lockout all power and utilities from any ancillary equipment mounted on or connected to the machine. 7. Remove the two right cover plates located on the bottom of the power case. Save the mounting hardware to mount the new connector bases. Discard the plates. See Figure #1 2508PL-Barfeed I/O connector mounting location 2520PL-Barfeed power connector mounting location Figure #1 LO doc Page 7 of 40 Print Date 4/18/2008

9 8. In the power case, mount the fuse block (ML ), connector (ML CON), contactor (ML ADC), busbar (ML , and fuses (SG ). See Figure #2ML/2CM. Barfeed contactor mounting location Figure #2ML Barfeed contactor mounting location Figure #2CM LO doc Page 8 of 40 Print Date 4/18/2008

10 9. Mount 1703CR, and 1706CR (QC ) plus end cover (QC ) to the right of 3TB so terminal 14 is at the top. Install jumper (ML J2) between the two relays in the rear 14 terminal positions. See Figure # CR 1706CR Figure #3 10. Label components with tags supplied with machine. 11. Mount the eight relays (LC ) using clips (LC ) onto 1500I/O position 1CR-8CR. See Figure # I/O-1CR 1500I/O-8CR Figure #4 12. For 2508PL mount the connector (MC ) to base connector (MC ) (with hinge closest to A column). Use pin (TT PIN) at positions A1, and A5. Use bushing (TT BUSH) at position C1 and C5. Note: Ground wire must be connected to connector before mounting, see Table # For 2520PL mount the connector (MC ) to base connector (MC ) (with hinge closest to A column). Use pin (TT PIN) at positions A5. Use bushing (TT BUSH) at position A1, C1 and C5. Note: Ground wire must be connected to connector before mounting, see Table # Using the wire package (ML BF) and Table #1, run wires and wire up components. Use machine schematics as added reference. LO doc Page 9 of 40 Print Date 4/18/2008

11 MARKER WIRE P/N LENGTH END 1 TERM 1 END 2 TERM 2 404L BL M-2 CK PL-A1 TT F 404L BL M-4 CK PL-B1 TT F 404L BL M-6 CK PL-C1 TT F R CR-13 CK PL-B5 TT F R CR-13 CK PL-C5 TT F ACCOM BULT 15 3TB-7(B) CK PL-A5 TT F G GY 37 G G R 7 3TB-1(T) CK L 1703CR-14 CK L BU M-A1 CK I/O-2TB-2 CK BU CR-A1 CK I/O-2TB-5 CK BU CR-A1 CK I/O-2TB-8 CK DCCOM LTBU CR-A2 CK I/O-2TB-4 CK DCCOM LTBU CR-A2 CK I/O-2TB-7 CK DCCOM LTBU M-A2 CK I/O-2TB-1 CK Wire up 2508CBL cable per Table #2. Table #1 1ST END POINT 1ST END TERMINATION CABLE-COLOR 2ND END POINT 2ND END TERMINATION 2508PL-A1 TT F Bk 1500I/O-1TB-1 CK PL-A3 TT F Rd 1500I/O-2TB-12 CK PL-B5 TT F Wh 4TB-1(B) CK PL-G RA Gn CK PL-A4 TT F Og 1500I/O-2TB-23 CK PL-B2 TT F Bu 1500I/O-1TB-5 CK PL-A2 TT F Bn 1500I/O-1TB-2 CK PL-A5 TT F Ye 1100ES-14 CK PL-B3 TT F Vt 1500I/O-2TB-17 CK PL-B4 TT F Gy 1500I/O-2TB-11 CK PL-C2 TT F Pk 1500I/O-1TB-8 CK PL-C1 TT F Tn 1500I/O-2TB-14 CK PL-C5 TT F Rd-Gn 4TB-2(B) CK PL-C4 TT F Rd-Ye 1100ES-13 CK PL-C3 TT F Rd-Bk 1500I/O-2TB-20 CK CUT OFF Shield CUT OFF Table #2 16. Mount 2508PL to power case with row #5 closest to power case door. 17. Mount 2520PL to power case with row #5 closest to power case door. 18. Wire tie as needed 19. Check for shorts and loose wires. 20. Reapply power and utilities to machine and any ancillary equipment. 21. Power up machine and bring out of E-Stop. 22. Check functionality of all safety equipment on machine (E-Stop buttons, Guard door switches, Etc.). 23. Check operation of interface. End Barfeed Interface LO doc Page 10 of 40 Print Date 4/18/2008

12 I/O Block #3 Installation: ML/CM ML IO3 ELEC KIT, I/O #3 BOM QTY Part Number Description 1 ME LO INSTALLATION INSTRUCTIONS, ML 1 TT BOARD, I/O 1 LC I/O MODULE PHOENIX 4 MS SA SCREW, BH M5X.8X12 ASSY 4 MS SA SCREW ASSEMBLY, M4X.7X10MM LO 1 ML RMB RACKMOUNT, BOTTOM 1 ML RMT RACKMOUNT, TOP 1 ML RMP PANEL, RACK MOUNT 2 ML SCREW, SHOULDER, M5X.8,3.18MM 2 MS SCREW, SOC.HD.CAP M5X.8X8MM 1 ML IO3 WIRE PKG, IO3 1 ML IO3 CABLE PKG, IO3 1 ML K100 CABLE, GE/FANUC I/O JUMPER Installation Procedure 1. Put the machine in E-Stop. 2. Turn the machine s control off. 3. Turn off and lockout the main disconnect located on the left end of the machine. 4. Remove and lockout all incoming power to the machine. 5. Remove and lockout all utilities (air, water, etc.) from the machine. 6. Remove and lockout all power and utilities from any ancillary equipment mounted on or connected to the machine. 7. Mount the top mounting bracket (ML RMT) and bottom mounting bracket (ML RMB) to the power case panel using the four 5mm screws (MS SA). See Figure #1. The curved side faces to the right. Mounting brackets Figure #1 LO doc Page 11 of 40 Print Date 4/18/2008

13 8. Mount the panel (ML RMP) to the brackets using the two shoulder screws (ML ) that act as hinges. See Figure # I/O Shoulder screws Figure #2 9. Mount the GE/Fanuc I/O module 1813I/O (TT ) in the third from the right position as shows. Add jumper (ML K100) from 1513I/O-CA52 to 1813I/O-CA53. See Figure # Mount the I/O module (LC ) to the panel using the four 4mm screws (MS SA). See Figure #3 Figure #3 LO doc Page 12 of 40 Print Date 4/18/2008

14 11. Using the wire package (ML IO3) and Table #1, run wires and wire up components. Use machine schematics as added reference. MARKER WIRE P/N LENGTH END 1 TERM 1 END 2 TERM 2 +24VDCB BU 28 2TB-3(T) CK L 1800I/O-4TB-1 CK L DCCOM BULT 28 2TB-8(T) CK L 1800I/O-3TB-1 CK L Table #1 12. Using cable package (ML IO3) and Table #2, run cable 1820CBL and wire up. Use machine schematics as added reference. 1ST END POINT 1ST END TERMINATION CABLE-COLOR 2ND END POINT 2ND END TERMINATION 1813I/O-CB CS Bk 1800I/O-1PL-25A CN I/O-CB CS Bn 1800I/O-1PL-20A CN I/O-CB CS Rd 1800I/O-1PL-20B CN I/O-CB CS Og 1800I/O-1PL-21A CN I/O-CB CS Ye 1800I/O-1PL-21B CN I/O-CB CS Gn 1800I/O-1PL-22A CN I/O-CB CS Bu 1800I/O-1PL-22B CN I/O-CB CS Vt 1800I/O-1PL-23A CN I/O-CB CS Gy 1800I/O-1PL-23B CN I/O-CB CS Wh 1800I/O-1PL-10A CN I/O-CB CS Wh-Bk 1800I/O-1PL-10B CN I/O-CB CS Wh-Bn 1800I/O-1PL-11A CN I/O-CB CS Wh-Rd 1800I/O-1PL-11B CN I/O-CB CS Wh-Og 1800I/O-1PL-12A CN I/O-CB CS Wh-Ye 1800I/O-1PL-12B CN I/O-CB CS Wh-Gn 1800I/O-1PL-13A CN I/O-CB CS Wh-Bu 1800I/O-1PL-13B CN CUT OFF Wh-Vt CUT OFF 1813I/O-CB CS Wh-Gy 1800I-3TB-5 CK I/O-CB CS Wh-Bk-Bn 1800I-3TB-6 CK I/O-CB CS Wh-Bk-Rd 1800I-3TB-7 CK I/O-CB CS Wh-Bk-Og 1800I-3TB-8 CK I/O-CB CS Wh-Bk-Ye 1800I-3TB-9 CN I/O-CB CS Wh-Bk-Gn 1800I/O-1PL-01A CN I/O-CB CS Wh-Bk-Bu 1800I/O-1PL-06A CN I/O-CB CS Wh-Bk-Vt 1800I/O-1PL-06B CN I/O-CB CS Wh-Bk-Gy 1800I/O-1PL-07A CN I/O-CB CS Wh-Bn-Rd 1800I/O-1PL-07B CN I/O-CB CS Wh-Bn-Og 1800I/O-1PL-08A CN I/O-CB CS Wh-Bn-Ye 1800I/O-1PL-08B CN I/O-CB CS Wh-Bn-Gn 1800I/O-1PL-09A CN I/O-CB CS Wh-Bn-Bu 1800I/O-1PL-09B CN I/O-CB CS Wh-Bn-Vt 1800I/O-1PL-25B CN I/O-CB CS Wh-Bn-Gy 1800I/O-1PL-16A CN I/O-CB CS Wh-Rd-Og 1800I/O-1PL-16B CN I/O-CB CS Wh-Rd-Ye 1800I/O-1PL-17A CN I/O-CB CS Wh-Rd-Gn 1800I/O-1PL-17B CN LO doc Page 13 of 40 Print Date 4/18/2008

15 1813I/O-CB CS Wh-Rd-Bu 1800I/O-1PL-18A CN I/O-CB CS Wh-Rd-Vt 1800I/O-1PL-18B CN I/O-CB CS Wh-Rd-Gy 1800I/O-1PL-19A CN I/O-CB CS Wh-Og-Ye 1800I/O-1PL-19B CN I/O-CB CS Wh-Og-Gn 1800I/O-1PL-02A CN I/O-CB CS Wh-Og-Bu 1800I/O-1PL-02B CN I/O-CB CS Wh-Og-Vt 1800I/O-1PL-03A CN I/O-CB CS Wh-Og-Gy 1800I/O-1PL-03B CN I/O-CB CS Wh-Ye-Gn 1800I/O-1PL-04A CN I/O-CB CS Wh-Ye-Bu 1800I/O-1PL-04B CN I/O-CB CS Wh-Ye-Vt 1800I/O-1PL-05A CN I/O-CB CS Wh-Ye-Gy 1800I/O-1PL-05B CN CUT OFF Wh-Gn-Bu CUT OFF CUT OFF Shield CUT OFF 1813I/O-CB CS W-1 5TB-5(B) CK I/O-CB CS W-2 5TB-5(B) CK Table #2 13. Check swing of panel. 14. Install the two screws (MS ) to hold the panel in place 15. Check for shorts and loose wires. 16. Reapply power and utilities to machine and any ancillary equipment. 17. Power up machine and bring out of E-Stop. 18. Check functionality of all safety equipment on machine (E-Stop buttons, Guard door switches, Etc.). End I/O Block #3 Installation LO doc Page 14 of 40 Print Date 4/18/2008

16 Mist Collector Interface: ML/CM ML MC ELEC KIT, MIST C. INSTALLATION BOM QTY Part Number Description 1 ME LO INSTALLATION INSTRUCTIONS, ML 1 ML MC WIRE PKG, MIST COLLECTOR 1 ML MC KIT, MIST COLLECTOR CABLE 1 MC BASE, CONNECTOR 1 MC CONNECTOR, 15 POS FEMALE 2 TT PIN CODE PIN, GUIDE PIN 2 TT BUSH CODE PIN, BUSH 1 ML BUSBAR, 2 X 45MM 1 ML MANUAL MOTOR STARTER, A 1 ML MANUAL MOTOR STARTER, 2.5-4A 1 ML C1NO BLOCK, CONTACT 1 NO 1 ML ADC CONTACTOR, 9A 24VDC 1 ML CON CONNECTOR 1 LC RELAY, MINI 24VDC 1 LC CLIP, RETAINING 8 AH TY RAP *4 ML /8 SCREWX2-1/2 LONG LAG *4 ML ANCHNOR, 3/8 LAG BOLT * ZN WASHER, 3/8 STD (NOM) *4 MD WASHER, 3/8 LOCK *6 MS SCREW, SOC HD CAP M4X.7X16MM *6 MW WASHER, LOCK DIN-7980 M4X.7 *6 MW WASHER, FLAT M4 X.7 STEEL *6 MN NUT, HEXAGON, 934 PLATED *1 LO LAYOUT, MRL MIST COLLECTOR 1 RF BAG - MAIL Additional option needed on machine: ML IO3 If the mist collector interface is being installed at time of machine assembly, bag parts noted with a *. Mark bag MIST COLLECTOR PARTS and then tape the bag on the inside bottom of the power case. Installation Procedure 1. Put the machine in E-Stop. 2. Turn the machine s control off. 3. Turn off and lockout the main disconnect located on the left end of the machine. 4. Remove and lockout all incoming power to the machine. 5. Remove and lockout all utilities (air, water, etc.) from the machine. 6. Remove and lockout all power and utilities from any ancillary equipment mounted on or connected to the machine. 7. Remove the center cover plate located on the bottom of the power case. Save the mounting hardware to mount the new connector base. Discard the plate. See Figure #1 LO doc Page 15 of 40 Print Date 4/18/2008

17 Mist collector connector mounting location Figure #1 8. In the power case, mount the manual motor starter (ML for 60 Hz or ML for 50 Hz), connector (ML CON), contactor (ML ADC), contact (ML C1NO), and busbar (ML ). See Figure #2ML/2CM. Mist collector contactor mounting location Figure #2ML LO doc Page 16 of 40 Print Date 4/18/2008

18 Mist collector contactor mounting location Figure #2CM 9. Label components with tags supplied with machine. 10. Mount relay (LC ) using clip (LC ) onto 1800I/O position 13CR. See Figure # I/O-13CR Figure #3 11. Mount connector (MC ) to base connector (MC ) (with hinge closest to C column). Use pin (TT PIN) at positions C1, and C5. Use bushing (TT BUSH) at position A1 and A5. Note: Ground wire must be connected to connector before mounting, see Table #1ML/1CM. 12. Using the wire package (ML MC) and Table #1ML/1CM, run wires and wire up components. Use machine schematics as added reference. Discard unused L1, L2, and L3 wires. LO doc Page 17 of 40 Print Date 4/18/2008

19 MARKER WIRE P/N LENGTH END 1 TERM 1 END 2 TERM 2 516L BL M-2 CK PL-A1 TT F 516L BL M-4 CK PL-B1 TT F 516L BL M-6 CK PL-C1 TT F G GY 24 G PL-G VDCB BU MMS-11 CK I/O-1TB-52 CK BU MMS-12 CK I/O-1TB-53 CK BU M-A1 CK I/O-2TB-38 CK DCCOM LTBU M-A2 CK I/O-2TB-37 CK Table #1ML MARKER WIRE P/N LENGTH END 1 TERM 1 END 2 TERM 2 412L BL M-2 CK PL-A1 TT F 412L BL M-4 CK PL-B1 TT F 412L BL M-6 CK PL-C1 TT F G GY 24 G PL-G VDCB BU MMS-11 CK I/O-1TB-52 CK BU MMS-12 CK I/O-1TB-53 CK BU M-A1 CK I/O-2TB-38 CK DCCOM LTBU M-A2 CK I/O-2TB-37 CK Table #1CM 13. Mount 516PL/412PL to power case with row #1 closest to power case door. 14. Wire tie as needed 15. If mist collector is available at time of interface installation (i.e. field installation) wire up cable (ML MC) to mist collector per manufactures instructions; tightening cord grips when finished. Wire tie (AH ) cable to mist collector column. If interface is being installed without mist collector (i.e. subassembly installation) pass cable and wire ties along with case/machine. 16. Check for shorts and loose wires. 17. Set 516MMS/412MMS to the FLA of the motor (2.4 for 60Hz or 2.8 for 50Hz). 18. Reapply power and utilities to machine and any ancillary equipment. 19. Power up machine and bring out of E-Stop. 20. Check functionality of all safety equipment on machine (E-Stop buttons, Guard door switches, Etc.). 21. Check operation of interface. Note: The above is based on the use of a Torit Dryflow model DMC-A that uses a Leeson model C6T34FC9C motor with the following specifications: 3/4HP 230VAC 3 PHASE 50/60HZ 2.8/2.4 A 2850/3450 RPM End Mist Collector Interface LO doc Page 18 of 40 Print Date 4/18/2008

20 Stack Light: ML/CM ML SL5 ELEC KIT, STACKLIGHT 5 POS BOM QTY Part Number Description 1 ME LO INSTALLATION INSTRUCTIONS, ML 5 LC RELAY, MINI 24VDC 5 LC CLIP, RETAINING 1 QC B STACKLIGHT BASE 1 QC TERM STACKLIGHT TERMINAL 1 QC T250 STACKLIGHT TUBE 250MM 1 QC RED STACKLIGHT RED LED 1 QC YEL STACKLIGHT YELLOW LED 1 QC GRE STACKLIGHT GREEN LED 1 QC BLU STACKLIGHT BLUE LED 1 QC WHI STACKLIGHT WHITE LED 1 ML STLK CABLE PKG, STACKLIGHT 6 LM TY-RAP Additional option needed on machine: ML IO3 Installation Procedure 1. Put the machine in E-Stop. 2. Turn the machine s control off. 3. Turn off and lockout the main disconnect located on the left end of the machine. 4. Remove and lockout all incoming power to the machine. 5. Remove and lockout all utilities (air, water, etc.) from the machine. 6. Remove and lockout all power and utilities from any ancillary equipment mounted on or connected to the machine. 7. Mount the five relays (LC ) using clips (LC ) onto 1800I/O position 1CR-5CR. See Figur #1 1800I/O-1CR * * * 1800I/O-5CR Figure #1 8. Remove the cover plate located on the top of the power case, saving the mounting hardware for mounting of the stacklight base. Discard the plate. See Figure #2 LO doc Page 19 of 40 Print Date 4/18/2008

21 RED YELLOW GREEN BLUE WHITE Figure #2 9. Wire cable 2000CBL (cable package ML STLK) to the stacklight terminal (2ND END POINT) as shown in Table #1. 1ST END POINT 1ST END TERMINATION CABLE-COLOR 2ND END POINT 2ND END TERMINATION 1800I/O-2TB-2 CK CBL-Bk 2000L-5 CK I/O-2TB-5 CK CBL-Bn 2000L-4 CK I/O-2TB-8 CK CBL-Rd 2000L-3 CK I/O-2TB-11 CK CBL-Og 2000L-2 CK I/O-2TB-14 CK CBL-Ye 2000L-1 CK I/O-2TB-13 CK CBL-Gn 2000L-0 CK Table #1 10. Run the free end of cable 2000CBL through the stacklight mounting hole then into the power case and ending up on the I/O swing panel. Wire tie as needed. 11. Mount the stacklight to the top of the control case using the hardware saved earlier. See figure #2 12. Finish wiring up cable 2000CBL by terminating to 1800I/O. See Table #1 above. 13. Check for shorts and loose wires. 14. Reapply power and utilities to machine and any ancillary equipment. 15. Power up machine and bring out of E-Stop. 16. Check functionality of all safety equipment on machine (E-Stop buttons, Guard door switches, Etc.). 17. Check operation of stacklight. End Stack light LO doc Page 20 of 40 Print Date 4/18/2008

22 Spare M Codes: ML/CM ML SMC ELEC KIT, SPARE M CODES BOM QTY Part Number Description 1 ME LO INSTALLATION INSTRUCTIONS, ML 5 LC RELAY, MINI 24VDC 5 LC CLIP, RETAINING Additional option needed on machine: ML IO3 Installation Procedure 1. Put the machine in E-Stop. 2. Turn the machine s control off. 3. Turn off and lockout the main disconnect located on the left end of the machine. 4. Remove and lockout all incoming power to the machine. 5. Remove and lockout all utilities (air, water, etc.) from the machine. 6. Remove and lockout all power and utilities from any ancillary equipment mounted on or connected to the machine. 7. Mount the five relays (LC ) using clips (LC ) onto 1800I/O position 6CR, 7CR, 8CR, 14CR, and 15CR. See Figur #1 1800I/O Figure #1 LO doc Page 21 of 40 Print Date 4/18/2008

23 8. Reapply power and utilities to machine and any ancillary equipment. 9. Power up machine and bring out of E-Stop. 10. Check functionality of all safety equipment on machine (E-Stop buttons, Guard door switches, Etc.). 11. Check operation of each relay. End Spare M Codes LO doc Page 22 of 40 Print Date 4/18/2008

24 Tool Probe: ML ML TOOL PROBE ASSEMBLY Electrical Installation Procedure 1. Put the machine in E-Stop. 2. Turn the machine s control off. 3. Turn off and lockout the main disconnect located on the left end of the machine. 4. Remove and lockout all incoming power to the machine. 5. Remove and lockout all utilities (air, water, etc.) from the machine. 6. Remove and lockout all power and utilities from any ancillary equipment mounted on or connected to the machine. 7. Mount the four relays (LC ) using clips (LC ) onto 1500I/O position 9CR, 10CR, 11CR, and 12CR. See Figur #1 Figure #1 8. Mount the Renishaw TSI2 interface (2400PCB) unit to the left of 1513I/O, 1813I/O, or 2113I/O. See Figure #2. LO doc Page 23 of 40 Print Date 4/18/2008

25 2400PCB Figure #2 9. Plug in 2400CBL cable into 2400PCB and terminate the other end per Table #1. CABLE-COLOR 2ND END POINT 2ND END TERMINATION 2400CBL-Bk 1200I/O-1TB-7 CK Br 1200I/O-1TB-8 CK Rd 1200I/O-1TB-11 CK Og 1200I/O-1TB-14 CK Ye 1200I/O-1TB-17 CK Gn 1200I/O-1TB-20 CK Bu 1200I/O-1TB-32 CK Vt CUT OFF CUT OFF Gy CUT OFF CUT OFF Wh CUT OFF CUT OFF Pk CUT OFF CUT OFF Tq CUT OFF CUT OFF Bk-Wh 1200I/O-1TB-9 CK Bn-Wh 1500I/O-2TB-26 CK Rd-Wh 1500I/O-2TB-29 CK Og-Wh 1500I/O-2TB-32 CK Gn-Wh 1500I/O-2TB-35 CK Bu-Wh CUT OFF CUT OFF Vt-Wh CUT OFF CUT OFF Rd-Bk CUT OFF CUT OFF Og-Bk CUT OFF CUT OFF Ye-Bk CUT OFF CUT OFF Gn-Bk CUT OFF CUT OFF Gy-Bk CUT OFF CUT OFF Pk-Bk 1200I/O-1TB-12 CK Table #1 LO doc Page 24 of 40 Print Date 4/18/2008

26 10. Run the TSA tool probe cable (2400INST) through the location shown in figure #3 using QC cord grip, gasket, and AH locknut. 2400INST cord grip location 11. Terminate 2400INST cable per Table #2 Figure #3 CABLE-COLOR 2ND END POINT 2400INST-Bu 2400PCB-PL INST-Gy-Bk 2400PCB-PL INST-Gn 2400PCB-PL2-3 Table #2 12. Reapply power and utilities to machine and any ancillary equipment. 13. Power up machine and bring out of E-Stop. 14. Check functionality of all safety equipment on machine (E-Stop buttons, Guard door switches, Etc.). 15. Check operation of tool probe. End Tool Probe LO doc Page 25 of 40 Print Date 4/18/2008

27 Through Spindle Coolant: ML ML TS THRU SPINDLE COOLANT Electrical Installation Procedure 1. Put the machine in E-Stop. 2. Turn the machine s control off. 3. Turn off and lockout the main disconnect located on the left end of the machine. 4. Remove and lockout all incoming power to the machine. 5. Remove and lockout all utilities (air, water, etc.) from the machine. 6. Remove and lockout all power and utilities from any ancillary equipment mounted on or connected to the machine. 7. Mount the relay (LC ) using clip (LC ) onto 1500I/O position 15. See Figur #1 Fiure #1 8. Run 1741CBL cable (ML TS) from the valve and into the back of the power case using cord grip (QC ), gasket ( ), and lock nut (AH ). See Figure #2. LO doc Page 26 of 40 Print Date 4/18/2008

28 1741CBL cord grip location Figure #2 9. Terminate 1741CBL cable per Table #2 CABLE-COLOR 2ND END POINT 1741CBL -Bk1 1500I/O-2TB CBL -Bk2 1500I/O-2TB-43 Table #2 10. Wire tie cable as need with tye-raps supplied. 11. Reapply power and utilities to machine and any ancillary equipment. 12. Power up machine and bring out of E-Stop. 13. Check functionality of all safety equipment on machine (E-Stop buttons, Guard door switches, Etc.). 14. Check operation of through spindle coolant. End Through Spindle Coolant LO doc Page 27 of 40 Print Date 4/18/2008

29 Part Probe: ML ML P PART PROBE, VDI 30 Additional option needed on machine: ML IO3 Electrical Installation Procedure 1. Put the machine in E-Stop. 2. Turn the machine s control off. 3. Turn off and lockout the main disconnect located on the left end of the machine. 4. Remove and lockout all incoming power to the machine. 5. Remove and lockout all utilities (air, water, etc.) from the machine. 6. Remove and lockout all power and utilities from any ancillary equipment mounted on or connected to the machine. 7. Mount the relay (LC ) using clip (LC ) onto 1800I/O position 16CR. See Figure #1 1800I/O Figure #1 8. Mount the probe holder (ML PH) to the panel using two 5mm screws (MS SA). See Figure #2. LO doc Page 28 of 40 Print Date 4/18/2008

30 Figure #2 9. Run 2601PEC cable (Renishaw OMM cable) into the power case, using cord grip (QC ), gasket ( ), and lock nut (AH ). Run the cable over to the probe interface mounting location. See Figure # PEC cable cord grip location Figure #3 LO doc Page 29 of 40 Print Date 4/18/2008

31 10. Using the right most cord grip on the MI-12 unit, run and wire up the 2601PEC cable per Table #1. CABLE-COLOR POINT TERMINATION Ye 2600PCB-1 CK Gy 2600PCB-2 CK Wh 2600PCB-3 CK Gn 2600PCB-4 CK Br 2600PCB-5 CK Shield 2600PCB-18 CK Table #1 11. Using the second from the left cord grip on the MI-12 unit, run and wire up 2600CBL cable (ML PP) per Table #2. 1ST END POINT 1ST END TERMINATION COLOR 2ND END POINT 2ND END TERMINATION 26OOPCB-10 CK Bk 1500I/O-1TB-68 CK OOPCB-21 CK Bn 1800I/O-2TB-47 CK OOPCB-11 CK Rd 1500I/O-1TB-67 CK OOPCB-16 CK Og 1200I/O-1TB-22 CK OOPCB-22 CK Ye 1800I/O-2TB-46 CK OOPCB-18 CK Gn G RA 26OOPCB-17 CK Bu 1500I/O-1TB-69 CK OOPCB-12 CK Vt 1800I/O-1TB-71 CK OOPCB-13 CK Gy 1800I/O-1TB-70 CK OOPCB-15 CK Wh 1200I/O-1TB-23 CK CBL-18 CK Shield CUT OFF 26OOPCB-14 CK J1 If the machine does not have a tool probe, use the 26OOPCB-16 26OOPCB-10 26OOPCB-14 CK CK CK J2 Table #1 3 piece of 22AWG blue wire for J1. If the machine has a tool probe, use the 3 piece of 22AWG blue wire for J Using Figure #4 as a guide, remove the four feet (H) and discard. Mount the lower cover (G) to the probe holder using the four 4mm screws (MS SA). LO doc Page 30 of 40 Print Date 4/18/2008

32 Figure #4 13. Reassemble the MI12 interface. 14. Wire tie all cables as needed with wire ties supplied. 15. Reapply power and utilities to machine and any ancillary equipment. 16. Power up machine and bring out of E-Stop. 17. Check functionality of all safety equipment on machine (E-Stop buttons, Guard door switches, Etc.). 18. Check operation of part probe. End Part Probe LO doc Page 31 of 40 Print Date 4/18/2008

33 HP Coolant: ML ML HP HIGH PRESSURE COOLANT Electrical interface BOM QTY Part Number Description 3 LC RELAY, MINI 24VDC 3 LC CLIP, RETAINING 1 ML CON CONNECTOR 1 ML BUSBAR, 2 X 45MM 1 ML FUSE BLOCK, CLASS CC 3 SG FUSE, CLASS CC - 30A 1 ML AD CONTACTOR, 25A, 24VDC 1 ML HPC WIRE PKG, HP COOLANT 1 LO INSTALLATION INSTRUCTIONS ML 1 LO INSTALLATION INSTRUCTIONS ML TERM#10R 16-14AWG MAX.INS.19 8 CK FERRULES, 18 AWG 4 TT PIN CODE PIN, GUIDE PIN 4 TT BUSH CODE PIN, BUSH CONDUIT 3/4" CONNECTOR 3/4 INCH 90 DEGRE GASKET ASSEMBLY 3/4 INCH 2 AH NUT LOCK 1 ML PE TAG PE 1 MS SA SCREW BH M5X.8X16 ASSY Additional option needed on machine: ML IO3 Electrical Installation Procedure 1. Put the machine in E-Stop. 2. Turn the machine s control off. 3. Turn off and lockout the main disconnect located on the left end of the machine. 4. Remove and lockout all incoming power to the machine. 5. Remove and lockout all utilities (air, water, etc.) from the machine. 6. Remove and lockout all power and utilities from any ancillary equipment mounted on or connected to the machine. 7. Mount the relays (LC ) using clips (LC ) onto 1800I/O position 9CR, 11CR, and 12CR. See Figure #1 LO doc Page 32 of 40 Print Date 4/18/2008

34 1800I/O Figure #1 8. Remove the left cover plate located on the bottom of the power case. Save the mounting hardware to mount the new connector base. Discard the plate. See Figure #2 HP Coolant connector mounting location Figure #2 LO doc Page 33 of 40 Print Date 4/18/2008

35 9. Add a 3/4" NPT (1 3/32 diameter) slip hole 1.5 to the left of the HP connector mounting location and centered front to back with connector. See Figure #3 Figure #3 10. In the power case, mount the 408FU fuse block (ML ), connector (ML CON), 408M contactor (ML AD), busbar (ML , and fuses (SG ). See Figure #4. LO doc Page 34 of 40 Print Date 4/18/2008

36 HP Coolant contactor mounting location Figure #4 11. Label components with tags supplied with machine. 12. Using the wire package (ML HPC) and Table #1, run wires and wire up components. Use machine schematics as added reference. Discard 2323 wire. Save remaining wires for steps below. MARKER WIRE P/N LENGTH END 1 TERM 1 END 2 TERM BU I/O-2TB-26 CK M-A1 CK DCCOM LTBU I/O-2TB-25 CK M-A2 CK Table #1 13. Thread the three 12 awg black wires and the one 12 awg green wire through the conduit ( ). Attach the two fittings ( ) to the ends of the conduit. Install one end of the conduit in the hole added in the step above (the black wires with rings go to the HP unit). Use a sealing ring ( ) and locknut (AH ). If locknuts are supplied with connectors, discard any unused locknuts at end of installation. 14. If a dedicated incoming ground tie point on the panel or case is not provided by the high pressure coolant unit manufacture, drill and tap a 5mm X 0.8mm hole below and too the right of the main circuit breaker. Remove the paint from around the newly added hole. Add a ground wire (part of ML HPC wire package) from this point, using screw (MS SA), to the ground terminal block. Mark taped hole with the PE tag (ML PE). 15. Using Table #2, connect up the power wires and plug assembly supplied with the HP Coolant unit. Use machine schematics as added reference. LO doc Page 35 of 40 Print Date 4/18/2008

37 VENDOR TERMINATED POINT CABLE-COLOR WIRE # MACHINE TERMINATED POINT TERMINATION L1 408L1 408M-2 ST-.35 L2 408L2 408M-4 ST-.35 L3 408L3 408M-6 ST-.35 PE G G RC PL-A1 A1 1800I/O-1TB-42 CK PL-B1 B1 1800I/O-1TB-40 CK PL-C1 C1 NC 2724PL-A2 A2 1800I/O-2TB-32 CK PL-B2 B2 1800I/O-TB1-41 CK PL-C2 C2 NC 2724PL-A3 A3 NC 2724PL-B3 B3 1800I/O-TB1-44 CK PL-C3 C3 NC 2724PL-A4 A4 1800I/O-2TB-35 CK PL-B4 B4 1800I/O-TB1-47 CK PL-C4 C4 NC 2724PL-A5 A5 NC 2724PL-B5 B5 1800I/O-TB1-50 CK PL-C5 C5 NC 2724PL-G G G Table #2 16. Add code pins and bushings (TT PIN, TT BUSH) to both sides of 2724PL. See Figure #5. Figure #5 17. Wire tie all cables as needed. 18. Reapply power and utilities to machine and any ancillary equipment. 19. Power up machine and bring out of E-Stop. 20. Check functionality of all safety equipment on machine (E-Stop buttons, Guard door switches, Etc.). 21. Check operation of HP coolant. End HP Coolant LO doc Page 36 of 40 Print Date 4/18/2008

38 Air Blast ML AIR BLAST Electrical Installation Procedure 1. Put the machine in E-Stop. 2. Turn the machine s control off. 3. Turn off and lockout the main disconnect located on the left end of the machine. 4. Remove and lockout all incoming power to the machine. 5. Remove and lockout all utilities (air, water, etc.) from the machine. 6. Remove and lockout all power and utilities from any ancillary equipment mounted on or connected to the machine. 7. Mount the relay (LC ) using clip (LC ) onto 1500I/O position 14. See Figure #1 Figure #1 8. Run 1738CBL cable (supplied with CLA ) from the valve and into the back of the power case using the 1 ¼ conduit. See Figure #2. LO doc Page 37 of 40 Print Date 4/18/2008

39 1738CBL cable location Figure #2 9. Terminate 1738CBL cable per Table #1 CABLE-COLOR 2ND END POINT 1738CBL Rd 1738CBL Bk 1500I/O-2TB I/O-2TB-40 Table #1 10. Wire tie cable as need with tie-raps supplied. 11. Reapply power and utilities to machine and any ancillary equipment. 12. Power up machine and bring out of E-Stop. 13. Check functionality of all safety equipment on machine (E-Stop buttons, Guard door switches, Etc.). 14. Check operation of the air blast. End Air Blast LO doc Page 38 of 40 Print Date 4/18/2008

40 Turret Coolant ML TCV TURRET COOLANT VALVE Parts shown below are for electric interface only. Full set of parts are on ML TCV BOM. BOM QTY Part Number Description 1 LC RELAY, MINI 24VDC 1 LC CLIP, RETAINING 1 ML VA5L CABLE VALVE FORM A 5M LEAD 2 F LABEL CABLE 2 CK FERRULES 20 AWG 1 LO INSTALLATION INSTRUC. ML/CM 1 LO INSTALLATION INSTRUC. ML Electrical Installation Procedure 1. Put the machine in E-Stop. 2. Turn the machine s control off. 3. Turn off and lockout the main disconnect located on the left end of the machine. 4. Remove and lockout all incoming power to the machine. 5. Remove and lockout all utilities (air, water, etc.) from the machine. 6. Remove and lockout all power and utilities from any ancillary equipment mounted on or connected to the machine. 7. Mount the relay (LC ) using clip (LC ) onto 1500I/O position 14. See Figure #1 Figure #1 LO doc Page 39 of 40 Print Date 4/18/2008

41 8. Run 1738CBL cable (ML VA5L) from the valve and into the back of the power case using the 1 ¼ conduit. See Figure # CBL cable location Figure #2 9. Terminate 1738CBL cable per Table #1 using ferrules (CK ) on ends of wires. CABLE-COLOR 2ND END POINT 1738CBL Bk1 1500I/O-2TB CBL Bk2 1500I/O-2TB-40 Table #1 10. Add wire markers (F ) to both ends of cable. Labels to be hand written with 1738CBL if field installed or computer printed if line installed. 11. Wire tie cable as need with tie-raps supplied. 12. Reapply power and utilities to machine and any ancillary equipment. 13. Power up machine and bring out of E-Stop. 14. Check functionality of all safety equipment on machine (E-Stop buttons, Guard door switches, Etc.). 15. Check operation of the turret coolant valve. End Turret Coolant LO doc Page 40 of 40 Print Date 4/18/2008