SYIL 5 Series Installation Manual

Welcome to the SYIL 5 Series Installation Manual

To learn more about SYIL 5 Series machines or to resolve any issues or questions you may have, use the navigation menu on the left to find your desired topic.

Overview

This manual provides important instructions for the transportation, installation, leveling, and electrical setup of SYIL 5 Series machines. Following the procedures in this manual is essential to prevent damage to the machine and installation site, as well as to reduce the risk of injury for machine operators and other personnel who will work on the machinery following installation.

This manual is organized in several sections that should be read in sequence, as follows:


Technical Specifications of the Machine

Before beginning installation, ensure you are familiar with the technical specifications of the machine and its components:

SYIL 5 Series Technical Specifications

1 Dimensions of the worktable (length x width) 550mm×160mm
2 Width of the T-shaped groove 12mm
3 Maximum load capacity of the worktable 50kg
4 Stroke of X-spindle 280mm
5 Stroke of Y-spindle

150mm

6 Stroke of Z-spindle 270mm
7 Specifications of the main spindle BT30
8 Rotational speed of the main spindle 5000 rpm
9 Main spindle motor power 1.1kw
10 Feeding motor Torque/power of X-spindle 3.5Nm/0.75kw
Torque/power of Y-spindle 3.5Nm/0.75kw
Torque/power of Z-spindle 3.5Nm/0.75kw
11 Maximum feeding speed 10000mm/min
12 Screw road parameter (diameter/thread pitch) XY 5mm/16mm
Z 5mm/16mm
13 Width of Wire Rail XY 20mm
Z 20mm
14 Precision Positioning Precision 0.02mm
Repeated Positioning Precision 0.02mm
15 Air Pressure 0.5
16 Machine Weight Net Weight 400kg
Gross Weight 600kg
17 Machine dimensions Bare Machine 685x560x830mm
Complete machine 840x820x1040mm

Transportation and Installation

This section of the manual introduces the correct procedures and requirements for selecting and transporting SYIL 5 Series machines to a suitable installation site.

Ensure you have read and understood the following requirements before beginning transportation and installation procedures.

Installation Site Requirements

Transportation

Fixing Devices

Installation Site Requirements

Selecting a suitable installation site is essential to ensuring the performance and safety of SYIL 5 Series machines.

This section specifies general and environmental requirements for machine installation sites.

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  • Before installing the machine, ensure you have full read and understand the safety instructions in this manual.

  • Ensure the ground is free of lubricant oil, grease, or water to prevent slipping and falling during installation.

  • Ensure that the machine has been correctly installed before operating it for the first time.

General Conditions

The following environments are suitable machine installation sites:

  • Environments free of condensation or dew brought by daily temperature changes.

  • Environments with flat, slip-resistant surfaces.

  • Well-supplied, well-maintained public facilities.

  • Environments with sufficient space for adjustment or repositioning of the machine.

  • Environments without fire or explosion hazards.

The following installation environments are not suitable machine installation sites:

  • Environments with direct sunlight, proximity to a heat source, or with heavy temperature fluctuations.

  • Environments with high levels of dust or humidity.

  • Environments located near vibrating machinery.

  • Environments built on soft foundations.

  • Environments with slanted or slippery flooring.

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  • Vibration dampeners should be installed around the machine if sources of vibration are present in or around the worksite.

    If any special components have been selected for installation on the machine, ensure there is enough space for maintenance.

Environmental Requirements

The following table specifies detailed environmental requirements for machine installation sites:

 
Environmental Factors Requirements
Temperature Between 0°C and 4°C
Relative Humidity Between 10% and 75%
Clearance Space No less than 600mm at all points on the machine to ensure repair and maintenance access
Lighting No dimmer than 300 lux
Air Quality No higher than AQI 100
Noise No higher than 70db
Storage Temperature Between -20°C and 65°C

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  • An air source equipped with a dehumidifier should be installed at the worksite to prevent excess humidity from damaging the machine.

Transportation

To prevent potential injuries and equipment damage before, during, and after installation, it is essential to follow the correct procedures for transporting SYIL 5 Series machines to their installation sites.

This section specifies the correct methods and precautions for ensuring correct handling of the machine throughout the transportation process, as well as risks to be aware of.

General Requirements and Precautions

The machine is comprised of two main components: the machine body, and the control system. Ensure that all components and devices are properly installed on the machine’s body before transporting the fully assembled machine to its intended position.

The machine should be moved either by crane or by forklift.

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  • Do not lift any other articles during transportation of the machine.

  • Do not go under the machine while it is being lifted.
  • Keep a safe distance from the machine and lifting equipment to avoid being struck during transportation.

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  • Before transporting the machine, check to ensure its components are correctly and securely installed.

  • Lift the machine slowly to ensure it remains completely balanced throughout the moving process.
  • Ensure the machine’s body, electrical control panel, and other electrical equipment are not subjected to strong vibrations during transportation.

  • The coolant compartment should be detached from the machine before transportation.
  • Ensure that the machine is positioned so that it will not hinder transportation in any way. If there is insufficient space for loading the machine on the transport mechanism, contact the person in charge of the worksite where it will be installed about adjusting the machine or other measures for ensuring transportation.

  • Once the machine is placed at the installation site and does not need to be moved further, ensure operating personnel are aware of any safety considerations arising from the installation process before they begin work.

Instructions for Crane Transportation

When transporting the machine by crane, be sure to take the following precautions:

  • Position the base of the crane and the horizontal support plate so that the machine can be loaded with the fulcrum of the overhanging steel cable directly above its center.

  • Ensure the angle of the steel cable’s fulcrum does not exceed 90°. If possible, adjust the angle to 60°.

  • Ensure that the steel cable is secured on both sides of the pedestal or with a fixing device designed for transporting heavy equipment.

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  • Lift the machine slowly while ensuring it is balanced on all sides and that the lifting cables are taught against its external casing or outermost components.

  • If two or more people are lifting the machine, they should communicate to ensure they exert force on it simultaneously and in the same direction.
  • Do not use cables of inadequate length or that have sustained rust or other damage to lift the machine.

  • Lift the machine slowly. When one of the steel cables has reached maximum tension, temporarily halt lifting and check that the machine is balanced before continuing to lift it to the designated height.
  • The machine should be lowered slowly. When lowered almost to the ground, temporarily halt lowering and check that the machine’s base is level and aligned with the intended position, then resume lowering to set it down completely.

  • Lifting work should be performed only by experienced personnel.

Instructions for Forklift Transportation

When transporting the machine by forklift, be sure to take the following precautions:

  • Ensure you have read and understood the manual’s safety instructions before installing the machine.

  • Ensure the ground is free of lubricant oil, grease, or water to prevent slipping and falling during installation.

  • Before beginning installation, check and confirm that the machine has been placed in the correct position.

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  • Only personnel qualified to operate a forklift should attempt to transport the machine.

  • In order to avoid damaging the machine or its surroundings, a minimum of two people should be present while operating the forklift.
  • Lower the machine slowly to prevent impact with the ground.

  • A wooden pallet can be used to support the machine during the lifting process.

Fixing Devices

To ensure safety, always use fixing devices to hold the machine’s spindles in place during transportation.

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  • Never operate the machine until you have completely dismounted the fixing devices for all components.

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  • Never use oil or other chemicals that may create a risk of fire.


Leveling and Electrical Device Installation

Following transportation, precise horizontal leveling and careful installation of the SYIL 5 Series machine's electrical components is needed ensure its long-term performance and safe operation.

Ensure you have fully understood and completed the following procedures before beginning to operate the machine following installation.

Horizontal Leveling

Power Supply and Wiring

 

Performing careful horizontal leveling is one of the most important procedures for ensuring the sustained precision and service life of SYIL 5 Series machines.

Perform horizontal leveling in the following sequence using a spirit level with a unit scale sensitivity of 0.02mm/m:

  1. Place the horizontal adjustment seat on the installation position at the bottom. The machine should be installed so as to facilitate adjustment of the positioning bolts used to level the machine.

  2. Place the spirit level on the worktable and collect measurements.
  3. Adjust the machine using the positioning bolts until leveled within 0.04mm/m in the front-to-back direction.

  4. Adjust the machine using the positioning bolts until leveled within 0.04mm/m in the front-to-back direction.

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  • Keep the level gauges’ contact surfaces clean and prevent any dirt or dust from entering the measurement area.

  • Tilting or abrasion of the machine’s body during transport can cause horizontal leveling imbalances that will impact its control system, resulting in equipment faults.

  • When the level gauge is moving, make sure it is not obstructed by the chuck or tailstock.

  • Ensure the machine’s anchor bolts and nuts are firmly installed and use them to make final horizontal leveling adjustments.
  • Following initial leveling during installation, perform routine leveling at the intervals specified in the following table:

Leveling
Stage of Service Life Frequency
Two to three days after installation of the machine Daily
Within 6 months of installation Monthly
After six months have passed since installation Quarterly

 

Power Supply and Wiring

Correct grounding, inspection, and power supply connection procedures are necessary ensure the safety and performance of the machine and its electrical components.

Ensure that you have fully understood and completed the following procedures before beginning to operate the machine following installation.

Grounding

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  • Grounding must be performed by an authorized engineer during installation of the machine to ensure safe operation and prevent electrical hazards.
  • All electrical facilities must be grounded with the correct technical specifications to prevent risking injuries or faults in the equipment.
  • The grounding point should be close to the machine and should be arranged with separate wiring.
  • Ensure that an authorized engineer performs Class III grounding operations with the following criteria:

    1. Ground resistance of less than 100Ω

    2. Measurement using 500v high-resistance tester
    3. Cabling as specified in the following table:

      Cabling Specifications
      Cross-Section of Power Cord (mm²) Minimum Cross-Section of Grounding Wire (mm²)
      S≤16 S
      16<S≤35 16
      S>35 S/2
  • To ensure proper grounding, ground each machine at the worksite separately, and never ground multiple machines in series. Each machine should connect to its corresponding grounding terminal, and each terminal should have only one grounding wire.
  • The grounding resistance for the entire installation (in Ohms) is equal to 100 divided by the number of machines.

Checking the Power Supply

Strict quality control standards should observed throughout transport and delivery of the machine. However, due to vibrations and temperature changes that can affect it during transportation, the machine may require readjustment before beginning operation.

Installation personnel should perform the following inspections before connecting the machine to the power supply:

  • Check that components of the control panel are installed securely.

  • Check that the wire connections on the wiring board are secure and tighten them as needed.

  • Check the current rating of the breaker to ensure the motor is properly protected from overages.
  • Check that the the connectors on the control panel have been properly tightened.

  • Check that the general connection of all motors, the signal connectors of the server motor and main spindle motor, and power connectors are all functioning without error.

  • Check the connecting section of the machine’s hose connector.

Pre-operation Inspections

  1. Before beginning to operate the machine, be sure you have fully read and understood the Installation Manual and the controller operation manual.

  2. To ensure safe operation, employees must have completed basic training before working on the machine.

  3. After connecting the power supply and confirming the machine is properly lubricated for normal running conditions, check for any electricity leakage in the machine’s main components.

Connecting the Main Power Supply

Before connecting the main power supply, take the following precautions to ensure the safety of doing so:

  • Check that the machine is installed in a position where the switch can be easily reached and turned off or on.

  • Confirm the voltage and frequency requirements at the installation site before configuring the equipment and replace electrical devices as needed.

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  • Serious voltage fluctuations may cause the machine to run abnormally, resulting in electrical component faults. Installing an external transformer or voltage stabilizer can help resolve this issue.

  • Equipment that generates high-frequency electrical noise (such as welding machines, high-frequency drivers, and so forth) should use an independent distribution board. It is recommended that you install separate distribution boards a minimum of 20 meters away from the machine.

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  • Stabilizing equipment should be used where voltage level exceeds the allowable range or fluctuates heavily. If other devices and equipment (such as welders or other tools) are connected to the same power line, the electrical noise it generates may cause a fault in the machine, making it necessary to remove this equipment from the machine’s power line.

After completing installation of the machine and its electrical components, connect the power cord and check the main power switches. Connect the machine to the grounding wire and confirm the power supply to the distribution board is connected, then connect the switches in the following sequence:

  1. L01

  2. L02
  3. L03

If running a power cord in reverse direction, confirm that the three-phase voltage and the setting values of the voltage meet the requirements of the installation site’s power inlet, then connect the wire to the breaker in the following sequence:

  1. PE

  2. L11

  3. L12

  4. L13

After completing the above procedures, connect the machine’s power supply in the following sequence:

  1. Turn on the distribution board breaker.

  2. Switch on the main power switch.
  3. Turn on the operating panel power switch.

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  • Check the grounding line (PE) at least once every six months.

  • If the machine needs to be moved, check the grounding line (PE) in advance.