Hyundai SKT 100/200 CNC TURNING CENTER. INSTALLATION MAINTENANCE MANUAL (VERSION No.: VOL1.0)

I. INTRODUCTION

Outline of the Manual

This manual contains the followings for a proper use and overall understanding of this machine.

(1) NC device Operation manual

Contains operating instructions.

(2) Installation & Maintenance Manual

Contains the periodic inspection an the installation and maintenance instructions.

(3) Parameter List

Contains detailed parameters.

(4) Alarm List

Contains detailed alarm informations.

(5) Part List

Contains the details required to purchase the part.

(6) Electric Circuit Diagram

Contains electric circuit diagram.

The record of values including the "parameter table" enclosed here should be kept as it is

necessary for maintenance and adjustment of machine.

Thank you!

1-1

1-1

Symbol and Description

(1)

This manual contains 7 chapters shown in the Roman numerals.

Ex)

INTRODUCTION

Title

Chapter 1

(2)

Each chapter contains several sections.

Outline of MANUAL

Ex)

Title

Chapter 1

(3)

A section contains several items

Ex)

1 - 1

Symbol and Description

Title

Item

Section 1

(4)

Each item contains several paragraph

Ex)

4 - 1 - 1

Installation Condition

Title

Paragraph

Item

Section 1

(5)

The figure and Table are shown in accordance with each "Chapter"

Ex)

Figure 3 - 7

Major Dimensions of Head Stock

Title

The seventh figure of Chapter 3.

Chapter 3

Ex)

Table 3 - 1

Specification

Title

The 1st table of Chapter 3

Chapter 3

1-2

I. INTRODUCTION

Characteristics

This machine is two axis CNC lathe with drum type turret, and has the following features.

(1) Enables both chuck and center works.

(2) Uses AC built-in motor to directly change the speed in a wide range [5,5/7,5 kW (SKT100),

7,5/11 kW (SKT200)]

(3) Adapts the constant surface speed function as a standard option.

(4) Adapts the permanent set as a standard option, machines a variety of workpieces in the

same setting and uses the tool available in the market.

(5) Epoch-making reduction of the tool indexing time and the turret rotation speed by applying

the servo motor-driven tool post.

(6) Accurate positioning by using the advanced LM-guide and ball screw.

(7) The greatest feed rate (36m/min) of axis in the world.

(8) Minimized heat displacement in X-axis by double pre-tension structure.

(9) Stable bed structure of 45°.

(10) Ensures rapid and easier operating by applying the FAUNC Oi-TB CNC of 32 bit.

(11) High quality one with a beautiful color and the cover designed somatologically.

(12) Adding special accessories enable to maximize the request for automatization and higher

productivity.

Standard Accessory

•

Ø 165 (6.5") hollow chuck & rotary cylinder (SKT100)

•

Ø 210 (8.3") hollow chuck & rotary cylinder (SKT200)

•

Leveling seat

•

Spanner & wrench

•

Soft jaw

•

Spindle override (50 ~ 150%)

•

Hydraulic unit

•

Foot switch (For chuck)

•

Auto-coolant device

•

Test report

•

Auto-lubricant device

•

Operation manual

•

Base holder for Inside (Internal

•

Chuck open/close M function

Diameter) tool

•

Work Light ON/OFF Switch

•

Sectional base holder

•

Work Light

•

Chuck open/close confirmation device

•

Spindle load meter

•

Door lock system

1-3

Special Accessory

•

Auto door

• Chip conveyor (both for side and rear)

•

Spindle internal stopper

• Chip box

•

Spindle rpm meter

• Air blow

•

Work counter

• Coolant gun

•

Auto power cut off system

• Jet coolant

•

Integrating timer

• Spindle internal coolant

•

Weekly timer

• Chuck upper coolant

•

Workpiece attachment confirmation device

• TR robot

•

Spare tool call function

• KN robot

•

Rotary tool post

• Chuck open/close confirmation device

•

Sub spindle

• Tail stock For./Ret. foot switch

•

QCT tool post

• Chuck pressure 2nd stage converting device

•

CALL LIGHT (1, 2 or 3 colors)

• Spindle positioning device

•

Q-setter

• Tail Stock

•

Parts catcher

• Tail stock For./Ret. M function

1-4

II. SAFETY

General

(1) The purpose of safety notice is to avoid personal injury or damage to the equipment from

accidental events.

(2) The expressions DANGER, WARNING or CAUTION used in this manual, have a special

meaning, which is stated below:

DANGER Failure to comply may result in personal death.

WARNING Failure to comply may result in personal severe injury or lethal

damage to the machine.

CAUTION

Failure to comply may result in personal light injury or damage

to the machine.

(3) Read and observe instructions of the name plate on the machine. Also, do not change the

position of the name plate or damage it. If broken, purchase it with the no. of item shown in

Part List.

(4) Before Servicing this machine, thoroughly be familiar with this instruction and the notice of

nameplate.

We're not responsible for damage due to your careless use.

2-1

General Safety Precautions

DANGER

(1)

Do not touch any device in the Electric Control Panel and Operating Panel and in which

the mark

is located.

(2)

Prior to operating the machine, always close the door and check if safety shield located.

If the door opened, immediately turn off the main power.

WARNING

(1)

Remember where the Emer-gency stop

switch is to operate it anywhere at all

times.

(2)

Before operating the machine, check if

the switches are functioned correctly to

avoid malfunction.

(3)

Never touch any rotating part or tool by

hands while operating.

(4)

Remove oil and water left on the floor to

prevent workers from slipping.

(5)

Do not enter the inside of machine

Figure 2-1. Emergency Stop Switch

except for repairing work.

2-2

II. SAFETY

(6) When temporarily stopping a work and leaving the machine, first switch off the Operating

Panel and then the main power.

(7) When finishing a daily work and leaving the machine, switch off the Operating Panel, the

main power switch, and then the power supply switch at factory.

(8) It is dangerous to operate the machine when being operated or repaired by the other worker.

Be careful when more than two people have to work together.

2-3

(9)

There are potentially dangerous situations inside of the machine such as rotating

workpiece, feeding tool post, dispersing coolant and hot chip. Always close the door of

machine while operating.

(10) Install the machine in a sufficiently bright, dry and arranged place free from any obstacles.

(11) Do not place device workpiece and other items either on the machine moving part or the

machine frame.

(12) Do not reconstruct the machine without our prior permission.

CAUTION

(1) Check the machine regularly according to this manual.

(2) Always close the door during the automatic operation.

(3) Immediately turn off the main power during a service interruption.

2-4

II. SAFETY

(4) Do not change the position of nameplate attached to the machine. If damaged, purchase it

with the item No. of Part List or one in the lower right of nameplate.

(5) Always wear protective glasses during working.

(6) Always wear safety shoes.

(7) Wear the safety cap and do not wear your uniforms loosely.

(8) Never operate the machine while wearing gloves.

(9) Keep the workbench near the machine enough to be strong and not to be slippery.

(10) Do not operate the machine while drinking of taking a medicine.

(11) Do not operate the machine when feeling a sick or sleepy.

(12) The max. noise of this machine is approximately 76 db. It is recommended to wear

earplugs.

2-5

Notice When operating the Machine.

Before operating the machine, make sure the followings.

WARNING

(1) Always close the door of the Electric Control Panel to avoid damage due to water, chip or oil.

(2) It is dangerous to remove the chip attached or dropped to the tool with bare hands.

Therefore, stop the machine and wear gloves and then do a job using brush.

(3) Do not adjust the location of coolant nozzle while operating.

(4) Gradually increase the rpm of spindle to allow sufficient warming-up. Otherwise, it may result

in damage of the chuck cylinder (Refer to Repair and Preservation, step 2-9/5-1par. "A.

Warm up of spindle" ).

2-6

II. SAFETY

(5) Do not pull out or modify the

instruments or electric circuits

installed for a safety such as the

stroke limit dog of feed system, the

limit switch, the interlock limit switch,

and etc.

(6) Check the belt for tension. Make it

sure that your hands of fingers are not

hold between the belt and the pulley.

(7) Always clamp the workpiece or the tool exactly. For the cutting depth and feederate, begin

form the minimum level.

(8) When the machine rotated at a high speed, the clamping force of chuck will be decreased

rapidly. Be careful to set up the pressure of chuck and cylinder.

(9) When chucking and centering the center workpiece, take care of its weight, the hole of

center, configuration, and thrust of center. If centering and loading through a small hole, the

lead-edge of center may be broken and the workpiece sprung out.

2-7

(10) When self Boring of the soft jaw, pay attention to the location of self Boring Ring and

configuration of self Boring. After cutting the jaw, clamping the jaw correctly and check

the pressure of chuck is proper.

(11) If rotating the spindle when the center is not placed on the center of rotation and being

eccentric, it may cause the machine it self vibration and affect its working accuracy. Keep

its balance by attaching the balance.

CAUTION

(1) Do not touch kinds of switch with wet hands.

(2) While heavy cutting, a fire can happen due to a hot chip. Make it sure the chip not to be

accumulated.

(3) Check each bolt is clamped properly.

(4) Check there is a strange sound from the motor or anywhere else on working.

2-8

II. SAFETY

(5) Warm up the spindle and feed system prior to operating.

(6) When installing the tool, stop the feeding axis and the spindle.

(7) When installing the tool, pay special attention to the edge of tools. Install it not to be

protruded over the specified length.

(8) After installing the tool, first perform a test operation.

(9) When installing the workpiece on the standard chuck, make the outer circumference of

jaw positioned in the external diameter of chuck.

(10) Visually check the switch on the Operating Panel and then operate it correctly.

(11) Check the pressure gage indicates correctly.

(12) For the machine with special accessory, follow the specified instructions.

2-9

Notice When Repairing and Checking

After reading this manual thoroughly, perform the maintenance.

DANGER

(1) Before repairing the machine, always ensure the main power is off.

(2) For a while even after the power off, always check there is residual current in the Electic

Control Panel and the Electric device and then perform the maintenance.

(3) Open the door of the Electric Control Panel only for repairing.

2-10

II. SAFETY

WARNUNG

(1) Only the qualified personnel can perform maintenance on the electric device.

(2) When cleaning the machine, always stop its operation turn OFF and then lock the main

power.

(3) When repairing and cleaning the machine, do not use compressed air.

(4) When repairing at a high place, use a proper support or ladder and wear a safety helmet.

(5) Never operate the machine with the cover removed for repairing.

(6) While repairing or cleaning the machine, keep the floor free from water or oil.

2-11

WARNUNG

(1) Before repairing, completely read the

installation and Maintenance Manual.

(2) Keep enough parts in stock for repairing

and replacing.

(3) The person who responsible for

maintenance should obey the instructions

on the machine.

(4) Clean the machine after a completion of

daily work to make it easier to find out

anything wrong.

(5) When repairing, record the work.

(6) Do not attempt to remodel the device or

electric circuit such as the limit switches for

stoke limit, of interlock of the machine.

(7) Check each gage indicates its normal

value.

(8) Check the lubricating oil is supplied for

each wet moving part.

(9) Only use the specified hydraulic and

lubricating oils and greases in this manual.

(10) When cleaning the chip, always wear glove.

(11) Filling and changing oil should be performed periodically according to this manual.

(12) Apply each part with rust-proof oil after a completion of work, especially if using the

solvable coolant.

(13) Use the specified spanner or wrench when adjusting and repairing the machine.

2-12

II. SAFETY

Notice on the Electric and NC Devices

DANGER

(1) Do not give a shock on the NC device and

the Electric Control Panel, etc.

(2) In case of the power cable, use it with the

same thickness provided in this manual,

and do not use longer cable than needed.

When the power cable has to be passed

the floor, be sure to prevent it from being

damaged by chips.

(3) In case of test operation, check the

parameter of NC device is set properly with

our instructor attended. Also, do not

change any parameters except one for

backlash.

WARNING

(1) The Electric Control Panel is sealed to prevent

the ambient air from entering. Do not open the

door of Control Panel for long while applying the

power. Direct ray of sun or flash of camera may

result in damage of the part.

2-13

(2) The instruments specified by our company should be used in the Electric Control Panel.

Especially use the specified fuse and never use that of great capacity or a copper wire.

(3) When repairing the electric instrument, switch OFF the power of the Operating Panel. Also

switch OFF the Electric Control Panel and then the Power Supply at factory.

(4) Do not change a current setting of the overload relay in the Electric Control Panel and any

settings of various volumes.

CAUTION

(1) Do not open the door of the Electric Control Panel or the Operating Panel, if possible. The

penetration of foreign material or humidity may result in misoperation.

(2) Special care should be taken in handling the electric instrument of the body.

(3) Clean the fan and filter in the Electric Control Panel regularly.

(4) Check the no of program on the screen of the Operating Panel.

2-14

6-2. Safety Device

* Applicable only to

the C.E.

No.

Name

Function

Door Lock System

If the door opened while operating the

machine, it may be in Emergency Stop sate.

Emergency Stop Switch

If Pressing this switch, all operating parts

except hydraulic ones will be stopped.

6-2-1. Door Lock System (Applicable only to the C.E)

WARNING

Set the "LOCK / UNLOCK" switch of door lock system to "LOCK" .

If setting it to "UNLOCK" , it may allow the door to be opened while operating and cause

serious risks.

2-16

III SPECIFICATION

Introduction

3-1

1-1. Head Stock

3-1

1-2. Tool Post

3-1

1-3. Tail Stock

3-1

Specification

3-2

2-1. Spindle Output and Torque Diagram

3-3

NC Device Specification (FANUC Oi-TB)

3-4

3-1. G Function

3-7

3-2. M Function (Auxiliary)

3-9

Head Stock

3-12

4-1. SUPER KIATURN 100

3-12

4-2. SUPER KIATURN 200

3-13

4-3. Major dimension of Head Stock

3-14

Chuck and Rotary Cylinder

3-15

5-1. Hollow Chuck Major Dimension

3-15

5-2. SUPER KIATURN 100 Hollow Chuck

3-16

5-2-1. Connecting Parts for Rotary Cylinder

3-16

5-2-2. Major Dimensions

3-17

5-3. SUPER KIATURN 200 Hollow Chuck

3-17

5-3-1. Connecting Parts for Rotary Cylinder

3-17

5-3-2. Major Dimensions

3-18

Tool Post

3-19

6-1. Turret

3-19

6-2. SUPER KIATURN 100

3-20

6-3. SUPER KIATURN 200

3-21

III. SPECIFICATION

Introduction

1-1. Head Stock

Ensures the wide-range change in speed by the AC spindle motor as follows:

For SUPER KIATURN 100, between 30 and 6.000 rpm and for SUPER KIATURN 200, between

30 and 4.000 rpm.

Besides, it enables the constant surface speed control by the AC spindle motor.

1-2. Tool Post

Ensures more rapid and accurate indexing work (0,12 sec/surface) by the servo motor and the

3-pice coupling.

1-3. Tail Stock (Option)

Install the taper of MT No. 4 sold as a commercial live center.

The tail stock is set to random position by controlling the key above the support. Also, the thrust

can be adjusted between 50 and 450 Kgf (500N and 4.500N) according to the hydraulic

adjustment.

3-1

Specification

Table 3-1

Specification

Item

Unit

SUPER KIATURN

SUPER KIATURN 200

100

Swing over Bed

mm (in)

φ550 (21.6)

Max. machine dia.

mm (in)

φ350 (13.8)

Chuck size

mm (in)

φ 165 (6)

φ 210 (8)

Capacity

Swing over cross

mm (in)

φ350 (13.8)

Max. turning length

mm (in)

300 (11.81)

Bar capacity

mm (in)

φ45 (1.77)

φ65 (2.6)

Speed

rpm

6,000

4,000

Speed variation

randomly

Spindle

Spindle dia (Bearing)

mm(in)

φ90 (3.54)

φ110 (4.3)

Spindle nose

A2-5

A2-6

Bearing arrangement

ball bearing

Floor-Center height

mm(in)

1,010 (39.76)

Turret type

sec

12-angle variable arrangement

Tool Post

Tool size

25/Ø32(1Ø11/4)

25/Ø40(1Ø11/2)

Indexing time (1step/full)

each

0.12/0.24

Mechanism

sec

Servo

Guide type

LM-Guide

Travel

X-axis

mm(in)

210 (8.2)

Travels

Z-axis

mm(in)

330 (12.99)

Traverse

X-axis

m/min(in/min)

36 (1,417)

Z-axis

m/min(in/min)

36 (1,417)

Tail stock taper

MT4

Tail stock dia.

mm (in)

φ56 (2.2)

Tail Stock

Tail stock travel

mm (in)

80 (3.15)

(Option)

Tail stock thrust

kgf (N)

450 (17.72)

Feeding method

manual

Spindle

kW (Hp)

5.5/7.5 (7.4/10)

7.5/11 (10/55)

Feed drives

X-axis

kW (Hp)

1.6

(2.2)

Motor

Z-axis

kW (Hp)

1.6

(2.2)

Coolant

kW (Hp)

0.18

(0.24)

Power Capacity

KVA

11.4

14.1

External size (L x W x H)

mm (in)

1,943x1,650x1,820 (76.5x64.96x71.65)

Others

Machine weight

kg (N)

3,800 (38,000)

3,900 (39,000)

controller

FANUC 0i-TB

The standard CHUCK & CYL should be attached, otherwise, it might cause serious injury to

human body. You should use the approved one by our company.

3-2

Hyundai SKT 100/200 CNC TURNING CENTER. INSTALLATION MAINTENANCE MANUAL (VERSION No.: VOL1.0) - page 1