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Emcoturn 365 Modular CNC-Turning Center for Complete Machining

Machine Description Emcoturn 365 Ref.-No. EN 4054

EMCO Maier Ges.m.b.H. P.O. Box 131 A-5400 Hallein-Taxach/Austria Phone ++43-(0)62 45-891-0 Fax ++43-(0)62 45-869 65 Internet: www.emco.at E-Mail: [email protected]

Edition F2002-04

Introduction For more than five decades EMCO has been developing wood and metal working machines and has been successfully on the market since 1980 with computer controlled machine tools and systems for industry and training. Our experience over decades and new customer requirements led to the development and the construction of the EMCOTURN 365 lathe for complete machining from blank to components ready for installation. Due to an optimum distribution of machining sequences high production flexibility, half processing time and, thus, double productivity are achieved. Due to various accessories and special equipment such as integrated swivelling loader, bar feed and loading magazine, tool holder, tool fracture control and an external measurement station still a higher degree of automation can be achieved. Due to the worldwide industrial use of our machines we dispose of a service network which covers all world areas. Immediately available service engineers, telephone service as well as a 100 % spare part supply exceeding the 10-year obligatory provision is something natural for us. One of our more than 100 general representatives worldwide will inform you on particular new developments and their retrofitting possibilities. The present user's manual for the EMCOTURN 365 comprises the description of the machine and the accessories, instructions and procedures for handling and realization of cleaning and maintenance work by the user as well as stipulations to be observed for the prevention of accidents and machine damage. We therefore ask all machine operators to read the subject user's manual prior to start-up and also at a later point of time and to observe the guidlines attending it as exactly as possible. Your machine will ofer you, on the other hand, permanent operatability and long live. For any inquiries or proposals for improvement with a view to the present operating instructions please get directly in touch with EMCO MAIER Gesellschaft m. b. H. Abteilung Technische Dokumentation A-5400 HALLEIN, Austria

EC conformity The CE sign certifies together with the EC declaration of conformity that the machine and the manual correspond to the EC guideline for machines 89/392/ EEC and its modifications 91/368/EEC and 93/68/EEC. All rights reserved, duplication only upon authorization of Messrs. EMCO MAIER © EMCO MAIER Gesellschaft m. b. H. , Hallein/Taxach - Austria

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Contents Adequate Use ............................................................................ 9 Warranty conditions for new EMCO machines ......................... 9 Safety recommendations ......................................................... 10 Technical data of the machine - metric ................................... 13 Technical data of the machine - inch ....................................... 17 Declaration of conformity ......................................................... 21

A Installation of the machine

The Main Spindle ø45 ........................................................... B10 Dimensions spindle connection ......................................... B10 Clamping cylinder with bore .............................................. B11 Clamping cylinder without bore ......................................... B11 Connection values for tensioning tubes ............................ B12 Machine with clamping cylinder with bore ..................... B12 Machine with clamping cylinder without bore ................ B12 Position of tensioning tube during the change of clamping devices ....................................................... B13 Clamping devices - General hints ......................................... B13 Position of tensioning tube by changing clamping devices ..... B13

Machine acceptance ................................................................ A1 Machine number .................................................................. A1 Electrics number .................................................................. A1 Operation panel number ...................................................... A1 Scope of supply ....................................................................... A3 Basic machine ...................................................................... A3 Tool set ................................................................................ A3 Packing ................................................................................ A3 Modules ............................................................................... A3 Transport of machine ............................................................... A4 Transport with pallet ............................................................ A4 Transport without pallet ....................................................... A4 Transport with crane ............................................................ A5 Transport safety devices ...................................................... A6 Installation plan, dimensions of the machine .......................... A7 Basic machine ...................................................................... A7 Machine with bar loader and chip conveyor ........................ A8 Machine with gantry loader and chip conveyor ................... A8 Installation criteria .................................................................... A9 Requirements on installation surface .................................. A9 Installation possibilities ........................................................ A9 Anchoring on the ground ................................................. A9 Without anchorage on the ground ................................. A10 Additional criteria for installation ........................................ A10 Electrical connection - Machines with Sinumerik 810D/840D ..... A11 Mains connection data ....................................................... A12 Machine without counter spindle ................................... A12 Machine with counter spindle ........................................ A12 Electrical connection - Machines with Fanuc-Control ........... A13 Mains connection data ....................................................... A14 Pneumatic connection ........................................................... A14 Initial start-up ......................................................................... A15

B Description and operation Reference points ...................................................................... B2 Machine zero point M .......................................................... B2 Tool fixture reference point T ............................................... B2 Measurement of the tools .................................................... B2 Coordinate system ............................................................... B2 Working area ........................................................................... B3 Tool turret ................................................................................ B4 Working area ........................................................................ B4 Tooling the tool turret ........................................................... B4 Weight counterbalance ........................................................ B5 The main spindle ø65 .............................................................. B6 Dimensions spindle connection ........................................... B6 Clamping cylinder with bore ................................................ B7 Clamping cylinder without bore ........................................... B8 Connection values for tensioning tubes .............................. B9 Machine with clamping cylinder with bore ....................... B9 Machine without clamping cylinder with bore .................. B9

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Clamping devices - spindle ø65 ............................................ B14 Screwing the tensioning tube into the clamping cylinder .. B14 Spindle insert sleeves ........................................................ B14 Order numbers ............................................................... B14 Necessary hollow-out diameter ..................................... B14 Mounting the insert sleeves ........................................... B15 Dismounting the insert sleeves ...................................... B15 Three-jaw power chuck ...................................................... B16 Mounting the chuck ........................................................ B16 Adjusting the minimum value "X" ................................... B17 Dimensions of the chuck ................................................ B17 Dimensions of the jaws .................................................. B18 Clamping ranges of the chuck ....................................... B19 Clamping force diagram KFD-HS 175/3 ........................ B19 Clamping force diagram KFD-HS 200/3 ........................ B20 Clamping force diagram KFD-HS 250/3 ........................ B20 Collet chuck QUADRO-NC ................................................ B21 Technical data ................................................................ B21 Clamping possibilities - outline ...................................... B21 Clamping variant 1 (basic variant) ................................. B22 Clamping variant 2 ......................................................... B22 Clamping variant 3 ......................................................... B22 Mounting the collet chuck .............................................. B23 Changing the collets ...................................................... B23 Clamping force diagrams ............................................... B24 End face driver ................................................................... B25 Mounting the end face driver ......................................... B25 Dimensions of the carrier plates .................................... B25 Clamping force diagram for end face driver .................. B26 Clamping devices - spindle ø45 ............................................ B27 Screwing the tensioning tube into the clamping cylinder .. B27 Spindle insert sleeves ........................................................ B27 Order numbers ............................................................... B27 Necessary hollow-out diameter ..................................... B27 Mounting the insert sleeves ........................................... B28 Dismounting the insert sleeves ...................................... B28 Three-jaw power chuck ...................................................... B29 Mounting the chuck ........................................................ B29 Dimensions of the chuck ................................................ B29 Dimensions of the jaws .................................................. B30 Clamping ranges of the chuck ....................................... B30 Clamping force diagram KFD-HS 160/3 ........................ B31 Röhm - Collet chuck .......................................................... B32 Technical data ................................................................ B32 Outline collets ................................................................ B32 Clamping principle ......................................................... B32 Mounting the collet chuck .............................................. B33 Dismounting the collet chuck ......................................... B33 Clamping force diagrams ............................................... B34 Changing the collets ...................................................... B34 Hainbuch - Collet chuck ..................................................... B35 Tecnical Data ................................................................. B35 Order numbers ............................................................... B35 Clamping principle ......................................................... B35 Clamping force diagrams ............................................... B35

End face driver ................................................................... B36 Mounting the end face driver ......................................... B36 Dimensions of the carrier plates .................................... B36 Clamping force diagram for end face driver .................. B37 Counter headstock ................................................................. B38 Traversing range ................................................................ B38 Tailstock ................................................................................. B39 Travelling range ................................................................. B39 Mounting the tailstock adapter ........................................... B39 Tailstock thrust ................................................................... B40 Removing the centre .......................................................... B40 Adjusting the detector of the tailstock stroke ..................... B41 Hydraulics .............................................................................. B42 Hydraulic unit equipment ................................................... B42 Oil level control .................................................................. B42 Hydraulic scheme .............................................................. B43 Setting work on hydraulics ................................................. B44 System main pressure ................................................... B44 Clamping device pressure and ...................................... B44 sleeve thrust ................................................................... B44 Minimum pressure for clamping devices ....................... B44 Pneumatics ............................................................................ B45 Compressed air supply ...................................................... B45 Pressure setting ................................................................. B45 Pneumatic scheme ............................................................ B45 Central lubrication .................................................................. B46 Function and monitoring .................................................... B46 Lubrication after longer standstill periods .......................... B47

C Programming and Operation EMCO-specific - Sinumerik 810/840D Survey M Commands machine .............................................. C1 Survey M Commands Gantry ................................................. C2 Survey Machine Configuration M99 ....................................... C2 Channel 1 (machine) ....................................................... C2 Channel 2 (Gantry) ......................................................... C2 Axes Description ..................................................................... C3 Machine Control Panel ........................................................... C4 Key Description ....................................................................... C5 Open Machine Door ............................................................. C15 Door Automatic ................................................................. C15 Clamping device control ....................................................... Purpose ............................................................................. Function ............................................................................ Condition displays of the clamping device ....................... Adjustment of the clamping device control ....................... Bridging the final position clamping device detectors ...... Switching off the final position detector ........................ Activate the final position detector ................................

C16 C16 C16 C16 C17 C18 C18 C18

Switch On/Off Sequence ...................................................... Switch On the Machine ..................................................... Approach Reference Point ............................................ Switch Off the Machine .....................................................

C19 C19 C19 C20

Chip Conveyor ...................................................................... C20

Workpiece collection device (option) ..................................... B48 Adjustment of the height of the collecting tray .................. B48 Adjusting the stroke of the collecting tray .......................... B49

Spindle Brake ....................................................................... C21

Workpiece ejector with flushing system (option) ................... B50 Mounting the ejector .......................................................... B51 Self-made ejector ............................................................... B51 Examples for self-made ejectors ................................... B52 Adjusting the stroke ........................................................... B53 Operating instructions ........................................................ B53

C Axes .................................................................................. C22

Y-Axis (option) ....................................................................... B54 Technical datas .................................................................. B54 Working Area ..................................................................... B54 Toolholders ............................................................................ B55 Single toolholders VDI-30 .................................................. B55 Double toolholders VDI-30 ................................................ B57 Driven toolholders VDI-30 .................................................. B58 Performance curve spindle ø65 ............................................ B59 Performance curve spindle ø45 ............................................ B59 Environmental Protection Notes ............................................ B60 Environmental burdens in machining production .............. B60 Lubricants ....................................................................... B60 Cooling lubricants .......................................................... B60 Solvents and cleaning agents ........................................ B61 Special problems with chips containing residual oil ...... B61 Problems with oil mists and oil vapours, dust etc. ......... B62 Further burdens ............................................................. B62 Measures of environmentally compatible design in machining production ......................................................... B62 General hints .................................................................. B62 Hints for correct handling of utilities ............................... B62

Workpiece Collection Device (Option) .................................. C21 Tailstock ................................................................................ C21 Tool Turret ............................................................................ C22 Influencing the Tool Turret in AUTOMATIC and JOG Mode ....................................... C22 Machine Configuration .......................................................... Clamping Device Left ........................................................ Clamping Device Right ..................................................... Continuous Operation ....................................................... Programming ....................................................................

C23 C23 C23 C23 C23

R Parameter ......................................................................... C24 Workpiece Counter (R90, R91) ........................................ C24 Machining Time (R98, R99) .............................................. C24 Freeprogrammable Outputs ................................................. C25 Survey ............................................................................... C25 Standard Setting ............................................................... C25 Y-Axis .................................................................................... C26 Programming .................................................................... C26 Programming example for using the Y-axis ..................... C26 Cycle Programming .............................................................. Roughing Cycle "CYCLE95" ............................................. Threading Cycle "CYCLE97" ............................................ Drilling Cycle "CYCLE83E" ............................................... Tapping "CYCLE84E" ....................................................... Grooving Cycle "CYCLE93" .............................................. TRANSMIT-Programming ................................................ Cylinderinterpolation ......................................................... Synchronization of two Spindles ....................................... Programming the automatic tailstock ............................... Supporting on more length positions ............................ "TAKEOVER" - Cycle Mainspindle-Counterspindle ......... Bar Loading Cycles ...........................................................

C27 C27 C30 C33 C35 C37 C40 C42 C44 C45 C45 C46 C49

Bar Loader Interface ............................................................. C50 Serial Interface ...................................................................... Signal names .................................................................... Maximum Cable Length .................................................... Connection to PC ..............................................................

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C53 C53 C53 C53

D Programming and Operation EMCO-specific - Fanuc 21i-T Machine Control Panel ........................................................... D1 Axes Description ..................................................................... D1 Description of Keys ................................................................. D2 Switch On/Off Sequence ...................................................... Switch ON the machine .................................................... Approach reference point ............................................. Switch OFF the Machine ..................................................

D10 D10 D10 D11

Open Machine Door ............................................................. Door Automatic (Option) ................................................... Open door automatically ............................................... Close automatic door .................................................... Automatic program start ...............................................

D11 D12 D12 D12 D12

Clamping Device Control ...................................................... Purpose ............................................................................. Function ............................................................................ Condition displays of the clamping device ....................... Adjustment of the clamping device control ....................... Bridging the final position clamping device detectors ...... Switching off the final position detector ........................ Activate the final position detector ................................

D13 D13 D13 D13 D14 D15 D15 D15

Standard Tailstock ................................................................ D16 Programming .................................................................... D16 Adjusting the detection of the tailstock quill ..................... D16 Automatic Tailstock .............................................................. D17 Programming .................................................................... D17 Adjustment of the tailstock stroke monitoring ................... D17

Cutter Radius Compensation ........................................... D33 G40 Cancel Cutter Radius Compensation ....................... D35 G41 Cutter Radius Compensation Left ............................ D35 G42 Cutter Radius Compensation Right .......................... D35 G52 Local Coordinate ....................................................... D36 G53 Selection of the Machine Coordinate System .......... D37 G54 to G59 Selection of a Workpiece Coordinate System D37 G70 Measuring in Inches .................................................. D39 G71 Metrical Measuring .................................................... D39 G72 Finishing Cycle .......................................................... D39 G73 Contour Roughing Cycle ........................................... D40 G74 Face Roughing Cycle ................................................ D42 G75 Pattern Repeating Cycle ........................................... D44 G76 Face Cut-in Cycle ..................................................... D45 G77 Side Cut-in Cycle (X Axis) ........................................ D46 G78 Multiple Threading Cycle (Thread cutting OD/ID) .... D47 Drilling cycles with driven tools ......................................... D48 G12.1/G13.1 Polar Coordinate Interpolation .................... D56 G7.1 Cylindrical interpolation ............................................ D59 G51.2 / G50.2 Polygonal Turning .................................... D61 G90 Absolute Programming ............................................. D64 G91 Incremental Programming ........................................ D64 G92 Adjustment for maximum Spindle Speed ................. D64 G92.1 Coordinate System Setting .................................... D64 G94 Feed Rate in Minutes ................................................ D65 G95 Feed Rate in Revolutions ......................................... D65 G96 Constant Cutting Speed ............................................ D65 G97 Constant Rotational Speed ....................................... D65 M-Commands - Survey ......................................................... D66 Bar Feed / Bar Loader Interface ........................................... D72

Spindle Brake ....................................................................... D18

Reversing Play Compensation ............................................. D77 Input of the reversing play ............................................ D77

C-axis .................................................................................... D18

Chip conveyor ....................................................................... D78

Workpiece Collection Device (Option) .................................. D19

Program interruption to open the door ................................. D78

Tool Turret ............................................................................ Manual operation .......................................................... Influencing the Tool Turret in AUTOMATIC and JOG Mode ....................................... Programming ................................................................

D19 D19

Macro Variables .................................................................... Calling up Variables .......................................................... Workpiece Counter ........................................................... Machining Time ................................................................

D20 D20 D20 D21

D19 D20

Free Programmable Outputs ................................................ D21 Standard Setting ............................................................... D21 Survey Program Input, Administration ................................. D22

Tool Data Measuring with Scratching ................................... D79 Tool Data Measuring with the Optical Preset Device ........... D80 Serial Data Interface ............................................................. Signal names .................................................................... Transmission cable ........................................................... Settings for data transmission .......................................... Transmission of NC-programs ..........................................

D81 D81 D81 D81 D81

E Maintenance of the machine Maintenance survey ................................................................. E1 Filling quantities ................................................................... E2

G-Commands - Survey ......................................................... D23

Lubricant recommendations .................................................... E2

Short description G-Commands ........................................... G00 Rapid Traverse ........................................................ G01 Linear Interpolation (Feed) ...................................... Einfügen von Fasen und Radien ...................................... Insertion of Chamfers and Radii ....................................... Direct Drawing Input ......................................................... G02 Circular Interpolation Clockwise ............................... G03 Circular Interpolation Counterclockwise ................... G04 Dwell ......................................................................... G10 Data Setting .............................................................. Zero point shift G92 ...................................................... Zero point shift with workpiece coordinate systems G54 to G59 ................................... G20 Longitudinal Turning Cycle ....................................... (OD/ID Machining Cycle) .............................................. G20 Longitudinal Turning Cycle ....................................... G21 Thread Cutting Cycle ................................................ G24 Face Turning Cycle ................................................... G28 Reference Point Return ............................................ G33 Thread Cutting .........................................................

Cooling lubricants .................................................................... E3 Chlorin-free coolants ............................................................ E4

D24 D24 D25 D25 D25 D26 D28 D28 D28 D29 D29 D29 D30 D30 D30 D31 D31 D32 D32

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Clamping pressure and clamping dev. function ...................... E5 Power chuck ............................................................................ E5 Collet chuck ............................................................................. E6 Bright parts .............................................................................. E6 Visula examination of all hoses ............................................... E6 Central lubrication .................................................................... E7 Oil level check ...................................................................... E7 Air inclusions ........................................................................ E7 Lubrication in case of major periods of standstill ................ E7 Installation of lines ............................................................... E8 Hydraulic unit ........................................................................... E8 Reduction of hydraulic pressure .......................................... E8 Additional regular checks ..................................................... E8 Cleanliness .......................................................................... E8 Hydraulic oil change ............................................................ E9

Coolant device ....................................................................... E10 Drawing out the cooling lubricant tank .............................. E10 Cooling lubricant level ........................................................ E11 Cleaning the cooling lubricant tank .................................... E11

F Additional instructions

Belt tension ............................................................................ E12

Bristol - Electrostatic Airfilter

Change of battery in the control Siemens 810 D/840 D ........ E13 Change of battery in the hard disk unit MMC .................... E13 Change of the battery ventilator insert of the NC-CPU board (Sinumerik 840D) ..................................... E14 Change of the battery of the CCU-board (Sinumerik 810D) ........................................... E14

Sauter - Tool Turret Knoll - Chip Conveyor

G Spare Parts List

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ADEQUATE USE / WARRANTY CONDITIONS

Adequate Use The EMCOTURN 365 lathe is designed for complete machining by turning, drilling and milling of machinable metals and plastics. Machining of other materials is not admitted and may be carried out in particular cases only after consultation with the machine manufacturer. Adequate use also includes compliance with the operating, maintenance and repair instructions indicated by the manufacturer. The EMCOTURN 365 may excusively be operated by persons familiar with the operation, maintenance and repair and who know the hazards. All regulations for the prevention of accidents and safety instructions for work with machine tools and CNC machine tools have to be complied with at any time. In case of inadequate use of the EMCOTURN 365 the manufacturer renounces any liability and the responsibility is transferred exclusively to the user.

Warranty conditions for new EMCO machines 1. The warranty period for new EMCO machines is, without limitation of operating hours, 12 months after initial shipment of the machine from EMCO or its authorized representative. Should the installation be completed by EMCO or its authorized representative, the warranty period begins with the completed installation of the machine. If a delay of installation occurs which is not caused by EMCO or its representative, the warranty period becomes invalid 12 months after scheduled installation date. 2. The warranty extends to the elimination of all defects in material or workmanship which affect the regular function of the machine. 3. Occuring defects must be immediately reported to the EMCO respresentative or the next EMCO service department with detailed description of the defect in written or oral form, followed by a written verification. 4. Defects which are correctly reported and under warranty will be corrected by either repair or replacement delivery to the original buyer free-of-charge; defective parts are to be returned to EMCO or the EMCO authorized respresentative, freight prepaid, if requested. 5. Warranty for spare parts: Emco guarantees to the original buyer that, only those parts sold directly by Emco or through an authorized representative will be free from defects, which render part commercially unacceptable in material and workmanship, for a period according to applicable national law, at least three (3) months, but not to exceed six (6) months from the date of initial shipment or installation by Emco or its representative. In the case of repeated claims for the same part: Warranty replacement does not extend the period of the original warranty. 6. There is no claim of warranty for defects which occured by: Negligence of operating instruction manuals, safety and handling regulations or other instructions regarding delivery, installation, set-up or usage of the machine, incorrect set-up resp. installation, as well as, unauthorized, not expressed regulated or allowed alternations or modifications of the machine by the original buyer or third parties, natural wear, improper or negligent handling, chemical, electro-chemical or electrical influences, inadequate energy supply or force majeure. 7. Any service performed by EMCO or its authorized representative beyond warranty will be charged at EMCO¦s or its authorized representative’s regular rates.

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SAFETY

RECOMMENDATIONS

Safety recommendations Personal protective equipment Do not wear loose working clothes. Mind that the working clothes are tight around the wrists and hips. Mind that your hair does not get caught in the machine (in such a case wear hair protection). Protect your eyes with safety-glasses. When removing chips use a chip hook and gloves.

Read instructions Read the instructions completely before you start up the machine. Prior to start of work get familiar with all functions and operating elements. During the work it might be too late. Electrical connection Electrical connection of the machine must only carried out by an authorized electrics expert. Local protection measures have always to be borne in mind.

Setting, maintenance and adjusting work All setting, maintenance and adjusting work must only be carried out during standstill of machine and EMERGENCY-OFF key actuated. The inspection and maintenance instructions for machine and accessories are to be observed. This saves costs, excludes major standstills of the machine, reduces hazards and saves the environment.

Observe local regulations Observe your country's regulations for work involving machine tools and CNC machine tools Authorized operation The machine may only be operated by authorized persons. Authorized persons are exclusively persons familiar with operation, maintenance and repair and who are instructed on hazards.

Tools, operating materials and spare parts Only use tools, operating materials and original spare parts recommended by EMCO. For parts not supplied by EMCO, EMCO does not assume liability.

Protect machine Protect the machine (main switch can be locked) during adjustment, maintenance and repair work against unauthorized start-up.

Disposal of noxious materials When handling auxiliary and operating materials (cooling lubricants, cleaning solutions, lubricating oils, etc.) observe the safety regulations for these materials. Take adequate measures for the appropriate storage and disposal of noxious materials.

Start-up Make sure that prior to each start-up the machine is in perfect maintenance state and that no safety features have been removed.

Claim In the event of a collision or other instance of damage contact immediately the representative or manufacturer. In case of complaints, damage, confusions and spare part orders always indicate the machine number, electric number and software version.

No modifications on machine Modifications on your own on safety features, bridgings of control features as well as any interference with the electric/electronic part of the machine are prohibited. In case of hazards EMERGENCY-OFF In case of hazards immediately stop machine with EMERGENCY-OFF.

Machine supervision Never leave running machine unattended. Before leaving the working place switch off machine and protect against unauthorized startup (lock main switch and remove key).

Tool change Change machining tools only during standstill of machine. Only use tools and sealing bolts with O ring on the shaft, always close all stations (otherwise danger of coolant and chip entry in the internal area of the tool turret!). In case of tool change always turn driven tool holder into locking position.

10

SAFETY

RECOMMENDATIONS

Danger, Attention, Note Please always mind the regulations for prevention accidents and safety rules indicated in the individual chapters and the additional instructions. Important instructions concerning the technical safety and the staff protection are emphasized particularly:

Danger refers to possible danger to persons during working and operating procedures.

Attention is indicated in working and operating procedures which have to be observed exactly to avoid possible damage of the machine and slight danger of injury for operators.

Note is indicated if something particular has to be observed when an activity is carried out.

Enviromental Protection Notes refer to the avoidance of special waste, responsible handling of environmentally noxious substances as well as possibilities for saving auxiliary and operating materials.

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TECHNICAL DATA

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20

Declaration of conformity

Product:

CNC Turning Centre

Machine data:

Model

Type

EMCO

ET 365

Address of manufactorer: Emco Maier Ges.m.b.H. Salzachtal Bundesstrasse Nord 58 A-5400 Hallein

Bases of standards:

EN 292-1; EN 292-2; EN 294; EN 418; EN 60204-1; EN 954-1; EN 1037; EN 1050; EN 1088

Regulations:

MSV (BGBl. Nr. 306/1994, 27.4.94)

Test certificates:

Particular notes, enclosures:

Electrical documentation as applicable

We herewith declare that the above-mentioned product referring to the subject declaration is in conformity with the currently valid stipulations of the directive of the Council dated June 22th, 1998 for the alignment of the legal stipulations of the member states for machines (98/37/EEC), with the directive of the Council dated May 3rd, 1989 for the alignment of the legal stipulations for electromagnetic compatibility (89/336/EEC) and its modifications dated April 28th, 1992 (92/31/EEC) and July 22nd, 1993 (93/68/ EEC), and with the directive of the Council dated February 19th, 1973 concerning low voltage equipment (73/23/EEC) and its modification dated July 22nd, 1993 (93/68/EEC). Furthermore, the conformity of the subject product with the above-mentioned standard bases and regulations is effective.

Place, date:

Hallein, 27.12.00

Authorized person: Head of quality department

EN

Peter Binggl

..............................................

A Installation of the machine Machine acceptance heck the machine for any transport damage and completeness of the delivery. If you find any defects, please contact the dealer or the insurance company. In case of complaints always specify the exact designation of the machine and the machine number and the electric number.

9 , 1 $

3(

Machine number

+]

, PD[ $

The adhesive plate with the machine number (1) is to be found laterally on the machine above the lockable main switch. The machine numer is also stamped into the machine bed.

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Hints for cooling lubricant selection: An incorrectly selected or used sooling lubricant may show decisive effects on the manufacturing process and thus, cause high costs indirectly. After the end of service life cooling lubricants represent special waste that need supervision and have to be disposed of adequately. The disposal costs accuring are of decisive influence on the economy or the cooling lubricant use. If machining is carried out with high power, the main task of a cooling lubricant consists in an effective cooling of tool and workpiece. Therefore use of water-soluble cooling lubricants is to be preferred. For complicated machining processes better results can be achieved with non-water soluble cooling lubricants. High efficiency for flushing away the chips is influenced less by the type of cooling lubricant than by the kind and arrangement of the cooling lubricant nozzles as well as by the quantity and pressure of the cooling lubricant stream. In addition the following items are to be observed: • Disposal (cleavage-, decomposition property)

• • • • • • • • • • • • • • • •

Content mateials (chlorine, nitrite, phenols, etc.) Corrosion protection Viscosity Resistence to aging, serving life Resistence against microorganisms Emulsifying capacaty Foaming behaviour Dirt elimination property Wetting capacity Filtering capacity Transparency Compatibility with metals, plastics Residual behaviour Inflammability odour Compatibility with health (formation of mist, skin compatibility, toxicity, cancerogenity,..) Non-water soluble sooling lubricants are generally without problems. Problems occur with the formation of mist and chip deoiling.

E4

MAINTENANCE

CLAMPING DEVICES

Clamping pressure and clamping dev. function Clamping pressure and clamping device function must be controlled at least every 8 hours (daily) to be able to detect possible errors or damage in time.

Clamping pressure • The clamping pressure set for clamping device 1 (3) and 2 (4) can be read at the manometers (1) or (2). • Check all control lines to the valves and clamping cylinder for damage.

Clamping device function 1

2

3

• Check total condition of clamping device every day and remove dirt.

4

Clamping dev. manometer and clamping device • Reduce clamping pressure to approx. 3–4 bar and open and close clamping device via control keyboard. The clamping device must move perfectly.

Power chuck Danger: • Maintenance work on the chuck may only be carried out during standstill of the machine. • Also observe the instruction supplied with the chuck.

Every 8 operating hours • Lubricate the chuck at all existing 6 grease nipples (5) and (6). • Remove clamping jaws from guides and clean the guides and oil them slightly.

Every 1000 operating hours • Dismantle chuck, clean all parts and grease them again. 5 (3×)

During the cleaning intervals check smooth running of the chuck. It must be possible to open and close the chuck perfectly with a clamping pressure of approx. 4 bar.

6 (3×)

Grease nipples on power chuck

E5

CLAMPING DEVICES/BRIGHT PARTS

MAINTENACE

Collet chuck Danger: Maintenance work on mounted collet chucks may only be carried out during standstill of the machine. The general condition of the collet chuck has to be checked every day and possible dirt has to be removed from the collet chuck. Lubrication interval ...... every 40 operating hours • Slightly oil movable parts of the collet chuck with slideway oil.

Caution: The collets should be free from oil during use, otherwise the clamping force may be reduced by too little friction.

slightly oil

Maintenance of collet chuck

Bright parts Danger: Cleaning and oiling of parts in the working area of the machine may only be carried out during standstill of the machine.

The bright parts such as cover sheets and plate covers have to be cleaned every week. Then slightly oil the parts with slideway oil.

slightly oil bright parts

Visual examination of all hoses To increase the operational safety, all hoses (hydraulic, pneumatic, collant device) should be checked for leaks in regular intervals (all six month). Therefore dismount cover sheets ans check, if hoses fret or are wet or damaged.

E6

MAINTENANCE

CENTRAL LUBRICATION

Central lubrication The slide guides are supplied with slideway oil via the central lubrication. The lubrication is carried out automatically according to the way traversed of the individual slides.

Oil level check Interval of checks ......... every 40 operating hours • Check oil level in the oil tank • Check lubricant lines and connection points for tightness and penetrability. The oil tank (1) with the slideway oil is on the rear side of the machine and can be seen via an opening in the machine shell. The oil level must be between the two limit marks on the tank. If the oil level is too low, an alarm message is indicated by the control. If necessary, refill slideway oil in the charging hole (oil quality see "Lubricant recommendations"). 1

Central lubrication at the machine

Air inclusions In case of air inclusions in the lubricant lines slightly untighten the screw connections upstream of the dosing elements and actuate lubricant pump until oil flows out without bubbles from the screwed connections. Retighten screwed connections.

PD[

PLQ 1

Lubrication in case of major periods of standstill

2

Central lubrication / detail

If the machine is not used for a major period, the lubrication should be activated manually prior and after the period of standstill. To do this, press the "AUX ON" key approx. 10 times. Whenever you press, a lubricating impulse is transmitted.

$8;

E7

HYDRAULICS

MAINTENACE

Hydraulic unit Danger: Maintenance work at the hydraulics may only be carried out with the machine switched off and with reduced hydraulic pressure.

Reduction of hydraulic pressure After switching off the machine the hydraulic pressure is decreased automatically down to a residual pressure. The residual pressure must be reduced by a service engineer prior to every maintenance work. • Open door (1) at the rear side of the machine. • Open the accumulator drain valve (2) with an allen wrench.. • Wait a few seconds, until the residual pressure is reduced to 0, then close the valve (2). • Carry out maintenance work.

1

3

Reduction of hydraulic pressure

Installation of lines

Additional regular checks

By changing and installation of hydraulic lines note the following points:

• Pay attention to noises • Monitor oil level • Check for leaks In addition we would like to draw your attention to the following:

• Never use brute force in order to avoid transverse forces and stresses in pipes and equipment. Ensure the pipes are fastened well.

• VDI-guidelines, commissioning and maintenance of hydraulic equipment, VDI-3027 • Prosals of the CE TOP

• Do not use hemp or putty as sealants. This can result in contamination and thus functional breakdowns. • In order to prevent external leaks, observe the installation instructions of the manufactorers of screwed joints. We recommend screwed joints with flexible sealing elements.

Cleanliness Pay attention to the cleanliness to the following: • for the enviroment • for units, line connections, equipment

• Ensure hose lines are laid correctly. Avoid scuffing or knocking the lines.

• for the hydraulic oil • Caution - pay attention to contamination, moisture Only fill using filters (system filters or mobile filter stations with fine filters)

E8

MAINTENANCE

HYDRAULICS

Hydraulic oil change Attention: Upon purchase of the machine the hydraulic system is equipped with a special initial filling oil. The first oil change including filter change must therefore be carried out after 500 operation hours at the latest. Interval .................... every 1000 operation hours Filling quantity ................................................. 10 l

1

The hydraulic oil should be changed in hot operation state. With each oil change the oil filter, too, has to be changed. • Switch off machine and reduce residual pressure in the hydraulic system (see side before). • Open oiling screw (1).

2

• Open oil drain screw (3) and drain used hydraulic oil into a suitable container. • Close drain screw (3) again. • Dismount filter (4) by opening the four hexagon socket screws (5) and replace it. • Fill in new hydraulic oil. The oil level can be controlled at the oil level gauge (2). Mind not to fill beyond the maximum mark (approx. 10 l).

3

4

Attention: Pay attention to the positions of the hydraulic cylinders by refilling hydraulic oil: Door autom.: door closed Tailstock: moved backwards (right side) Clamping cyl.: forwards (chuck open / collet closed)

5

Maintenance work at the hydraulics

• Dispose used oil and filter according to the environmental regulations. • Close door. • Switch on machine and check pressure on the manometer. The pressure varies between 70 and 80 bar.

E9

COOLANT DEVICE

MAINTENACE

Coolant device

Danger: Maintenance work at the cooling system may only be carried out during standstill of the machine.

Drawing out the cooling lubricant tank For refilling the cooling lubricant or for cleaning, the cooling lubricant tank can be drawn out forward.

A • Open door (1) at the rear side of the machine. • Swivel out backward coolant pump (4) and possibly jetting pump on the sheet (2) (see direction of arrow in fig. on the opposite). The pump brackets engage in swivelled-out state.

1

• Draw coolant tank forward.

View of the machine from the rear

• Carry out maintenance work. 1

• Insert coolant tank again.

2

• Swivel coolant pump in again by slightly lifting the rail (3). • Close door (1).

3

4

Swivelling out the coolant pump - view A

E10

MAINTENANCE

COOLANT DEVICE

Cooling lubricant level Check interval ....................... 8 operation hours The cooling lubricant level is checked at the front side of the machine on the display (2) of the cooling lubricant tank (1). When refilling the cooling lubricant observe the composition and the miscibility of the existing liquid (also see cooling lubricant recommendations).

Attention: Use fundamental only chlorine-free coolants. The share of chlorine in the coolant is responsible for the rusting of bright machine parts. 1

2

Display of the cooling lubricant level

Cleaning the cooling lubricant tank Cleaning interval ............. 200 operation hours • Remove dirt from coolant tank and inserted sieves (chips, etc.). • Check return flow lines for cleanness and rinse them if necessary.

Notes: • Dispose cooling lubricants acc. to environmental requirements (special waste!) • Do not use fluorine chlorinated hydrocarbons (e.g. trichloroethylene, trichloroethane etc.) for cleaning the tank. • During cleaning mind complete elimination without residues of deposits! Remaining contaminations are sites of growth for bacteria which attack the newly filled emulsion and reduce its service life. • Use rags and solvents only sparingly. • Dirty cleaning rags (cleaning paper) have to be disposed of as special waste.

E11

BELT TENSION

MAINTENACE

Belt tension Check the belt tension of the drives in regular intervals according to the table below. In addition the belts have to be checked for their general condition. In case of defects such as severe contamination with lubricants and cooling lubricants or fractures or similar, the belts have to be changed. Control interval ................ 2000 operation hours Belts to be controlled (acc. to equipment of machine): • • • • •

Danger: The belt tensions may only be checked with the machine switched off. Make sure that the machine is protected against unauthorized start-up!

Control of belt tension

drive

main spindle (spindle 1) ø65, ø45 counter spindle (spindle 2) ø65, ø45 X-slide Z-slide Z2-slide (Z-stroke of spindle 2)

impression depth

E [mm]

control force Fp [N] initial assembly

belt type

order-no.

after run-in

Spindle 1 ø65

7,3

120-143 98-120

Polyflex 4-grooves, 11M-1400 mm

ZRM 471 114

Spindle 1 ø45

7,2

86-102

Polyflex 4-grooves, 11M-1320 mm

ZRM 471 113

Spindle 2 ø65

4,1

104-123 85-104

Polyflex 4-grooves, 11M-975 mm

ZRM 471 109

Spindle 2 ø45

4,2

87-103

71-87

Polyflex 3-grooves, 11M-925 mm

ZRM 471 110

Slides X, Z, Z2

2,0

11

11

HTD 5M-25-450; 90 teeth

ZRM 600 903

70-86

E12

MAINTENANCE

CHANGE OF BATTERY

Change of battery in the control Siemens 810 D/840 D In the control battery-buffered storages and clock units are used to save data in case of power failure. Buffer time of the batteries .......... min. 3 years The buffer batteries are monitored by the control. If the buffer tension falls below a certain value a message is emitted on the screen by the control. To avoid data loss the buffer batteries have to be changed within 6 weeks after the first display of this message.

Danger: Never try to reactivate batteries by heat or other means or to recharge them. The batteries may run out and/or explode!

Change of battery in the hard disk unit MMC Battery: Order no. (Siemens) ...... 6FC5 247-0AA18-0AA0

Note: To avoid data loss the control must not be switched off during the battery change.

• Remove back cover of control. • Take out plug X11 (2) and pull battery (1) out of the fixing device. • Insert new battery into fixing device and insert plug X11 again. • Remount cover of control. 1

2

Buffer battery on the hard disk unit MMC

E13

CHANGE OF BATTERY

MAINTENACE

Change of the battery ventilator insert of the NC-CPU board (Sinumerik 840D) Ventilator insert: Order no. (Siemens) ...... 6FC5 247-0AA06-0AA0

1

3

2

Danger: • The exchange of the ventilator insert may only be carried out with the machine switched off. • The exchange must be carried out within 15 minutes after switching off the machine, since the data can be protected only during this period.

3

• Switch off machine. • Open switch cabinet of the machine. • The ventilator insert (3) is situated on the NCU box (1). • Press catch (2) on the ventilator insert (3) to the top and at the same time pull out insert. • Introduce new ventilator insert (3), mind engaging of the catch (2). • Close switch cabinet.

2

Ventilator insert on the NC-CPU board

Change of the battery of the CCU-board (Sinumerik 810D) 4

5

6

7

Battery: Order-n.. (Siemens) ....... 6FC5 247-0AA18-0AA0 • Switch off machine. • Open switch cabinet of the machine. • Pull out CCU-board (5) of the CCU-box (7) after untightening of the 4 screws (4). Danger: The CCU-board has to be handled with care, because it is an very high sensitiv electronical part. • Change battery (6) with a new one of the same type. The buffer of the stored datas will be inherited of a capacitor for approx. 15 min. • Set CCu-board (5) in CCU-box (7) and tighten the screws (4).

4

Battery on the CCU-board

E14

F Additional instructions

Sauter

Tool Turret

Knoll

Chip Conveyor

Bristol

Electrostatic Airfilter

F1

F2

BA

O p e r a t i n g

640 e

i n s t r uc ti on s

for Disk-Type Tool Turret with electrical drive and slide unit 0.5.453.216 - 085 612 087 822 104 410 105 672

Type plate at turret housing

Series

Size

0.5.453.2 16 F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\640db.fm

085 612

Classification number Identification number Order number

Gear ratio

Edition:

02-04-05

Table of contents

1

Safety information . . . . . . . . . . . . . . . . . . . . 5 1.1

Use within specifications . . . . . . . . . . . . . . . . . . . . . . 5

1.2

Required skills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3

Electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.4

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.6

Liability and warranty . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.7

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.8

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.9

Symbols in instructions for specific actions . . . . . . . . 8

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\ba640eIVZ.fm

1.10 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3

Product description . . . . . . . . . . . . . . . . . . 11 3.1

The parts of the turret and the slide unit. . . . . . . . . . 11

3.2

Possible options and deviating designs . . . . . . . . . . 13

3.3

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.4

Admissible loads and dimensions . . . . . . . . . . . . . . 17

2

Table of contents

4

Assembly and installation . . . . . . . . . . . . . 19 4.1

As-delivered condition . . . . . . . . . . . . . . . . . . . . . . . 19

4.2

Fitting the turret-drive motor . . . . . . . . . . . . . . . . . . . 20

4.3

Fit turret onto the machine . . . . . . . . . . . . . . . . . . . . 22

4.4

Align turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.5

Fitting the tool disk . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.6

Align tool disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.7

Electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . 27

4.8

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.9

Cooling lubricant supply . . . . . . . . . . . . . . . . . . . . . . 28

4.10 Determination of reference point . . . . . . . . . . . . . . . 29

5

Additional equipment, toolholders and spindle units . . . . . . . . . . . . . . . . . . . . . . . . 30 5.1

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\ba640eIVZ.fm

6

Toolholders and spindle units. . . . . . . . . . . . . . . . . . 30

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 33 6.1

Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.2

Check lubricant of turret gearbox chambers . . . . . . 34

6.3

Bevel gears and roller bearings on gearbox nose . . 35

6.4

Spindle units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6.5

Slide unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3

Table of contents

7

8

Fault finding and repair . . . . . . . . . . . . . . . 36 7.1

Faults and remedies. . . . . . . . . . . . . . . . . . . . . . . . . 36

7.2

Engaging the ratchetting clutch . . . . . . . . . . . . . . . . 39

7.3

Determining belt tension on the slide unit . . . . . . . . 41

7.4

Belt replacement – belt tension . . . . . . . . . . . . . . . . 41

7.5

Basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

7.6

Replacing the cooling lubricant valve . . . . . . . . . . . . 46

7.7

Replacing and setting the proximity switches. . . . . . 47

Replacement parts . . . . . . . . . . . . . . . . . . . 54 8.1

Proximity switches . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.2

Tool disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.3

Cooling lubricant system . . . . . . . . . . . . . . . . . . . . . 57

8.4

Gear head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

8.5

Housing and indexing unit . . . . . . . . . . . . . . . . . . . . 61

8.6

Carrier and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . 63

8.7

Slide unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Ordering replacement parts

Appendix Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EP-1039 e Function diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . SK-1226 e

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\ba640eIVZ.fm

Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . HP-446 e

4

Safety information

1

Safety information The disk-type tool turret corresponds to the state of the art and the recognized technical safety rules. Nevertheless hazards and risks can occur.

1.1

Use within specifications Install and operate turret only in machines complying with the relevant regulations for workspace protection.

1.2

Required skills Only trained and competent personnel may work on the disktype tool turret; this personnel must have been instructed in accordance with the operating instructions and directly on the disk-type tool turret.

1.3

Electrical installation All work on the electrical system is to be carried out by a competent specialist engineer only in order to avoid any incorrect installation which may cause a hazard of injury to persons or damage to equipment.

1.4

Hydraulic system IMPORTANT On delivery, the cylinders of the turret are filled with hydraulic oil and its openings are plugged.

1.5

Disposal

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_si.fm

Comply with all national and regional disposal regulations and laws.

5

Liability and warranty

1.6

Liability and warranty

The information contained in these Operating Instructions is in conformity with the knowledge at the point of printing. Subject to modifications which occur within the framework of continuous further development.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_si.fm

All liability and warranty shall be excluded if •

use within specifications is not complied with,

•

the disk-type tool turret including accessories is incorrectly operated,

•

the disk-type tool turret including accessories is incompetently repaired and maintained,

•

conversions and functional changes are implemented without approval by the manufacturer,

•

no original replacement parts are used,

•

no spindle heads complete with position locking device according to product information PI 29.3 are used,

•

no tool holders with a cylinder shank according to DIN 69 880 are used.

6

Warnings

1.7

Warnings WARNING1 Designates a potentially hazardous situation which may cause serious injury or even death. WARNING1 Risk of electric shock due to high voltages! WARNING1 Risk of injury due to a hanging load! CAUTION1 Designates a potentially hazardous situation which may cause damage to the product or property in its vicinity. IMPORTANT1 For application notes and other useful information.

Disconnect energy supply Before continuing work release machines.

1.8

➪

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_si.fm

i

Symbols Designates an instruction for a specific action. Specific actions to be executed in sequence are additionally numbered. Designates additional information.

1) Classification of signal words according to ANSI Z535.4

7

Symbols in instructions for specific actions

1.9

Symbols in instructions for specific actions •

Use lifting gear.

•

Maximum load XXX kg, for inclined pull of 45° maximum load YYY kg. max. YYY kg

max. xxx kg

•

Tightening torque of 23 Nm

23 Nm •

Screw M10, quality 12.9, at marked places lubricated with MoS2, tightening torque 70 Nm.

M10 - 12.9

•

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_si.fm

1.10

MoS2

70 Nm

Visual inspection

Abbreviations adm.

admissible

a.o.

among others

approx.

approximately

fig.

figure

if nec.

if necessary

incl.

inclusive

max.

maximum

8

Transport

2

Transport WARNING Serious injury hazard (crushing) to fingers and hands posed by any unexpected and sudden slide unit movements. Therefore: Before each transportation, the slide must be brought into its bottom position and held there in position by means of the transport retainer device (1). To this end, use retaining plate complete with 2 bolts M10X20.

1

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_tr.fm

•

Before the turret is operated or the motors installed the transport packing (1) must be removed!

9

Transport

WARNING Do not stay underneath or within the swivelling range of hanging loads! IMPORTANT

Slinging •

Screw in ring bolts DIN 580 on the turret housing and on slide unit up to the contact surface. A further ring bolt must be screwed into the fastening hole of the SAUTER tool disk.

•

Make sure that the hoisting angle at the ring bolts does not exceed 45°. Use the ring bolt only for transporting the tool turret with the tool disk and tool drive.

2

3

2

Size of turret Ring bolts

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_tr.fm

Mass of turret with motor and standard tool disk (without toolholders) max. dimensions: Length (without motor) Width Height

.16 2 ×M16 approx. 300 kg

approx. 515 mm approx. 450 mm approx. 550 mm

Lift •

Use lifting gear.

10

Product description

3 3.1

Product description The parts of the turret and the slide unit

1

2

3 4

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_pb.fm

5

1

Tool disk

2

Electric supply

3

Turret drive motor

4

Hydraulic supply/Cooling lubricant connection

5

Turret housing

11

Product description

7 6

10

9

8

6

Locating disk

7

Slide unit

8

Tool holder

9

Locating hole

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_pb.fm

10

Setbold bore for clamping the tool holders

12

Product description

3.2

Possible options and deviating designs Cooling lubricant valve IMPORTANT The cooling lubricant transfer of the disk-type tool turret can be designed variously. The standard version as well as the option medium pressure cooling lubricant device, are described in these Operating instructions. However, the design of your disk-type tool turret could deviate from these. Standard version

7 / 14 bar

see chapter 8.3, page 57

Medium pressure cooling lubricant device

≤ 25 bar

see chapter 8.3, page 57

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_pb.fm

with Fluid Rotary Feedthrough

see Operating Instructions BA 691 for Fluid Rotary Feedthrough

13

Technical data

3.3

Technical data Turret Turret size

0.5.453. ...

.216

Number of indexing positions

(8) 12 (24)

Adm. mass moment of inertia of tool disk with holders Maximum unbalanced load (load torque) of tooling

kgm2

2.5

Nm

32

Operating times 1) Turret rotation per 30° indexing step •

incl. acceleration and braking

s

0.14

•

rotation only

s

0.06

s

0.14

min-1

18

bar

50

cm3

35

Turret unlock or lock Maximum indexing frequency 2) Hydraulic operating pressure

± 10 %

Hydraulic fluid volumes: Turret unlock or lock Mass •

Turret including tool disk and slide unit

kg

approx. 300

•

Maximum tooling

kg

approx. 60

°F

+50 .... +104

°C

+10 ... +40

bar

7

bar

14

bar

25

Ambient temperature range

Adm. cooling lubricant pressure •

constant flow

•

flow cut off during indexing

•

with medium pressure valve (Option)

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_td.fm

1) Conditions:

standard version

– hydraulic supply adequately dimensioned – turret at operating temperature – with the given mass moment of inertia – without any non-productive times caused by the control

2) There may possibly occur a reduction in the permissible switching frequency, depending on the cutting efficiency of the tool drive.

14

Technical data

Turret and tool drive Turret size

0.5.453. ...

.216

Turret drive max. adm. motor speed

with SW1) 270

min -1

4,000

with SW 340

min -1

2,000

max. adm. motor torque

Nm

10

Turret – drive ratio

12

Tool drive S3 - 40%ED, 10 min max. adm. motor speed max. adm. motor torque 2)

min Nm

Drive ratio Coupling according to DIN 5480 (standard version, further possibilities on request)



8,000 10 2 16x0.8

Use together with SAUTER Spindle units series 0.5.941. ... with patented integrated spindle locking system, according to Product information PI 29.3, shank diameter 30mm. 1) SW: Spanner width of the tool disk

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_td.fm

2) The torques specified refer to processing without shock loads. When processing is subject to shock loads (e.g. milling) a reduction in the values by up to 50% or more needs to be taken into account!

15

Technical data

Slide unit Turret size

0.5.453. ...

.216

Slide unit drive: •

max. adm. motor speed max. adm. motor torque max. motor torque continuous duty

min -1 Nm

5

Nm

2

Drive ratio of the synchronous belt drive

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_td.fm

4,000

2

Height of stroke

mm

±40

Stroke inclusive overshoot

mm

±48

Pitch of ball spindle

mm

5

Quick motion speed

m/min

10

Adm. cutting force for turning

kN

6

Positioning accuracy

µm

≤ 10

16

Admissible loads and dimensions

3.4

Admissible loads and dimensions

carriage of the machine

additional fixing device

Illustration corresponds to right-hand version ( left-hand version - mirror image ).

Maximum tangential torque 1) Ttan

Nm

1,500

equivalent tangential torque ± Fy

N

5,500

mm

265

mm2

2.5

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_ld.fm

at tool overhang D equivalent chip cross section A (St60; ks ≈ 2.200 N/mm 2 )

17

Admissible loads and dimensions

Adm. axial load1)

± Fz

at tool overhang D Adm. radial load1)

± Fx

N

8,000

mm

220

N

10,000

Loads with a calculated safety ≥1,3

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_ld.fm

1) The admissible loads apply when processing without shock loads. In combined and/or shock load situations (interruptions in cutting), the values will reduce!

18

Assembly and installation

4

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_li.fm

4.1

Assembly and installation As-delivered condition •

The disk-type tool turret is supplied aligned in Position 1, with or without tool disk and AC servomotor in accordance with the order.

•

The pistons have been bled and connections A1 / B1 und L1 are closed with plastic plugs to prevent hydraulic oil from escaping.

•

Parts, which are not possible to assemble or parts, which are necessary for the assembly, are enclosed loose.

•

The disk-type tool turret has been test run.

•

The slide unit is locked in its bottom position by means of a transport retaining device.

•

The drive motor for the slide unit is not fitted (motor not included in the scope of delivery).

1.

see Hydraulic diagram “HP-...” in the appendix to these operating instructions

19

Fitting the turret-drive motor

4.2 4.2.1

Fitting the turret-drive motor Motor shaft with key groove according to DIN 6885/1

8

9

10

7 6

5

➪

4

3 2

1

1. Check the height of the feather key (10) on the motor shaft (1). If necessary replace or adapt feather key (according to motor manufacturer). 2. Mount ratchetting clutch (2) on motor shaft (1). Secure screw (3) with suitable locking fluid (e.g. LOCTITE 221). 3. Check: •

Are marking (7) on motor support (8) and pin (6) in pinion (5) in line?

•

Is slot (4) in ratchetting clutch (2) in line with the pin (6)?

•

Is the sealing ring (9) in place and undamaged?

4. Mount AC motor with ratchetting clutch (2) and make sure that slot (4) and pin (6) engage. IMPORTANT Set proximity switch S10 “Ratchetting clutch engaged”, F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ac.fm

see chapter 7.7.4 Proximity switch S10 “Ratchetting clutch engaged“, page 51.

20

Fitting the turret-drive motor

4.2.2

Motor shaft with key clamping hub

7

8

9

TA

6

5

4

➪

3

2 1

1. Check whether circlip (9) is fitted in the hub of the ratchetting clutch (2). 2. Fit the ratchetting clutch (2) on motor shaft (1), make sure that the circlip (9) is in touch with the end face of the motorshaft (1). 3. Tighten hexagon socked screw on ratchetting clutch (2). Tightening torque TA [Nm] M6 DIN 912-12.9

17

M8 DIN 912-12.9

41

M10 DIN 912-12.9

83

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ac.fm

4. Check: •

Are marking (6) on motor support (7) and pin (5) in pinion (4) in line?

•

Is slot (3) in ratchetting clutch (2) in line with the pin (5)?

•

Is the sealing ring (8) in place and undamaged?

5. Mount AC motor with ratchetting clutch (2) and make sure that slot (7) and pin (8) engage. IMPORTANT Set proximity switch S10 “Ratchetting clutch engaged”, see chapter 7.7.4 Proximity switch S10 “Ratchetting clutch engaged“, page 51.

21

Fit turret onto the machine

4.3

Fit turret onto the machine

1

3, 4

2

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_arm.fm

IMPORTANT The hole for the pivot bush (2) must already exist in the slide in the required position and quality.

➪

1. Mount turret together with pivot bush (2) and fasten with screws and washers (3,4) supplied. 2. Note the tightening torque!

M16 - 12.9

MoS2

280 Nm

22

Align turret

3. Make electrical connections, see Wiring diagram “EP-...” and Function diagram “SK-...” in the appendix to these Operating Instructions.

4. Make hydraulic system connections, see Hydraulic diagram “HP-...” in the appendix to these Operating Instructions.

Central lubrication (1) is not included within the scope of delivery of the turret. (For details on how to connect the central lubrication system, see the operating instructions of the machine).

4.4

Align turret

Pivot bush

1

2

3

➪

1. Lock turret. 2. Align the connecting surface (1) or face surface (3) of the tool disk parallel or vertical to the feed axes (2).

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_arm.fm

3. Note the tightening torque!

M16 - 12.9

MoS2

280 Nm

23

Fitting the tool disk

4.5

Fitting the tool disk

Working position

(if tool disk not already fitted)

➪

1. Remove the cover plate (2). 2. Clearly mark the rotational position of the teeth (tooth gap to tooth, item 8) on both bevel gears.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_mws.fm

3. Remove the coupling sleeve (6), for that: •

Loosen circlip (3),

•

Withdraw the coupling sleeve (6).

4. Force back piston (5) to the stop - direction disk-type tool turret central point, perhaps slightly open vent screw E. 5. Put the T-slot nuts (7) into their correct angular positions. 6. Fit tool disk (1) in the correct angular position [- fitting area (9) -].

24

Fitting the tool disk

7. Slightly slacken the screw in the working position to allow the tool disk to be aligned later. It is covered by the coupling sleeve (6). 8. Insert coupling sleeve (6) in marked position (marking in turret axis direction) into gearing, using bush (4).

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_mws.fm

9. Insert circlip (3).

25

Align tool disk

4.6

➪

Align tool disk

1. Lock turret with prescribed pressure. 2. Unscrew cover plate (1). 3. Insert plug gauge (4) in locating hole (2) of the tool disk. Put the dial gauge to machine spindle, scan the plug gauge (4) above and below. 4. Twist the tool disk, until dial gauge display - difference equals zero. CAUTION If this is not done, clutch problems and bearing damage can occur. 5. Tighten screws.

M8 - 12.9

MoS2

39 Nm

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_mws.fm

IMPORTANT The screw is covered in working position (3) by the coupling sleeve and is accessible only after swivelling the tool disk. 6. Screw on the cover plate (1); remember the sealing rings [are they in place and undamaged?].

26

Electrical installation

4.7

Electrical installation •

Circuit, see Wiring diagram “EP-...” and Function diagram “SK-...” in the appendix to these Operating Instructions.

4.8

Hydraulic system •

Circuit, see Hydraulic diagram “HP-...” in the appendix to these Operating Instructions.

•

Filtering ≤ 20 µm

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ehk.fm

Description of the hydraulically actuated functions •

Lock and unlock turret.

•

Disengage and engage turret drive.

•

Disengage and engage tool drive.

•

The functions are initiated via a 4/2-way valve.

•

All pistons can be bled separately.

•

The turret has 3 connections: A / B / L.

•

The leakage oil port L is provided to allow leakage oil to be returned and to protect the gearbox chamber from overpressure.

27

Cooling lubricant supply

4.9

Cooling lubricant supply

• •

Transmitted through a valve (1) in the working position. Supply pressure, see “Technical data – Turret”.

•

Connection, designated “K”, on rear bedding plate (2).

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ehk.fm

IMPORTANT In order to achieve an extended service life of the cooling lubricant valve, it is recommended to filtrate the cooling lubricant by ≤ 100 µm. Post-connected loads (spindle units with internal cooling lubricant guide a.o.) may require a higher degree of filter fineness. Note and comply with the manufacturer's instructions!

28

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ref.fm

Determination of reference point

4.10

Determination of reference point

➪

1.

Hydraulic pressure: 10 bar !

2.

Lock turret in position 1.

3.

Put marking (2) between tool disk (1) and cooling lubricant ring (3).

4.

Rotate coupling sleeve until marking (4) points to turret axis.

5.

Unlock turret hydraulically, proximity switch S5 (8) energized.

6.

By means of AC motor, rotate tool disk (1) clockwise (as viewed on the tool disk (1)) until the proximity switch S1 “Reference point turret“ (5) is deenergized and then energized again.

7.

Rotate tool disk (1) further until the zero pulse is detected at the rotary encoder (6). The reference point offset is determined from this zero pulse.

8.

Rotate tool disk (1) further until the two markings (2) on the tool disk (1) and on the cooling lubricant ring (3) are positioned exactly one above the other.

9.

Check the function with spindle units in place.

10. Increase pressure: Hydraulics approx. 50 bar.

29

Additional equipment, toolholders and spindle units

5

Additional equipment, toolholders and spindle units This turret has been designed for use with the following toolholders and additional equipment:

5.1

•

toolholders with cylinder shank for stationary tools

•

spindle units with cylinder shank for drive tools

Toolholders and spindle units •

Use only toolholders, spindle units and plugs with O-ring in accordance with DIN 69 880 Part 1 (July 1990 Issue). For information on SAUTER toolholders and spindle units for the SAUTER disk-type tool turret 0.5.450/460.2.../3... please ask for Product information PI 29.3. The warranty loses its validity if defective third-party makes are used.

CAUTION Functional faults may be caused by an ingress of chips and contamination. Close open tool locations and cooling lubricant bores by means of closing plugs Z2-30 according to DIN 69 880. •

If at all possible, change the toolholder in a horizontal position!

•

Clean contact surfaces of tool disk and toolholder.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_zus.fm

Tightening torques for the locking screws for the thrust pieces

Shank diameter d1 DIN 69 880 [mm]

Max. tightening torque TA max [Nm]

20

10

25

10

30

25

40

50

50

50

30

Toolholders and spindle units

5.1.1

1

Installing/changing the toolholders

3

2

Chips Cooling lubricant

4

TA max

7

5 6

➪

1. Check the sealing rings (4) on the new toolholder (6) [make sure they are in place and undamaged!]. 2. Pay attention to position of the aligning shoulder (2); if necessary modify. 3. Unscrew pressure pieces (1). 4. Remove toolholder (6) or seal plug (3) to be replaced. 5. Insert new toolholder. Tighten thrust piece (1) with 20% of maximum tigthening torque. 6. Align toolholder to centre of rotation with set screws (5). 7. Firmly screw on pressure piece (1). Observe tightening torques,

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_zus.fm

see table Tightening torques for the locking screws for the thrust pieces, page 30.

31

Toolholders and spindle units

5.1.2

Installing/changing the spindle units CAUTION Do not change tools while the tool disk is in the working position as this can cause overloading of the drive train!

1 - ENgaged

2 - DISengaged

1. Check: •

Are the sealing rings in place and undamaged?

•

Is the clutch profile undamaged and has it been cleaned?

•

Is the spindle locking mechanism engaged?

2. Remove toolholder (6) or seal plug (3) to be replaced. 3. Insert new holder. Tighten thrust piece with 20% of maximum tigthening torque. Observe index position of spindle units (7). 4. Align holder to centre of rotation with set screws (5). [Necessary with angled spindle units]. If necessary modify aligning shoulder. 5. Firmly screw on thrust piece (1). Observe tightening torques,

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_zus.fm

see table Tightening torques for the locking screws for the thrust pieces, page 30.

32

Maintenance

6

Maintenance

WARNING Danger of serious injury in result of sudden movement of the slide unit. Before start working with the slide unit secure the slide in lowest stop position.

Clearing required prior to any works

6.1

•

Use the EMERGENCY-OFF switch of the machine.

•

Set motor protection switch for disk-type tool turret into OFF position.

Lubricant table

Lubrication of the roller bearings, bevel gears and seals

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_wart.fm

Element

Amount of lubricant

Roller bearings

Initially: Fill 1/3 of bearing space

Seals

Fill space around sealing lips

Toothing

Fill teeth gaps

Lubricant

ISOFLEX NBU 15

Manufacturer

Klüber

33

Check lubricant of turret gearbox chambers

6.2

Check lubricant of turret gearbox chambers

•

The condition of the lubricant must be checked after no more than 4,000 operating hours. Before checking, remove the proximity switch S1 “Reference point turret” (1) or VSTI plug (2).

Possible conditions of the turret chamber when checking

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_wart.fm

Condition of grease

Grease None left

Severely used

Mixed with water

Mixed with oil

Cause

Natural wear

Turret sealing defective

Hydraulic seals in turret defective

Action needed

Add approx. 20 g of grease

Risk of breakdown! Call for service (Check turret sealing).

If oil loss ≥ 1 cm3/ minute: Call for service.

34

Bevel gears and roller bearings on gearbox nose

6.3

Bevel gears and roller bearings on gearbox nose •

6.4

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_wart.fm

6.5

Bevel gears (1) and roller bearings (2) can be accessed after removing the cover plate (3). Regrease the bevel gears and check for unwanted cooling lubricant after 4,000 operating hours, see table Lubrication of the roller bearings, bevel gears and seals, page 33.

Spindle units •

Clean clutch profile each time before using.

•

Lubricant should be checked according to the conditions of use but after no more than 2,000 operating hours.

Slide unit •

The guide of the slide unit is greased by the centralized lubricating system of the machine.

•

Proportioning by intergrated proportioning valves.

•

The number of grease pulses may be adapt to the machine. The minimal number of gear pulses is 1 pulse per hour.

35

Fault finding and repair

7

Fault finding and repair

WARNING Danger of serious injury in result of sudden movement of the slide unit. Before start working with the slide unit secure the slide in lowest stop position.

7.1

Faults and remedies

Fault

Cause

Remedy

Implementation

1. Turret gears damaged

replace damaged parts

service

drive motor defective

replace motor

user

axis misaligned relative to locating disk

align the axle to the locating disk

service

proximity switch S1 defective or misadjusted

check proximity switch, replace if necessary, or readjust

does not engage / disengage

clutch sleeve damaged

replace damaged parts

user

does not rotate

drive motor defective

replace motor

user

gearwheels damaged

replace damaged parts

service

does not swivel

does not lock

user, see 7.7.1, page 47

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_st.fm

2. Tool drive

36

Fault finding and repair

Fault

Cause

Remedy

Implementation

3. Center height is not correct, tool disk misaligned relative to locating disk

collision with turret in a locked condition

turn back tool disk in ring groove, and align

service

4. Cooling lubricant is not being transferred

outlet between tool disk and turret

cooling lubricant valve damaged

replace damaged parts

cooling lubricant valve/ line blocked

blow cooling lubricant valve and line clear

cooling lubricant valve leaking

replace cooling lubricant valve

user, see 7.6, page 46

user

user see 7.6, page 46

5. Ratchetting clutch

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_st.fm

is disengaged

preset torque exceeded

engage ratchetting clutch as per manual, adjust the current limiter at the motor

user see 7.2, page 39

37

Fault finding and repair

Fault

Cause

Remedy

Implementation

6. Slide unit center heigth no longer correct

no movement possible in slide direction

incorrect positioning in slide direction

i

turret displaced in slide unit

realign turret

user

drive motor defective

replace motor

user

synchronous belt torn

replace synchronous belt

see 7.4, page 41

proximity switch S13 misadjusted

check proximity switch, replace if necessary, or readjust

motor shaft encoder or control unit defective

replace motor

user see 7.7.5, page 53

user

Service SAUTER Feinmechanik GmbH Carl-Zeiss-Straße 7 D-72555 Metzingen Germany Telephone Fax Telex e-mail

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_st.fm

user

++49 (0) 7123 –926 – 0 ++49 (0) 7123 –926 – 193 254 328 wisa service@sauter- gmbh.com

38

Engaging the ratchetting clutch

7.2

Engaging the ratchetting clutch

1

2

7

Variant A

6

3

Variant B

4

5

CAUTION After disengaging the ratchetting clutch check the locking state!

7.2.1

Variant A: Motor with brake Procedure, if the turret is unlocked:

➪

1. Dismount tool in working position. 2. Turn the tool disk (7) manually until ratchetting clutch (2) engages. 3. Check on proximity switch S10 (1). 4. Drive to reference point.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_kupp.fm

Procedure, if the turret is locked:

➪

1. Dismount tool in working position. 2. Rotate coupling sleeve (6) with hexagon wrench (5) until ratchetting clutch (2) engages. 3. Check on proximity switch S10 (1). 4. Drive to reference point.

39

Engaging the ratchetting clutch

7.2.2

Variant B: Motor without brake Procedure, if the turret is unlocked:

➪

1. Turn tool disk by hand approximately to position 1 ±1.5°. 2. Put out the tool in position 1. 3. Lock hydraulically => turret is locked.

Procedure, if the turret is locked:

➪

1. Rotate coupling sleeve (6) jerky with hexagon wrench (5) until ratchetting clutch (2) engages. 2. Check on proximity switch S10 „Ratchetting clutch engaged“ (1). 3. Drive to reference point.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_kupp.fm

IMPORTANT The ratchetting clutch has only one latching position.

40

Belt replacement – belt tension

7.3

Determining belt tension on the slide unit

3

5N

s/2 s

7.4

Belt replacement – belt tension

1

4

3

F:\Sauter\FRAME-AR\TD\0-5-453-\453_riem.fm

2

➪

1. Move to lowest stop position. 2. Switch off power to turret. 3. Unscrew the 3 screws (2).

41

Belt replacement – belt tension

4. Use the drive motor to move the plate (4) such that the synchronous belt can be removed. 5. Remove existing synchronous belt (1) and clean abrasions from turret. 6. Mount new synchronous belt. 7. Tense synchronous belt (1) by lever in hole (3) - pay attention to test load, see chapter 7.3 Determining belt tension on the slide unit, page 41

8. Fasten the screws (2).

F:\Sauter\FRAME-AR\TD\0-5-453-\453_riem.fm

9. Move away lever.

42

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_grund.fm

Basic setting

7.5 Basic setting

43

Basic setting

➪

1.

Install turret hydraulically. Reduce hydraulic pressure to 10 bar for the purposes of setting.

2.

Install turret electrically, without AC servo motor.

3.

Unlock hydraulically (pressure approx. 10 bar). If not possible via control, relocate connector on hydraulic valve.

4.

Turn tool disk by hand approximately to position 1 ±1.5°.

5.

Lock hydraulically.

6.

Align tool disk (1) in accordance with description, see chapter 4.6 Align tool disk, page 26

7.

Mark exactly the rotational position of tool disk (1) and cooling lubricant ring (3).

8.

Turn gearwheel (6) by hand until pin (11) and marking (18) line up.

9.

Unlock hydraulically, take down proximity switch S4, place round sock (9) - approx. 15 mm thick - between control piston (5) and housing.

10. Lock hydraulically; marking on tool disk (1) must be in line with that of the cooling lubricant ring (3). 11. Pull plug (7), take down the bore-circlip ring (17), remove the pinion shaft (13) to the back, until the gearing (12 and 16) is disengaged. 12. Turn coupling sleeve (4) until marking - centre tooth - is in line with the turret axis. 13. Carefully place straight spindle unit, centered locking, in working position and tighten. 14. Unlock disk-type tool turret hydraulically. Do not remove round sock (9), mark rotational position of spindle locking mechanism with a pencil (15).

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_grund.fm

15. Move pinion shaft (13) axial until the gearing (12) is engaged; go on moving and try, if it is possible to engage the gearing (16) without big expenditure of force. Displace the pinion shaft in the gearing until it is possible to engage both gearings (12 and 16) without big expenditure of force. While doing it the marking (15) at the spindle unit (14) must not twist. IMPORTANT In case of best gearing it is not possible to assemble the neighbouring rotational positions. 16. Lock hydraulically and observe the spindle head while doing so. When locking, the rotational position at the spindle head should be maintained. If necessary, correct as described under step 15.

44

Basic setting

17. Fit bore-circlip ring (17) and plug (7). 18. Fit AC servo motor with ratchetting clutch in correct position and install electrically. 19. Hydraulically unlock disk-type tool turret, remove round sock (9), and add proximity switch. 20. Increase hydraulic pressure up to 50 bar. 21. Determine reference point,

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_grund.fm

see chapter 4.10 Determination of reference point, page 29.

45

Replacing the cooling lubricant valve

7.6

Replacing the cooling lubricant valve

1 2

➪

3

1. Unscrew the grub screw (1), through several turns. 2. Remove the valve carrier (2). The valve bushing (3) is now accessible.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_akm.fm

3. Install in reverse order.

46

Replacing and setting the proximity switches

7.7

Replacing and setting the proximity switches For location of the proximity switches, see Wiring diagram “EP-...“ in the appendix to these Operating Instructions.

7.7.1

Proximity switch S1 “Reference point turret“

0.6

Changing the proximity switch

➪

1. Loosen clamps (1). 2. Pull out holder (2) for proximity switch (5), measure dimension X and note this. 3. Unscrew thrust screw (3). 4. Unscrew proximity switch (5). 5. Fit new proximity switch with existing sealing ring and disk (4), and screw into holder (2); but replace sealing ring, if necessary. IMPORTANT If necessary, redetermine the reference point after replacing proximity switch S1,

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_NähS.fm

see chapter 4.10 Determination of reference point, page 29.

47

Replacing and setting the proximity switches

Setting the proximity switch 1. Put the turret into any defined position (pos. 1... 4..) - lokked or unlocked. 2. Set the proximity switch (5) according to the noted dimension X, or measure dimension a with depth gauge, paying attention to hole (10) and gear (9). Set proximity switch (5) to X = a - 0.6 and lock with thrust screw (3), during that control dimension X. 3. Insert holder (2) and fasten. 4. Electrically install proximity switch (5). 5. Check - proximity switch energized.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_NähS.fm

6. Check - proximity switch deenergized when hole (10) under proximity switch.

48

Replacing and setting the proximity switches

Proximity switch S4 “Checking turret drive disengaged“ and proximity switch S5 “Checking turret drive engaged“

0.6

7.7.2

Changing the proximity switch 1. Loosen clamps (1) and pull out holder (2). 2. Measure dimension X and note. 3. Unscrew thrust nut (4) and inset (5). 4. Unscrew proximity switch (3). 5. Screw the new proximity swich in the holder (2). 6. Set the proximity switch according to the noted dimension X or measure dimension a with depth gauge, set proximity switch to X = a - 0.6 and counterlock with inset (5) and thrust nut (4), during that control dimension X. 7. Position holder (2) in hole and fix with clamps (1). 8. Install proximity switch (3) electrically.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_NähS.fm

Setting the proximity switch 1. Lock turret; proximity switch S4 can now be set. Unlock turret; proximity switch S5 can now be set. 2. Loosen clamps (1); turn holder (2) until proximity switch (3) is deenergized. 3. Move back through about 90°. 4. Fix holder (2) with clamps (1). 5. Check switching function several times.

49

Replacing and setting the proximity switches

7.7.3

Proximity switch S6 “Checking tool drive engaged“ and proximity switch S7 “Checking tool drive disengaged“ 1

Eccentric

0.6

S6

Engaged

0.6

Disengaged

S7

Replacing the proximity switch 1. Unscrew clip and pull proximity switch (2) out from eccentric bush (1). 2. Fit new proximity switch (2). 3. Fit new proximity switch (2) with gap to switching surface. 4. Take cable through hole (4) in terminal box and install electrically, see Wiring diagram “EP-...“ in the appendix to these Operating Instructions.

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_NähS.fm

Setting the proximity switch 1. Lock turret; proximity switch S6 can now be set. Unlock turret; proximity switch S7 can now be set. 2. Undo fixing screw (3); set proximity switch (2) to correct gap with 0.6 mm shim. 3. With eccentric bush (1), set proximity switch centre on circuit board. 4. Check switching function several times.

50

Replacing and setting the proximity switches

Proximity switch S10 “Ratchetting clutch engaged“

0.6

7.7.4

Changing the proximity switch 1. Loosen clamps (1) and pull out holder (2). 2. Measure dimension X and note. 3. Unscrew thrust nut (4) and inset (5). 4. Unscrew proximity switch (3).

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_NähS.fm

5. Screw new proximity switch into holder (2). 6. Set proximity switch according to noted dimension X or measure dimension a with depth gauge, set proximity switch to X = a - 0.6 and counterclock with inset (5) and thrust nut (4), during that control dimension X. 7. Position holder (2) in hole and fix with clamps (1). 8. Install proximity switch (3) electrically.

51

Replacing and setting the proximity switches

Setting the proximity switch 1. Ratchetting clutch engaged. 2. Slightly slacken clamps (1). 3. Set initial state for proximity switch as attenuated (LED on), turn holder (2) if necessary. 4. Turn holder (2) until signal change is detected as unattenuated (LED off). 5. Turn back holder (2) by approx. 45° (LED on). 6. Fix holder (2) with clamps (1).

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_NähS.fm

7. Check: rotate ratchetting clutch by 360°; the LED must be permanently ’illuminated’.

52

Replacing and setting the proximity switches

7.7.5

Proximity switch S13 „Reference point slide unit“

3 0.6 2

1

Changing the proximity switch

➪

1. Loosen setscrew (3). 2. Pull out bush (2), measure dimension X and note. 3. Unscrew proximity switch (1). 4. Screw new proximity switch into bush (2) and fasten with setscrew (3) - maximum tightening moment 0.2Nm! IMPORTANT If necessary, redetermine the reference point of the slide unit after replacing of proximity switch S13.

Setting the proximity switch

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_NS_S13.fm

1. Set the proximity switch according to the noted dimension X or measure dimension a with depth gauge, set proximity switch to X = a - 0.6, during that control dimension X. 2. Insert bush (2) and fasten. 3. Electrically install proximity switch (1). 4. Check - proximity switch energized. 5. Check - proximity switch deenergized.

53

Replacement parts

8 8.1

Replacement parts Proximity switches

IMPORTANT Only use the order form if you wish to order any replacement parts.

Table: Summary: Proximity switches

Denomination S1

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_NÄHS.fm

S4 S5

Proximity switch “Reference point turret”

Proximity switches “Turret drive disengaged“and “Turret drive engaged“

Figure

1

Denomination

2 3 4

1

Ident No.

Qty.

1

Proximity switch

004 157

1

2

Sealing ring

061 465

1

3

Thrust ring

061 466

1

4

O-ring

060 308

1

1

Proximity switch

076 749

2

2

Thrust nut DIN 46320

081 754

2

3

Inset DIN 46320

081 755

2

4

O-ring

060 308

2

2 3 4

54

Proximity switches

Table: Summary: Proximity switches

Denomination S6 S7

S10

Figure

Proximity switches “Tool drive engaged“ and “Tool drive disengaged“ Proximity switch “Ratchetting clutch engaged”

Denomination 1 2 3

Ident No.

Qty.

1

Proximity switch

076 749

2

2

Eccentric bush

059 349

2

3

Clip

034 133

2

1

Proximity switch

004 157

1

2

Thrust nut DIN 46320

081 754

1

3

Inset DIN 46320

081 755

1

4

O-ring

060 308

1

1

Proximity switch

004 157

1

2

Bush

036 515

1

3

Setscrew DIN 913 - 45H

000 245

1

2

1

3 4

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_NÄHS.fm

S 13

Proximity switch "Reference point slide unit"

1

2

3

55

Tool disk

8.2

Tool disk

Clamping for tool holders DIN 69880 (standard)

1)

d [mm]

Ident-N°

Qty.

18

067 502

..1.)

22

042 973

1.)

28

042 784

1.)

36

043 287

1.)

42

043 951

1.)

Number of positions

F:\Sauter\FRAME-AR\TD\0-5-695-\eng\760_8_WzSch.fm

IMPORTANT Only use the order form if you wish to order any replacement parts.

56

Cooling lubricant system

8.3

Cooling lubricant system The cooling lubricant transfer of the disk-type tool turret can be designed variously, see chapter 3.2 Possible options and deviating designs, page 13.

1 2

3

6 5

9 8

4

7

IMPORTANT

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_KE16.fm

Only use the order form if you wish to order any replacement parts.

No.

Ident-No.

Denomination

Qty.

1

060 885

FU-groove ring

1

2

064 593

O-ring

1

3

036 588

Spaghetti hose

0.6m

for standard version 4

101 904

Cooling lubricant valve, complete

1

of this: 5

033 424

Bush

1

6

059 658

O-ring

1

57

Cooling lubricant system

No.

Ident-No.

Denomination

Qty.

for medium pressure valve 7

101 353

Cooling lubricant valve, complete

1

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_KE16.fm

of this: 8

086 925

Bush

1

9

058 501

O-ring

1

58

Gear head

8.4

Gear head

10

140 130

120

100 90 20 80

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_GeKo16.fm

70

60

30

50

40

IMPORTANT Only use the order form if you wish to order any replacement parts.

No.

Ident-No.

Denomination

Qty.

10

039 405

FU groove ring

1

20

084 301

Angular ball bearing

4

59

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_GeKo16.fm

Gear head

No.

Ident-No.

Denomination

Qty.

30

062 201

Deep groove ball bearing

3

40

067 468

O-ring

1

50

085 017

Rotary shaft seal

1

60

030 013

Stepped ring

2

70

058 521

O-ring

1

80

067 467

O-ring

1

90

084 912

Surface ring

1

100

062 132

O-ring

2

120

067 228

O-ring

4

130

062 351

O-ring

1

140

058 521

O-ring

1

60

Housing and indexing unit

8.5

Housing and indexing unit

220

150 210 200

230

190

210 240

180

250

170 260

160

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_GuIndex16.fm

150

IMPORTANT Only use the order form if you wish to order any replacement parts.

No.

Ident-No.

Denomination

Qty.

150

077 321

ROTO surface ring

2

160

058 076

O-ring

1

170

064 915

T-slot nut

11

61

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_GuIndex16.fm

Housing and indexing unit

No.

Ident-No.

Denomination

Qty.

180

077 298

FU groove ring

1

190

058 951

O-ring

1

200

063 466

O-ring

1

210

076 787

Surface ring

2

220

074 390

O-ring

1

230

058 665

O-ring

1

240

060 801

O-ring

1

250

040 937

Thrust needle roller and cage assembly

1

260

079 073

Added-process part

1

62

Carrier and gearbox

8.6

Carrier and gearbox 320 330

340 310 350 300 290 360 280

370 380 390 400

410

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_TuG16.fm

IMPORTANT Only use the order form if you wish to order any replacement parts.

No.

Ident-No.

Denomination

Qty.

280

033 929

Rotary shaft seal

1

290

077 325

Needle roller and cage assembly

2

300

036 584

Needle bearing cup with open end

1

310

084 404

Auxiliary cylinder

1

320

000 008

DU bush

1

330

076 677

Deep groove ball bearing

1

63

F:\Sauter\FRAME-AR\TD\0-5-450-\ENGLISCH\450_ers_TuG16.fm

Carrier and gearbox

No.

Ident-No.

Denomination

Qty.

340

084 030

Inner ring of needle roller bearing

1

350

076 677

Deep groove ball bearing

1

360

066 853

O-ring

3

370

065 138

Rotary shaft seal

1

380

073 354

Deep groove ball bearing

1

390

076 753

O-ring

1

400

058 501

O-ring

2

410

067 228

O-ring

2

64

Slide unit

8.7

Slide unit

Motor Fanuc α 2/3000 with brake

1

Motor Siemens 1 FT6061 with brake

MA =2.9Nm

MA =12Nm

6

IMPORTANT Only use the order form if you wish to order any replacement parts.

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\453_ers_SchlE.fm

No.

Ident-No.

Denomination

Qty.

1

085 794

Synchronous belt

1

6

085 788

Axial angular contact ball bearing

1

65

Ordering replacement parts

FAX

Company:

++49 (0) 7123–926–193

Street: ++49 (0) 7123–926–0 Post Code Location: [email protected] Name: After Sales Service SAUTER Feinmechanik GmbH Postfach 1551 D-72545 Metzingen Germany

Assembly

Ident-N°

i

Tel.: Fax:

Denomination

Read off the following data from the type plate and always complete.

Typ Ident-Nr. Com. Nr.

We will be pleased to answer your enquiries and receive your feedback information.

Qty.

Anhang

F:\Sauter\FRAME-AR\TD\0-5-453-\ENGLISCH\640_Anhang.fm

I

Appendix

A

Wiring diagram . . . . . . . . . . . . . . . . . . . . .EP-1039 e

B

Function diagram . . . . . . . . . . . . . . . . . . . SK-1226 e

C

Hydraulic diagram . . . . . . . . . . . . . . . . . . . HP-446 e

67

Installation and Operating Instructions Hinge band conveyor type S GB

Hinge band conveyor type S

Table of contents Page 1

Description of machine and functions .............................................................................. 5

2

Danger and safety instructions .......................................................................................... 6 2.1 General instructions ....................................................................................................... 6 2.2 Instructions for repair and maintenance work and malfunctions ................................... 7

3

Unpacking and handling ..................................................................................................... 8 3.1 Unpacking ...................................................................................................................... 8 3.2 Handling ......................................................................................................................... 8

4

Assembly and installation ................................................................................................ 9 4.1 Screwing together several container parts .................................................................... 9 4.2 Electrical connection ...................................................................................................... 9 4.3 Loosening the tension device hinge band .................................................................... 10 4.4 Mounting the hinge band ............................................................................................. 12 4.5 Mounting the shackle type connectors ........................................................................ 13 4.6 Mounting the locking bolts ........................................................................................... 14 4.7 Tensioning the hinge band ........................................................................................... 16

5

Switching on and operating ............................................................................................. 18 5.1 Before initial operation ................................................................................................. 18 5.2 Switching on ................................................................................................................. 18 5.3 Switching off ................................................................................................................ 18

6

Maintenance ....................................................................................................................... 19 6.1 Adjusting the drive shaft .............................................................................................. 19 6.2 Changing the broach bars ........................................................................................... 19 6.3 Checking the hinge bande tension ............................................................................... 20 6.4 Changing individual hinge band plates ......................................................................... 20 6.4 Maintenance table ....................................................................................................... 18

7

Information on coolants / tanks ....................................................................................... 21

8

Maintenance table ............................................................................................................. 22

9

Eliminating malfunctions ................................................................................................. 25

10 Accessories ....................................................................................................................... 26 10.1 Stripping device ........................................................................................................... 26

3

Hinge band conveyor type S

1 Description of machine and functions Function -

Conveying metal shavings and small parts

-

Prepurifying the cooling lubricant (for wet processing)

Scope -

Decentral use in single and interlinked machine tools

-

Central use for waste disposal from machine groups and entire production areas

-

Suitable for long swarfs, snarl chips, wool-type filings, dry and wet processing

Mode of operation -

Loose material falls in feed opening onto the endless hinge band

-

Continuous transfer of the loose material to the discharge opening

-

Throwing the loose material at the discharge opening into the container or another conveyer for removal. - Do not use the plant for other than the intended purposes. - Note the Regulation for the Prevention of Accidents (Unfallverhütungsvorschrift) VBG 10 when operating the plant. - The discharge station must be visible during machine controlled operation.

Noise level: < 70 dB(A) Optional equipment -

Coolant tank Coolant purification systems (e.g. magnetic separator, centrifugal separator, band filter, superfine strainer) Low lift and jetting pumps for purification elements and machines Swarf mill Brush-off device Sustainer Chip carriage Sieve drum Piping with aggregates, valves, etc.

Since nearly every plant is constructed for the special needs of the customer, deviations from the form and position of the parts and structural components described in this documentation may occur. In this case the operating instructions should be applied analogously.

5

Hinge band conveyor type S

2 Danger and safety instructions 2.1 General instructions - Always observe all statements and instructions in the operating instructions delivered with the plant. - It is forbidden for unqualified persons to work at the plant. - Observe correct fastening if components were installed by customer. - Never bypass safety contrivances (e.g. safety clutch). - The operation of safety contrivances must always be guaranteed.

- Work on the electrical plant may only be carried out by qualified personnel. - Observe the relevant VDE requirements and connection requirements of the responsible Electricity Board.

- Do not stand in or reach into the feed opening.

- Do not reach into the discharge opening.

- Cover the scraper belt and all driving elements before starting. - Do not remove covers while plant is in operation.

6

Hinge band conveyor type S

2.2 Instructions for repair and maintenance work and for malfunctions

I

0

- Switch off the main switch. - Secure the plant against being started accidentally.

- Ensure that the plant is dead.

- Depressurize the plant.

- Close pipe valves. - Remove all noxious materials. - Coolants must not enter the environment.

- When handling chips, wear protective clothing, safety boots and protective gloves.

7

Hinge band conveyor type S

3 Unpacking and handling 3.1 Unpacking Scraper conveyors over 8 m in length are delivered in several container parts. The hinge bands of divided conveyors are rolled up on separate pallets. For conveyors in several parts, scraper belts are rolled up on separate pallets. Small parts (screws, sealings etc.) are delivered loose in the scraper conveyor container or in separate packing. If mounting rails are required for inserting the hinge band, they are fastened to the hinge band or pre-mounted on the hinge band conveyor and lacquered in red. Mounting rails must absolutely be preserved because the hinge band cannot be inserted without them.

3.2 Handling - Do not stop beneath suspended loads!

-

By crane: Always transport by crane if no longer in the original packing. Use the suspension devices provided (e.g. eye hooks, lifting screws)

-

By stacker truck: Only in the original packing and with the greatest of care.

8

Hinge band conveyor type S

4 Assembly and installation - Put plant on even ground! - Ensure a firm and secure position. - Secure the plant against being started accidentally.

4.1 Screwing together several container parts -

Join container parts at the joint locations and align in parallel. Note identification markings (2) of the container flanges. The identification marking (numbers or symbols) must agree with that of the opposite flange (3).

(1)

1 2

2

4

2

3

-

Insert the sealings supplied (1) and join container parts completely.

-

Align the containers such that all bore holes are in alignment with the container flanges opposite.

-

Insert but do not tighten hexagon head screws and hexagon nuts.

-

Drive in preassembled rollpin spring (4).

-

Tighten hexagon head screws

4.2 Electrical connection -

Connect power supply to motor(s) and pump(s)

-

Note the correct direction of rotation (see arrow) 9

Hinge band conveyor type S

4.3 Loosening tension device hinge band Type 1 type 1 Model with flange bearing: -

Remove the top coverings (2)

-

Loosen the fastening screws (4) on both sides of the gearing end frame but do not unscrew completely

-

Loosen clamping bolts (3) on both sides of the gearing end frame and turn backward completely

-

Loosen hexagon head cap screw (5) on both sides and remove hand guard (6)

-

Push backward gearing end frame (1) against the conveying direction to the stop

-

Tighten fastening screws (4) on both sides of the gearing end frame

-

Mount hinge band mounting rails (see Chapter 4.4)

2

1

6 5

3 4

Type 2 2

type 2 Model with pedestal bearing: -

Dismantle protective covering at the drive

-

Loosen the fastening screws (1) on the drive motor (2)

-

Turn back clamping bolts (3) on both sides

-

Release the tension of the drive chain by moving the drive motor in the direction of the arrow (2)

-

Loosen the fastening screws (4) on the pedestal bearing

-

On both sides, evenly screw in the clamping screws (6) and tighten the hinge band in the direction of the arrow

-

Tighten the fastening screws (4) at the pedestal bearing

-

Mount hinge band mounting rails (see Chapter 4.4)

10

1 1 3

6 4

5

Hinge band conveyor type S

Type 3 Model with band support: -

Disassemble hand guard (1) on the left and on the right by removing the fastening screw (6)

-

Loosen the fastening screws (2) on both sides of the drive motor (3) but do not unscrew completely

-

Loosen lock nuts (4) of the clamping bolts (5)

-

Turn back the clamping bolts (5) completely

-

Push backward the drive motor against the conveying direction (direction of arrow) to the stop

-

Tighten fastening screws (2) on both sides of the drive motor

-

Mount mounting rails (see chapter 4.4)

Type 3

2 2

1

3

6

2 5

Type 4

4

Type 4

Deflection side model: -

Loosen lock nuts (2) of the clamping bolts (3) on both sides

-

Open the clamping bolts (3) at the guide roller as far as possible

-

Press the guide roller (1) towards the discharge opening (direction of arrow)

-

Fix clamping bolts (3) with lock nuts (2) in loosened position on both sides

-

Mount mounting rails (see chapter 4.4)

1

2 3 11

Hinge band conveyor type S

4.4 Mounting the hinged band 1 For heavy, divided hinge bands, mounting rails (2) are included in the delivery. The hinge band cannot be inserted without mounting rails! Keep mounting rails (2) !

2 3

4 -

Position the beginning of the hinge band (3) on the mounting rails (2) The driver webs (6) of the hinge band point upward in conveying direction. The side rims (5) of the hinge band must be closed at the back (against conveying direction).

-

Turn the drawing chain wheel (1) so that the first roller (3) of the hollow pin chain can be pushed into a tooth space

-

Insert the hinge band into the container (4)

-

Insert the hinge band up to the guide sprocket wheel using the drive motor in jogging skip or the crank handle - Danger of injuries during the inserting procedure: - Never touch movable parts of the hinge band conveyor with the hands! - Do not pull or push the hinge band without the proper tools!

5 6

7 If the hinge band jams and piles up: Briefly change the sense of rotation of drive motor or crank handle. -

When the hinge band has reached the guide sprocket wheel:

-

Use a hook (7) or a suitable tool to pull the hinge band around the chain wheel. At the same time, switch on or slowly move on the drive motor in jogging skip

12

Hinge band conveyor type S

- Danger of injuries! - Never pull the hinge band around the guide sprocket wheel by hand -

Continue the inserting procedure until the beginning of the hinge band has reached the drawing chain wheels.

-

Steadily pull the hinge band with a hook or a suitable tool in conveying direction to avoid piling up or jamming.

-

8

Switch off the drive motor 9

-

Only Type S2:

-

Position the beginning of the hinge band on the mounting rails (10) Insert a roller (8) between the cover plates (9) of the hollow pin chains and fasten with locking bolts (11). Blocking of the hinge band (12) is thus rendered more difficult

10 11 12

Depending on the hinge band size, two or more people are needed for inserting. The drive motor or a crank handle can be used for inserting. See chapter 6.2 for mounting the crank handle

4.5 Mounting the shackle type connectors -

Insert the roller (3) between the cover plates (2) of the hollow pin chain (only required for Type S2)

-

Connect the ends of the hollow pin chains with shackle type connectors (1)

1

2

3

4

5

The bolts of the shackle type connectors (1) point outward. -

Place the cover plates (4) onto the inserted shackle type connectors

-

Mount the locking rings (5)

-

Remove the mounting rails 13

Hinge band conveyor type S

4.6 Mounting the locking bolts Type 1 Type 1 Model with flange bearing: -

-

Turn the hinge band such that the connecting brackets of the hinge band plates are flush with the mounting boring (4) Mount a washer (2) with split-pin (1) on the locking bolt (3)

-

Join the hinge band plates.

-

Put the locking bolts (3) through the shackle type connectors (7) and the connecting brackets (6) of the joint hinge band plates

-

Mount the second washer (2) and split-pin (1) on the locking bolt

1 3 2

1 2

4

Type 2 Type 2 Model with pedestal bearing: -

5

Turn the hinge band such that the connecting brackets (6) of the hinge band plates are accessible through the oblong hole (5)

-

Mount a washer (2) with split-pin (1) on the locking bolt (3)

-

Join the hinge band plates

-

Put the locking bolts (3) through the shackle type connectors (7) and the connecting brackets (6) of the joint hinge band plates

-

Mount the second washer (2) and split-pin (1) on the locking bolt

1 3

2

1 2

Dismantling is carried out in reverse order

6

3 7 14

Hinge band conveyor type S

Type 3 Type 3

with band support: -

Turn the hinge band such that the connecting brackets of the hinge band plate are in flush with the mounting boring (8)

-

Mount a washer (2) with split-pin (1) on the locking bolt (3)

-

Join the hinge band plates

-

Put the locking bolts (3) through the shackle type connectors (7) and the connecting brackets (6) of the joint hinge band plates

-

Mount the second washer (2) and split-pin (1) on the locking bolts

8

1 1

2

3 2

Type 4 Deflection side model: -

Turn the hinge band such that the connecting brackets (6) of the hinge band plates are accessible through the oblong hole (8)

-

Mount a washer (2) with split-pin (1) on the locking bolt (3)

-

Join the hinge band plates

-

Put the locking bolts (3) through the shackles type connectors (7) and the connecting brackets (6) of the joint hinged band plates

-

Type 4 8

1

1

2 3

Mount the second washer (2) and split-pin (1) on the locking bolt

2

Dismantling is carried out in reverse order.

6

3 7

15

Hinge band conveyor type S

4.7 Tensioning the hinge band Type 1

Type 1 Model with flange bearing: -

Loosen the fastening screws (3) on both sides of the gearing end frame

-

Loosen the lock nuts (1) of the clamping bolts (2) on both sides

-

On both sides, evenly screw in the clamping bolts in the direction of the arrow

-

Check hinge band tension as described in chapter 6.3

-

Tighten the lock nuts of the clamping screws

-

Tighten the fastening screws (3) at the gear end frame

1 2

3

Type 2

Type 2

2

Model with pedestal bearing: -

Loosen the fastening screws (1) at the drive motor (2)

-

Turn back the clamping bolts (3) on both sides

-

Loosen the fastening screws (4) on the pedestal bearing on both sides

-

On both sides, evenly screw in the clamping bolts (5) and tension the hinge band in the direction of the arrow

-

Check hinge band tension (see chapter 6.3)

-

Tighten the fastening screws (4) at the pedestal bearing

-

Tension the drive chain by means of the clamping bolts (3) by moving the drive motor (2) in the direction of the arrow

-

Check the chain tension of the drive chain (see chapter 8)

16

1 1 3

5 4

Hinge band conveyor type S

Type 3 Type 3

with band support: -

Loosen the fastening screws (1) on both sides of the gearing end frame (4), but do not unscrew completely

-

Loosen the lock nut (2) of the clamping bolt (3) on both sides

-

On both sides, evenly tighten the clamping bolts while checking the hinge band tension continuously as described in chapter 6.3

-

Tighten lock nuts (3)

-

Tighten fastening screws (1) on bothsides of the gearing end frame (4)

1

1

4 1 3 2 Type 4 Deflection model: -

Loosen lock nuts (2) on both sides

-

On both sides, evenly tighten the clamping bolts (3) in the direction of the arrow

-

Check hinge band tension continuously as described in chapter 6.3

-

Check the adjustment of the guide roller (1) (see chapter 6.3)

-

Tighten lock nuts (2)

Type 4

1

2 3 17

Hinge band conveyor type S

5 Switching on and operating 5.1 Before initial operation -

Electrical components must be connected by qualified personnel (note voltage, frequency, strength of current and direction of rotation)

-

Do a leak test on pipings for liquids (possible transport damage)

-

Set all switches at “0” or “OFF”

-

Fill up with required liquids (coolants, lubricants, oils, etc.)

-

The entire installation must be free of coarse parts (tools, etc.)

5.2 Switching on - Make sure that nobody is in the danger area of the hinge band conveyor! - For the operation of the installation, the regulations for prevention of accidents VBG 10 must be observed! - All danger areas accessible to people must be covered!

Sequence for switching on: -

Lifting pump(s)* Low lift pump(s)* Scraper conveyor Auxiliary aggregates (swarf mill, sieve drum, magnetic drum etc.)* Jetting pump(s)*

5.3 Switching off Switch off scraper conveyors with coolant system with a time delay of approx. 5 mins. to the processing machine (purification of the coolant) Sequence for switching off: -

Jetting pump(s)* Low lift pump(s)* Lifting pump(s)* Auxiliary aggregates (swarf mill, sieve drum, magnetic drum etc.)* Scraper conveyor

*if supplied with this model

18

Hinge band conveyor type S

6 Maintenance 6.1 Adjusting the drive shaft Only necessary if distance “A” is not the same on both sides -

Loosen the axial shaft locks on both sides of the drive shaft bearings

-

Move the chain wheels with the shaft in an axial direction until distance “A” is the same on both sides

-

Fasten the axial shaft locks on both sides

A

A

6.2 Attaching the manual crank Examples for the use of the crank handle: Aligning the hinge band for dismantling Loosening coarse parts blocking the hinge band Reversing mode when not possible with drive motor -

Loosen connection between drive motor and safety clutch. If necessary remove drive motor.

-

Expel the rollpin spring of the safety clutch

-

Remove the safety clutch from the drive shaft

-

Attach the manual crank to the drive shaft and insert hexagon head screw. If necessary make manual crank as illustrated.

A 12

mm

3

00

mm

B

Ø

A

B

25

M8

26

35

M10

36

19

Hinge band conveyor type S

6.3 Checking the hinge band tension Switch off the hinge band conveyor and secure against unintended start-up

-

Check the hinge band tension between the drive shaft and container bottom

A

~ 10 mm

-

Hinge band tension: When applying moderate pressure from below, the hinge band must give approx. 10 mm Dimension A must be the same on both sides

6.4 Changing individual hinge band plates -

Dismantle the hinge band

-

Cut off the heads (3) of the connecting bolts (1) using appropriate tools (e.g. by means of a abrasive cutting-off machine, saw, etc.) on one side

-

Pull the connecting bolts (1) out of the hinge band plate

-

Remove hinge band plate (2) 2 Hinge band plate

2 1

Hinge band plate with scraper

2 Hinge band plate with driver rail

1 3

To install a new hinge band, clamping bolts (1) (with borings), washers and split-pins have to be used. Mind the length of the connecting bolts such as they do not rub at the container. 20

Hinge band conveyor type S

7 Information on coolants / tanks -

Circulate coolants continuously (weekend circulation recommended)

-

Do not feed any organic matter

-

Avoid foreign oil charge

-

Temperature should be below 25°C for emulsion, if possible

-

pH-value should be within neutral range

-

Hardness of the initial water should not exceed 15° dH

-

Hardness due to upgrading must not exceed 20° dH

Cleaning the coolant tanks -

Cleaning intervals greatly depend upon the kind of processing, material, coolant and working hours; no general interval can therefore be specified A cleaning interval between four and eight weeks is recommended as standard value

21

Drive - Drive chain (only for model with flange bearing with chain drive)

Interval

3 months

Action

Safety instructions/ remarks

Check tension and tighten if necessary, lubricate drive chain

Steps: - Remove protective covering (1) - Loosen hexagon head cap screw (2) - Press take-up pulley (4) in the direction of the arrow (5) against drive chain (3) (force of pressure approx. 20 N) - Tighten hexagon head cap screw (2) - Mount protective covering (1)

1 5

2

4

3

- Drive chain (only for model with pedestal bearing with chain drive)

3 months

Check tension and tighten if necessary, lubricate drive chain

6

8

Hinge band conveyor type S

7

- Remove protective covering Loosen hexagon head cap screws (7) - Evenly unscrew hexagon head cap screws (8) in the direction of the arrow (6) until the tension of the drive chain is approx. 20 N - Tighten hexagon head cap screws (7) - Mount protective covering

8 Maintenance table

22

Subassembly/ component

Subassembly/ component

Interval

Action

Safety instructions/ remarks

- Bearing of drive shaft and lateral axis, chain wheels

---

Check wear and smooth running

Check and replace if necessary when changing the hinge band

Hinge band

3 months

Check tension and tighten if necessary

For setting, see Chapter 4.5

3 months

Check for damage

Replace damaged parts

- Motor(s)

---

See operating instructions of manufacturer

- Wiring

3 months

Check for ruptures and damage

Replace defective wiring

- Level switch

3 months

Check function

Exceed both switch points by manual actuation

- Protective gear

3 months

Check function

Sieve basket

---

Empty and clean

Pumps

---

See operating instructions of manufacturer

Containers

6 months

Check for leaks, damage and corrosion

Hazardous substances must in no case penetrate

6 months

Check stability

Container must be safely and solidly fastened

---

Check guide rails for wear

Check when changing the hinge band

Electrical equipment

Hinge band conveyor type S

23

24

Subassembly/ component Coolant tanks

Interval

500 working hours

Action

Safety instructions/ remarks

Check for contamination (sludge deposits) and clean, if need be.

Depending on the tooling method, the interval may be greatly shortened. Coolant tanks are special accessories and are therefore not installed in every plant.

Hinge band conveyor type S

Remedy

Drive motor races, hinge band does not move

Drive chain torn (for model with chain drive)

Replace drive chain

Rollpin spring of the safety clutch on the drive sheared off

Drive in new rollpin spring

Hinge band blocked by large parts, safety clutch has triggered

Remove parts Turn the drive band in reverse direction if necessary (see Chapter 6.2) After restarting, the safety clutch automatically reengages and continues to operate

Safety clutch defective (loud rattling noise)

Immediately switch off swarf conveyor Inform service technician or replace complete safety clutch Never bridge the safety clutch or modify the setting

Accumulation of swarfs in front of the guide sprocket wheel

Dismount hinge band and look over installation

Axial shaft lock loose

Adjust drive shaft (see Chapter 6.1)

Hinge band does not move centrally (strikes the hand guard on one side) 25

Hinge band conveyor type S

Possible causes

9 Eliminating malfunctions

Malfunction

Hinge band conveyor type S

10 Accessories 10.1 Stripping device Scope -

Used in case snarl chips are forming as well as in case chips are conglutinating (e.g. due to oil)

Function -

By means of spring pressure (4) a movable scraper (1) will be moved along the hinge band (2)

-

Conglutinated chips will be eliminated

2 A 1

3

4 B

C

Setting -

The stripping device (1) has to fit close to the hinge band (2) (A)

-

Move stripping device fully in the direction of the arrow (B) until it reaches the stop

-

Set the adjusting screw (3) to a distance (C) of 2 mm approx between the screw (3) and the scraper (1).

26

22174/S-bed-gbV1.3.p65/08.01Wü

Kühlmittelreinigungsanlagen Späneförderanlagen Nieder- und Hochdruckpumpen

KNOLL Maschinenbau GmbH Schwarzachstr. 20, Postf. 1362 D-88342 Bad Saulgau

Telefon Telefax E-mail web

07581/2008-0 07581/2008-140 [email protected] www.knoll-mb.de