2013-07 Bedienung Power Clamp 5-Sprachig PDF
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Operating Manual
POWER CLAMP
Contents Preface..................................... .............................................................................. .................................................................................. ................................................................................. ......................................................68 ..............68 Symbols and Pictograms ................................................. ......................................................................................... ................................................................................. .......................................................68 ..............68 1 Safety ......................................... .................................................................................. .................................................................................. .................................................................................. ................................................69 .......69 1.1 Safety notes ........................................... ........................................................................................ ......................................................................................... ................................................................................ .................................... 69 1.2 Intended use ......................................... ...................................................................................... ......................................................................................... ................................................................................ .................................... 70 1.3 Workplace equipment ........................................ .................................................................................... ......................................................................................... .................................................................. ..................... 70 1.4 Authorised operators..........................................................................................................................................................71
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2 Device Description .................................................................................. ........................................................................................................................... ....................................................................72 ...........................72 2.1 Function description.................................................... description................................................................................................. .......................................................................................... .......................................................... ............. 72 2.2 Dynamic Dynamic power controller ......................................... ...................................................................................... .......................................................................................... .......................................................... ............. 72 2.3 Coil technology ........................................... ........................................................................................ .......................................................................................... ......................................................................... ............................ 72
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2.3.1 Adjustable coils........................ 2.3.1 ................................................ ................................................. .................................................. .................................................. ................................................. ................................................. ..........................72 .72 2.3.2 Coils with stop disks ..................................................... ............................................................................. ................................................. .................................................. .................................................. ......................................73 .............73
2.4 Unit variations .....................................................................................................................................................................74 2.5 Device overview ................................................................................................................................................................76 2.5.1 Powe 2.5.1 Powerr Clamp Comfort and Profi Plus...................... .............................................. ................................................. .................................................. .................................................. ..........................................76 .................76 2.5.2 Powe Powerr Clamp Economic, Economic Plus ................................................................. .......................................................................................... .................................................. ..........................................77 .................77 2.5.3 Powe Powerr Clamp PRESET......... PRESET.................................. .................................................. .................................................. .................................................. ................................................. ................................................. ..............................78 .....78 2.5.4 Powe Powerr Clamp Basic...................................................................... ............................................................................................... .................................................. .................................................. ..............................................78 .....................78 2.5.5 Optional equipment..................................................................... .............................................................................................. .................................................. ................................................. ..............................................79 ......................79 2.5.6 Keypad and Display................................................................ ......................................................................................... .................................................. ................................................. ................................................. ..........................79 .79
3 Transport and Packaging ....................................................................... ................................................................................................................ ....................................................................80 ...........................80 3.1 Delivery ......................................... ...................................................................................... .......................................................................................... ........................................................................................ ........................................... 80 3.2 Unpacking the machine............................................. .......................................................................................... .......................................................................................... .......................................................... ............. 80
4 Start-up ....................................... ................................................................................ .................................................................................. .................................................................................. ................................................ ....... 81 4.1 Electrical connection ..........................................................................................................................................................81 4.1.1 POWER CLAMP ....................... 4.1. ............................................... ................................................. .................................................. .................................................. ................................................. ................................................. ..........................82 .82 4.1.2 4. 1.2 SPEED COOLER.................................................................... ............................................................................................. ................................................. ................................................. .................................................. ..............................83 .....83
4.2 Setup and assembly assembly............................................ ......................................................................................... ......................................................................................... ................................................................. ..................... 83 4.2. 4.2.1 1 POWER CLAMP ...................... .............................................. ................................................. .................................................. .................................................. ................................................. ................................................. ..........................83 .83 4.2.2 SPEED COOLER (option).................................... (option)............ ................................................. .................................................. .................................................. .................................................. ..............................................85 .....................85 4.2.3 4.2. 3 Cooling body temperature display (option)........................................................................................................................................................87 ..............................................................87
5 Operation ......................................... .................................................................................. .................................................................................. ..................................................................................88 .........................................88 5.1 Switching the devices on ........................................... ........................................................................................ .......................................................................................... .......................................................... ............. 88 5.2 Menu operation .......................................... ....................................................................................... .......................................................................................... ......................................................................... ............................ 89 5.2.1 Shrink fit menu.................................................. 5.2.1 ........................................................................... .................................................. .................................................. ................................................. ................................................. ........................... 91 5.2.2 Set maximum heating time .................................. ........................................................... .................................................. .................................................. ................................................. ..............................................92 ......................92 5.2.3 Set languages................................................................... ............................................................................................ .................................................. ................................................. ................................................. ..................................93 .........93 5.2.4 Set system of units........... units.................................... .................................................. .................................................. ................................................. ................................................. .................................................. ..................................93 .........93 5.2.5 Read program..... program.............................. ................................................. ................................................. .................................................. .................................................. ................................................. ..............................................94 ......................94 5.2.6 History ......................... .................................................. .................................................. ................................................. ................................................. .................................................. .................................................. ......................................94 .............94 5.2.7 Restoring the factory default settings .......................... .................................................. ................................................. .................................................. .................................................. ......................................95 .............95 5.2.8 I-button......................... .................................................. ................................................. ................................................. .................................................. .................................................. ................................................. ......................................96 ..............96
5.3 Work procedures ..............................................................................................................................................................97 5.3.1 Selecting and changing the coil .............................. 5.3.1 ...................................................... ................................................. .................................................. .................................................. ..........................................97 .................97 5.3.2 Putting a tool holder in place .......................................... ................................................................... ................................................. ................................................. .................................................. ..................................97 .........97 5.3.3 Selecting the t he size at the display......................... ................................................. .................................................. .................................................. ................................................. ..............................................98 ......................98 5.3.4 Adjusting the coil ...................................................... .............................................................................. ................................................. .................................................. ................................................. ....................................... ............... 100 5.3.5 Preparing the shrink fit chuck and the tool ............................. ...................................................... .................................................. ................................................. ............................................... ....................... 103 5.3.6 Heating the shrink fit chuck ......................................................... .................................................................................. .................................................. ................................................. ........................................... ................... 104 5.3.7 Cooling the shrink fit chuck ..................................................... .............................................................................. .................................................. ................................................. ............................................... ....................... 108
5.4 PRESET operating procedure procedure ............................................ ........................................................................................ ......................................................................................... ................................................. .... 109 5.5 Switching the devices off ........................................... ........................................................................................ .......................................................................................... ......................................................... ............1 112
6 Correcting POWER CLAMP Faults ................................................ ......................................................................................... .......................................................................... .................................1 113 6.1 Error messages..................................................................................................................................................................113 6.2 Other errors ......................................................................................................................................................................114 6.3 Correcting SPEED COOLER faults ............................................................................................................................. ................................................................................ ..................................................11 .....116 6
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6.3.1 Water pump does not start .................................................................. 6.3.1 ........................................................................................... .................................................. .................................................. .................................... ........... 117 6.3.2 Setting the cooling temperature ...................................... ............................................................... ................................................. ................................................. .................................................. ................................ ....... 117
7 Service and Maintenance .......................................... ................................................................................... .................................................................................. ..................................................... ............ 118 7.1 Cleaning ................................................................................................................... ...................................................................... .......................................................................................... ......................................................... ............1 118 7.1 .1.1 .1 POWER CLAMP shrink fit machine....................................................... ............................................................................... ................................................. .................................................. .................................... ........... 118 7.1 .1.2 .2 Speed Cooler ...................... ............................................... .................................................. .................................................. .................................................. ................................................. ................................................. ............................ ... 118
7.2 Maintenance ............................................................................................................ ............................................................... .......................................................................................... ......................................................... ............1 119
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7.2.1 Checking electrical safety ....................... ................................................ .................................................. ................................................. ................................................. .................................................. ................................ ....... 119 7.2.2 POWER CLAMP....................... CLAMP............................................... ................................................. .................................................. .................................................. ................................................. ................................................1 ........................119 19 7.2.3 SPEED COOLER....................... ............................................... ................................................. .................................................. .................................................. ................................................. ................................................1 ........................120 20 7.2.4 Replacement of the basic unit POWER CLAMP......................... CLAMP .................................................. .................................................. ................................................. ............................................1 ....................120 20
8 Disposing of the machine .................................................. ........................................................................................... .................................................................................. ..............................................1 .....122 22 9 Technical Data.................................. Data........................................................................... .................................................................................. ................................................................................1 .......................................122 22 10 Spare Parts and .................................................................................................. Accessories .......................................................................................... ................................................. ................................................................................1 .......................................124 24 11 Circuit Diagrams ......................................................... .................................................................................. ....................................................1 ...........128 28 11. 1.1 1 Power Clamp Basic, Economic, Economic Plus, Comfort, Preset...................................... ............................................................................... ......................................... 128 11.2 Power Power Clamp Profi Plus ............................................ ......................................................................................... .......................................................................................... ........................................................ ........... 129
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Operating Manual
Preface
Preface With the POWER-CLAMP, POWER-CL AMP, you are the owner of an innovative and simple-to-run device for changing tools on a shrink fit chuck. The long life of this device and more importantly, the safe use of the POWER CLAMP depend on you reading and adhering to the safety information and operating instructions in this
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manual before commissioning. All personnel that are associated with the operation of the POWER-CLAMP shrink fit machine must also have an understanding of the material in this operating manual and adhere to it before firsttime operation. Store the operating manual in a safe place so that you have access to this information at any time. Without previous written approval of the producer producer,, no information from this operating manual may be duplicated, stored in a data processing system or transferred by any other means. The producer reserves the right to make technical and optical changes without wit hout notice in the course cou rse of further development. All dimensions, notes and information in this operating manual are therefore not subject to any guarantee. Legal claims resulting from this operating manual are therefore invalid.
Symbols and Pictograms Warnings General warnings concerning danger to personnel or damage to equipment are indicated with the following symbol: Warnings concerning electrical dangers or the danger of Warnings electrical shock:
Warnings concerning special dangers. Pictogram with a Warnings rectangular frame standing on its corner:
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Mandatory signs Mandatory signs are round, light pictograms on dark backgrounds:
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Safety
1 Safety The POWER-CLAMP shrink fit machine is constructed using the latest technology and is dependable. A function and safety check was carried out. However, the machine can be dangerous if it is not operated by persons who have not been trained or at least instructed. The same applies for improper or non-intended use
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of the POWER-CLAMP POWER-CLAMP. . If the operating manual is not complied with there is a risk of injury or damage.
1.1 Safety notes • The POWER-CLAMP shrink fit machine and the SPEED COOLER cooling unit must be operating using the t he correct supply voltage. Make sure that you pay attention to the rating plate. • The power connector is only to be plugged into an outlet with a ground conductor! Using an extension cord is only permitted if the cord does not break the protective earth conductor connection. If the protective earth conductor is not connected, inside or outside of the device, this is dangerous and is not allowed. • The devices are are only to be operated in a fault-free state. If there are faults or damage in any of the devices, the system may no longer be used. • The shrink fit chuck will become very hot in places. There is an acute danger of being burnt if these areas are touched. The device has been designed such that a shrink fit chuck that has become hot locally does not need to be taken out. Always leave it in the holder until it has cooled down again. • Always wear gloves gloves when working with shrink fit chucks and tools. The tools have sharp edges. There is a danger of sustaining sus taining injuries from cuts and burns. In addition, the gloves also protect you against the risk of burns from a shrink fit chuck that has become hot locally. • Always wear wear protective glasses glasses when working with the shrink fit machine. Traces Traces of oil and cooling water can also be heated when the shrink fit chuck is heated and could evaporate. There is a danger of being scalded by steam and drops of hot water being ejected violently.
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• Allow the shrink fit chuck to come in contact with only those liquids and media that when heated do not generate vapours hazardous to health (such as cooling water, anti-corrosive agents). • Before they are are heated, shrink fit chucks should be dried and cleaned cleaned as thoroughly as possible, so that t hat no vapours are generated during the shrink fit process.
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• If the generation of vapours hazardous hazardous to health cannot be avoided, such vapours must be extracted. The applicable regulations regarding hygiene at the workplace must be complied with. • The shrink fit machine machine works at high frequencies. Therefore, people who must use a pacemaker may not operate the t he device. During operation, these people are to keep a minimum distance of at least 1 meter as well. 69 Quality Wins.
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Operating Manual
Safety • Do not allow any any metal objects to come into the vicinity vicinity of the induction coil. This would cause the unit to t o overheat quickly if the shrink fit machine was activated. This applies especially to jewellery, e.g. a ring on the finger or a necklace or chain, since this could cause severe burns to the person. • Always unplug the relevant unit before carrying out any cleaning, maintenance or servicing work, and the same applies if it will not be used for a longer period. • Do not allow any any liquid to enter the interior of the housing housing during cleaning. cleaning. Protect the device from moisture as it may create an electrical shock hazard. • Lay out the power cord so that nobody can can trip over it or get tangled in it. it. • Repairs to the POWER POWER CLAMP shrink fit machine machine may be performed performed by specialised specialised personnel only. Any work done to the electronics of the device is to be performed perfo rmed by electronics technicians technicia ns only. The housing is not to be opened by unauthorized personnel. Attention! Dangerous residual voltages are present in the housing for up to 5 minutes after switching the unit off. • Safety mechanisms may not be removed, removed, bypassed bypassed or taken out of operation. • Unauthorised modifications or changes are not permitted for safety reasons.
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1.2 Intended use
The POWER CLAMP shrink fit machine has been designed for changing tools on shrink fit chucks and is constructed exclusively for this purpose. The device is suitable for shrinking tools having a diameter from 3 mm to 32 mm. All the current shrink fit conical chuck chu ck sizes can be used due to the chuck adapter system. syst em. In addition, the cooling device adapter system makes it possible to cool chucks of any external shape. This device is only meant to be used for industrial applications. Franz Haimer assumes no liability for the utilisation of this product for any application other than that described in this operating manual. This also eliminates any guarantee claims.
1.3 Workplace equipment Ensure that your workplace is always orderly and clean. An unorganised workplace increases hazards. The device must be positioned of a sufficiently stable and level sub-structure. Do not shake or tip the device during operation. The device must be protected from moisture and contamination. In general the obligations on the operating company regarding safe operation specified in the EC Directive 2009/104/EC 2009/104/EC must be complied with by the operating company.
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POWER CLAMP
Safety
1.4 Authorised operators Only operators and personnel that are assigned and authorised aut horised by the administration are allowed to perform any operation using the POWER-CLAMP shrink fit machine. The operator is responsible for any other persons located in the working area. The administrator must: • • • •
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inform the operator of his duties, ensure that the operator operator has access to the operating manual and ensure that the operator operator has read the manual and has has understood it. familiarize the operator with the safety notes. notes.
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POWER CLAMP
Operating Manual
Device Description
2 Device Description 2.1 2. 1 Function description descrip tion h s i l g n
The POWER CLAMP shrink fit machine uses an induction coil, also called an inductor, as its function principle. The coil creates a magnetic alternating field. If a metallic object with iron parts is located
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inside the coil, it will be heated. The frequency of the alternating field is set so that the metallic object, in the present case a shrink fit chuck, is only heated on the surface. Heating of the shrink fit chuck is only continued with the POWER-CLAMP until the tool can be inserted or removed by hand, which lasts approx. 5 seconds. This happens before the tool itself can heat up. The shrink fit chuck is only hot locally at this point and has not had enough time to heat through. This means that only a relatively small amount of energy is supplied and used. It is therefore possible to keep the subsequent cooling down phase very short. Cooling is achieved by applying a cooling device with water cooling. The cooling is provided by the SPEED COOLER. The cooling water circulates permanently through the cooling body. The heated shrink fit chuck remains in its holder. The water-cooled cooling body is applied. The cooling action is provided by direct contact with the shrink fit chuck. It is possible to touch the shrink fit chuck again after a short time. The procedure and the construction of the POWER-CLAMP shrink fit machine enable very quick tool changing. This results in a long life for the shrink fit chuck, since it only becomes hot locally and must therefore not be touched until it has cooled down again. This ensures simple and safe operation. The POWER CLAMP versions of the shrink unit have a turntable which is designed to allow continuous exchange of tools.
2.2 Dynamic power controller Depending on the local power supply, the voltage in the system is subject to considerable fluctuation. This also has an affect af fect on the heating capacity of conventional shrink fit units. If the voltage is too low, the heating capacity may also be insufficient to quickly and effectively ef fectively heat the chuck. If the voltage is too high, there is a danger of the chuck overheating. The dynamic power controller of the POWER-CLAMP solves so lves this problem. The heating capacity is detected and controlled throughout the shrink fit process. This thus ensures that optimum working results are achieved under all operating conditions.
2.3 Coil technology The induction coil is the heart of shrink fit systems. It must heat the shrink fit chuck quickly and yet evenly and without damage for all dimensions. The POWER CLAMP shrink fit units recognise automatically which coil is connected and adjust themselves to it.
2.3.1 2.3. 1 Adjustable coils Adjustable coils adapt themselves in diameter and length to suit the relevant tool and chuck. Elements made of a magnetically conductive material (ferrite) can be opened and closed like a camera iris.
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Device Description The coil itself comprises a fixed and a moveable part. The distance between the two parts of the coil depends on the length of the clamping area of the chuck. chuck . This ensures that only the clamping region of the chuck is heated. Heating and cooling are significantly faster than with rigid coils.
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2.3.1.1 VS 32 M
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The VS 32 M coil is the top product in induction technology. It adapts itself fully automatically to the size of the chuck. The ferrite elements are arranged at an angle, like a collar. They lie on the chuck and are brought as close as possible to the tool. The adjustment is done with the aid of two servo-motors, one for the aperture diameter and the other for the coil clearance. The coil can be used from the t he Power Power Clamp Economic type onwards.
2.3.1.2 VS 32 H The VS 32 H functions in just the same way as the VS 32 M. However, it is adjusted manually by means of a rotary disk. For special chucks (such as those with a large diameter but a short length) the aperture diameter and coil length can also be selected independently. The coil can be used from the t he Power Power Clamp Economic type onwards.
2.3.2 Coils with stop disks In this variation there is only one coil winding. It is adapted to suit different shrink fit chucks by using stop disks that can be quickly and easily inserted into the coil. The stop disks bring the coil and the shrink fit chuck together to the correct position and guide the magnetic field into the chuck.
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2.3.2.1 V 2008 The induktor has five stop disks that can be swapped over easily by means of a bayonet-type connector. The stop disks are provided with an additional gripper ring. 2.3.2.2 Coil 20 kW Large tools of up to ø 50 mm can be shrunk on and unshrunk with this coil. A shrink fit unit with an extremely high power rating (20 kW) is required to ensure secure operation with this coil, the Power Clamp Profi Plus.
V 2008
20 kW
The coil can heat up under very heavy loads. For that reason it has an additional supply line for cooling air that can be connected up as required. 73 Quality Wins.
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Operating Manual
Device Description
2.4 Unit variations POWER CLAMP Clamp Basic (coil V 2008) The full range of tools can be shrunk
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using the POWER CLAMP Basic: HM and HSS from 3 to 32 mm. Cooling can be done with the AIR COOLER (option). No further configuration of the unit is possible.
POWER CLAMP Economic (coil V 2008), POWER CLAMP Economic NG (coil VS 32 H or VS 32 M) The POWER CLAMP Economic is the entry-level version with the adjustable coil feature. It has powerful electronics and easy to use software for carbide and HSS tools up to 32 mm in diameter. A shrinking station is provided, but no cooling. The Economic version can be upgraded to the Economic Plus by means of an add-on set.
POWER CLAMP Economic Plus (coil V 2008), POWER CLAMP Economic Plus NG (coil VS 32 H or VS 32 M) The POWER CLAMP Economic Plus also has a cooling unit and cooling body for rapid cooling of the shrink fit chuck. The Economic Plus version can be upgraded to the Comfort version with
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an add-on set.
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Device Description
POWER CLAMP Comfort (coil V 2008), POWER CLAMP Comfort NG (coil VS 32 H or VS 32 M) The POWER-CLAMP Comfort provides the full configuration for efficient work. In addition to cooling, this device has a turntable with three shrinking stations. This makes possible continuous operation without any breaks.
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POWER CLAMP Profi Plus NG (coil VS 32 H or VS 32 M or 20 kW) The POWER CLAMP Profi Plus NG provides a universal solution for the shrink fitting of tools. The special electronics have double the capacity compared to the other models. Carbide and HSS tools of up to 50 mm in diameter can be shrunk by using an additional coil. Cooling and a turntable with three t hree shrinking stations are provided as standard. s tandard. The unit has an additional cooling body to cool large shrink fit chucks. It is not possible to upgrade the standard versions to the Profi Plus version.
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POWER CLAMP Preset NG (coil VS 32 H or VS 32 M) The adjustable length length stop for the t he tool tip allows tools to be shrink fitted to the exact length required. The maximum length setting is 500 mm, with an accuracy of ± 0.02 mm. The Economic, Economic Plus and Comfort versions can be upgraded upgraded to the Preset version.
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Operating Manual
Device Description
2.5 Device overview 2.5.1 2.5. 1 Power Clamp Comfort and Profi Plus
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1 2
Mains switch SPEED COOLER Circulation line return
3 Circulation line advance 4 Plug coil Ø 3 - 32 mm 5 Mains switch POWER CLAMP 6 Linear guide 7 Handle with brake 8 Start key 9 Inductor energy cable 10 Spring tensioner 11 Operatio Operational nal display lamp 12 Cooling body 12a Cooling body with quickchange connector 13 Inductor 14 15 16 17 18 20
23 24 25 26
Tool holder Turntable Tool deposi depositt Operationn and display field Operatio Trolley (optio (optional) nal) Plug coil Ø 40 - 50 mm (only POWER CLAMP Profi Plus) Cooling body Ø 40 - 50 mm (only POWER CLAMP Profi Plus) Rotary disk Adjusting segments Adjustment scale Reference arrow
27 28 29 30 31 40
Locking pin Height stop Sleeve cooling manager Ferrite ring Cooling body LED display USB interface
21
41
40 29
18
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POWER CLAMP
Operating Manual Device Description 2.5.2 Power Power Clamp Economic, Economic E conomic Plus 4
Plug connector coil Ø 3 - 32 mm 5 Mains switch POWER CLAMP 6 Linear guide 7 Handle with brake 8 Start key 9 Inductor energy cable 10 Spring tensioner 11 Operatio Operational nal display lamp 12 Cooling body 12a Cooling body with quick-change connector 13 Inductor 14 Tool holder 16 Tool deposi depositt 17 Operatio Operationn and display field 23 Rotary disk 24 Adjusting segments 25 Adjustment scale 26 Reference arrow 27 Locking pin 28 Height stop 30 Ferrite ring 31 Cooling body LED display 42 Chuck holder 43 Stop clamp
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43
42
23
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Device Description 2.5.3 Power Clamp PRESET 14 42 43 44 45 46 47 48
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Tool holder Chuck holder Stop clamp Measuring head Tool stop Handwheel Clamping lever Stop clamp
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43
42
2.5.4 Power Clamp Basic 4
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42
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Connecting plug Inductor Mains switch
6 7 8 9 10 11 13 14 17 42 43 49
Linear guide inductor Handle with brake Start key inductor Energy cable inductor Spring tensioner Operational Operati onal display lamp Inductor Tool holder Operation Operati on and display field Chuck holder Stop clamp Stop disks
43
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Operating Manual Device Description / Startup and Operation 2.5.5 Optional equipment
for Power Clamp Economic, Economic Plus, Comfort, Profi Plus and PRESET 31 Cooling body LED display 32 Motor connection 33 Motor controller controller for automatic
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31
35
34 35 36 37 38 54 56 57 58
coil VS 32 M Controller for cooling body with temperature display Connecting cable cable for cooling body with temperature display Interface RS 232 Controller power supply Interface to motor controller for coil VS 32 M (re item 67) Cooling manager Premium SPEED COOLER COOLER power power cable cable Cooling manager manager power power cable Controllers power supply
34
36
37
59 Status LED 67 Interface to motor controller for coil VS 32 M (re item 38) 68 Mains connection motor controller
56 54
33 67 68 57
58 59
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2.5.6 Keypad and Display a Enter / Confirm key b Plus key to increase the tool diameter c Minus key to reduce the tool diameter d Start key e LCD display f ESC key
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ESC
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Transport and Packaging
3 Transport and Packagin Packaging g 3.1 Delivery h s i l g E n
The POWER-CLAMP shrink fit machine is supplied in suitable packaging so that it can reach its destination in perfect condition during normal transport. Note: The carrier is liable for any transport damage. If any signs of damage are visible on the packaging that indicate damage to the contents, please contact the carrier immediately to make a claim for damages. Transport Tra nsport and storage should be completed under normal conditions, i.e. at temperatures between +5°C and +70°C and at a relative humidity of maximum 80%. Attention! Storage and transport under the wrong conditions may cause permanent damage to the machine. The damage may not be evident from the outside. In this case the manufacturer will not accept any guarantee or liability for the consequences.
3.2 Unpacking the machine Remove all packaging and remove the device with all accessories. Remove Check for whether all parts of the POWER-CLAMP shrink fit machine are present according to the delivery note and that all documents are complete and that everything is undamaged. Compare the information on the rating plates against the delivery note and your ordering documents. If you do not wish to keep the packaging for later use, e.g. return shipment for repairs, dispose of it ecologically ecologically..
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Start-up
4 Start-up The start-up procedures for the POWER-CLAMP shrink fit machine are described in the respective sequence of actions required. requi red. The operation of the device is relatively simple. You should be familiar with the t he device before working with it, however. however. Incorrect operation can cause dangers to the user and the device, in particular, the shrink
fit chuck could co uld overheat. Please note as well the safety instructions at the beginning of these instructions!
4.1 4. 1 Electrical connection POWER CLAMP or SPEED-COOLER are supplied from the factory factor y with plugs fitted, and these t hese have been designed to meet the t he relevant power power and safety requirements. If these plugs do not comply with the local power supply or legal stipulations of the country countr y of the user, then they must be replaced by other plugs that have been approved. Important: This work should only be done by a skilled electrician. The user is responsible for ensuring that the relevant local safety regulations are complied with. Points to be noted especially: • Voltage and current loading • Mains fusing • Use plugs with an advanced protective earth contact, otherwise additional grounding is required. • If changes are made the CE conformity may be rendered invalid. • For preference use CEE standard approved approved plugs that are suitable suit able for the nominal voltage range values stated in the rating plate. The shrink fit unit can generate an increased leakage current due to a built-in mains filter. For technical reasons the mains filter is connected before the main switch directly to the power supply cable. For that reason note the following: • The connection of the protective earth conductor (PE) must be done properly to ensure safe operation. Have it checked by a skilled electrician to ensure that it functions properly before starting it up for the first time. A connecting screw is provided on the device housing to connect an additional protective earth conductor or to provide equipotential bonding. • If using residual current operated devices (RCD) choose a type with a short shor t delay. • Switching the supplied power on the mains side (before the mains filter) can lead to current peaks and feedback (transients) and so trigger the t he mains fuses. If it is necessary to have a main switch on the mains side before the mains filter, then special protection to switch capacitances should be used.
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Operating Manual
Start-up 4.1.1 POWER CLAMP The power connection must be made as a 4-pole connection. The 3 phases and the protective earth conductor must be connected. The protective earth conductor must be connected without fail to ensure electrical safety during operation. The neutral (fourth wire) is not connected. It is not necessary to worry about the rotary field of the 3 phases.
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Please note the following: • The power connection connection (wall socket) provided provided by the customer must have the protective earth contact connected properly properly.. • If the plug is replaced, replaced, the green/yellow core core is to be connected to the protective earth conductor (PE). • Ensure that the power supply voltage corresponds with that specified on the rating rating plate. • The wire cross-section of the customer power connection connection must be sufficiently large, depending depending on the distance from the main distributor. No other devices should be connected on the same circuit. If these guidelines are not followed, the voltage can drop too much during the shrinking process. This can cause insufficient shrinking performance. • If making the connection connection via a transformer, transformer, ensure that the protective protective earth conductor connection continues all the way through from the machine plug up to the power supply outlet provided by the customer. The transformer must have adequate capacity reserves. Fuses to be provided by the customer: POWER CLAMP Basic, Basic, Economic, Economic Plus, Comfort, Preset: 3 x 16 16 Amps POWER CLAMP Profi Profi Plus: 3 x 32 Amps Attention! Under no circumstances operate the t he devices with fuses of a higher rating.
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Operating Manual Start-up 4.1.2 SPEED COOLER The power connection must be made as a 3-pole connection. The phase, neutral and protective earth conductor are to be connected. Please note the following:
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• Ensure that the power supply voltage voltage corresponds corresponds with that specified on the rating plate. • The power connection (wall (wall socket) provided by by the customer must have the protective earth contact connected properly properly.. • When using adapter plugs, plugs, check carefully to ensure ensure that the protective earth conductor connection goes all the way through to the socket. Often the protective earth conductor is not connected in adapter plugs. • If the plug is replaced, replaced, the green/yellow green/yellow core is to be connected to the protective earth conductor. • Fuses to be provided by the customer: 15 - 16 Amps • If making the connection connection via a transformer, ensure that the protective earth conductor connection continues all the way through from the machine plug up to the power supply outlet provided by the customer.
4.2 Setup and assembly
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The POWER CLAMP and the SPEED COOLER must be set up on a suitably stable substrate that is horizontal. In particular if the unit is mounted on a roller cabinet or other mobile chassis, care must be taken that the roller unit is adequately secured against rolling away. The brakes on the rollers must always be applied except when the roller unit is being moved. The roller unit may be moved only on level ground. During operation, the t he devices are not to stand at an angle, be tipped or subjected to vibration.
4.2.1 4.2. 1 POWER CLAMP CL AMP
B1
1
H
B2
2
H
Space required in mm: Type
P O W E R C L A M P
Basic Economic Economic Plus Comfort, Profi Plus, Preset
B1
B2
H1
L
670 870 870
500 700 700
890 1000 1000
0 0 150
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Operating Manual
Start-up The POWER CLAMP is almost completely preassembled. Only the linear guide (6) needs to be bolted to t o the housing and aligned suitably. Important: For safety reasons there must be a conductive contact between the linear guide and the housing. For that reason the linear guide must be installed very carefully carefully.. • Remov Removee the screws (50) (50) and the locking washers (51). (51). The stop clamp (43) remains in its position. • Set the linear linear guide (6) on the stop clamp (43) (Comfort version: There is no stop clamp here. The linear guide is set directly on the baseplate).
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50 10 51
• Thread the bolts (50) in and turn them so that there is still some play. Safety note: The four locking washers (51) must be directly underneath the screw head. 43
• Insert the spring tensioner (10) (10) into the socket under the baseplate. • Pull the locking bolt (19) (19) and place the coil (13) (13) in the holder of the linear guide. Ensure that the locking bolts (19) are properly seated. • Two Two ferrite screening disks (30) are supplied with the inductor. Place the standard disk with the large hole in the inductor (13) and lock it into position by turning it clockwise. • Place the chuck holder (42) (42) on the baseplate baseplate and push it up against the stop clamp (43) beside the linear guide (6). The chuck holder (42) must be up against the stop clamp (not applicable in the Comfort version). • Now place a chuck support (14) (14) in the chuck holder (42). Comfort version: Place the chuck chuc k support (1 (14) 4) in the turntable. • Place a suitable shrink-fit chuck (52) (52) in the chuck supsupport (14). • Adjustable coil, NG version: version: Place the coil with the rotary disk (23) on the diameter of the chuck.
52
32
Coil with stop disks: Place a stop disk (49) in the coil (13). The stop disk must match the diameter of the selected shrink fit chuck.
42
Turn the stop disk clockwise until it audibly clicks into place (bayonet-type connection). • Slowly lower the coil (13) (13) until it rests on the chuck (52).
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4
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POWER CLAMP
Start-up • Align the linear unit (6) so that the coil (1 (13) is centred over the chuck (52). Tighten the four bolts (50). • Connect the coil with the plug (4) at the housing and close the retaining clip.
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• Motor coil VS VS 32 M: M: Attach the motor connection (32) (32) at the motor controller (33) (back of the machine) • Plug in the mains plug. Only POWER CLAMP Profi Plus: The two coil connections have plugs of different diff erent sizes. This prevents the plugs from being confused with one another. The plug connections at the POWER CLAMP CL AMP Profi Plus are arranged such that only one connection can ever be used at one time. This prevents both coils from being connected conne cted at the same time. Attention! The electronics of the POWER CLAMP Profi Plus must be cooled by the SPEED COOLER to prevent them from overheating. A temperature monitor would
otherwise theagain deviceafter off after a short time and only allowswitch it to start a brief co oling cooling down phase. The POWER CLAMP Profi Plus may therefore only be operated together with the SPEED COOLER when the latter is switched on.
4.2.2 SPEED COOLER (option) Space requirements: Important! The SPEED COOLER cools the water from the cooling circuit with ambient air. Ensure that there is sufficient room to allow the air to circulate freely (see the top view). Otherwise the cooling capacity will not be adequate. • Place the SPEED COOLER COOLER on a suitably stable and horizontal structure near to or underneath the t he POWER CLAMP. • Fill the SPEED COOLER with a mixture of tap water water and antifreeze (ordinary antifreeze as used in car radiators). Mixing ratio water: antifreeze = 3 : 1 As a rule, new machines have already been filled with antifreeze. The cooling body only needs to be topped up with tap water in such cases. Filling is done via the screw closure at the top of the
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Front view Top view
device. The cooling coil in the water tank must be completely covere covered. d.
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Start-up Attention! Avoid direct contact with anti-freeze. Surplus anti-freeze or water/anti-freeze mixtures must be disposed of properly properly.. They must not be placed in domestic rubbish or released into the drains. • Bleeding the SPEED COOLER: Close the nipple with the hose section (53) (provided as standard) at the inlet (3) of the SPEED COOLER. Do not not switch the SPEED COOLER on. The pump could be damaged if it runs dry. Water runs from the hose after a short time. Remove the nipple with the hose section. • Bleeding the air from the cooling circuit: Connect one of the two circulation lines of the POWER CLAMP to the inlet (3) of the SPEED COOLER. The connection is made by quick-connectors. • Connect the power cable of the SPEED COOLER. Ensure that the mains voltage matches the one o ne specified on the rating plate of the SPEED COOLER.
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• Switch on the SPEED COOLER COOLER at the mains switch (1). Water is now pumped into the cooling coolin g system. The lines and the cooling body are thus bled. • Wait until water comes out of the open line. Then connect the line to the return line (2) of the SPEED COOLER. • Switch the SPEED COOLER COOLER off. • Fill up the tap water in the SPEED COOLER. The cooling coil in the water tank must be completely covered. Note: The fins of the air cooled condenser must be kept clean to allow the return cooling unit to function properly. The condenser fins get more dirty and more quickly if the ambient air contains oil in connection with dust. It is necessary to carry out regular cleaning as described in the section "Service and maintenance". As an option we offer a trolley that is optimally suitable for setting up the t he two devices (see Device overview).
53
1
1
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Start-up Cooling manager The cooling manager switches the SPEED COOLER on and off automatically. This means the user will not forget to switch the cooler on, nor will he leave it running continuously. This protects the cooler and reduces the need for maintenance. • Hang the cooling manager (54) on the perforated plate at the t he rear. • Insert the plug plug (55) into the POWER POWER CLAMP housing. • Plug the mains cable (56) of the SPEED COOLER into the socket of the t he switching unit (54). • The main switch switch (1) of the SPEED COOLER must be permanently switched to ON. • The mains cable (57) (57) of the cooling cooling manager (54) is then plugged into a mains socket.
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55 54 56 57
1
4.2.3 Cooling body temperature display (option) There is an LED at each cooling body. The cooling body is cold if the t he LED lights up green. If the LED lights up red then the cooling process has not been completed yet. Attention!! The display is not always reliable. Attention Above all, there can still be residual heat in the chuck chuc k even if the LED is green in the case of chucks with a small cooling area, when
using cooling adapters and if the cooling circuit has been switched off or is blocked. The shrink fit chuck chuc k must always be handled with care even after cooling down. • Connect the power supply (37) (37) of the controller (34) to the cooling manager (54).
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34
37
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Operation
5 Operation 5.1 5. 1 Switching the t he devices on h s i l g E n
• Before switching on, check that the inner wall of the inductor has no evident signs of damage (such as scorched areas or cracks). Attention! The inductor operates at a high voltage. Using the device if the inner wall of the inductor is damaged carries the risk of electric shock! • Check that the mains mains cable of the SPEED COOLER has been connected correctly. • Check that the mains mains cable of the POWER POWER CLAMP has been connected correctly. • Switch on the POWER CLAMP at the mains switch (5). The device now performs a self-diagnosis test. After Aft er a few seconds, the following information is displayed: Safety check: Coil damaged inside? Yes/No: Yes
• If you have not yet checked the inner wall of the inductor for signs of damage, do so now. The suggested response is „Yes“. If you acknowledge this response with the key,, the following message key appears: Change coil! Contact the manufacturer!
This message can be cleared down only when the device is switched on and off. • If the inner wall wall of the inductor is in good condition, use the + or - key to change the response to „No“ and confirm with the key.. key The device is now ready to operate.
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Operating Manual Operation
5.2 Menu operation After switching on you find yourself in the Shrink Fit menu. Here you can select the type and size of the shrink fit chuck and start the shrink fit process. A number of setting options are available in the sub-menu. • Keys Keys simultaneously • Key • Key
Branching in the sub-menu
• Key • Key
Select menu item Jump to the highe r level menu, without saving Jump Ju mp to Sh Shrin rinkk Fi Fitt me menu, nu, wit withou houtt saving (from the sub-menu)
• Key
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Jump to the previous menu item Jump to the next menu item
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Operation Full menu Shrink Fit menu
Shrink fit chuck display
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key
key
keys simultaneously key
keys simultaneously
Start key or key
Select previous chuck from the list or Automatic Select next chuck from the list or Automatic Select next group from the list Display shrink fit parameters Shrink fit process with display of the data
HeatingTime key
key key
change Heating Time key
Languages key
key
choose Languages key
Units y e k
key
key
choose Units key
Reading Program key
key
start reading
key
key
choose History key
Default Parameter key
P M A L C R E W O P
key
History
key
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Resetting Default Parameter key
I-Button key
change function
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Operating Manual Operation 5.2.1 5.2. 1 Shrink fit menu
The shrink fit chuck being used currently is always shown on the display. Type of shrink fit chuck
Standard Ø 10 - 12 pos. #4 Setting the coil
• • • •
Key Key Keyss Key Key
Size of shrink fit chuck
A3
Shrinking code
Jump to the previous chuck or Automatic Jump to the next chuck or Automatic Jump to the next chuck type (simultaneously) Retain display of shrink fit parameters
Frequency
Energy
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Max. Heating Time Parameter 7,0 kHz 4.5 s 545 E 450 r 525 V 23 C
Voltage in intermediate circuit
• Start key of the coil
Tool check value with tolerance
Temperature Electronics
Start the shrink fit process
or When setting the system of units to "Inch / mm" • Key Switch system of units mm Inch 3 sec.
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Operating Manual
Operation 5.2.2 Set maximum heating time key
Heating Time
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Back to Shrink Fit menu
key Standard Ø 10 - 12 Heating Time 0 - 20: 4.5 s
Display the heating time for the set chuck
key
Select previous / next chuck from list
key
keys simultaneously
key Marking* flashes Time can be changed within the specified range
Standard Ø 10 - 12
Select next group from the list
key
Back without saving
key
Back without saving
Heating Times 0 - 20: 4.5 key Change numeric value key Safe and back
Display max. heating time of the current chuck Type of shrink fit chuck
Standard
Size of shrink fit chuck
Ø 10 - 12 Heating Time 0 - 20: 4.5 s Setting range
P M A L C R E W O P
Set value
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Operating Manual Operation 5.2.3 Set languages
key
Languages
Back to Shrink Fit menu
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key Save and back
key
Language deutsch
key
Back without saving
key Save and back
key
Language english
key
Back without saving
Save and back
key
Language français
key
Back without saving
Save and back
key
Language italiano
key
Back without saving
Save and back
key
Language español
key
Back without saving
5.2.4 Set system of units Back to Units
key
Shrink Fit menu
key
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Save and back
key
Units mm
key
Back without saving
key
Back without saving
key
P O W E R C L A M P
Save and back
key
Units Inch/mm
The system of units can be selected in the Shrink fit menu for the "Inch / mm" setting.
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Operating Manual
Operation 5.2.5 Read program The software can be updated with this function. The parameters that had been set previously are lost when this is done. The update is done via the USB interface. A PC with suitable software is required to do this. The update should therefore only be carried out by suitably trained persons.
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Read Programm
Back to Shrink Fit menu
key
key key
Read Programm Yes / No: No
key
key Reading Programm
key
Read Programm Yes / No: Yes
key
5.2.6 History The data from past shrinking operations is stored in the history. The data can be shown on the display or sent to a PC via the USSB interface. This data makes is easier to diagnose problems.
History
key
Back to Shrink Fit menu
key key
Window 1
key
History Display
key
key key
key key
P M A L C R E W O P
Window 2
Window 3
Exporting history via USB
key key
key
History Print
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key
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Operating Manual Operation
A PC with suitable software is required to do this. The update operation should therefore only be carried out by suitably trained t rained persons. It is essential that you remove the USB cable before starting any new shrinking operations.
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Window 1 Error code: 0 = No error
Event: Error-ID: Idle Time: Tot. Events:
Displayed process (0 to 100) 0 = Last process Scroll between processes using +/- keys
0 0 4 sec 10
Total number of shrink processes
Down time since the previous process (0 to 3600 sec.)
Window 2 Actual data for process 0
Actual heating time Controller load Min – Max intermediate circuit voltage
Results 0 1.9 sec 5 sec 34 % 325 m 523 - 532 V 22 C
Window 3
Pause time Measured control value Temperature in housing
Shrink parameters for process 0 Frequency
Parameter 0 7,0 kHz 2.5 sec 465 E 323 45
Power
Max. heating time Setpoint control value with tolerance
5.2.7 Restoring the factory default settings The shrink fit parameters can be reset back to the original factory settings with this function. The parameters that had been set before are lost when doing this. © 2 0 1 3 / 0 6 H a i m e r
Default Parameter
key
Back to Shrink Fit menu
key
P O W E R C L A M P
Back
key
Default Parameter Yes/No: No
key
Back
key
Back
key Reset to Default Parameter
key
Default Parameter Yes/No: Yes
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Operation 5.2.8 I-button The induction process can be started by means of the I-button. Depending on the setting in the menu, the I-button can function in various ways. • Setting 0: The I-bu tto n fun ctio ns jus t like the St art key at the coil . Heating is applied for as long as the button is pressed and held down,
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until the maximum heating time is reached. • Setting 1 – 100: With this setting the heating is only started when the I-button is pressed and is switched off automatically after a certain time. The key does not need to be held down. The heating time is calculated as a percentage of the maximum heating time. Example: Max. heating time: 12 seconds Setting I-button: 80 (= 80 %) Actual heating time: 80 % of 12 s = 9.6 s For example, this function is very helpful with the POWER CLAMP Preset because the chuck is always heated by the same amount. The function of the Start key is not affected by this setting.
I button
key
Back to Shrink Fit menu
key
I button 0 - 100 : 0
key
key
*flashes
button 0 - I100 :0*
key
key P M A L C R E W O P
Change number value key
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Save and return
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Operation
5.3 Work procedures 5.3.1 5.3. 1 Selecting and changing c hanging the coil The POWER-CLAMP was designed in the first instance for shrink fit chucks with an outside contour as per DIN 69882 – 8. In addition, there is a large selection of shrink fit chucks and extensions that can likewise be used with the POWER CLAMP. (e.g. S chuck, Mini Shrink). Please contact the manufacturer regarding chucks of any other dimensions. The chuck (52) may not under any circumstances touch the inner wall of the coil (13). This results in a maximum permitted size of the chuck (see illustration). Coil for clamping Ø 3 - 16: max. Ø 44 Smin= 3 mm Coil for clamping Ø 3 - 32: max. Ø 45 Smin= 3 mm Coil for clamping Ø 40 - 50: > Ø 45 to (only Profi Plus) max. Ø 82 Smin= 7 mm Switch off the machine Open the retaining clip at the coil plug Pull out the coil plug Pull the locking bolt (19) (19) Pull the coil (13) forwards out of the t he holder Install the other coil in the reverse order
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52
Only coil 20 kW: If the coil heats up strongly in operation then the cooling air line can be connected as well at the coil plug: Compressed air, max. 2 bar and unoiled. Note: The retaining clip at the coil plug must always be clicked into place correctly. Otherwise there is a risk that the t he contacts of the plug will melt. © 2 0 1 3 / 0 6 H a i m e r P O W E R C L A M P
5.3.2 Putting a tool holder in place The tool holders (14) (14) are marked with the size of the chuck chuc k taper. It is essential to use the correct tool holder for the respective type of shrink-fit chuck. chuck. Otherwise the chuck is not centred correctly in the coil. The chuck could touch the inside of the coil and melt away the insulation of the coil winding. In extreme cases there could be a risk of fatal electric shock due to exposed live parts! 42
t holder he correct support(15). (14) from above above into the • Insert chuckthe (42)chuck or turntable
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Operating Manual
Operation 5.3.3 Selecting the size at the display.
The performance parameters of the shrink fit machine must be adapted to the geometry of the shrink fit chuck (esp. the hole and outside diameter). This is easiest with HAIMER shrink fit chucks via a code, which is visible
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Standard
both on the t he on the display. The can also be chuck found and quickly by selecting the parameters groups, followed by the sizes on the display. Only part of the t he parameters are available depending depending on the device features (performance (perfor mance class, connected coil).
Group
Size
Shrinkcode
Standard Standard Standard Standard Standard Standard Standard Extension Extension Extension Extension Extension Extension Extension Extension S-chuck S-chuck S-chuck S-chuck S-chuck S-chuck
Ø 3- 5 Ø 6- 8 Ø10-12 Ø14-16 Ø18-20 Ø25-32 Ø40-50 ØA12-16 ØA20 ØA25ØI 8-12 ØA25ØI14-16 ØA32ØI10-12 ØA32ØI14-16 ØA32ØI18-20 ØA50ØI25-32 Ø10S-12S Ø14S-16S Ø18S-20S Ø25S Ø32S Ø40-50
A1 A2 A3
H Heea avvyy d duuttyy Heavy duty Heavy duty Heavy duty Heavy duty Ultra-shor t Ultra-shor t Ultra-shor t Ultra-short Ultra-short Ultra-short Mini-Sh Mini -Shrink rink / \ MiniMi ni-Shr Shrin inkk / \ MiniMi ni-Shr Shrin inkk / \ MiniMi ni-Shr Shrin inkk / \ Mini-Sh Mini -Shrink rink / \ MiniMi ni-Shr Shrin inkk / \
Ø Ø1 16 6-20 Ø 20 Ø 25 Ø 32 Ø40-50 Ø3-5 Ø6-8 Ø10-12 Ø14-16 Ø18-20 Ø 25- 32 Ø3-4 Ø34 > < 1,5 1,5 Ø3-4 Ø3 -4 > < 3 Ø5 > < 1,5 1,5 Ø5 > < 3 Ø6-1 Ø616 > < 1,5 Ø6-1 Ø6 -16 6> < = wall thickness of the chuck for Mini Shrink
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Ø 6-8
VS32-H VS32-M X X X X X X
V2008 X X X X X X
X X X X X X X X X X X
X X X X X X X X X X X
X
X
X X X X X X X X X X X X
X X X X X X X X X X X X
20 kW
X
P M A L C R E W O P
X X X X X
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Operating Manual Operation Press the and keys simultaneously to jump from one group to the next.
Standard
Extension
S-chuck
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.....
Y o u c an a n sw s w i t c h b et e t w e e n t h e i n di di v i d u al sizes by using the or keys. The size that has been set is visible in the display display.. Extension
ØA 25 ØI 14 - 16 Pos. #4 B4 Size of Shrink Fit chuck
Settttin Se ing g the the coi coill
Type of Shrink Fit chuck Shri Sh rink nkco code de
Example 1: Shrinking in a shrink fit extension (external diameter 25, internal diameter 10) in a standard shrink fit chuck Group: Standard Shrinkcode: A6 Size: Ø 25 - 32 Coil position: #8 Example 2: Shrinking in a milling cutter with shank diameter 10 in a shrink fit extension with outside diameter 25, inside diameter 10): Group: Extension Shrinkcode: B3 Size: ØA 25, ØI 8-12 Coil position: #3
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Automatic function In most groups of shrink fit chucks the automatic function is available as well as the size details. If this function is selected the shrink fit chuck that is used is detected automatically. The software then searches from the parameters of the group that has been set for the matching ones. This function is also very helpful in the case of chucks of unknown origin or for chucks that do not comply to any standard. You You only need to select a group of chucks that resemble the one being used. Such chucks can usually shrink without any problems by using the automatic function.
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Operation 5.3.4 Adjusting the coil 5.3.4.1 Manually adjustable coil VS 32 H 5.3.4.1 The coil is simply adjusted by turning the rotary disk (23) to match the chuck and the tool. The tool Ø is shown on the position No. a) Parameters selected: • Rotate the coil to the position shown on the display. display. b) Automatic function Set the coil to the clamping diameter of the chuck (see the display or the markings on the coil)
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In some cases a number of special points need to be noted: Clamping Ø 3 – 5 mm: Small tools are usually very short and thus are not easy for access. Use an insert ring of Ø 3 – 5 mm for easier handling.
55
Coil VS 32 H: • Set the coil to Ø 3 – 5 mm. • Unlock the ferrite ring (30) by turning it anticlockwise. • Remove the ferrite ring (30). • Pull the locking pin (27) (27) of the coil. • Set the aperture aperture to the largest Ø. • Adjust the insert ring (55). • Lock the insert ring (55) by by turning it clockwise. Mini Shrink An additional shrink shri nk fit and cooling sleeve (56) is required required for Mini Shrink chucks. • Rotate the coil into the position shown. shown. • For clamping diameters of 6 mm and greater the locking pin (27) mist be released subsequently and the aperture aper ture opened wide enough to allow the tool to pass through the aperture (leaving a gap of approx. 1 – 2 mm).
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56 Mini Shrink Ø 3-4 Position # 1
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Operation T-slot milling cutters When milling T-slots the cutting diameter is greater than the shank. • Rotate the coil into the position shown. shown. • Release the locking pin (27) and lock it by turning it
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by 90°. • Set the aperture aperture to the largest Ø. • Only for coil VS 32 H and T-slot milling cutter Ø > 34 mm: Unlock the ferrite ring (30) by turning it counterclockwise and take it out. • Lower the coil onto the chuck. • Unlock the locking pin (27). (27). • Close the aperture until the locking pin (27) clicks into place again. • Only coil VS 32 H: Insert the ferrite ring (30) again once the shrink fit operation has been completed. Ultra-short chucks and special shapes In the case of very short chucks it can happen that the coil with its stop element does not lie on the chuck but instead its underside sits on the collar of the chuck. • Adjust the coil to the item specified specified for the chuck. • Pull the locking pin (27). • Set the coil to the clamping diameter of the chuck (see the display or the markings on the coil) 5.3.4.2 Automatically adjustable coil VS 32 M Start the positioning with the coil raised up. • Select the shrink fit parameters from the display. The coil position is shown in inverse.
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• Press the key . The coil travels automatically to the selected position. The position on the display is displayed normally again. Note: In the case of the VS 23 M coil the settings are travelled to automatically by means of actuators. Objects or parts of the body could be trapped and crushed. • Never reach into the opened aperture. • The clamping forces are low. low. If parts of the body or objects get trapped (the coil does not reach the desired position), immediately open the aperture and
Standard Ø 14-16 Position # 5
A4
coil again. • With With the aperture opens fully again.
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Operation Clamping Ø 3 – 5 mm:
55
• Select the parameters for Ø 3 – 5. • Press the key. The coil travels to the desired position.
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• Press the key
. The aperture opens.
• Unlock the ferrite ferrit e ring (30) by turning it clockwise. • Remove the ferrite ring (30). • Insert the insert ring (55). • Lock the insert ring (55) by rotating it counterclockwise. • Insert the ferrite ring (30) again once the shrink fit operation has been completed.
5.3.4.3 Coil with stop disks The purpose of the stop disk (49) is to correctly position posit ion the coil under the shrink fit chuck (52). In addition, the stop disk (49) protects the shank of the tool against heating up due to stray magnetic fields. Caution: If the stop disk (49) is missing or set incorrectly, stray fields could be emitted from the coil coi l area. On a long-term basis these stray fields could affect the health of the operator. For that reason the coil should never be used without a stop disk (49).
49 52
The stop disk (49) is inserted by hand. The stop disk (49) is attached by a bayonet fastening. Caution: After long use or after resting on a hot chuck for a long time, the stop s top disks can become hot. There is a danger of being burnt. When changing c hanging the disks, always wear protective gloves. This applies in
particular to the disks for the inductor for Ø 40 – 50 mm (20 kW), since they are not jacketed. • Select a stop disk (49) to match the tool. • Insert the stop disk (49) into the coil from above. above. • Turn the stop disk (49) clockwise until it audibly audibly clicks into place. A spring element clicks into place in a notch in the stop disk (49). In the case of tools with an increased cutting diameter (e.g., T-slot milling cutters), under certain circumstances the cutting diameter is greater than the hole in the stop disk. For such a situation there are split stop disks. These washers are in two halves. After the shrink shri nk fitting operation the washer halves are removed removed first before the coil is lifted out over the tool. In an unshrinking operation the coil is
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Operation first lowered over over the tool without a washer disk. The disk washer halves can be inserted insert ed subsequently. Ultra-short chucks and special shapes
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Special stop disks are available for use with ultra-short chucks. Please contact the manufacturer regarding chucks of a special shape or construction.
5.3.5 Preparing the shrink fit chuck and the tool Always wear gloves when working with shrink fit chucks and tools. The tools are sharp-edged and there is a risk of being cut. In addition, the gloves also protect you against burns in the event that you accidentally touch a hot shrink fit chuck. We recommend gloves made of Kevlar. Gloves of this material are breathable and wear-resistant against the sharp tools used. Kevlar does not melt and offers excellent protection from burns. Please ensure that • The shrink fit chuck and tools are clean, free of grease grease and dry. Special brass brushes are available to clean the chuck. • The cutter has a shank tolerance tolerance of h6 or better • The shank shank is not uneven. uneven. Scratches, ridges or even improper laser labelling can complicate the shrink fit process.
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Do not use any easily combustible cleaning agents as they can create a risk of fire during shrinking. • Clean the shrink fit chuck so that it is is free of swarf swarf and cutting emulsion, etc., and dry dr y it. Oily residues can burn into the tool holder when heated! Note: When a shrink fit chuck is put into storage, sto rage, it should be oiled lightly to provide some protection against corrosion. • Mini shrink fit chucks Due to their thin walls, mini shrink fit chucks are very easily overheated. For this reason mini shrink fit chucks c hucks should only be heated with the shrinking and cooling sleeve (56) in position (available as an accessory). The shrinking and cooling sleeve (56) also serves as an adaptor for cooling the chuck.
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Operation 5.3.6 Heating the shrink fit chuck Safety notes: The inner wall of the coil is made of a heat-resistant plastic. plastic . However,, heat radiation and direct contact with However wit h the heated chuck can damage the plastic. In an extreme case the coil winding could be exposed as a result. For that reason note the following: • The inductor must be lifted from the hot shrink fit fit chuck immediately after completing the shrinking process. Otherwise the inner wall of the coil could melt due to the radiated heat. • Under no circumstances circumstances allow the hot hot shrink fit chuck to touch the inner wall of the coil. • Check each time before use that the inner wall of the coil is still undamaged. if necessary, send the coil back to the manufacturer manufacturer.. The shrink fit chuck will naturally become very hot in places. There is a risk of burns if you touch those hot points. Do not touch the hot shrink fit chuck. Always leave it in the holder until it has cooled down again. • Place the shrink fit chuck (52) in the chuck holder (14). • Push the chuck support (42) with the shrink fit chuck into the stop st op clamp (43) underneath the coil (13). (13). Comfort version: Turn the shrink fit chuck (52) with the turntable (15) underneath the coil (1 (13). 3). Make sure that the t he turntable (15) (1 5) is locked in position. posit ion.
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• Check that the inner side of the coil is not damaged (see the Safety notes not es above). • Release the brake of the coil slide by pulling the handle (7) forward and slowly lower the coil (13) onto the shrink fit chuck until it lies in place properly. Caution: Parts of the coil are made of brittle material. Set the coil down gently onto the chuck. Otherwise the coil could be damaged. If the stop elements of the coil do not come up to the stop on the chuck, check whether it is an ultra-short chuck.
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56
52
42 43
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Operating Manual Operation Clamping the tool: • Hold the tool (57) at the chuck hole with your right hand. • Press the start key (8) or hold the key down until the tool can be inserted. The procedure takes about 5
57
seconds. As long as the start key (8) or key is pressed, the operational display lamp (11) lights up. However, the maximum duration of the heating process is restricted for safety reasons. Devices with SPEED COOLER: As soon as the shrink fit process is started, the cooling manager switches on the SPEED COOLER. The cooling must kick in audibly. If this does not happen, refer to the „Troubleshooting“ „Tr oubleshooting“ section. The following is shown on the display during the shrinking process: Load on power controller
Voltage in intermediate circuit
80 % 410 Int. 510 V 565 r
Check value set
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Spare heating time Coil current Temperature Electronics Check value actual
If a fault occurs, an error message is displayed here. • Press the start key (8) or key no longer than is necessary. The device allows the process to run only once for the maximum duration of shrinking. Another shrinking procedure is only allowed again after a pause of around 5 seconds. The pause time and the remaining shrinking time that is still available are displayed. Pause: 1.2 s Spare Spa re tim time: e: 2. 2.4 4s
Waiting time until next shrink fit process Spare heating time
Before the same shrink fit chuck can be heated again, it must first be cooled completely. Otherwise the chuck could become overheated and be destroyed as a result. Unclamping the tool: • Hold the tool (57) with your right right hand and give give it a slight upwards tug. 105
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Operation • Press the start key (8) or hold the key down until the tool can be removed. The procedure takes about 5 seconds. • After the shrink fit process has finished, release the brake of the coil slide by pulling the handle (7) and
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immediately lift the coil (13) up from the shrink fit chuck. • Push the chuck holder with the hot chuck to the cooling. When doing this, only hold the chuck holder and not the chuck. Comfort version: Rotate the turntable (15) clockwise by a further clickstopped position. The procedure is simple and quick. If the t he tool cannot be clamped or unclamped at the end of the maximum heating time then there is a fault. Important notes on the shrink fit process 1. Make sure that the shrink fit chuck is correctly centred with regard to the coil and will not come into contact with the coil housing after af ter heating. The plastic housing of the coil is damaged on contact. It is therefore also important that the tool holder matches the tool holder interface and the holder is always up against the positioning stop. 2. After the shrinking or unshrinking process (retraction, expansion) the coil must be immediately raised from the shrink fit chuck to prevent the radiating heat from heating the coil. 3. If a tool cannot be unshrunk within the set time, never never heat it up a second timefitimmediately afterwards. In again such afor case the shrink chuck would be overheated and thus destroyed. Allow the shrink fit chuck to cool down completely before starting a new unshrinking operation. 4. If it is still impossible to unshrink a tool, this may be due to one of the following causes: • Shrink fit machine machine parameters not set optimally • Coil not set correctly or the wrong stop disk was was used • Tool shank is too large (not tolerance tolerance h6 or better) • Tool shank has been damaged (e.g. scratches, ridges, incorrectly applied laser markings) • Shrink fit chuck is defective defective due to overheating overheating 106
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Operating Manual Operation • Shrink fit chuck does not have a suitable shape (wall too thick) • Shrink fit chuck or tool dirty (oil) • Strong voltage drop during the shrinking operation
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The voltage can drop during the heating procedure with small wire cross sections or if extension extensi on cables are being used. This can be checked as follows: Press the key. The following is displayed: Frequency Voltage in intermediate circuit
Parameter 7,0 kHz 545 E 525 V
Max. heating time Temperature Electronics
Compare the voltage in a no-load state with the voltage that is displayed during the heating process. If the voltage drops by more than 35 V, the supply must be improved. • A phase is missing missing in the power power supply. supply. If you cannot find the cause, have the device checked by the manufacturer manufacturer.. 5. Remove any traces of coolant (particularly from the inside) before commencing the shrink fit process. The coolant could otherwise evaporate and eject the tool violently. 6. The machine operates at high voltage. For your own safety, therefore, keep the machine clean at all times. Remove coolant, swarf and used tools from the machine at regular intervals.
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Operation 5.3.7 Cooling the shrink fit chuck The heated shrink fit chucks can be cooled down within a very short time with the aid of the cooling bodies. The prerequisite for this is a good contact between the cooling body and the chuck (surface contact). Modern shrink
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fit chuckssoare on theshrink basisfitofchucks a standardised outer contour thatmade all current can be cooled with just 5 different cooling bodies. The cooling bodies are labelled with the hole diameters of standard shrink fit chucks. However, there are also a great many shrink fit chucks that do not comply with wit h these standards. This involves, involves, for example, chicks of an older design or also shrink fit extensions. There is an adapter system to allow these chucks to be cooled down quickly and economically. Cooling bodies of sizes 14–16 and 25–32 have a quick-change connector. Adapters with any desired type of inside contour can be inserted into these cooling bodies. Adapter blanks are available from your supplier. These blanks have already been machined on the outer oute r side and only need to be adapted inside to match the t he shape of the desired shrink fit chuck. Note: The adapters can get stuck on the shrink fit chuck when cooling down. For that reasons the adapters must have a slit running down the full length of at least on side. • Place the matching cooling body (12) onto the shrink fit chuck that has just been heated (if applicable, first place the adapter in the cooling body). The cooling bodies are labelled with the diameters of the chuck holes. If arelarger working with body. S-chucks for heavy cutting, use theyou next cooling You require an adapter (58) for shrink fit extensions and standard chucks of diameters 3-5. Attention! The cooling body (12) is only to be put in place when the SPEED COOLER has been switched on. Otherwise the cooling body (12) can overheat and leak. The cooling process lasts from 20 to 150 seconds. The next clamping process can be carried out during this t his time. This makes it possible to work continuously. Units with cooling body temperature display: There eachup cooling is coldisifan theLED LEDatlights green.body. If the The LEDcooling lights upbody red then the cooling process has not been completed yet.
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Operation Attention! The display is not always reliable. Above all, there can still be residual heat in the chuck even if the LED is green in the case of chucks with a small cooling area, when using cooling adapters and if the cooling circuit has been switched off or is blocked. The shrink fit chuck must always be handled with care even after cooling down. • Pull the cooling body (1 (12) 2) off. • Remove the cooled shrink fit chuck. Attention! There may still be residual heat in the chuck. Always handle the chuck with care!
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5.4 PRESET operating procedure The POWER CLAMP PRESET has an integral length setting settin g facility. The length of the tool can be set up to max. 500 mm. The setting accuracy is ± 0.02 mm. No stop screws are necessary in the shrink-fit chuck. The length setting is independent of the length of the tool. The highest degree of precision in the length setting is attained if the chuck is always heated up to the same temperature. For that reason it should always be heated until it is switched off automatically. Note: In order not to always heat the chuck up to the maximum temperature, the heating time can be reduced up to the point of switching off automatically (see the menu description for the I-button). Length setting using PRESET is very easy:
46
44 ON/OFF ORIGIN ABSS ERO/ O/AB ZER in/mm in/ mm HOLD HOLD DATA
45
59
14
Set the zero
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On commissioning andmust chuck support (14) (1 4)first is changed, the zero muevery st be time resetthe / checked. • Wind the measuring device device (44) down until the tool stop (45) rests flat on the chuck support (14). • This point is stored as as the starting point for for the measuremeasurements by pressing the “Zero/ABS” (59) key and then t hen the ORIGIN (60) key key.. The zero point is non-volatile non-volatile even when the measuring head is switched on and off. Set the stop to the desired length • Use the handwheel (46) to move move the tool stop (45) (45) to the desired length.
44 46
ON/OFF ORIGIN ABSS ZERO/AB
60
m in/mm in/m HOLD DATA
59
Make allowance for the fact that as the tool cools down it will reduce in length. For this reason a correction allow-
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Operation ance must be added to the desired length of the tool. too l. The correction allowance can be found in the table.
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Standard Clamping Ø mm 4 5 6 Correction value mm 0,15 0,18 0,18
8 0, 2
C lamping Ø mm mm 1 Correction value 04,12
1 06,14 1 08,15
2 00 ,13 2 05 ,21 3 02 ,16
S - Chuck Clamping Ø mm 10S 12S 14S Correction value mm 0,17 0,13 0,18
16S 18S 20S 0,16 0,18 0,17
10 12 0,15 0,14
Example: Clamping a tool with wit h a shank Ø 20 mm. Desired length 210 210 mm. Additonal Addit onal length lengt h from the table: t able: 0.13 0.13 mm. Set the stop to 210 mm + 0.13 mm = 210.13 mm. The length setting is performed differently depending on whether or not the shrink-fit chuck has a tension spring: - Fix the measuring device with the clamping lever (47) and swivel it to the rear – for chucks without tension spring - For chucks with a tension spring – use the stop clamp to lock the length setting on the PRESET and bring the PREST upwards
47
ON/OFF
ORIGIN
Chucks without tension spring • Locking the length setting. The tool stop (45) is locked using the clamping lever (47) on the top of the device. Push the lever (47) (47) backwards. • Swing the tool stop (45) to the rear. rear. • Heat up the shrink-fit chuck. All other preparations and settings on the POWER CLAMP proceed as normal. The shrink-fit chuck will be heated for the full time until the unit switches off automatically. Do not stop the heating prematurely prematurely.. This is important for the accuracy of the length setting, because the correction allowances are based on these fixed heating times. • Fully raise the coil. • Insert the tool (57). (57). • Swing the tool stop (45) over the tool (57). (57). • Grasp the tool (57), (57), pull it out to the tool stop (45) and hold it until it is firmly positioned.
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ZERO/ABS in/mm
ORIGIN RO/AB ABSS ZE RO/ in/m in/ mm HOLD HOLD DATA
45
57
ORIGIN
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ZERO// ABS ZERO m in/m in /mm OLDD HOL DATTA DA
45
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Operation Gently twisting the tool too l lets you tell when the tool t ool (57) is locked. For short tools we recommend special pliers (61), because the tool can become very hot close to the chuck.
in/mm in/m m HOLD DATA DA TA
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• Lift the tool stop (45) from from the cutting edge and swing it to the t he rear. • Push the chuck holder with the chuck support (14) (14) and tool (57) into the cooling position and place a suitable cooling body over them. • Check the result. When the shrink fit chuck has fully cooled down the length can be checked. If the actual length varies from the desired length the additonal length can be adjusted and the tool shrunk-fit into the chuck again.
Chuck with tension spring • Place the tension spring (62) (62) in the shrink-fit chuck. A suitable tension spring (62) is simply pushed into the hole for the tool. The tension springs (62) are conical in shape. The tool rests on the tip of the cone. The stop screw normally fitted in the shrink-fit chuck must be screwed right back or removed altogether. The tension spring (62) can simply be pulled out of the chuck again with a hook. • Set the tool stop (45) (45) to the desired length. length.
61
ON/OFF ORIGIN O/ABSS ZERRO/AB ZE in/mm in/m HOLD HOLD DATA
62
• Lock theclamping stop gripscrew (48). under the measurement head Use the (44) to tighten the stop grip (48). © 2 0 1 3 / 0 6 H a i m e r P O W E R C L A M P
44
• Push the measurement head head (44) upwards upwards by about 100 10 0 mm and swing the t he tool stop (45) to the rear.
46 ON/OFF ORIGIN
45
BS ZERO/ABS ZERO/A in/mm HOLD DATA
48
• Heat up the shrink-fit chuck. All other preparations and settings on the POWER CLAMP proceed as normal. The shrink-fit chuck will be heated for the full time until the unit switches off automatically.
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Operation Do not stop the heating prematurely. This is important for the accuracy of the length setting, because the correction allowances are based on these fixed heating times. • Fully raise raise the coil.
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• Insert the tool (57). (57). • Swing the tool stop (45) over over the tool (57) (57) and lower lower it 45 until the measurement head (44) is resting on the t he stop grip (48). The tool stop (45) presses the tool (57) down, com- 57 pressing the tension spring (62) in the chuck to the desired length. Gently twisting the tool lets you tell when the tool (57) is locked. • Lift the tool stop (45) from from the cutting edge and swing it to the t he rear. • Push the chuck holder with the chuck support (14) (14) and tool (57) into the cooling position and place a suitable cooling body over them. • Check the result. When the shrink fit chuck has fully cooled down the length can be checked. If the actual length varies from the desired length the additonal length can be adjusted and the tool shrunk-fit into the chuck again.
ORIGIN ZERO/ABS ZER O/ABS
48
in/mm in/mm HOLD HOLD DATA
ON/OFF ORIGIN RO/AABS ZERO/ in/mm in/mm HOLD HOL DATAA DAT
5.5 Switching the devices off In daily use of the units: • Switch off both devices are work, using the mains switch. • Clean the shrink shrink fit machine as required required (see section "Service and maintenance“). For longer periods of disuse: • Switch off both devices devices with the mains mains switch. • Disconnect the power power cables cables for both. • Clean the shrink shrink fit machine (see section 5). • Top up the water water tank of the SPEED COOLER. The cooling coil in the water tank must be completely covered.
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6 Correcting POWER CLAMP Faults 6.1 Error messages Error message Wrong diameter
Error code 1
Wrong se selection of of sh shrink fit fit chuck at the control panel
• Choose the correct setting • Use the automatic function
8
Temperature in the coil is too high
• Allow coil to cool down for approx. 10 minutes
Coil missing
2
No coil connected
• Connect a coil
Coilil co Co conn nnec ecto torr def defec ectitive ve
• Se Send nd the co coilil wi with th the the un unitit ba back ck to the ma manu nufa fact ctur urer er for repair (see above the section "Service and maintenance")
Coil is defective
• Replace coil
Temperature too high in the housing
• Allow the device to cool down
Device defective
• Send the unit back to the manufacturer for repair (see above the section "Service and maintenance")
4
housing
P O W E R C L A M P
Solution / Correction
Coil is too hot
Temperature too high in the
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Possible cause
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Mains voltage too low
16
Mains vo voltage to too lo low
• Mains vo voltage mu must lilie be between 38 380 V an and 500 V
Mains voltage too high
32
Mains voltage too high
• Mains voltage must lie between 380 V and 500 V
Mains problem
48
Mains voltage drops excessively during the shrink fit process
• When using an extension cable: Connect the device directly with the outlet or try using a cable with a larger cross-section. • Connect the device to a higher voltage outlet • Run a separate feed directly from the mains distributor to the machine
One phase missing in the power supply
• Check the fuses at the t he customer’s power supply • Have an electrician check whether whet her all three phases are present and connected correctly (socket and plug of the machine)
Device de defective
• Send the unit back to the manufacturer for re repair (see above the section "Service and maintenance")
1 phase in in po power supply missing or device defective
• Have an electrician check whether all three phases are present and connected correctly (socket and plug of the machine) • Send the unit back to the manufacturer for repair (see above the section "Service and maintenance")
Power section errors
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6.2 Other errors h s i l g E n
Problem Possible cause After switching on, Mai Mains ns volt voltage age und under er 350 350 V nothing can be seen on the display One phase missing in the or only black bars power supply appear Defective di display The shrinking process is aborted after a short period of time (approx. 0.5 sec)
Major drop in the supplied voltage
One phase missing in the power supply
Solution / Correction • Con Connec nectt the the devic devicee to a highe higherr volt voltage age out outlet. let. • Use a voltage transformer • Check the fuses at the t he customer’s power supply • Have an electrician check whether whet her all three phases are present and connected correctly (socket and plug of the machine) • Send the unit back to the manufacturer for re repair (see above the section "Service and maintenance") • When using an extension cable: Connect the device directly with the outlet or try using a cable with a larger cross-section. • Connect the device to a higher voltage outlet • Run a separate feed directly from the main distributor to the shrink fit machine. • Check the fuses at the t he customer’s power supply • Have electrician check whet her whether all three presentanand connected correctly (socket andphases plug ofare the machine)
Device defective General notes Tool or extension cannot be unshrunk properly
• Send the unit back to the manufacturer for repair (see above the section "Service and maintenance") • Do not use excessive force to remove the tool from the chuck. The clamping hole and shank could be damaged • Do not temper the chuck
For adjustable coils and clamping diameter 3 – 5 mm
• Use insert inser t ring
Shank Sha nk diamete diameterr is too great great
• On Only ly us usee tool toolss with with a sh shan ankk tole tolera ranc ncee of of h6
Tool shank is dirty or damTool • Clean the tool shank before shrinking in aged (ridges, scratches, dents) • Use undamaged tools only Wrong parameter settings at Wrong the device
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• Correct any unevenness (truing) • Set the correct setting in the display
Chuck holder not cooled down completely
• Always cool the chuck holder completely before using it again
Chuck overheated (glowing)
• Shrinking and unshrinking are no longer possible. Send the chuck with the tool to the manufacturer, repair may be possible
Main Ma inss volta voltage ge too too low low
• Connect the device to a higher voltage outlet • Use a voltage transformer
Power supply unstable. VoltPower age display sinks to under
• When using an extension cable: Connect the device directly with the outlet or try using a
495 V during the shrinking process.
with larger cross-section. • cable Connect thea device to a higher voltage outlet • Run a separate feed directly from the main distributor to the shrink fit machine
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Correcting Faults Problem Possible cause Tool or extension One phase missing in the cannot be unshrunk power supply properly Hole in shrin Hole shrinkk fit chuc chuckk is dirty dirty Wro rong ng sto stop p dis diskk in th thee coi coill
• Clea Cleann the hole hole with with a bru brush sh • Pu Putt the the cor corrrec ectt stop stop di disk sk in in plac placee
Coil set incorrectly
• Set the coil correctly
Too little holding Shank diamet Shank diameter er is too too small small tension of the chuck Hol Holee of the chuc chuckk is too lar large ge Chuck walls too thin
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Solution / Correction • Check the fuses at the t he customer’s power supply • Have an electrician check whether whet her all three phases are present and connected correctly (socket and plug of the machine)
• On Only ly us usee too tools ls wi with th a sha shank nk to tole lera ranc ncee of of h6 h6 • Use Use a diffe differen rentt shrink shrink fit chuc chuckk • Use a stronger version (S-Chuck).
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Correcting Faults
6.3 Correcting SPEED COOLER faults h s i l g E n
Problem No cooling, or cooling capacity
Possible cause System with cooler has not been bled
Solution / Correction • Bleed (see below)
too low
No water or too little water in the tank
• Top up with a mixture of water and antifreeze until the cooling coils are well covered. Mixing ratio of water: antifreeze = 2 : 1
Water pump with drive motor does not work
• Use a screwdriver s crewdriver to turn the motor by the vanes (see below)
Water pump defective (for example, from running dry for too long)
• Send the unit to the manufacturer for repair
Water tank or cooling spirals in tank frozen
• Allow to thaw out and fill with water/anti-freeze mixture. Mixing ratio water: antifreeze = 2 : 1
Too little throughput in the water circuit
• Check the throughput: Disconnect the water return line switch on cooler Flow rate min. 2 l/min • Check that the hoses are not kinked. • If no improvement: Send the cooling system back to the manufacturer for checking
Cooling body leaking Wate aterr tank tank leak leaking ing
Cooling body is sweating
Wrong power supply
• Check voltage see rating plate
Heat ex exchanger di dirt rtyy
• Clean th the co cooling fin fins wi with co compressed ai air
Air circulation at the SPEED COOLER is hindered.
• Check that enough free space s pace is available (see also the notes on setting up)
Compressor has overheated, • Switch the cooler off, wait 15 minutes and reset the therthermal cut-out has tripped mal cut-out. If the thermal cut-out trips again, the compressor is defective. Send the t he cooler for repair. Ambient temperature too high, compressor defective Cooling body set on hot chuck • Exchange the cooling body in replacement with cooling system switched off seal melted Pinch-typ Pinchtypee conne connecti ction on has has come undone Brazed joints have failed
• Tighten up the connection
Water temperature temperature has been set too low
• Regulate the cooling power (see below)
• Send the unit to the t he manufacturer for repair
Thermostat defective (does not • Send the unit to the t he manufacturer for repair switch off) No water or too little water in the tank
• Top up with a mixture of water and antifreeze until the cooling coils water: are well covered.= 2 : 1 Mixing ratio antifreeze
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Correcting Faults 6.3.1 6.3. 1 Water pump does not start sta rt • Switch off the SPEED COOLER • Move (rotate) the fan wheel (65) of the motor (64) by using a screwdriver placed through the cover (63) and the motor protective cover. cover. • Remove the screwdriver screwdriver • Switch the cooler on • Check whether the pump motor runs If it does not start: there is an electrical defect
h s i l g E n 63 65
6.3.2 Setting the cooling temperature The temperature of the cooling water is set at the factory to approx. 18 °C. If the relative humidity is high or the weather conditions are unfavourable the humidity in the air can condense out on the cooling bodies. The cooling body "sweats". In this case the temperature must be increased somewhat. Caution: This work should only be done by a skilled electrician. • Disconnect the mains cable • Remove the cover (63) • Remove the cover from from the switchbox (66) (66) • Turn the temperature regulator by approx. approx. 15° 15° clockwise. The cooling temperature is reduced if the temperature regulator is turned counter-clockwise. • Close the switchbox switchbox (66). (66). • Replace the cover cover (63) Repeat the process if the cooling bodies still "sweat". © 2 0 1 3 / 0 6 H a i m e r P O W E R C L A M P
64
63 66
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Service and maintenance
7 Service and Maintenance h s i l g E n
Repairs to the POWER CLAMP shrink fit machine or to the SPEED-COOLER may be performed by specialised personnel only. Work that is carried out incorrectly can affect the safety of the devices. The housings are not to be opened by unauthorised personnel. Attention! Dangerous residual voltages are present in the housing for up to 5 minutes after switching the unit off. Have the devices checked regularly, and after any repair work, for electrical safety by a skilled electrician. In general, we recommend that you have such work carried out by the manufacturer. This will guarantee that the maintenance is handled professionally. professionally. This will also ensure safe operation and a long life of the devices.
7.1 Cleaning 7.1.1 POWER CLAMP shrink fit machine The POWER CLAMP shrink fit machine should be cleaned regularly. • Turn off the machine with the mains switch. • Disconnect the power power cable. cable. • Clean the surface of the device device with a damp, lint-free cloth. Do not allow any liquid to enter the interior of the housing during cleaning. Protect Pro tect the device from moisture as it may create an electrical shock hazard. Do not use abrasive cleaning agents.
7.1.1 .1.1.1 .1 Co Coilil The interior of the inductor is to be cleaned as necessary. Vaporised cutting emulsion or similar vapours can cause this type of contamination. This type of contamination can be prevented for the most part. Only use cleaned and dry shrink fit chucks, as specified, in the t he POWER CLAMP. Do not mechanically machine the inner side of the coil, otherwise the insulation of the coil could be damaged.
7.1.1.2 Linear guide The linear unit must be cleaned when dirty so to retain its functionality and ease of operation. The guide rods are to be oiled with a drop of resin-free oil, or else lightly saturate the felt on the carriage.
7.1 .1.2 .2 Speed S peed Cooler It is essential to ensure that the fins of the air cooled condenser are kept clean to ensure proper functioning of the cooling unit. Ambient air that contains oil in connection with dust leads to the condenser fins getting dirty more quickly. The cleaning should be done at regular intervals, the frequency of which depends on the t he amount of dirtiness at the place of use.
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Service and maintenance • Remove dust from the cooling fins fins with a hand brush • Carefully blow out the areas areas between the cooling fins with compressed air • Ensure when doing doing this that you do not not bend the cooling fins. fins. If the dirt sticks firmly then you should have the cleaning done by specialists. Attention! Solvents and liquids can affect the proper functioning and safety of the cooler. We recommend recommend the use of the cooling manager. The cooling manager switches the SPEED COOLER on and off automatically as required. • It is then impossible to forget to switch the Speed Cooler on and off. • The running time of the Speed Cooler is reduced. • The service intervals can be extended. extended. • The life of the Speed Cooler is lengthened. lengthened.
7.2 Maintenance The POWER CLAMP and SPEED COOLER devices need virtually no maintenance apart from cleaning.
7.2. .2.1 1 Checking Chec king electrical safety When a skilled electrician is checking the electrical safety, note any peculiarities that result from the mains filter switching that is used. • The filter is switched before the mains switch swit ch directly at the power supply. • In addition to capacitative and inductive inductive elements the filter also has multiple discharge discharge resistances. The components in the filter are in X- and Y-switching form. The filter has a direct influence on the measurement of the insulation resistance and the leakage current. • When checking the insulation, compare the measured values values with the mains switched switched on and off. The insulation resistance may not be less in the On position than in the Off position. • When measuring the leakage leakage current (protective (protective earth conductor current) the current peak must
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be noted the when the mains is switched on. If the testthis unitcan switches thethe mains currentdevices without clipping peaks, then power under certain circumstances lead to protective triggering. • The alternative of "substitute leakage current current measurement" cannot cannot be used. We have intentionally not given any details here regarding nominal values, since they depend on the test tes t device or measuring procedure being used and can lead to misinterpretations.
7.2.2 POWER CLAMP • Visual inspection of the housing housing for damage, cracks and deformation • Visual inspection of the inside inside wall of the induction coil for melted points Caution: If the insulating layer has melted this can expose live parts!
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• Visual inspection of the adjusting adjusting segments and the stop elements of the induction coil for damage, cracks, deformation • Visual inspection of the connection plug, pins and insulating hose of the induction coil for damage, cracks, deformation • Visual inspection of all all electrical cables for damage
7.2.3 SPEED COOLER Check the water level Check the water level in the SPEED-COOLER at regular intervals. Top it up as required with a mixture of clean tap water and radiator antifreeze (mixing ratio 3:1). The cooling coil in the water tank must be completely covered. Changing the water Change the water at least once a year (see also the section ‚Starting up‘). • Drain the water tank, using a wet wet vacuum cleaner if necessary. • Fill the tank with a fresh water/anti-freeze mixture. • Bleed the tubes of air. Caution: Avoid direct contact with anti-freeze. Surplus anti-freeze or water/anti-fr water/anti-freeze eeze mixtures must be disposed of properly. They must not be placed in domestic rubbish or released into the drains.
7.2.4 Replacement of the basic unit POWER CLAMP Repairs to the electronics of the POWER CLAMP should only be carried out by the manufacturer. In most cases it is only necessary to send the basic unit with the electronics to the manufacturer. To do this, all the add-on parts of the basic unit must be removed as follows:
POWER CLAMP Clamp Basic • Unplug all the electrical electrical cables on the left-hand side of the unit • Remove the screws (69) of the baseplate. baseplate. The basic unit is now free and can be sent for repair or replaced.
69
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Service and maintenance POWER CLAMP Economic / Economic Plus / Preset • Unplug all the electrical cables on the left-hand side of the unit • Detach the spring tensioner (10 (10). ). • Undo the screws (50). • Remove the linear guide (6) and the stop clamp (43).
50 10 51
h s i l g E n
43
• Remove the screws (70) (70) at the back as shown.
• Remove the screws (69) of the baseplate. baseplate.
70
The basic unit is now free and can be sent for repair or replaced.
69
POWER CLAMP Comfort / Profi Plus • Unplug all the electrical cables on the left-hand side of the unit • Remove the screws (70) (70) at the back as shown.
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• Remove the screws (69) of the baseplate. baseplate. The basic unit is now free and can be sent for repair or replaced.
70
69
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Technical data
8 Disposing of the machine h s i l g E n
At the end of its service life the machine should be professionally dismantled and disposed of in accordance with national regulations. Please consider the following when disposing of components of the machine: • Make sure metal parts are placed placed in the metal recycling recycling waste fraction • Make sure plastic parts parts are placed in the plastic recycling recycling waste fraction • Make sure electrical/electronic electrical/electronic components are placed in the special special processing waste fracfraction. Recommendation: Please contact a specialised disposal company.
9 Technical Data POWER CLAMP Basic shrink fit machine: Suitable for tools: .................................................................HM, Ø 3 - 32 mm, h6 HSS + extensions, 3 - 32 mm, h6 Mains connection (the details given on the rating plate shall apply): Nominal voltage ..................................................................3 400 V - 480 Min. actual operating voltage ...........................................3 xx 360 ˜ V˜ Max. actual operating voltage .......................................... ..........................................3 3 x 500 V ˜ Frequency...................................................................... ............................................................................. ....... 50 - 60 Hz Power Pow er consumption ............................................................10 kVA Fuse for mains supply ......................................................... 3 x 16 16 A Unclamping and clamping time ......................................... .........................................approx. approx. 8 seconds Dimensions (W x D x H) ..................................................... .....................................................approx. approx. 670 670 x 500 x 890 mm Weight ............................................................... .................................................................................. ................... approx. 35 kg
POWER CLAMP shrink fit machine Economic, Economic NG Economic Plus, Economic Plus NG Comfort, Comfort NG Preset NG: Suitable for tools: .................................................................HM, Ø 3 - 32 mm, h6 HSS + extensions, 3 - 32 mm, h6 Mains connection (the details given on the rating plate shall apply): Nominal voltage ..................................................................3 x 400 - 480 V ˜ Min. actual operating voltage ...........................................3 x 360 V ˜ Max. actual operating voltage .......................................... ..........................................3 3 x 500 V ˜ Frequency...................................................................... ............................................................................. ....... 50 - 60 Hz Power Pow er consumption ............................................................13 kVA kVA Fuse for mains supply ......................................................... 3 x 16 16 A Unclamping and clamping time ......................................... .........................................approx. approx. 5 seconds Dimensions (W x D x H) ..................................................... .....................................................approx. approx. 870 870 x 600 x 1,00 1,000 0 mm Weight ............................................................... .................................................................................. ................... approx. 45 kg
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Technical data
POWER CLAMP Profi Plus NG shrink fit machine: Suitable for tools: Coil NG................................................................................HM, NG................................................................................HM, Ø 3 - 32 mm, h6 HSS + extensions, 3 - 32 mm, h6 Large coil ................................................................. .............................................................................. ............. HM, Ø 32 - 50 mm, h6 HSS + extensions, 32 - 50 mm, h6 Mains connection (the details given on the rating plate shall apply): Nominal voltage ................................................................. ................................................................... 3 x 400 - 480 V ˜ Min. actual operating voltage ...........................................3 x 360 V ˜ Max. actual operating voltage .......................................... ..........................................3 3 x 500 V ˜ Frequency................................................................. ............................................................................. ............ 50 - 60 Hz Power Pow er consumption ............................................................20 kVA Fuse for mains supply .........................................................3 x 32 A Unclamping and clamping time ......................................... .........................................approx. approx. 5 seconds Cooling air for the coil, if required ....................................approx. 2 bar and unoiled. Dimensions (W x D x H) ..................................................... .....................................................approx. approx. 870 870 x 600 x 1,0 1,000 00 mm Weight ...................................................................... .................................................................................. ............ approx. 45 kg
SPEED-COOLER high performance cooling unit:
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Mains connection (the details given on the rating plate shall apply): Nominal voltage ................................................................. ................................................................... 230 V ˜ Frequency................................................................ ............................................................................. ............. 50 - 60 Hz Power Pow er consumption .............................................................1 ............................................................. 1 kVA Fuse for mains supply ..........................................................16 A Water circuit: Mixture of tap water and anticorrosive Mixing ratio............................................................. .......................................................................... ............. 2 : 1 Amount .................................................................................approx. .................................................................................approx. 5 l Cooling time ti me........................................................................ .......................................................................... 20 to 150 seconds Dimensions .............................................................. ........................................................................... ............. approx. 565 x 440 x 335 mm Weight ..................................................................... .................................................................................. ............. approx. 45 kg Total dimensions incl. i ncl. trolley ............................................... ...............................................600 600 x 10 1000 00 x 1530 mm Overall weight incl. trolley ..................................................approx. 10 100 0 kg
Permitted environmental temperatures: Storage and Transit .............................................................-25° to +70° C Operation................................................................ ............................................................................. ............. +5° to +40° C
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Spare Parts and Accessories
10 Spare Parts and Accessories
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2 V 2008
2 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10 2.11 2.12 2.13
C ,w Stooipl Vdi2sk00 Ø83 -5ithout stop disks Stop disk Ø 6-12 Stop disk Ø 14-16 Stop disk Ø 18-20 Stop disk Ø 25-32 Set of Stop disks Ø 3-32 Stop disk Ø 3-5 split Stop disk Ø 6-12 split Stop disk Ø 6-12 ultra-short Stop disk Ø 14-16 split Stop disk Ø 14-20 ultra-shor t Stop disk Ø 18-20 split Stop disk Ø 25-32 split
8 80 0..1 15 51 2..0003 80.152.06 80.152.14 80.152.18 80.152.25 80.152.00 80.152.03.1 80.152.06.1 80.152.06.2 80.152.14.1 80.152.14.2 80.152.18.1 80.152.25.1
2.14
Stop disk Ø 25-32 ultra-short
80.152.25.2
4
4 4.01 4.02 4.03
Variable coil VS 32-H Ferrite ring Additional disk Ø 3-5 Set of ferrite rings
P O W E R C L A M P
5 5.01 5.02 5.03
Motor coil VS 32 M Ferrite ring Additional disk Ø 3-5 Set of ferrite rings
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consisting of 2.01 to 2.05
4.01
80.101.02NG 170901-0010 170901-0012 80.101.02.01
5 © 2 0 1 3 / 0 6 H a i m e r
2.01-2.13
5.01
80.101.03NG 170901-0010 170901-0012 80.101.03.01
4.02
consisting of 4.01 und 4.02
5.02
consisting of 5.01 und 5.02
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h s i l g E n
6.01-6.06
20 kW 6 6.01 6.02 6.03 6.04 6.05 6.06 7 8 9 9.01 9.02 9.03 9.04 9.05 9.06 9.07 9.08 9.09 9.10 10 10.01 10.02 10.03 10.04 10.05 10.06
Coil 20 kW, without stop disks Stop disk Ø 16-20 Stop disk Ø 16-20 split Stop disk Ø 20-32 Stop disk Ø 20-32 split Stop disk Ø 40-50 Stop disk Ø 40-50 split Base unit 13 kW Base unit 20 kW Chuck suppor t for Comfor t,t, complete SK/BT/CAT 30 SK/BT/CAT 40 SK/BT/CAT 50 HSK- A/C/E/T 25, HSK-B/D/F 32 HSK- A/C/E/T 32, HSK-B/D/F 40 HSK- A/C/E/T 40, HSK-B/D/F 50 HSK- A/C/E/T 50, HSK-B/D/F 63 HSK- A/C/E/T 63, HSK-B/D/F 80 HSK- A/C/E/T 80, HSK-B/D/F 100 HSK- A/C/E/T 100, HSK-B/D/F 125 Cool Co olin ing g bo bodi dies es wit itho hout ut te temp mper erat atur uree dis isp pla layy Ø 6- 8 Ø 10-12 Ø 14-16 Ø 18-20 Ø 2 5 - 32 Ø 4 0 - 50
80.151.10 80.151.10.42 80.151.10.42.1 80.151.10.41 80.151.10.41.1 80.151.10.40 80.151.10.40.1 80.197.00.V 80.197.10.V
11 11.01 11.02 11.03 11.04 11.05 11.06 12.1 12.2 12.3 12.4 13 14 15
Cooling bo bodies wi with tem emp per era atur uree di display Ø 6- 8 Ø 10-12 Ø 14-16 Ø 18-20 Ø 2 5 - 32 Ø 4 0 - 50 Cooling manger Cooling manger USA Cooling manager Premium Cooling manager Premium USA Guide unit complete with spring tensioner Spring tensioner Cable package
80.105.12.3 80.105.13.3 80.105.14.3 80.105.15.3 80.105.16.3 80.105.18.3 80.127.21 80.127.31 80.127.20 80.127.30 113912-0008 907003-0101 113904-0002
16 17 18
Baseplate Sett swi Se swivvel elllin ing g com comp par artm tmen ents ts (2 (2xx wit withh ad addd-o on co comp mpo one nent ntss) System trolley
80.116.00 80..134. 80 4.00 00NG NG 80.124.00
only for Profi Plus
only for Profi Plus
80.102.30 80.102.40 80.102.50 80.103.25 80.103.32 80.103.40 80.103.50 80.103.63 80.103.80 80.103.10 80.105.12 80.105.13 80.105.14.1 80.105.15 80.105.16.1 80.105.18.1
230 V 110 V 230 V 110 V
for 5 cooling bodies for Comfort / Profi Plus
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19.1 19.2 19.3 20 21. 1.1 1 21.2 21.3 21.4 21.5 21.6 21.7 22 23
Speed Cooler Speed Cooler USA Speed Cooler Anti-freeze for the cooling body, 1 litre Cooling adapte adapterr for exten extensions sions No. 1 Cool Co olin ing g ad adap apter ter fo forr ex exten tensi sion onss No No.. 2 Cool Co olin ing g ad adap apter ter fo forr Ø3 Ø3-5 -5 N0 N0.. 0 Cooling adapter for the cooling body Ø 40 - 50 Cooling adapter for the cooling body Ø 40 - 50 Cooling adapter for the cooling body Ø 40 - 50 Cooling adapter for the cooling body Ø 40 - 50 Controller cooling body Motor controller for motor coil
80.105.02 80.105.01 80.105.03 807000-0001 80.105.1 80.1 05.14.1 4.1.1 .1 80..105 80 05..14. 4.1 1.2 80..105 80 05..14. 4.1 1.3 80.105.19.3.1 80.105.19.3.2 80.105.19.3.3 80.105.19.3.4 113004-0283 903012-0001
30 31
Length measuring device, complete Precision chuck holder
113004-0134 80.131.00
32 32.01
Precision chuck holder for Preset SK/BT/CAT 30
80.132.30
32.02 32.03 32.04 32.05 32.06 32.07 32.08 32.09 32.10
SK/BT/CAT 40 SK/BT/CAT 50 HSK- A/C/E/T 25, HSK-B/D/F 32 HSK- A/C/E/T 32, HSK-B/D/F 40 HSK- A/C/E/T 40, HSK-B/D/F 50 HSK- A/C/E/T 50, HSK-B/D/F 63 HSK- A/C/E/T 63, HSK-B/D/F 80 HSK- A/C/E/T 80, HSK-B/D/F 100 HSK- A/C/E/T 100, HSK-B/D/F 125
80.132.40 80.132.50 80.133.25 80.133.32 80.133.40 80.133.50 80.133.63 80.133.80 80.133.10
33
Stop clamp
113004-0263
34 51
Baseplate Chuck holder for Basic / Economic / Economic Plus
113014-0201 113004-0008
52 52.01 52.02 52.03 52.04 52.05 52.06 52.07 52.08 52.09 52.10
Chuckk ho Chuc hold lder er fo forr Ba Basi sicc / Ec Eco ono nomi micc / Ec Eco ono nomi micc Plu Pluss SK/BT/CAT 30 SK/BT/CAT 40 SK/BT/CAT 50 HSK- A/C/E/T 25, HSK-B/D/F 32 HSK- A/C/E/T 32, HSK-B/D/F 40 HSK- A/C/E/T 40, HSK-B/D/F 50 HSK- A/C/E/T 50, HSK-B/D/F 63 HSK- A/C/E/T 63, HSK-B/D/F 80 HSK- A/C/E/T 80, HSK-B/D/F 100 HSK- A/C/E/T 100, HSK-B/D/F 125
80.112.30 80.112.40 80.112.50 80.113.25 80.113.32 80.113.40 80.113.50 80.113.63 80.113.80 80.113.10
71 72 74
Guide unit Base Ba sepl plat atee Base unit 10 kW
113904-0203 1139 3904 04-0 -02 212 80.197.00.V
230 V / 50 - 60 Hz 110 V / 60 Hz 230 V / 50 Hz only Profi Plus 2 litres are required for a filling
for HD chucks Ø 16 and Ø 5/8“ for HD chucks Ø 20 and Ø 3/4“ for HD chucks Ø 25 and Ø 1“ for HD chucks Ø 32 and Ø 1 ¼“
for Preset for Preset
for Basic / Economic / Economic Plus / Preset for Economic / Preset
for Basic forr Ba fo Basi sicc for Basic
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Circuit Diagrams
11 Circuit Diagrams 11.1 Power Clamp Basic, Economic, Economic Plus, Comfort, Preset h s i l g E n
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Circuit Diagrams
11.2 Power Clamp Profi Plus h s i l g E n
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