ShrinkPRO Machines Operations Manual

Transcription

1 ShrinkPRO Machines Operations Manual Complete Machine installation and troubleshooting guide. Model ShrinkPRO Model ShrinkPRO Quencher Techniks Inc E. 56th St. Indianapolis, IN

2 Important Cautions & Warnings The Model and the Model have been constructed using the latest technology and are extremely safe and easy to operate. Despite that, there is still some danger if these units are operated incorrectly and/or by untrained personnel. Pay particular attention to the following Cautions and Warnings marked with the Attention and Danger symbols. Failure to follow safe operating practices may cause injuries, death, or damage to the machine, and may void your manufacturers warranties. Before attempting to use the unit you must have read and fully understood this Owners Manual. Keep this Owners Manual within easy reach of operating personnel. Visually inspect the unit, power cord, and accessory items for any signs of wear or damage before operating the unit. Do not use the unit if there is any sign of damage, or if the unit is not performing normally. Never operate the machine without the correct induction stop ring in place on the induction head. Do not allow any part of the induction head to contact the toolholder or cutting tool during operation or damage to the machine may occur. Do not wear rings, bracelets, or other metallic objects while operating the machine. Metallic objects may heat up very quickly when near the induction head during operation. Use the provided thermal insulated glove whenever handling tools or toolholders. Never try to handle hot tools or toolholders until the cooling cycle is complete. If the machine is moved from a cold environment to a warm one, wait two hours before operating to prevent condensation build-up from causing electronic system errors. Persons with heart pacemakers may not operate the machine, and must maintain a minimum safe distance of 6 feet (2 meters) from the machine at all times. Cutting tools have sharp edges. Handle with caution. The power cord provided must be plugged into the correct NEMA L16-20R outlet. Operating the unit while improperly connected or at the wrong voltage may damage the unit and could possibly cause death or injury. Position the power cord so it cannot be damaged by fork trucks or other equipment, or cause a tripping hazard for personnel. Do not operate the machine in a wet environment where exposure to coolant or spills are likely to occur. Electric shocks or damage to the machine may occur. Never operate the machine around flammable materials, or fumes. Do not use flammable liquids or aerosols to clean toolholders. Never expose the machine or hot tools to combustible materials. Never open the machine or attempt repairs or you will VOID the manufacturer s warranty. Dangerous residual voltage is inside that may cause death or injury. Unauthorized modifications or changes to the ShrinkPRO machine will VOID your manufacturer s warranty. Do not try and service your unit yourself. Techniks can provide any necessary repairs or maintenance. Do not modify or disable the built-in safety features of the machine. Turn off the power switch and disconnect the power cord from the outlet before cleaning, servicing, or storing the unit. Make sure you read, understand and follow these Cautions and Warnings, as well as the complete technical notes, setup and operation instructions before installing and using your machine. 2 Phone: (800) or (317) Fax: (317)

3 Important Technical Notes Power Requirements & Heating Speeds Techniks Model and have been designed to operate on a wide range of power supply voltages. They will operate on 208VAC 3 phase through 480VAC 3 phase power. We recommend 480 VAC, 3 phase, 20 amp connection for optimum performance at all shank sizes. 480VAC 3 phase power has the highest heating capacity for all sizes of our toolholders. The maximum power output exceeds 10,000 watts, when supplied with 480VAC 3 phase. NOTE: Do not activate the heat controls without a toolholder in position. Audible Feedback During operation, ShrinkPRO machines power source generates an audible feedback tone that changes frequency depending on the toolholder size and temperature. It is not unusual to hear a pitch change as the toolholder temperature increases. Do not be alarmed if you hear this tone as it is normal. ShrinkFIT Toolholders Techniks ShrinkPRO machines make it easy and safe to perform shrink fit tool changes without causing damage to the toolholder or cutting tool, as long as the machine is correctly installed and proper operating procedures are followed. ShrinkPRO machines are designed to work best with Techniks shrink fit toolholders made from H13 tool steel with bore diameters from 1/8 to 1-1/4 (3mm to 32mm). They are designed for shrink fitting tools with carbide shanks. Tool shank diameter tolerance is critical. At least an H6 tolerance is advised for optimum performance. Make sure toolholders are clean and free from defects before inserting the tool in the toolholder. If debris or a burr is inserted into the toolholder with the tool, tool-life may be reduced. Damage to the tool or toolholder may also occur as the tool may be difficult or impossible to extract. NOTE: Toolholders must be at room temperature before attempting to extract the cutting tool. Cutting Tools Cutting tool shanks must be perfectly clean and free from burrs, scoring, or any damage. Any imperfections in the shank can cause the cutting tool to lodge permanently in the toolholder. Burnished shanks can slip in Shrink Fit holders under some conditions. Sand blasting the cutter shanks has improved the holding power. Techniks ShrinkFIT holders are made of H13 tool steel, tempered at 1050 F. Heating a toolholder to or above temper point will permanently damage the holding power of the toolholder. Never use an alternate heat source on shrink fit toolholders or damage to the toolholder and cutting tool may occur. Satisfaction guaranteed on all our CNC tooling solutions. 3

4 Parts Identification & Machine Requirements Model ShrinkPRO Quencher width 36.75" x depth 24" x height 71" - Weight: 292 lbs Model ShrinkPRO width 20 x depth 20 x height 37 - Weight: 84 lbs induction head tower induction head tower induction ring induction head cutting tool cooling bath NPT air inlet (on back) upper air nozzles lower air nozzles pedestal & pedestal ring touch screen control well Quench tank tank full level coolant nozzle start heating (red button) power ON/OFF mechanicals toolholder seats power cord (on back) air pressure regulator coolant drain valve tool storage mechanical access door pedestal speed flow controls coolant flow control coolant flow bypass control induction ring induction head NPT air inlet (on back) touch screen Models / Parts List Part No. Includes 1 each induction ring (3-5mm) induction ring (6-12mm) induction ring (14-20mm) induction ring (25-32mm) TAR-BT30 TAR-CAT40 pedestal & pedestal ring tool seat - 30 taper tool seat - 40 taper start heating (red button) power ON/OFF toolholder seats power cord (on back) TAR-C6 TAR-HSK40 TAR-HSK50 TAR-HSK tool seat - 50 taper tool seat - HSK40 tool seat - HSK50 tool seat - HSK63/100 induction ring toolholder seats insulated glove rated to 500 F L thermal insulated glove Requirements: Electrical Supply: VAC, 3 phase, 20 amp connection (recommended). 50/60 Hz. Power output is watts. NEMA L16-20R receptacle. Air Supply: 90 psi supply of dry shop air. The use of an in-line filter is required. 4 Phone: (800) or (317) Fax: (317)

5 00600 ShrinkPRO Setup Features Change 1/8" shanks in 2 seconds. 1" in 6 seconds Flexible Operates on 208V up to 480V Automatic cooling cycle by compressed air View the video. Part No. Description Tool Change Rating L x D x H Ship Wt ShrinkPRO Machine 2 6 seconds 3 phase, 480V, 20A 20"x 20"x 37" 84 lbs Model ShrinkPRO setup The ShrinkPRO requires a level, stable surface and good ventilation for proper operation. Keep the machine clean and dry at all times. Connect the machine to your power supply. The machine operates on 480V on a 3-phase 20 amp circuit. NEMA L16-20P NEMA L16-20R Minimum Power Supply Maximum Power Supply 440 VAC, 3-phase 20 amp 480 VAC, 3 phase, 20 amp A NEMA L16-20P plug comes installed on the power cord. Requires a NEMA L16-20R receptacle. Connect the source air line to the machine s air inlet (90 psi required). Your machine is now ready to verify proper installation. Verifying proper installation Turn the power switch clockwise to turn on the machine. Wait as your machine powers up and displays the input screen. Touch the Head Air On button to test the Air connection. Head Air Off to cancel. Your ShrinkPRO is now ready for use. WARNING: This machine heats the cutting tool and toolholder assembly. All personnel should be clear of the machine before starting a tool change cycle. Wear the provided insulated glove to prevent accidental burns. Any glove used when operating this machine should be rated at 500⁰F (260⁰C) or higher. Satisfaction guaranteed on all our CNC tooling solutions. 5

6 00500 ShrinkPRO Setup Features Change tool and back to spindle in under 1 minute! Auto-Quench means you never touch hot toolholder Flexible Operates on 208V up to 480V View the demo video. The Quencher machine features a liquid cooling cycle that is 250% faster than air-cooled units. The hot tool is immersed in the Quench Tank and the cool tool is returned to the shrink position in only 30 seconds and automatically dried using shop air. Part No. Description Tool Change Rating L x D x H Ship Wt ShrinkPRO Quencher 2 6 seconds 3 phase, 480V, 20A 37"x 24"x 71" 660 lbs Model Quencher setup Perform the same power supply and air connection setup procedure found on the previous page. Verify the gauge on the Air Pressure Regulator reads 90 psi. Using a hose, or some other method, carefully pour approximately 20 gallons of clean water into the Quench tank through the pedestal hole. Fill the tank up to the Fluid Level line. Do not spill any water on the machine. Air pressure regulator Pedestal hole without tool Fluid level line on Quencher tank Verifying proper installation Perform the same verification procedure from the previous page. Touch the Quench Start button on the touch screen. The pedestal should lower into the coolant well and return automatically. Verify coolant is flowing out the coolant nozzles into the pedestal well. Your Quencher is now ready for use. coolant nozzles 6 Phone: (800) or (317) Fax: (317)

7 Powering up the machine Turn the power switch clockwise, located on the right side of the machine. Wait for the machine to display the input screen. You can press the Help button from any screen for more information about that screen s functions. Inserting your cutting tool Operation Guide Choose the toolholder seat that corresponds with your toolholder. Place the seat over the pedestal hole and insert your toolholder. Choose the induction stop ring that corresponds with your toolholder. Place the stop ring into the induction head, rotate it 90 to secure its position. Lower the induction head until there is an a 1/8 gap between the stop ring and the end of the toolholder. From the main screen, select your tool shank size. You can switch between inch or millimeter using the setup screen. Use the drop down menu to choose your shank size Touch units to switch between inches or metric Reminder: Always inspect your cutting tool for any imperfections on the shank such as chips, burrs, or scarring. If you find any, do not use that cutting tool in a shrink-fit toolholder, or it may no be able to remove it. The ability to insert and remove tools is enhanced when cutting tools and holders are dry and clean. Heating Cycle Heating duration is set by default based upon shank size. Use the gray slider bar on the touch screen to add or subtract time if needed. Wearing the insulated glove on one hand, with your other hand, press and hold the red Start button located on the induction head. After 2 3 seconds attempt to insert the cutting tool into the toolholder. Continue holding the Start button until the cutting tool is successfully inserted into the toolholder. You can stop the heating cycle at any time by releasing the red button. If the heat cycle ends before the cutting tool can be inserted, increase the duration by 10%. If the cutting tool is inserted before the cycle ends, you may reduce the duration for that shank size. Note: Never allow any part of the induction head to contact the toolholder or cutting tool during the heating cycle or damage to the machine may occur. Satisfaction guaranteed on all our CNC tooling solutions. 7

8 Operation Guide Cooling Cycle (00600 ShrinkPRO) The cooling cycle automatically begins 5 seconds after the heating cycle ends. The cooling cycle automatically stops after 3 minutes. You can manually stop the cooling cycle after 30 seconds by touching the Head Air Off button. Touch the Head Air On buttons to restart. Cooling Cycle (00500 Quencher) Touch the Quench Start button to begin the 30 second cooling cycle. The hot tool will be automatically lowered into the coolant tank, the Head Air will automatically begin cooling the head. As the toolholder returns to the start position, high-pressure air nozzles will remove excess moisture. Make sure to raise the induction head out of the way to make room to remove the cutting tool. Extracting your cutting tool Toolholders must be at room temperature before attempting to extract the cutting tool. Repeat the steps listed on the previous page for choosing the toolholder seat and stop ring which correspond with your toolholder. Place the toolholder / cutting tool assembly into the seat and secure the stop ring into the induction head. Lower the head until there is an 1/8 gap between the stop ring and the end of the toolholder. From the main screen, select your tool shank size. Begin heating procedure: Wearing the insulated glove on one hand, with the other hand, press and hold the red Start button located on the induction head. Continue holding the Start button throughout the heating cycle. Approximately 2 or 3 seconds before the heating cycle ends attempt to remove the cutting tool from the toolholder with the gloved hand. If the tool cannot be extracted on the first try, cool the tool to room temperature and increase the heating duration by 10% and try again. The heating cycle will stop automatically at the end of the set duration. Note: Always wear the insulated glove when handling tools, even after the cooling cycle has completed. Note: Toolholders for smaller cutting tools require less power to heat, but must be heated to a higher temperature than larger tools to perform insertion and extraction. 8 Phone: (800) or (317) Fax: (317)

9 Model Quencher System Adjustments Adjusting Cooling Time The descending speed of the toolholder is adjusted by the speed flow control on Port B of the air valve, located within he mechanical housing compartment. If the descending speed is set too slow, there may not be adequate cooling time. On the Setup screen, adjust the Quench Time to account for poor cooling due to a slow descending speed. A ports B ports Adjusting Drying Time The ascending speed of the toolholder is adjusted by the speed flow control on Port A of the air valve. If the ascending speed is too high, there may not be adequate time for the toolholder to dry. On the Setup screen, adjust the Lower Dry Time so the lower dry air valve shuts off after the pedestal passes the lower nozzles. Adjust the Upper Dry Time so the upper dry air valve shuts off when the pedestal reaches the top position. Note: The drying cycle is not meant to remove all of the moisture from the toolholder. The drying cycle should be adjusted to remove most of the dripping coolant from the toolholder. upper air nozzle Reminder: Always use the supplied insulated glove and exercise caution when handling toolholders. All personnel should be clear of the machine before starting the tool change or Quench cycle. Never touch any toolholders that are not properly cooled. The Quenching Time and coolant flow must be set to provide adequate cooling time to protect personnel from injury caused by improperly cooled toolholders. In case of contaminated coolant If the coolant becomes contaminated it will need to be replaced. Begin by draining the coolant through the Coolant Drain Valve. Then flush the Quench tank and close the drain valve. Be sure to dispose of the contaminated coolant following the appropriate environmental guidelines in the back of this manual. Remove, clean and replace the strainer from the pump inlet hose in the tank. Add 1 gallon CIMTECH 310 (Techniks Part No C) to 20 gallons fresh water. Refill the tank with clean approved coolant and run a Quench cycle to verify coolant is flowing properly. Satisfaction guaranteed on all our CNC tooling solutions. 9

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16 00400 ShrinkSTATION Compact Reliable Affordable Features Changes tools in 6 8 seconds (1/2" shank) Easy-to-Use touch screen controls Automatic cooling using 90 PSI shop air Ease-of-Use Simple to program presets for improved efficiency Automated tool positioning for optimum heating Jog feature for easy height adjustments Contact us to see if this is the right machine for you. Ph: info@techniksusa.com Achieve Greater Flexibility with SFS12 Modular ShinkFIT System Designed and built in Indianapolis, IN. Great for fast tool changes using shrink adapters Balanced to 25,000 G2.5 T.I.R. only.0001" Powerful drawbar system is fast and easy to use Bonus: SlimFIT 12 is compatible with other modular shrink fit systems! Adapters fit inch size shanks: 1/8" up to 1/2" Metric shanks: 3mm 12mm Use SlimFIT 12 shrink adapters with our CAT40, CAT50, BT30, BT40, or HSK40E toolholders and you don t have to buy so many holders, just use adapters for your tool shanks. The slim design provides excellent nose clearance, great for mold & die applications. Learn More online LIT-SFPR02017 Techniks Inc E. 56th St. Indianapolis, IN info@techniksusa.com