OPERATING MANUAL ThermoGrip Induction unit ISG 3200-400V / 480V Bilz Werkzeugfabrik GmbH & Co. KG Vogelsangstrasse 8 DE- 73760 Ostfildern Phone ++49/711/34801-0 Fax ++49/711/3481256 August 2010 ISG3200-400V/480V 1
Table of Contents Table of Contents 1 Product liability and guarantee 4 1.1 General 4 1.2 Guarantee 4 1.3 Service 5 1.4 Intended purpose 5 1.5 Symbols and Pictograms 6 2 Safety 7 2.1 Selection of the installation site 7 2.2 Risks relating to electrical energy 7 2.3 Risks from hot parts 8 2.4 Protecting the chuck against overheating 8 2.5 Risks relating to electromagnetic radiation 9 2.6 Special risks 9 3 General information about ThermoGrip 10 4 Controls and commissioning ISG3200 11 4.1 Assembly 11 4.1.1 Mounting the guide unit 11 4.1.2 Aligning the guide unit 12 4.1.3 Connecting the compressed air supply 13 4.1.4 Connecting the power supply 13 4.2 Commissioning 13 5 Operating the ISG3200 14 5.1 Operating buttons 14 5.2 Display 14 5.3 Switching the device on 15 6 Shrinking 17 6.1 Basic shrink-fitting information 17 6.2 Work sequences when gripping, releasing or changing a tool 18 6.2.1 Clamping 18 6.2.2 Releasing 18 6.2.3 Tool change 19 6.2.4 Special shrinking: Inverse shrinking 19 6.2.4.1 Shrinking-in 19 6.2.4.2 Shrinking-out 19 6.2.5 Tool change 20 6.2.6 Change the coil 20 6.2.7 Change the disc 21 6.2.8 Shrinking with coil stop ISGF3200-N 22 August 2010 ISG3200-400V/480V 2
Table of Contents 6.3 Shrink-fitting operating modes 23 6.3.1 ThermoGrip clamping chucks: PARAMETER 23 6.3.2 Shrinking with free Parameter selection: MANUAL 30 6.3.3 Shrink-fitting according to programmed special parameters: SPECIAL 32 7 Configuration Menu Item 34 7.1 Tool Memory (Programming your own shrinking parameters) 36 7.2 Setting the language 38 7.3 Adjust the display brightness 39 7.4 Switching between mm / inch 39 7.5 Enter start delay 39 7.6 Entering dwell time 41 7.7 Setting up of Fantime 42 7.8 Photoelectric barrier sensitivity 42 7.9 Password on / off 43 7.10 Lock manual shrinking operation 43 7.11 Change or assign password 44 8 Service Menu Item 45 9 Cleaning and Servicing 46 10 Contacting the Manufacturer 47 11 Appendix 48 11.1 Error messages and corrective measures 48 11.2 Technical data 50 11.2.1 ISG3200-400V 50 11.2.2 ISG3200-4800V 50 11.2.3 Overview Shank Tolerances 50 11.3 Scope of supply 50 11.3.1 Possible additions and optional accessories 51 11.3.2 Length pre-setting for ThermoGrip chucks 52 11.3.3 Ejecting broken tools 52 11.3.4 Cooling adapters with integrated temperature sensors 52 11.3.5 Trolley for ISG3200 and ISG2000 52 11.4 Menu Overview 53 11.5 EU STATEMENT OF CONFORMITY 57 11.6 Instructions Safety Glove 58 11.7 Connection socket of ISG3200 59 11.8 Connection socket of ISG3200-480V 60 11.9 Wiring diagram 61 11.9.1 ISG3200-400V 61 11.9.2 ISG3200-480V 62 August 2010 ISG3200-400V/480V 3
1.Product liability and guarantee 1 Product liability and guarantee 1.1 General These operating instructions are part of the technical documentation for the ThermoGrip induction device ISG3200. These operating instructions are important so that the device can be used safely, correctly and efficiently. Observing these instructions will help to avoid risks, repair costs and downtimes and will raise the general level of performance and the lifespan of the machine. The contents correspond to the constructional status of the ISG3200 at the time these operating instructions were compiled. The construction and technical data is subject to changes due to continuous further developments and for customised models. Therefore no claims may be made on the basis of the content of these operating instructions (details, charts, drawings, descriptions etc.). Subject to errors! These operating instructions, in particular the chapter "Safety", page 7, must be read and observed by all persons who work with the device: Operation Including tooling, troubleshooting whilst working, clearing production waste, machine care, disposal of operating supplies and materials Maintenance Servicing, inspection, repairs Transport In addition to the operating instructions and the accident prevention regulations relevant in the country and the place where the device is used, the recognised technical rules relating to safe and professional work and the respective workshop-specific regulations must be observed. If you have any questions, please do not hesitate to call us. You can contact us at the address stated above. If the reader discovers any printing errors, ambiguous information or inaccurate information in these operating instructions please let us know. 1.2 Guarantee It is expected that the device will remain fully functional, safe and that it will work accurately for many years, however this is only possible if the regulations governing the operation, maintenance and repairs are observed in accordance with the manufacturer s guidance. Any faults that occur during the guarantee period will be remedied as defined in our guarantee conditions. All claims resulting from unauthorised modifications and changes will be borne by the owner of the machine operator. This applies especially for those modifications that impair the safety of the device. Guarantee claims will only be recognised if original spare and replacement parts are used. These operating instructions are not a supplement to our terms and conditions of sale and delivery. August 2010 ISG3200-400V/480V 4
1.Product liability and guarantee 1.3 Service We will be happy to help solve problems or perform repairs and modifications that are not described in these operating instructions. Always state the device's serial number in the event of claims, problems or questions. The serial number is on the type plate on the side of the device. 1.4 Intended purpose Lineareinheit Guide rails Spule mit Wechselscheibe Coil with changing plate ThermoGrip Spannfutter/chuck Werkzeugaufnahme Chuck cooling location Kühlplätze Cooling pad Bedienfeld Control panel Fig. 1: ThermoGrip induction device ISG3200 August 2010 ISG3200-400V/480V 5
1.Product liability and guarantee The ThermoGrip induction device ISG3200 is used for the thermal engagement and disengagement of carbide tools in chucks. Any other use above and beyond this is deemed not in accordance with the intended use. We will not be liable for any resulting damage. The operator bears the full risk. Intended use also includes observing the operating instructions and compliance with the stipulated inspection and servicing intervals. 1.5 Symbols and Pictograms Warnings are marked by warning triangles with hazard symbols to warn about risks that could result in damage to property or personal injury. Warning! Potentially fatal risk or risk of serious injury! Non-observance may lead to death or serious injury! Caution! Risk of minor injury! Non-observance may lead to minor injury! Information! Information about how to carry out an action effectively and to avoid damage. Instructions are marked by circles with hazard symbols or triangles with instruction specifying that an action needs to be carried out or that specific items need to be used. Goggles Gloves Risk of damage to the eyes! Wear goggles! During the heating phase it is possible that parts of the heated metal surfaces splitter off and cause injuries! Risk of injury! Sharp edges or metal chips adhered to the tool can cause injury, therefore protective gloves must be worn! Activities are marked by the symbol and state the action that needs to be carried out. The result of the activity may be stated beneath the symbol for clarification purposes. Example: Lower coil Start shrinking process Remove tool August 2010 ISG3200-400V/480V 6
2 Safety 2 Safety The induction generator has been built to comply with the state-of-the-art design at the time of delivery and is safe to operate. Nevertheless, there are still risks involved with operating the device if it is used by untrained or unqualified personnel or if it is not used as intended. Therefore, must be observed: Please read the operating instructions carefully and familiarise yourself with the operating elements before commissioning and using the device! The operating instructions are an integral part of the function of the induction generator and must be easily accessible, legible and available in full to all persons who work with the system. The device may only be operated by trained and compitent personnel! The device may only be used for its intended purpose and only when it is in a fully functional state! The induction generator is designed and suited for ThermoGrip chucks. Problems may arise when unshrinking / shrink-fitting other chuck types leading to damage to the chucks or to the induction device itself. The manufacturer cannot guarantee that the device will operate safely if unauthorised modifications are made to the device. The operator bears the sole risk of injury to the user or third parties and for any damage to the induction generator or other elements of the device! 2.1 Selection of the installation site The ISG3200 is designed as a table-top device and must be positioned in a place which is free of dust and dirt where it is safe and not exposed to vibrations. Position the device somewhere where it is not exposed to vibrations; protect against dirt and wet! Avoid direct sunlight to improve the legibility of the green LED. 2.2 Risks relating to electrical energy The device has live parts inside which are dangerous if touched. Please observe the following safety points: The device must not be operated without the change disc being inserted! The device must not be operated when the housing is open! The device must only be opened by our service personnel or under strict Bilz guidance! Do not allow metal chips and liquids to penetrate the device! Only shrink using clean tools in cleaned chucks! Keep the device clean. Clean regularly! August 2010 ISG3200-400V/480V 7
2 Safety 2.3 Risks from hot parts The very effective heating function only heats the relevant surface zones of the chuck with the lowest heat input possible. The surface of the heated chucks reach temperatures of up to 400 C. The coil and the cutting tool hardly heats up at all when operated properly. Caution! Risk of injury caused by burns from hot parts! As a result of the shrinking process the heated tool assembly radiates heat. Therefore, the heated chuck must be cooled in a suitable manner to avoid risk of injury and damage to the coil! After the shrink fitting process, move the coil into the upper position straight away and place the chuck immediately into a suitable cooler! For your own safety, follow the safety instructions below when working with the device: The device may not be operated in an explosive environment! Do not use easily ignitable cleaning agents! Ensure that hot parts cannot be touched accidentally! Always wear the gloves supplied when unshrinking / shrink fitting the tools to protect your hands from burns and cuts! Place hot tools on non-flammable, heat-resistant surfaces! Apart from the chuck and the tool, do not allow any metal objects inside the induction coil as otherwise these will also become hot! Never reach into the heating area of the coil during operation as rings or chains can also heat up very quickly! Always wear goggles during shrinking! Bits of the tools or holder can break off during the heating process and cause injuries! Foreign objects should not penetrate the ventilation grids! 2.4 Protecting the chuck against overheating If the shrinking process is too long or if the chuck is reheated several times within a short period without correct cooling, the chuck and tool may overheat. Therefore, always try to keep the shrinking times as short as possible during shrink fitting. Avoid overheating the chuck or repetitive cycles without correct cooling times! August 2010 ISG3200-400V/480V 8
2 Safety 2.5 Risks relating to electromagnetic radiation If used correctly the device does not emit any electromagnetic radiation that is dangerous to its environment. The radiation safety of the system is checked and verified via tests performed in accordance with DIN EN 61000 Part 6-2 and DIN EN 55011. If the induction heating is started when there is no chuck in the coil, the magnetic field also affects the area close to the coil. If the induction heating is started when there is no change disc, the magnetic field also affects the area close to the coil. Warning! 2.6 Special risks Potentially fatal risk for people with pacemakers! If you have a pacemaker, keep at least 3 m away from the device until you have checked with the manufacturer or your doctor that the pacemaker is not affected by the induction field. Risk of crushing and cuts in the coil's range of motion! Ensure that no parts of your body or objects are in the range of motion of the coil whilst the induction device is operating. The weight of the coil can cause crushing injuries and cuts in connection with the cutting tools. Damage of the coil and/or the electric instalment By using Non-ThermoGrip shrink chucks the hot chuck and the coil may be touched and so destroy the isolation. In case of any damage of the coil and/or the electric instalment the device has to be stopped immediately and the manufacturer has to be contacted. August 2010 ISG3200-400V/480V 9
3. General information about ThermoGrip 3 General information about ThermoGrip Shrinking is known as a technique for achieving nondetachable connections, and offers remarkable advantages for shrinking out of chucking tools. By the inductive heating with high energy density, tools can be changed in a matter of seconds. A heated cylindrical tool is pushed into a heated and expanded bore of the chuck; after the chuck has cooled a high radial clamping force is applied. When handled properly, the clamping operation is reversible and can be repeated as often as required. The possible clamping forces are higher than when using conventional clamping techniques. With the help of special coils, the specific clamping area of the chuck is heated. A special housing/screen surrounding the coil prevents magnetic flux to a large extent. The control components and the high frequency generator are integrated in the housing. The coil is moved down manually by the user and goes automatically upwards after the shrinking process. Only one coil is required for all clamping diameters. All cables to the movable coil are guided and protected. The energy acts briefly and only on the clamping Fig. 2: Shrunk-in tool area. This means that little energy is stored in the clamping chuck and the cooling-down time is reduced accordingly. In order to reduce the cooling-down time even further, the chucks are water-cooled inside the unit and then cooled/dried with compressed air. When the heating process is completed, the cooling process starts automatically and runs according to the set cooling time (1 to 99 seconds). Please note that the cooling of the heated tool part can only be guaranteed up to a max. length of 250mm when using HSK-A63 chucks, due to the length limitation of the pneumatic cylinder. When using other chucks, the max. cooling length varies according to the difference in the A- dimension to the HSK-A63 chucks. Please see BILZ catalogue for details. Advantages of ThermoGrip clamping technology at a glance: Quick shrinking times in and out High clamping forces Higher tool and spindle life due to small run-out accuracy (< 3 μm) Good surface finish due to high rigidity of the tool clamping system High flexural yield strength and radial clamping strength and stability also with long body lengths Slim body of the chucks for high speeds Only localised yet homogeneous heating of the chuck Fastest possible cooling time of the tool and chuck Specific heat-resistant steel give the chucks a high tool life and makes them dimensionally stable August 2010 ISG3200-400V/480V 10
4. Controls and commissioning ISG3200 4 Controls and commissioning ISG3200 4.1 Assembly Caution: Ensure that the unit is not damaged during the unpacking process. In particular the cable system must not be bent out of position of movement and over its 180 stopper! Do not damage the cable system during the assembly process and handle the unit with care. Comply with the order of assembly! 4.1.1 Mounting the guide unit Place the guide unit sub-assembly in the bores. (Fig. 3) Fasten the connector unit and the cable system to the slide unit with the two enclosed screws (DIN 912 M8x35). (Fig. 4) Fig. 3: Inserting the guide unit in the machine Fig. 4: Securing the connector unit August 2010 ISG3200-400V/480V 11
4. Controls and commissioning ISG3200 The green/yellow protection (PE) cable has to be connected in all cases! Please keep to the correct working order: Connect the compressed air feed pipe and the return pipe to the connections of the guide unit. Take special care of the marked direction of rotation (Left/Right) (see picture). Fig. 5: Connecting the compressed air hoses to the guide unit 4.1.2 Aligning the guide unit Fit the induction coil to the connector of the guide unit with a bayonet lock. The bayonet lock has been correctly fastened when the yellow location mark of the bayonet ring on the coil is in line with the opposite piece on the guide unit, the bayonet ring sits firmly and engages. Check correct installation and seat of the coil. Lift the whole guide unit including the induction coil and postion a tool holder under the coil with the correct changing plate together with the matching correctly inserted shrink chuck. It is a good idea to select the universal coil with the ferrit plate no. 3 (largest ferrit plate) and the largest available shrink chuck diameter suitable for the ferrit plate. Carefully lower the coil onto the shrink chuck. Using a test bar placed in the chuck ( in the vertically position), the coil can be centred to the chuck. Both fastening screws of the coil holder at the energy chain allow the adjusting to the left or to the right. Fig. 6: Aligning the guide unit Watch the (yellow) control points on the connector! In this condition, the fastening screws of the guide unit are tightened with the supplied 6 mmhexagonal socket key. These are accessible through the mounting bores on the the rear of the unit August 2010 ISG3200-400V/480V 12
4. Controls and commissioning ISG3200 Fig. 7: Tightening the fastening screws. 4.1.3 Connecting the compressed air supply The compressed air supply must be connected properly to the unit. The slide valve must be countered when fastening and must not be twisted (fluts in the unit). Do not twist the slide valve during installation! Compressed air must be free of oil! 4.1.4 Connecting the power supply The power supply is connected by means of a pre-mounted (CEE-CEKON) connector. 4.2 Commissioning Switch on the main switch Open the slide valve on the compressed air supply. To do so, push the blue sleeve to the right. Caution: The guide unit now moves upwards! If it does not: 1.) Check pressure in the supply line 2.) Check poles of the pressure lines (L/R) to the guide unit After switching on, the control panel shows the description and the software status of the unit It then please press the Start button to entert he shrinking menu. Caution: The guide unit moves down when the compressed air is switched off! August 2010 ISG3200-400V/480V 13
5. Operating the ISG3200 5 Operating the ISG3200 5.1 Operating buttons All the work and adjustment processes are carried out at the operator panel using 7 membrane switches. Button Button name in text Start Stop F1 Function Start the inductive heating of the shrink-fit chuck Stop the inductive heating of the shrink-fit chuck Interruption of Start Delay or Dwell-time Acknowledge error messages Manual up / down of the coil (press for at least 1s) Select special shrinking input Special functions up down Select various menu items right Confirm to the selection or settings left Return into the preceding menu 5.2 Display All the possible selection, menus and messages for the operator are shown on the display as text or symbols. The individual menus contain points of selection or input fields. A further menu is branched through moving the selection points with the arrow buttons up and down and by confirming with right. If an input box is skipped in a menu then a leap is made to the first input value. The values are modified using the up and down buttons and by pressing right you leap to the next input box. You can always skip to the preceding menu using left. August 2010 ISG3200-400V/480V 14
5. Operating the ISG3200 5.3 Switching the device on Switch on the main switch Open the slide valve at the compressed air supply. To do this, slide the blue adjustable adapters to the right (directly at the air supply, see Figure 8) The linear unit moves upwards. If no coil is fitted the carriage quickly moves upward due to the lack of weight! After switching on the main switch the unit description type and software status is shown in the display. The CONFIGURATION menu can now be displayed using the left arrow key and the Service menu using the right arrow key. By pressing the Start button automatically branched to the Shrinking menu. The ISG3200 is ready for use now. August 2010 ISG3200-400V/480V 15
6. Shrinking Main Menu ThermoGrip ISG 3200LK Configuration See page 34 Tool memory Language Display mm / inch Start delay Dwell time Fan time Lightbarrier Password on/off Change password Manuel on/ off Shrinking How would you like to shrink? - Parameter - Manual - Special Service See page 17 See page 45 Type Generator Software EEPROM Cycle no. 3200LK 2002-30 V4.0 LK40 Manual - Heating time - Power - Dwell time Coil Please put in 12 sec 100 % yes X Parameter WhichThermoGrip-geometry would you like to shrink? Special See page 30 See page 23 See page 32 - T - TSF. - TER - AllGrip Which special shrinking operation would you like to shrink? - Inverse Shrinking - Tool memory AllGrip TSF AllGrip Please put in: TSF Please put in: - Shrinking - Adaptor Coil Disc on AG06 T TER - Diameter - Dwell time Coil Disc 12 mm yes T Please put in: - Diameter - Dwell time Coil Disc 10-12 mm yes TER Please put in: - Diameter 8 mm - Adaptor ER16 - Dwell time yes Coil Disc August 2010 ISG3200-400V/480V 16
6. Shrinking 6 Shrinking Several operator menus have been integrated in the ISG 3200 to enable different tools to be gripped by (the shrink-in process) and released (shrunk-out) from the chuck. However here is some basic information and advice on shrinking. 6.1 Basic shrink-fitting information The ISG 3200 has been especially developed for high performance shrinking of hard metal and HSSE tools. In particular, the shrinking out of the HSSE tools can only be achieved with very short heating periods. To do this it is necessary to use different coils depending on the size of the tool to be shrunk. For this purpose, the ISG 3200 has a rapid change connection in the form of a bayonet fixing (see chapter on coil changing) for rapid and reliable exchange of the coils. Even if hard metal tools are not critical with respect to the coil adjustment, please ensure you adhere to the given coil and ferrit plate sizes and change them when necessary. This is the only way to achieve optimum shrink-fit results and to avoid overheating the clamping chucks and tools. In addition, if the wrong coil and ferrit plates are used the cover disc of the coil can cause damage to the tool cutting edge. The diameter of the cover disc bore is 2.5mm larger than the largest tool diameter that can be shrunk with this coil. In the case of ThermoGrip clamping chucks, the cover disc lies on the end face of the chuck which ensures that the coil is correctly positioned in conjunction with the chuck, even for extended clamping chucks. It is not possible to position slender shapes above the clamping chuck end face. In this case you require the coil limit stop available as an optional extra (see coil limit stop options). ThermoGrip chucks can be used up to temperatures of max. 450 C without structural or concentricity changes occurring. The discoloration of the front part of the chuck results from oxidation and does not lead to any impairment of the quality and functionality of ThermoGrip clamping chucks. Despite the high temperature resistance compared to conventional clamping chuck materials, the expansion of the clamping bore is in the order of only a few hundredths of a millimetre. For this reason, only tools with a ground shank and tolerance h4, h5 or h6 should be used. Tools with shank tolerance h7 cannot be securely clamped. For an overview of the shank tolerances, please refer to Section A 2.1. Please ensure that the tool shafts used in the clamping area. Due to the shrink temperatures required only move the chuck in the suitable tool holders, always wear safety Kühladaptor / cooling adaptor Cooling gloves. Shrinking chucks should only be handled with ISGK adapter 3002 T3-K/... gloves and only at the collar and not in the heated area. The maximum touching time should not exceed 5 sec. even when using the protective glove. Ensure that the chucks stand straight and secure in the tool holder. Cover the chuck with the matching cooling adapter as quickly as possible after shrinking. The longer you wait before covering it with the cooling adapter the more heat is transferred Werkzeugaufnahme / location Tool holder ISGK 3003 T3-W/.. from the chuck to the area of the holder (e.g. HSK, SK...) and to the tool. When putting on the cooling adapter ensure that the cutting edge is not damaged. Shrinking tools with shafts to DIN 1835 Form B and E or similar forms which do not have a closed cylinder geometry is possible, preference should be given to cylindrical holders such as e.g. DIN 1835 Form A as they enable the highest clamping forces. To achieve the best possible gripping forces only insert clean, grease-free shafts in the chuck. Ensure that there are no cutting flutes in the gripping area when deciding on the gripping depth. August 2010 ISG3200-400V/480V 17
6. Shrinking 6.2 Work sequences when gripping, releasing or changing a tool For your own safety, please observe the following rules when working with the ISG 3200: Always observe the safety instructions for all shrink-fitting processes! Use safety gloves! Shrinking chucks should only be handled with gloves and only at the collar and not in the heated area. The maximum contact time should not exceed 5 sec. even when using a protective glove. Wear safety goggles! 6.2.1 Clamping To clamp a tool insert the chuck in the matching tool holder (T3-W...) (coil is located in the upper end position of the cylinder) push it into the shrinking position above the holder. Ensure that the holder is positioned in the correct position. In the case of short tools to be clamped they can be inserted into the 5 mm deep counterbore at the front end of the chuck. The ISG3200 is already in the Shrinking menu and you can carry out additional tool-specific adjustments or select from previously saved parameters. If all the entries have been made, the shrinking process is triggered by the Start button. The coil slowly moves downwards until the cover disc in the coil touches the end of the chuck and the coil is thus correctly positioned. Around 3 secs pass before the generator starts. If this waiting period is too short, e.g. to insert bulky or awkwardly shaped tools, the Start Delay option can be used to set an additional delay of up to 30s. By pressing on the tool during the subsequent heating phase you assist the clamping process. If the tool has been inserted and the shrinking time has not yet ended, it is helpful to end the heating process with the Stop button, so as not to continue to heat the tool unnecessarily. In the case of long tools, and clamping chucks which do not match ThermoGrip, you should insert the tool during the heating phase. At the end of the selected shrinking period or after pressing the Stop button the coil quickly moves upwards. It is possible to insert the tool while the coil has moved back to the start position. Then place the matching cooling adapter over the tool and push the tool holder and cooling adapter onto one of the four cooling stations. 6.2.2 Releasing To release a tool insert the chuck into the holder (T3-W..) while the device is switched on (coil is located in the upper end position of the cylinder). Proceed following the instructions given under Item 6.2.1. Assist the release of the tool by lightly pulling on it. If the dwell time of the coil in the lower position is too short to safely remove heavy tools, the Stop Delay option can be used to set a delay of up to 30s. The coil then remains in the lower position, until the selected time has expired or if the Stop button is pressed. Place the removed tool on a heat resistant surface and protect people from accidentally touching the tool and the hot clamping chuck. Then immediately cover with the suitable cooling adapter and place the tool with the tool holder and cooling adapter onto one of the cooling stations. August 2010 ISG3200-400V/480V 18
6. Shrinking 6.2.3 Tool change You can remove a clamped tool during a heating phase and then immediately insert another tool. Unclamp the tool first as described under 6.2.2. Do not interrupt the heating process with the Stop button. Wait until the coil has moved back upward and then insert the new tool. Place the removed tool on a heat resistant surface and protect people from accidentally touching the tool and the hot clamping chuck. Then immediately cover with the suitable cooling adapter and place the tool with the tool holder and cooling adapter onto one of the cooling stations. 6.2.4 Special shrinking: Inverse shrinking ISG 3200 enables the shrinking in and out of tools inversely where the cutting edge diameter is larger than the coil diameter and would therefore not go through the coil during a conventional shrinking process. For this purpose you need a special slim tool holder, a coil stop and a special coil (ISGS 3200-3.1) without cover disc. The operation inverse shrinking can be selected in the menu Shrinking. Choose with the arrow keys up and down the symbol, which shows the operation shrinking top down. If this symbol is chosen, it is shown as inverse. Choose now with the arrow keys right or left the operation inverse shrinking, this is shown by the symbol. 6.2.4.1 Shrinking-in In order to shrink-in a tool, choose the function inverse shrinking in the menu Shrinking. The coil automatically goes in the lower end position of the cylinder. Now put the clamping chuck into the tool holder and position it in the coil. Take care that the tool holder with the chuck is positioned in the centre of the coil. Place the coil stop at the lift cylinder above the coil (see picture 10). Push up the coil manually, until it is placed in shrinking position to the chuck. The coil is in the correct position if the cover disc nut is on a level with the front side of the chuck. Now position the coil stop so that the coil will stop at that position when in automatic mode. Proceed as described under item 6.2.1 Shrinking-in. There is no suitable cooling fixture for the slim tool holder. Therefore, the clamping chuck cannot be cooled down in the conventional manner on a cooling station. Take the tool with the tool holder out of the coil, when the coil has retracted. Put both of them on a heat resistant mat and prevent people from touching the tool and the hot chuck accidentally. 6.2.4.2 Shrinking-out In order to shrink-out a tool put the chuck in the suitable tool holder with the unit switched on and the operation inverse shrinking selected. (The coil is located in the lower end position of the cylinder). Proceed as described in the chapter inverse shrinking-in. Assist the detaching of the tool by pulling the tool gently. August 2010 ISG3200-400V/480V 19
6. Shrinking Place the renewed tool with the tool holder out of the coil, after the coil has retracted. Put both of them on a heat resistant mat and prevent people from touching the tool and the hot chuck accidentally. 6.2.5 Tool change You have the possibility to take a clamped tool out during the heating phase and immediately replace in another tool. Firstly, shrink-out the tool, as described in the chapter inverse shrinkingout. Do not interrupt the heating process with Stop A new tool may be placed in the chuck directly after having shrunk-out the old tool without waiting for the coil to go to the lower end position of the cylinder. Put the taken out tool on a heat resistant mat and prevent people from touching the tool and the hot chuck accidentally. Remove the tool with the tool holder from the the coil after the coil has retracted. Put both the tool and the chuck on a heat resistant mat and prevent people from touching the tool and the hot clamping chuck accidentally. 6.2.6 Change the coil Ensure that there is no tool holder beneath the coil. Press the Stop button for approx. 1 sec: the linear unit moves into the lower position and it is therefore easier to change the coil. a) Dismantle the coil To do this twist the union nut on the bayonet fixing through approx. 90 anti-clockwise direction and at the same time pull the coil vertically forwards. Press the Stop button again for approx. 1s and the linear unit moves back to the start position. b) Fitting the coil When inserting the coil ensure that the lettering on the coil is on the correct side and is horizontal. Insert the coil straight and thread on the union nut. Turn the union nut through approx. 90 in a clockwise direction until you feel it locking into place. The bayonet fixing plug-in connector is correctly fastened and the yellow control points of the union nut are inline with the coil and the counterpart on the linear unit (Figure 6). Check the coil for correct installation and firm fit. Press the Stop button again for approx. 1s and the linear unit travels back upwards. Ensure that you protect the connector mechanism of coils not being used from soiling. Never leave the device for a lengthy period without a connected coil, to prevent soiling of the devices plug-in all connectors. August 2010 ISG3200-400V/480V 20
6. Shrinking 6.2.7 Change the disc Ensure that there is no tool holder beneath the coil. Press the Stop button for approx. 1 sec: the linear unit moves into the lower position and it is easier to change the disc. a) Dismantle the changing disc Press the clamping ring together and remove it from the coil. After that you can take the changing disc from the coil. b) Fit the changing disc Fit the correct changing disc suited to the correct shank-ø into the coil. After that fix the changing disc on the top of the coil housing with the clamping ring. Press the Stop button again for approx. 1s and the linear unit travels back upwards. August 2010 ISG3200-400V/480V 21
6. Shrinking 6.2.8 Shrinking with coil stop ISGF3200-N There is a possibility that with slim clamping chuck designs, special chucks or when inverse shrinking, that the coil cannot be positioned through its cover disk. In that case you should use the coil stop which can be obtained as an accessory. The coil stop is mounted bottom-up (or top down for inverse shrinking) into the lift cylinder groove (see the following picture). coil stop Fig. 9: Shrinking top down (standard) Fig. 10: Inverse shrinking bottom-up (inverse) Take care that the stop when not needed - is positioned at the lower or upper end of the lift cylinder and that the coil does not stop at the wrong position unintentionally. In order to position the coil stop, put a chuck in its tool holder in the shrinking position below the coil. The coil is in the correct position if the cover disk nut is on a level with the front side of the clamping chuck. Now position the coil stop so that the coil will be stopped at that position when going automatically. Unscrew the locking screw until the stop can be moved. Now position the coil stop so that the coil will stop at that position when going automatically. Lock the stop in this position with the locking screw. Fig. 11: Shrinking top down Guiding unit in stop position August 2010 ISG3200-400V/480V 22
6. Shrinking 6.3 Shrink-fitting operating modes PARAMETER MANUAL EXTRA..., for ThermoGrip chucks...., if you use another chuck or..., if a special chuck or tool, which tool and want to adjust the needs to be assigned a special shrinking parameters yourself. For personal shrinking adjustment shrinking program to (parameter set) or have already saved a specific parameter 6.3.1 ThermoGrip clamping chucks: PARAMETER The necessary parameters for the ThermoGrip chuck such as the generator output power, heating period, water rinsing time, coil and disc sizes for the chuck type are deposited in the factory equipment of the ISG3200 Attention: Special disc for TSF, TER and AllGrip shrinkfit chucks are necessary (see page 49).. T-chucks (Standard Type according to DIN69882-8) Designation of chuck Txxxx Coil Plate -range in mm -range in inches Shrinking time in seconds Shrinking output power in % 1 0 3-5,9 ⅛ - 3/16 3 75 1 1 6 9,9 ¼ - 5/16 3 95 1 1 10-12 3/8 3 100 1 2 12-16 ½ 5/8 3 100 1 2 16-22 ¾ 3 95 1 3 22-25 1 6 100 1 3 25-32 1-1¼ 4 100 TSF-clamping chucks (slim design) Chuck designation Futter TSFxxxx Coil Plate -range in mm Shrinking time in seconds Shrinking output power in % 1 ISGS3201-TSF03 3 2 25 1 ISGS3201-TSF04 4 2 35 1 ISGS3201-TSF05 5 2 30 1 ISGS3201-TSF06 6 2 40 1 ISGS3201-TSF08 8 2 45 1 ISGS3201-TSF10 10 2 55 1 ISGS3201-TSF12 12 3 45 1 ISGS3201-TSF14 14 2 50 1 ISGS3201-TSF16 16 2 70 1 ISGS3201-TSF18 18 2 70 1 ISGS3201-TSF20 20 2 65 1 ISGS3201-TSF25 25 3 90 August 2010 ISG3200-400V/480V 23
6. Shrinking Parameter for ISG3200 Series TER ER 16 ISG3200 d 1 [mm] Description Time Power Dwell Disc time 3 TER0300/16 0 4 TER0400/16 0 6 TER0600/16 4 47 4 1 8 TER0800/16 3 45 3 1 ER 20 d 1 [mm] Description Time Power Dwell Disc time 6 TER0600/20 4 90 3 1 8 TER0800/20 3 45 3 1 10 TER1000/20 3 45 3 1 ER 25 d 1 [mm] Description Time Power Dwell Disc time 3 TER0300/25 0 4 TER0400/25 0 6 TER0600/25 6 80 3 1 8 TER0800/25 5 85 3 1 10 TER1000/25 3 60 4 1 12 TER1200/25 3 55 3 1 14 TER1400/25 3 45 3 2 16 TER1600/25 3 45 3 2 ER 32 d 1 [mm] Description Time Power Dwell Disc time 6 TER0600/32 6 80 3 1 8 TER0800/32 4 70 5 1 10 TER1000/32 4 65 4 1 12 TER1200/32 3 60 4 1 14 TER1400/32 3 60 4 2 15 TER1500/32 3 60 4 2 16 TER1600/32 3 60 4 2 18 TER1800/32 3 60 4 2 20 TER2000/32 3 60 4 2 August 2010 ISG3200-400V/480V 24
6. Shrinking AG clamping chucks (for all standard shank tolerances) Holder designation AGxx Coil Holder Plate Collet Shrinking time in seconds Shrinking output power in % 1 AG06 AG06-G (Einschrumpfen) AG06-R (Ausschrumpfen) 3 mm 6 mm 3s 4s 100% The deposited coil is displayed in the parameter set in the type of shrinkage PARAMETER. If the deposited coil does not correspond with the actual coil that has been installed, the coil number will blink in the display. If no coil has been installed when the device is switched on a message appears in the display: STOP Please insert a coil and acknowledge this by pressing the Stop button. If the correct coil has been connected you can commence the shrinking process by pressing the Start button. Both during gripping and during releasing most tools can be inserted or removed before the set time has expired. This results from the design of the parameters to the most unfavourable tolerance conditions for the tool and chuck. If a tool can be quickly inserted or released it is purposeful to interrupt the heating purpose with the Stop button so that no more energy than is necessary is transferred to the chuck and the tool. Note: Shrink parameters are determined by the AG06 or AG20 holder only, and not by the tool diameter or the collet. Possible text displayed in the disc field would be: Shrinking in Shrinking out Holder AG06 ISG3201-AG06-G ISG3201-AG06-R The advantage of the AllGrip shrink chucks is that they can safely clamp tools with almost any shank tolerances, which is not possible with ThermoGrip -shrink chucks. After shrinking out there is a dwell time, the duration of which can be selected between 6 and 30 seconds. If the up button is pressed during the dwell time, the coil is raised and the process is interrupted. During this time, the collet can be removed using the extraction tool. August 2010 ISG3200-400V/480V 25
6. Shrinking Example for setting up: Shrinking with parameters, standard ThermoGrip-geometry shank Ø12 with dwell time ThermoGrip ISG 3200LK see page 34 see page 45 How do zou want to shrink? Select the function Parameter - Parameter - Manual - Special Which ThermoGrip-geometry would you like to shrink? - T - TSF - TER - AllGrip Select T (Standard) Enter Ø10-12mm using the up and down cursor and confirm the entries using the right button - T Please put in - Diameter 10-12 mm - Dwell time yes/no Coil Disc Set the Dwell time to yes using the up and down cursor and confirm the entries using the right button. The Coil and Disc that is needed is displayed here with the respective preset values August 2010 ISG3200-400V/480V 26
6. Shrinking Example for setting up: Shrinking with parameters,tsf-geometry shank Ø12with dwell time Note: Special change discs TSF are requirerd to shrink the TSF clamping chuck. ThermoGrip ISG 3200LK see page 34 see page 45 How do zou want to shrink? Select the function Parameter - Parameter - Manual - Special Select TSF Which ThermoGrip-geometry would you like to shrink? - T - TSF - TER - AllGrip Enter Ø12mm using the up and down cursor and confirm the entries using the right button TSF Please put in - Diameter - Dwell time Coil Disc 12 mm yes/no Set the Dwell time to yes using the up and down cursor and confirm the entries using the right button. The Coil and Disc that is needed is displayed here with the respective preset values August 2010 ISG3200-400V/480V 27
6. Shrinking Example for setting up: Shrinking with parameters, TER-geometry Toolhalder ER25 Ø12 with dwell timet ThermoGrip ISG 3200LK see page 34 see page 45 Select the function Parameter How do zou want to shrink? - Parameter - Manual - Special Select TER Which ThermoGrip-geometry would you like to shrink? - T - TSF - TER - AllGrip Enter Ø12mm using the up and down cursor and confirm the entries using the right button Select the toolholder ER25 using the up and down cursor and confirm the entries using the right button. TER Please put in - Diameter - Toolholder - Dwell time Coil Disc 12 mm ER25 yes/no Set the Dwell time to yes using the up and down cursor and confirm the entries using the right The Coil and Disc that is needed is displayed here with the respective preset values August 2010 ISG3200-400V/480V 28
6. Shrinking Example for setting up: Shrinking with parameters,allgrip AG06 ThermoGrip ISG 3200LK see page 34 see page 45 How do zou want to shrink? Select the function Parameter - Parameter - Manual - Special Select AG Which ThermoGrip-geometry would you like to shrink? - T - TSF - TER - AllGrip AllGrip Please put in: Select In for shrinking in or Out for shrinking out using the up and down cursor and confirm the entries using the right button - Shrinking In/Out - Toolholder AG06 Coil Disc After pressing Start, the following appears: The Coil and Disc that is needed is displayed here with the respective preset values Please verify: Red disc? / Green disc? ISG3201-AGXXX Shrinking with Abort with F1 August 2010 ISG3200-400V/480V 29
6. Shrinking 6.3.2 Shrinking with free Parameter selection: MANUAL This mode is intended for shrinking special tools or special clamping chucks, which only occur in seldom cases. Furthermore, this mode can be used to set the shrinking parameters for frequently used special chucks or tools, in order to deposit these as parameter set under a freely selectable name. For flexible adjustment to the various tasks both the shrinking time can be set in 1 sec steps (0 25 s) and the generator output power can be set in 5% steps (50% - 120%). By delivery of the ISG3200 the manual shrinking procedure is closed. The manual shrinking process can only be stopped after entering a password and by switching the manual shrinking process on in the configuration menu. There is also a possibility to carry out the shrinking process using the START button when the heating period = 0 seconds is selected. The chuck is heated with the set energy for the period where you press this button. The shrinking process is ended after letting go of the START button and the chuck is automatically driven downwards for the cooling process. If the heating energy selected (time x output power) is too high, the shrink-fit chuck and/or the tool can easily overheat. In serious cases, permanent damage can occur to the chucks and tools. Please therefore ensure the following is observed: If the suitable parameter is not known, begin with small values for the time and output power and increase them until the gripping and releasing functions workperfectly! Allow the chuck and tool to cool to room temperature between the attempts! An internal check of the coil cannot be carried out in this case. Therefore ensure that the coil is suitable for the chuck and the tool. To do this, check that the clamping area of the chuck fits in the coil, the coil cover disc touches the end face of the chuck (or is at least only a very short distance apart) and that the tool has sufficient clearance in the cover disc bore so that the cutting edge cannot be damaged! If you notice that the chuck, tool or coil heat to very hot temperatures, interrupt the process immediately using the Stop button and check the shrinking parameters! Guidelines for experimentally determining the necessary shrinking parameters for special chucks and special coils 1. Basic settings: Special chucks and HSSE / CARBIDE tool shafts with universal coil and changing disc (ISGS3201-1, ISGS3201-2 und ISGS3201-3) Special chucks and CARBIDE tool shafts with a special coil Output Power P Shrinking time T 100% 2 seconds 70% 3 Seconds August 2010 ISG3200-400V/480V 30
6. Shrinking 2. Sequence: Insert tool shank in the counterbore and start the shrinking process. a) If the tool slides completely in the chuck bore: Use the current values of Heating time and Output Power as suitable shrinking parameters. b) If the tool does not slide into the chuck bore: Increase the shrinking time T in steps of 1s and then repeat the shrinking process until the tool shaft completely slides into the chuck bore. It is important to ensure that the shrink-fit chuck is cooled down to room temperature before each further shrinking attempt. Then accept the last selected shrinking parameters Heating time and Output Power. c) The tool shaft only slides partially in to the shrinking chuck bore and is thus not correctly gripped during cooling process. Allow the chuck to completely cool down to room temperature and increase the shrinking time T in steps of 2s, shrink and try to pull out the tool. Repeat this step until the tool can be easily removed from the heated chuck. It is important to ensure that the shrink-fit chuck is cooled down to room temperature before each further release attempt. Then accept the last selected shrinking parameters Heating time and Output Power are taken over. Example for setting up: Manual shrinking, with a heating time of 4sec, Output power of generator 100% and with dwell time ThermoGrip ISG 3200LK see page 33 see page 45 How do zou want to shrink? Select the function manual. - Parameter - Manual - Special Set the Heating period to 4 seconds using the up and down cursors and confirm the entries using the righ button. Please put in - Heating time 4 sec - Power 100% - Dwell time yes Coil Set the Output power to 100% using the up and down cursors and confirm the entries using the righ button. Set the Dwell time to Yes using the up and down cursors and confirm the entries using the righ button. August 2010 ISG3200-400V/480V 31
6. Shrinking 6.3.3 Shrink-fitting according to programmed special parameters: SPECIAL In this menu different special shrinking procedures can be selected in the future. Special shrinking procedure : tool memory (Shrink after programmed special parameters) In this menu, you can shrink a Parameter set that has already been saved and consists of the shrinking time, shrinking output power, coil and the correct replacement disc through entering a determined name of the set. Parameter set entries are made in the menu Configuration- Tool memory (see chapter 7.1) ThermoGrip ISG 3200LK see page 34 see page 45 How do zou want to shrink? - Parameter - Manual - Special Select the function Special Wich special shrinking procedure would you like to shrink? Select Tool memory - Invers - Tool memory Tool memory S01: - Heating time 1s - Power 100% - Dwell time 0s - Coil 1 - Disc 1.1 Now the Parameter sets that have already been saved are displayed. (See chapter 7.1 to obtain more information concerning the saving of Parameter sets.) The shrinking process begins after pressing the START button. August 2010 ISG3200-400V/480V 32
6. Shrinking Special shrinking process: Inverse shrinking (shrinking from the bottom) With the ISG3200, tools with a larger cutting diameter than the coil diameter which would not go through the coil during the usual shrinking process can be shrunk-in and out from the bottom. For inverse shrinking a special slim tool holder, a coil stop and a special coil (ISG3200-3.1) without counterbore are required. ThermoGrip ISG 3200LK see page 34 see page 45 How do zou want to shrink? - Parameter - Manual - Special Select the function Special. Wich special shrinking procedure would you like to shrink? Select Inverse shrinking - Invers - Tool memory Set the Heating period to 5 seconds using the up and down cursors and confirm the entries using the righ button. Please put in: - Heating time 5s - Power 100% Set the Output power to 100% using the up and down cursors and confirm the entries using the righ button. - Coil 1 August 2010 ISG3200-400V/480V 33
7.Configuration Menu Item 7 Configuration Menu Item Configuration Tool Memory Language Displaz mm / inch Start delay Dwell time Fan time Lightbarrier Password on/off Change password Manual on/off - deutsch - english - francais - italiano - portugues - espanol Display Language Display light dark Choose brightness Start delay Start delay Insert time Dwell time Dwell time Insert time Fan time Water cool time min 2 4 6 8 10 Insert time Lightbarrier 4 7 1 6 Please enter new password 4 7 1 6 Password save? August 2010 ISG3200-400V/480V 34
7.Configuration Menu Item Individual adjustments to the device can be made in the CONFIGURATION menu. These adjustments are retained even after the unit is shut down until the operator makes a change. After switching on the mains the unit type designation and software status is shown in the display. For arriving at menu Configuration press left. If the input field for password evaluation is on in the main CONFIGURATION menu you must enter a password of your choice with max. 4 decimal figures (to deactivate the password evaluation see Chapter 7.7). The following appears in the display: 0 0 0 0 You can increase or decrease the decimal characters using the up or down arrow keys. Using the right button you can position the cursor onto the next decimal figure of the password. Please enter new password 0 0 0 0 Check password If all 4 decimal figures are set to the password known to you (f.e. 0000, corresponds delivery status ) use the right button to position the cursor on the confirmation field and then acknowledge with up or down. If the wrong password has been entered, you are given an error message and must repeat the input as described above. If the password is correct, the following appears in the main CONFIGURATION display: Configuration Tool Memory Language Displaz mm / inch Start delay Dwell time Fan time Lightbarrier Password on/off Change password Manual on/off Use the up and down arrow keys to move from one input field to the next. The field currently selected is then shown with an coloured background. The actual selection is carried out using the right button. For Quitting the menu press left. August 2010 ISG3200-400V/480V 35
7.Configuration Menu Item 7.1 Tool Memory (Programming your own shrinking parameters) After being selected in the Tool Memory Menu, the shrinking Parameters or Parameter sets consisting of the shrinking time, shrinking output power, dwell time, etc. can be repeatedly saved under a name that does not possess more that 17 characters. Before information is stored, do not overload (overheat) the chuck, tool and device with these values. (Read Chapter 6.3.2 Shrinking with free Parameter selection!) Use the up arrow keys to first position the cursor on the name field of the parameter set and then press up or down to select an already saved parameter set for changing or for an empty name field for setting up a new parameter set. Tool memory S01: - Heating time 1s - Power 100% - Dwell time 0s - Coil 1 - Disc 1.1 The storage location can be selected using the up and down cursors. The storage location that has been selected is confirmed using the right button. The actual deposited values are displayed in the input boxes. If no values have been programmed, the pre-set parameters appear as shown on the left. After accepting the storage location using the right button, the cursor leaps to the heating time input box. Now the required value can be set using the up and down cursors and are taken over using the right button. The cursor leaps automatically to the next input box. The display leaps to the mask for entering the name after the water cooling time has been set using the up and down cursors and has been confirmed using the right button. Tool memory!"#$%&'()+,-./0123456789 :;<=>\@ABCDEFGHIJKLM NOPQRSTUVWXYZ \ ^ S01: After leaping to the display Enter name, the cursor is now positioned by the character. This character is equivalent to the space character. Now the desired letters or characters can be selected using the up and down cursor keys. If you keep pressing the cursor key, you enter the fast mode. If the desired letter has been selected, this is accepted using the right button and is moved to the bottom. The cursor stays on the selected letter. Now the next letter can immediately be selected using the up and down cursor keys. After the name has been entered, the menu is left using the left button. To be able to delete a letter, the delete function must be selected using the up and down cursor keys and then the value that had been selected is deleted using the right button. A maximum of 17 characters can be attached together as a name. August 2010 ISG3200-400V/480V 36
7.Configuration Menu Item Flow-chart of Tool memory: ThermoGrip ISG 3200LK see page 45 Tool Memory Language Displaz mm / inch Start delay Dwell time Fan time Lightbarrier Password on/off see page 17 Tool memory S01: - Heating time 1s - Power 100% - Dwell time 0s - Coil 1 - Disc 1.1 Tool memory!"#$%&'()+,-./0123456789 :;<=>\@ABCDEFGHIJKLM NOPQRSTUVWXYZ \ ^ S01: The cursor is positioned on this symbol to delete letters or characters of the name and are then accepted using the righ button. To jump on the previous menus, press left August 2010 ISG3200-400V/480V 37
7.Configuration Menu Item 7.2 Setting the language After having chosen the Language menu use the up and down arrow keys to select the required national language. The respective current field is then displayed with an inverse coloured background. By pressing the left or right arrow keys the setting can be acknowledged and you jump back into the main CONFIGURATION menu. The diagram mapped below shows the conversion of the language to French. ThermoGrip ISG 3200LK see page 45 Tool Memory Language Displaz mm / inch Start delay Dwell time Fan time Lightbarrier Password on/off see page 17 - deutsch - english - francais - italiano - portugues - espanol August 2010 ISG3200-400V/480V 38
7.Configuration Menu Item 7.3 Adjust the display brightness Use this item to adjust the brightness of the display (contrast) to the ambient conditions. By pressing the up arrow key the image in the display becomes darker and lighter with the down arrow key. Display Display light dark Choose brightness The current value is taken over automatically. For leaving the menu quit with left or right 7.4 Switching between mm / inch The diameter of the tool can be shown on the display in mm or in inches. Configuration Tool Memory Language Display mm / inch Start delay Dwell time Fan time Lightbarrier Password on/off Change password Manual on/off To do this move the cursor in the main CONFIGURATION menu using the up or down arrow keys until the mm / inch input field is displayed with an inverse coloured background. Now use the right button to switch backwards and forwards between mm and inches. 7.5 Enter start delay Around 3 seconds pass before the generator starts. If this waiting time is too short to insert bulky tools say, the Start Delay option can be used to set an additional delay of up to 30s. Start delay Start delay Press the up arrow key to increase the delay time to the start of the heating phase and reduce it with the down arrow key. Insert time August 2010 ISG3200-400V/480V 39
7.Configuration Menu Item The current value is taken over automatically. For leaving the menu quit with left or right The diagram mapped below shows the conversion of the Start Delay - value to 15 sec. ThermoGrip ISG 3200LK see page 45 Tool Memory Language Display mm / inch Start delay Dwell time Fan time Lightbarrier Password on/off see page 17 Start delay Zeit wählen August 2010 ISG3200-400V/480V 40
7.Configuration Menu Item 7.6 Entering dwell time After the selected shrinking time has ended, the coil is rapidly driven upwards. If the dwell time of the coils in the lower position is not long enough, a delay time of 30 seconds can be set in the option of the dwell time that enables the safe extraction of heavy tools with shrink fitting. In this case the coil stays in the lower position until the selected time has expired or unless the Stop button is activated. Dwell time Dwell time Insert time The dwell time of the coil in the lower position is increased using the up arrow key and is reduced using the down arrow key after the heating time has ended. The current value is taken over automatically. For leaving the menu quit with left or right The diagram mapped below shows the conversion of the dwell time value to 15 seconds. ThermoGrip ISG 3200LK see page 45 Tool Memory Language Display mm / inch Start delay Dwell time Fan time Lightbarrier Password on/off see page 17 Dwell time Insert time August 2010 ISG3200-400V/480V 41
7.Configuration Menu Item 7.7 Setting up of Fantime Fan time Water cool time min 2 4 6 8 10 Insert time The fantime is increased using the up arrow key and reduced using the down arrow key. The current value is taken over automatically. For leaving the menu quit with left or right 7.8 Photoelectric barrier sensitivity To guarantee safe operation of the cooling station photoelectric barriers, it may be necessary to adjust the sensitivity of the photoelectric barriers to the ambient light. In a light environment a low sensitivity should be selected and in a dark environment a high sensitivity selected. Use the up and down arrow keys to select the required reflex light barrier position. The display symbolises the position of the reflex light barriers on the top view of the fan plate from left to right. The respective current position is then displayed with an inverse coloured background. Lightbarrier By pressing the right arrow key the reaction sensitivity of the reflex light barrier is increased, i.e. a cooling station positioned before it is detected at a greater distance and the fan is switched on. The left arrow key is used to reduce the reaction sensitivity of the reflex light barrier. When making these adjustments it must be noted that if the reaction sensitivity is set too high the fan can be accidentally switched on by external light (sun light). The following methods are therefore recommended: Fan positions Select a cooling position and place a cooling adapter at a distance of max. 1mm in front of the reflex light barrier. Press the right arrow key until the corresponding fan starts up and the LED on the control panel lights up. Now use the left arrow key to reduce the value, remove the cooling adapter, and test whether the fan remains off when external light acts on it and if necessary increase the value again. Repeat for all the other cooling positions. Shrinking position Proceed as above, however observe the LEDs on the control panel: If all 4 LEDs light up, the reflex light barrier is activated. August 2010 ISG3200-400V/480V 42
7.Configuration Menu Item 7.9 Password on / off Your settings can be protected against unintentional changes using a password in the Configuration menu of the ISG3200. To Tool Memory Language Display mm / inch Start delay Dwell time Fan time Lightbarrier Password on/off Configuration do this move the cursor in the main CONFIGURATION menu using the up or down arrow keys until the Password off / on input field is displayed with an inverse coloured background. Use the right button to now switch backwards and forwards between off and on. If Password on appears in the display the Change password input field is automatically added 7.10 Lock manual shrinking operation With the ISG3200, it is possible to lock the function Manual shrinking for the operator using a password. The function is only applied when ThermoGrip shrink fit chucks are used and any overheating occurs as a result of an operating error of the operator must be excluded. First of all a password must be assigned to be able to lock the manual shrinking process (see 7.10 change or assign password) For this purpose, proceed to the input box Password off / on in the Configuration of the main menu until this is displayed using the up or down arrow keys. Using the right button you can switch between on or off. If Password on appears in the display, the input box Change password is also automatically inserted. ThermoGrip ISG 3200LK see page 45 Tool Memory Language Display mm / inch Start delay Dwell time Fan time Lightbarrier Password off see page 17 Tool Memory Language Display mm / inch Start delay Dwell time Fan time Lightbarrier Password on Change password Manual on/off August 2010 ISG3200-400V/480V 43
7.Configuration Menu Item 7.11 Change or assign password If the input field for password evaluation in the main CONFIGURATION menu is set to on, you can enter a password of your choice with up to 4 decimal figures. Tool Memory Language Display mm / inch Start delay Dwell time Fan time Lightbarrier Password on Change password the up or down arrow keys until the Change password input field is displayed with an inverse coloured background. Press right to now select the next menu to enter the new password The following appears in the display: 0000 which corresponds to the delivery status 0 0 0 0 Please enter new password 0 0 0 0 Check password You can increase or reduce the decimal figure using the up or down arrow keys. Using the right button you can position the cursor onto the next decimal figure of the password. You can leave the menu without saving the password through pressing the left button. If all 4 decimal figures have been set as requested, position the cursor with right on the field and quit with up or down. As a precaution, you asked to confirm the entries using up or down, or you can correct it as described above or quit the menu without saving (press left). August 2010 ISG3200-400V/480V 44
8.Service Menu Item 8 Service Menu Item The Service menu item is used to display the number of shrinking cycles carried out and the software / hardware status of your shrinking device. Additionally in this menu you can securely and easily read in the control data required for future heating coils using a plug-in memory module. This memory module is part of the extent of delivery for special coils. After switching on the mains switch the type designation and software status of the unit is shown on the display. Before the ISG3200 directly switches to the main Shrinking menu, it is possible to browse through the Service menu for 10s by pressing the right arrow key. The following appears in the display: Type Generator Software EEPROM Cycle no. 3200LK 2002-30 V4.0 LK40 he displayed values have the following significance: Rel. Genarator Software EEPROM Cycles no the equipment family Number of the generator installed the control field software version the variable memory version number of all shrinking cycles carried out August 2010 ISG3200-400V/480V 45
9. Cleaning and Servicing 9 Cleaning and Servicing The unit must be cleaned regularly. To do this, switch it off at the mains and depressurise (remove the mains plug and switch off the compressed air). The device can be cleaned on the outside using a moist cloth and standard (solvent-free) cleaning agents. Keep the unit clean and clean as necessary! Do not use easily combustible cleaning agents! Never use compressed air to clean! The device may only be opened or repaired by skilled personnel! August 2010 ISG3200-400V/480V 46
10. Contacting the Manufacturer 10 Contacting the Manufacturer These operating instructions can only serve to generally describe the function and operation of the ThermoGrip induction generator. To solve special problems and to carry out repairs and make any changes not described in these operating instructions, please contact the Bilz Werkzeugfabrik GmbH & Co KG who will be pleased to help you. In case of problems or enquiries, please note the unit serial number and the software status. The series number is located on the rating plate on the back of the unit and the software status is displayed as part of the test in the operator display after switching the unit on and in the Service menu beneath the version numbers. Contact Bilz at: Bilz Werkzeugfabrik GmbH & Co. KG Vogelsangstrasse 8, 73760 Ostfildern Postfach 1155, D-73747 Ostfildern Tel. (049) 0711/34801-0 Fax (049) 0711/34812-56 info@bilz.de Up-to-date news about ThermoGrip can also be found on the Internet sites www.bilz.de and www.thermogrip.de. August 2010 ISG3200-400V/480V 47
11.Appendix 11 Appendix 11.1 Error messages and corrective measures Error message Possible cause Corrective measures No coil available Data invalid Tool holder is not in shrinking position Identification error Unsuitable shrinking geometry for shrinking process - Programmed coil and fitted coil are not identical - No coil fitted Values in the parameter set invalid reflex light barrier for the detection of a cooling adapter in the shrinking position has not been activated attempt to shrink with unsuitable chuck - Change programming or coil - Insert the correct coil - Fit a coil - Set the correct values for EXTRA shrinking - Place cooling adapter in better position - Increase the sensitivity of the reflexion light barrier in CONFIG - use Thermogrip-chucks or compatible Overtemperature cooling body - internal temperature of generator to high - Wait to cool down Safety circuit open - No compressed air -No compressed air - Operating pressure too low -Not enough operating pressure - Coil temperature > 60 C -Coil temperature Telegram error -Generator connection fault Requested power is not possible due to undervoltage Current defect in coil Current defect in IGBT Internal link disturbed Connection between generator and operating panel faulty mains supply is to low (400V±10%) or breaks down during shrinking Current monitoring of the coils diagnoses over/ under current: Missing 1 Phase, mains supply is to low (400V±10%) or breaks down during shrinking Relay fault Output stage relay doesn t close Try again - Check air supply - Increase operating pressure to 6 bar - Leave the coil to cool down &check the cause Check the connections in the device Check mains supply - at mains receptacle - in device behind the fuses - Try again - Check coil contacts Check mains supply - at mains receptacle - in device behind the fuses August 2010 ISG3200-400V/480V 48
11.Appendix Faults Possible cause Corrective measures Fan runs constantly Device cannot be started up and programmed direct sunlight on the fan s reflexion light barrier - Lack of compressed air - No electric supply - Adjust the sensitivity of the reflexion light barrier in CONFIG - Set up the ISG3200 in a suitable location - Fit sun protection - Connect and/or check the power and compressed air supply Should these measures fail to start up the ISG3200, please contact your supply firm or the customer service. August 2010 ISG3200-400V/480V 49
11.Appendix 11.2 Technical data 11.2.1 ISG3200-400V Ident Nr. 9070066 Voltage 400 V 50/60 Hz Maximum current 16 A Nominal power 11 kw Sound level < 70 db Weight 40 kg Dimensions L = 500mm x W = 650mm x H = 910mm Compressed air min. 6 bar to 10 bar, oil-free Compressed air: dried, oil-free and filtered (5 µm) 11.2.2 ISG3200-4800V Ident Nr. 9070460 Current supply 3 x 480 V / 15 A Sound level < 70 db Weight 40 kg Dimensions L = 500mm x W = 650mm x H = 910mm Compressed air min. 6 bar to 10 bar, oil-free Compressed air: dried, oil-free and filtered (5 µm) 11.2.3 Overview Shank Tolerances The following shank tolerances are required for the various shank diameters: Shank Ø 3mm 4mm 5mm 6mm Shank Tolerance h4 h4 h5 h6 11.3 Scope of supply Processor-controlled induction generator ISG3200 Designation Order No. Standard design: Basic machine ISG3200, guide unit with cable harness, quick-change coil technology and 4 air cooling stations, 6 mm hex.socket key with cross handle. Power supply 400 Volt/16 A, compressed air connction 6 bar, oilfree Goggles Manual ISG3200 6726139 black 6726140 grey August 2010 ISG3200-400V/480V 50
11.Appendix 11.3.1 Possible additions and optional accessories Coil 1 for ThermoGrip >3-32 mm ISGS 3200-1 6726141 Coil 2 for ThermoGrip >32-50 mm ISGS 3200-2 6726142 Changing plate 1 for Coil 1 Ø 3-5,9 mm ISGS 3201-0 6726157 Changing plate 1 for Coil 1 Ø 6-12 mm ISGS 3201-1 6726143 Changing plate 2 for Coil 1 Ø 12,1-22 mm ISGS 3201-2 6726144 Changing plate 3 for Coil 1 Ø 22,1-32 mm ISGS 3201-3 6726145 Tool holder for HSK-32 T3-W/HSK32 6725939 Tool holder for HSK-40 T3-W/HSK40 6725940 Tool holder for HSK-50 T3-W/HSK50 6725941 Tool holder for HSK-63 T3-W/HSK63 6725942 Tool holder for HSK-80 T3-W/HSK80 6725943 Tool holder for HSK-100 T3-W/HSK100 6725938 Tool holder for SK-40 T3-W/SK40 6725944 Tool holder for SK-50 T3-W/SK50 6725945 Cooling adapter for ThermoGrip 3.0 6 T3-K/3-5,9 6725996 Cooling adapter for ThermoGrip 6.1 9 T3-K/6-9 6725955 Cooling adapter for ThermoGrip 9.1 12 T3-K/9,1-12 6725956 Cooling adapter for ThermoGrip 12.1 16 T3-K/12,1-16 6725951 Cooling adapter for ThermoGrip 16.1 22 T3-K/16,1-22 6725953 Cooling adapter for ThermoGrip 22.1 32 T3-K/22,1-32 6725954 Measuring adapter 6mm T3-M 0600 6725959 Measuring adapter 8mm T3-M 0800 6725962 Measuring adapter 10mm T3-M 1000 6725963 Measuring adapter 12mm T3-M 1200 6725964 Measuring adapter 14mm T3-M 1400 6725966 Measuring adapter 16mm T3-M 1600 6725967 Measuring adapter 18mm T3-M 1800 6725968 Measuring adapter 20mm T3-M 2000 6725969 Measuring adapter 25mm T3-M 2500 6725970 Measuring adapter 32mm T3-M 3200 6725971 Cooling station with two additional fans ISGK2002 6725725 Fixing for ISG3200 with laserpointer ISGF3200 6726154 ThermoGrip chuck with various holders, coils and further cooling adapters, please see brochure or on request! August 2010 ISG3200-400V/480V 51
11.Appendix 11.3.2 Length pre-setting for ThermoGrip chucks On request 11.3.3 Ejecting broken tools On request 11.3.4 Cooling adapters with integrated temperature sensors On request 11.3.5 Trolley for ISG3200 and ISG2000 On request August 2010 ISG3200-400V/480V 52
11.Appendix 11.4 Menu Overview ThermoGrip ISG 3200LK Configuration See page 34 Tool memory Language Display mm / inch Start delay Dwell time Fan time Lightbarrier Password on/off Change password Manuel on/ off Shrinking How would you like to shrink? - Parameter - Manual - Special Service See page 17 See page 45 Type Generator Software EEPROM Cycle no. 3200LK 2002-30 V4.0 LK40 Manual - Heating time - Power - Dwell time Coil Please put in 12 sec 100 % yes X Parameter WhichThermoGrip-geometry would you like to shrink? Special See page 30 See page 23 See page 32 - T - TSF. - TER - AllGrip Which special shrinking operation would you like to shrink? - Inverse Shrinking - Tool memory AllGrip TSF AllGrip - Shrinking - Adaptor Coil Disc on AG06 T TER TSF - Diameter - Dwell time Coil Disc 12 mm yes T - Diameter - Dwell time Coil Disc 10-12 mm yes TER - Diameter 8 mm - Adaptor ER16 - Dwell time yes Coil Disc August 2010 ISG3200-400V/480V 53
11.Appendix Shrinking See page 17 How would you like to shrink? - Parameter - Manual - Special Manual - Heating time - Power - Dwell time Coil Please put in 12 sec 100 % yes X Parameter WhichThermoGrip-geometry would you like to shrink? Special See page 30 See page 23 See page 32 - T - TSF. - TER - AllGrip Which special shrinking operation would you like to shrink? - Inverse Shrinking - Tool memory AllGrip TSF AllGrip - Shrinking - Adaptor Coil Disc on AG06 T TER TSF - Diameter - Dwell time Coil Disc 12 mm yes T - Diameter - Dwell time Coil Disc 10-12 mm yes TER - Diameter 8 mm - Adaptor ER16 - Dwell time yes Coil Disc August 2010 ISG3200-400V/480V 54
11.Appendix Configuration Tool Memory Language Display mm / inch Start delay Dwell time Fan time Lightbarrier Password on/off Change password Manual on/off - deutsch - english - francais - italiano - portugues - espanol Display Language Display light dark Choose brightness Start delay Start delay Insert time Dwell time Dwell time Insert time Fan time Water cool time min 2 4 6 8 10 Insert time Lightbarrier 4 7 1 6 Please enter new password 4 7 1 6 Password save? August 2010 ISG3200-400V/480V 55
11.Appendix Data input shrinking EXTRA Back to the menue Configuration Tool Memory Language Display mm / inch Start delay Dwell time Fan time Lightbarrier Password on/off Tool memory!"#$%&'()+,-./0123456789 :;<=>\@ABCDEFGHIJKLM NOPQRSTUVWXYZ \ ^ S01: Service Type ThermoGrip Generator Software EEPROM Zyklenzahl 3200LK 2002-30 V4.0 LK40 August 2010 ISG3200-400V/480V 56
11.Appendix 11.5 EU STATEMENT OF CONFORMITY In accordance with the EU Machine Directive 2006/42/EG We herewith declare BILZ Werkzeugfabrik GmbH & Co. KG that the machine designated below corresponds to the pertinent safety and health requirements of the EU machine directive with regard to its design and construction and in the version brought into circulation. In the event of any changes to the machine for which we have not been consulted, this statement becomes null and void. Designation of the machine: Machine type: Relevant directives: Induction unit ISG3200 Low Voltage Directive 2006/95/EG Applied harmonized standards, DIN EN 61000-6-2 particulary: DIN EN 55011, Group 2,Kl.A DIN EN 60519, Part 1 and 3 Applied national standards (USA): FCC Part 18 (Edition 10-1-01) T H E C O M P A N Y Company name: Bilz Werkzeugfabrik Company form: GmbH & Co. KG Headquarters: Vogelsangstr.8 D 73760 Ostfildern Telefon : +49/711/3 48 01 0 Telefax : +49/711/3 48 12 56 E-Mail : vertrieb@bilz.de Internet : www.bilz.de Register of companies: HRA 210313, Amtsgericht Stuttgart Year founded: 1919 Ostfildern, September 29, 2009 General manager: Michael Voss August 2010 ISG3200-400V/480V 57
11.Appendix 11.6 Instructions Safety Glove Description: 5-Finger heat protection glove, outer layer consisting of para aramide yarn (KEVLAR) Fine knitted fabric lined with aramide felt and 100% Nornex knitted fabric Availability: Size 10 Colour: Manufacturer/ Supplier Description: Category: Instructions: Care and repairs Storage: yellow JUTEC GmbH, Mellumstr. 23-25, D-26125 Oldenburg These gloves have been designed to protect your hands. They are made of the materials named above. The characteristic features of these gloves are their long service life and outstanding comfort. 95 Check that the gloves offer suitable protection for the activity you are currently performing. Select the gloves to fit the size of your hands. Remove the gloves from the wrapping. When using the gloves, pay attention to the following points: The maximum touching time depends on the area touched. For safety reasons this time should never exceed 5 sec. The open structure of these gloves means that they cannot protect your hands from punctures and impacts from pointed objects. Penetration by liquids is also possible. For protection from chemicals, gloves resistant to such substances should be worn over these gloves. Oil, grease and moisture reduce the resistance of all gloves to cutting damage and should be avoided. KEVLAR gloves are resistant to tearing. Do not use these gloves near machines with moving parts, as your hands could get pulled into the machine. KEVLAR gloves can be dry-cleaned or washed according to the instructions on the label. Wash in water and mild detergent at maximum 40 C. DO NOT USE softening agents, bleach or oxidising agents, as these weaken the aramide fibres and reduce the cut-resistance of the gloves. After washing the gloves, check them carefully for any cuts and worn places. Do not use gloves which are damaged too much and can no longer be repaired, as these no longer offer adequate protection. The gloves should be kept in their original wrapping in a dry, clean place. Avoid exposing the gloves to moisture or high temperatures. Warning: The degree of protection required by a special task depends on the risks involved. You yourself bear final responsibility for selection of the best safety equipment for the risks involved in your workplace. Please check whether this article offers adequate protection for the jobs of work you have to perform. We offer a whole range of cut- and heat-proof KEVLAR gloves for high-risk jobs of work. August 2010 ISG3200-400V/480V 58
11.Appendix 11.7 Connection socket of ISG3200 1 Allocation of the CEE socket Pin name Pin designation Wire colour L1 Phase L1 brown L2 Phase L2 black / grey L3 Phase L3 black N Neutral blue PE Ground wire green-yellow The nominal voltages between the phases are 3x400V (-10/+10%) Measurement between the pins Voltage in VAC N L1 PE L1 230 N L2 PE L2 230 N L3 PE L3 230 L1 L2 400 L1 L3 400 L2 L3 400 Further hints: connecting the protected earth PE and connecting the neutral N is essential! if an earth-leakage circuit breaker is used for the protection of the CEE-socket, it must be 4-polar. August 2010 ISG3200-400V/480V 59