OPERATING MANUAL ThermoGrip Induction unit ISG2200 Bilz Werkzeugfabrik GmbH & Co. KG Vogelsangstrasse 8 73760 Ostfildern Phone ++49/711/34801-0 Fax ++49/711/3481256 April 2010 ISG2200 1
Guide to this operating manual Guide to this operating manual Foreword This operating manual is part of the technical documentation for the ThermoGrip Induction Unit ISG2200, manufactured by BILZ Werkzeugfabrik GmbH & Co. KG The operating manual contains all information necessary for correct use of the unit. All data contained in this manual is correct at the time of printing of this manual. Design and technical data can change according to further developments without notice. No claims will be accepted or deduced from the contents of this manual (data, diagrams, drawings, descriptions, etc.) Subject to errors! The operation manual intends to make it easier for the user to get to know the ThermoGrip ISG2200 induction unit and to use it properly and safely for its intended purpose. Structure The operating manual contains important instructions for operating the ISG2200 unit safely, correctly and economically, for the avoidance of dangerous activity, optimising machine performance thus increasing the reliability and service life of the induction unit. The manual consists of 8 chapters and an appendix containing further information. The headline shows the current chapter. The foot note shows the issue of compilation and, the name of the unit. Attention Please retain the packing material for the ISG2200 and use this for possible future shipping. This is the only way of guaranteeing safe transportation. April 2010 ISG2200 2
Symbols and pictograms Symbols and pictograms Warnings Warnings are marked by warning triangles with a hazard symbol, and warn of dangers resulting in personal injury or damage to property. General warning Hazard posed by electric current or voltage Commands Commands are marked by circles with hazard symbol or squares with instructions, and describe an activity or the use of certain items or objects. Wear goggles Wear safety gloves Shrinking chucks should only be handled with gloves and in the area of the collar not in the heated area. The maximum contact time should not exceed 5 sec. even when using a protection glove. Notes Notes are marked by the information pictogram and contain recommendations or other additional information. Example: Detailed instructions for the chemical test are available from your supplier. Lists Lists are marked by the symbol Example: Can be used for high speeds Highest clamping forces Slim body chuck Activities Activities are marked by the symbol and provide instructions for the stated activity. The result of the activity can be stated as explanation. Example: Change coil Set shrinking time Remove tool April 2010 ISG2200 3
Contents Contents Guide to this operating manual... 2 Foreword... 2 Structure... 2 Symbols and pictograms... 3 Contents... 4 1. Unit overview... 6 2. General information about ThermoGrip... 7 3. General safety instructions... 8 3.1 Choice of the Location... 8 3.2 Hazards from electric components... 9 3.3 Hazards from hot components... 9 3.3.1 Protecting the shrink chuck from overheating...10 3.4 Hazards from electromagnetic radiation... 10 3.5 Other hazards... 10 4.Commissioning ISG2200... 11 4.1 Assembly... 11 4.2 Commissioning... 11 5. Control buttons of the ISG2200... 11 5.1 Keys and light emitting diodes... 11 5.2 LED display... 12 5.3 Configuration of the ISG2200... 12 5.3.1 Configuration of the fan running time...12 5.3.2 Configuration of the parameter table for automatic mode...12 6. Shrinking... 13 6.1 Basic information on Shrinking... 13 6.2 Procedures involved in shrinking process and tool changing... 14 6.2.1 Shrinking in...14 6.2.2 Shrinking out...15 6.2.3 Tool change...15 6.3 Shrink-fitting operating modes... 16 6.3.1 Shrinking of ThermoGrip chucks : automatic mode...16 6.3.2 Shrinking of other chucks: manual mode...17 7. Cleaning and maintenance... 18 8. Service... 18 April 2010 ISG2200 4
Contents Appendix... 19 A 1. Troubleshooting... 19 A 2. Selection table for shrinking plates... 19 A 3. Technical data... 20 A 3.1 Overview Shank Tolerances...20 A 4. Scope of supply... 21 A 4.1 Optional extras...21 A 5. EC STATEMENT OF CONFORMITY... 22 A 6. Instructions Safety Glove... 23 A 7. Connection socket for ISG2200... 24 A 8 Transformer for ISG2200... 25 A 9. Wiring diagram... 26 April 2010 ISG2200 5
1. Unit overview 1. Unit overview Coil guiding unit ThermoGrip chuck toolholder control panel Fig. 1: ThermoGrip induction unit ISG2200 Fig. 2: control panel and display April 2010 ISG2200 6
2. General information about ThermoGrip 2. 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 area. This means that little energy is stored in the clamping chuck and the cooling-down time is reduced accordingly. Fig. 3: Shrunk-in tool 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 April 2010 ISG2200 7
3. General safety instructions 3. General safety instructions A new technique has been introduced for ThermoGrip which makes tool change with the matching ThermoGrip shrinking chuck practical, efficient and energy saving. The ThermoGrip induction generator has been designed with state-of-the-art engineering, and is safe to operate. Nevertheless, the unit can pose a hazard if it is not used by trained or at least instructed staff and/or not used for its intended purpose. Therefore please comply with the following instructions: Read the operating manual carefully before initial commissioning and operation of the unit, and become well acquainted with the control elements! The operating manual is an integral part of the ThermoGrip induction generator and must be easily accessible, legible and understandable for all persons working with the unit. The unit may only be operated by trained, instructed personnel! The unit may only be used for its intended purpose and in correctly functioning condition! The ThermoGrip induction generator is specially rated and designed for tool change process with ThermoGrip shrink chucks (frequency selection, heating time, etc.). When other shrink chuck designs are shrunk in or out, problems can occur including lasting damage to the chucks or to the induction unit itself. Use only ThermoGrip shrink chucks! No guarantee can be assumed for any other chucks! The manufacturer will no longer guarantee safe operation of the unit after unauthorised modifications or interference of the unit. The risk of endangering life and limb of the operator or third parties, and the risk of damage to the ThermoGrip induction generator and/or other items of property is borne by the user alone! 3.1 Choice of the Location ISG2200 is designed as a bench-top unit and should be located in a safe and vibration free area and in a dry workplace which is as free as possible from dust and dirt. Locate the unit free of vibration; protect from contamination and moisture! Avoid direct sunlight for better visibility of the LCD display. April 2010 ISG2200 8
3. General safety instructions 3.2 Hazards from electric components The unit contains live components with dangerous voltages. Please observe the following points for your own safety: The device must not be operated without the change disc being inserted! The device must not be operated when the housing is open! Opening the machine s electrical pannels is only allowed by Bilz service staff! Do not allow metal chips and liquids to penetrate the unit! Clean the unit frequently and regularly! Only suitable tools and chucks should be shrunk! Foreign objects should not penetrate the ventilation grids! 3.3 Hazards from hot components The effective of the induction heating process heats relevant and focus zones of the ThermoGrip chuck with very little heat soak. The surface of the chuck can heat up to approx. 400 C. The coil and tools only heat up marginally during correct operation. Caution! Risk of injury from burning on the hot components! For your own safety, comply with the following safety measures when working with the unit: Ensure that hot parts cannot be touched by mistake! Place heated tools on heat-resistant surfaces only! Do not place hot tools on flammable surfaces, but only on heat-resistant surfaces! When shrinking tools in and out, always wear the supplied gloves as protection from burning and injury from sharp tooling! Other than the chuck and tool, do not introduce metallic objects into the inner area of the coils, as these will also heat up in the heating process! During operation, never reach into the heating area of the coils, as rings, chains, or other jewellery can heat up very quickly! Wear goggles when shrinking! April 2010 ISG2200 9
3. General safety instructions 3.3.1 Protecting the shrink chuck from overheating The chuck and tool can overheat as a result of incorrectly entered shrink parameters and repeated heating of the chuck in a short period of time. This is why the shrink parameters must be entered with care (at a lower setting if in doubt). Avoid overheating of the shrink chuck from excessive shrinking energy and extended shrinking times! No flammable substances should be kept in the vicinity of the unit because of the potential risk of overheating of the unit and (chuck) tools. Do not keep flammable substances in the vicinity of the unit! Do not use flammable cleaning agents! 3.4 Hazards from electromagnetic radiation When the unit is used properly, there is no magnetic radiation in the immediate surroundings. The radiation safety of the unit has been tested and verified by CE/FSS-part 18 test. If the induction heating is started up without a shrink chuck being located in the coil, the magnetic field affects the immediate vicinity of 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. For your own safety, please comply with the following rules: Do not introduce any items susceptible to interference within the vicinity of the unit! If you have a cardiac pacemaker, please consult the manufacturer or your doctor before use. In rare cases, interference is possible! 3.5 Other hazards 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. April 2010 ISG2200 10
4. Commissioning ISG2200 5. Control buttons of the ISG2200 4.Commissioning ISG2200 4.1 Assembly Caution: Ensure that the unit is not damaged during the unpacking process. Tilt the unit, so that it stands on its feet and pull it out of the carton at the housing. Only carry the unit at the housing and not at the coil or the guide unit. 4.2 Commissioning Adjust feet and ensure the unit is located in a safe stable location Ensure that the ventilation slits at the back of the unit remain free of obstructions Remove the transport locks from the coil Move the coil downwards or upwards with the handle (check mobility) Remove the foam-transport locks from the pump Fill with cooling emulsion 3% fluid mix Connect compressed air with at least 6 bar (feed line cross section at least 6mm) Connect the power supply Switch on the main switch After switching on, the control panel shows the serial no. of the unit for 5 seconds. After this, the generator version number is displayed for 4 seconds. When the version numbers are displayed, the decimal point between the two parts of the display will light up. The unit is now ready for operation. 5. Control buttons of the ISG2200 5.1 Keys and light emitting diodes All work and adjustment procedures are triggered by means of 5 buttons on the control panel. The buttons can be used for the following procedures: Start shrinking (start of the generator ) or Stop shrinking ( stop of the generator ); Unlock coil clamping (Position) Switch between automatic- (LED on) and manual (LED off) mode. Start cooling process manually Increase the diameter of the tool (automatic mode only). Increase of power (manual mode only). Decrease the diameter of the tool (automatic mode only). Decrease of power (manual mode only). April 2010 ISG2200 11
5. Control buttons of the ISG2200 5.2 LED display Automatic-mode: When the unit is not in Operation, the selected tool diameter is displayed in mm. When starting the shrinking operation, the display changes to show the remaining operation time of the generator in seconds. Manual mode: The complete shrinking time is always displayed. Error: In case of error, an error number will be displayed (see Annex A1). 5.3 Configuration of the ISG2200 When the unit is switched on, the fan running time can be set. The fan starts every time the unit is operated and the running time can be set between 1 and 10 minutes. The fan can be switched off following the heating phase by means of the key. 5.3.1 Configuration of the fan running time Switch off ISG2200 Push Switch on ISG2200 while pressing Release The running time from 1 to 10 minutes can now be set using the + - und - keys. After setting the required running time, the ISG2200 can be returned to normal mode by means of the 5.3.2 Configuration of the parameter table for automatic mode When the unit is switched on, the parameter table for automatic mode can be selected. Setting the required parameter table Switch off ISG2200 Press START/STOP button Switch on unit when START/STOP button is pressed Release START/STOP button You can now select the required parameter table using the + und buttons 0 = Standard ThermoGrip chucks 1 = TSF chucks 2 = both chuck types Note: There are no cooling adapters suitable for TSF chucks Other cooling methods must be used, e.g. water cooler FKS03. After setting, use the START/STOP button in order to return the ISG2200 to its normal operating mode. April 2010 ISG2200 12
6. Shrinking 6. Shrinking Please note that with the ISG 2200 you can shrink carbide tools with diameters of 3-20 mm and HSSE tools with diameter 6 20mm due to the generator performance, contrary to the ISG 3200. First of all some basic information and advice for the shrinking of tools. Cooling adaptor T3-K/... Location T3-W/.. 6.1 Basic information on Shrinking ThermoGrip clamping chucks can be used for temperatures of up to 450 C, without effecting any changes in material or concentricity. The change in colour of the heated chuck is the result of oxidation and does not influence quality or performance of ThermoGrip clamping chucks. Despite the high temperature resistance compared to standard clamping chucks materials, the expansion is only in the range of few one-hundredth mm, 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 3.1.. Ensure that used tool shafts have no malformations in the chucking zone. It is essential that gloves are worn when working with the ISG2200. Shrinking chucks should only be touched 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 protection glove. Please make sure that the tools are positioned securely in the tool locations. Allow the shrinking and cooling process to run through completely. Wait until the drying time has finished, the chuck has returned to its original position and the air drying process is completed before removing the cooled and dried chucks. Although it is theoretically possible to shrink tools with shafts to DIN 6535 Form HB and HE or similar forms, preference should be given to cylindrical shafts such as e.g. DIN 6535 Form HA, as these allow the highest holding forces and smallest variations. In order to obtain the best chucking forces, only put clean, grease-free shafts in the chuck. Ensure that no cutting edges are in the chucking zone when selecting the shrink-in depth. Please use only clean chucks for the shrinking process. Badly soiled chucks must always be cleaned in order to avoid contamination of the cooling emulsion. There are no cooling adapters available for TSF chucks! Other cooling methods must be used, e.g. water cooler FKS03. April 2010 ISG2200 13
6. Shrinking 6.2 Procedures involved in shrinking process and tool changing For personal safety, when working with ISG2200 obey the following rules: Always observe the safety instructions for all shrinking procedures! 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 protection glove. Wear goggles! 6.2.1 Shrinking in Before shrinking in, the correct cover plate must be inserted into the coil. This is dependant on the type and the clamping diameter of the chuck. An overview can be found in Appendix A2 of this operating manual. To shrink in a tool, insert the chuck in the matching tool holder (see Appendix A3 changing the tool holder) with the machine switched on (coil is located at the upper end position). For ThermoGrip it is possible to pre-locate cutting tools in the patented counterbore in front of the bore. Move the coil downwards over the chuck, so that the front edge of the chuck lies on the metallic cover disc of the coil align the coil plate in the same position with smaller diameters. After achieving the coil position, the coil is fixed by pressing the green button. (see drawing) When coil is fixed, the green LED of the start-button is on (generator ready). In automatic mode ( AUTO LED on). Select the shrink diameter with the + or button and press Start/Stop. Apply light pressure on the tool during the subsequent heating phase to support the shrinking procedure. If the tool is inserted but the shrinking time has not finished, it is advisable to stop the heating process with the Start/Stop-button to avoid heating the tool unnecessarily. If the heating process has been stopped or after the shrinking process has been completed, the heated chuck remains in this position for 2 seconds. The green LED on the cooling button flashes several times during these 2 seconds. The chuck is then automatically moved down and liquid-cooled. In manual mode ( AUTO LED off ), the tool is only heated when the Start/Stop button is pressed. Maximum power is always used in this case. After the Start/Stop button has been released, the chuck automatically moves down and is liquid-cooled April 2010 ISG2200 14
6. Shrinking Then immediately fit the matching cooling adaptor and place the tool with the tool holder and cooling adaptor on one of the cooling positions. There are no cooling adapters available for TSF chucks! 6.2.2 Shrinking out Before shrinking out, the correct cover plate must be inserted into the coil. This is dependant on the type and the clamping diameter of the chuck. An overview can be found in Annex A2 of this operating manual. In order to shrink out a tool, put the chuck in the matching tool holder (T3-W..) on the ventilation grid underneath the guide unit with the machine switched on. Proceed in the same way as for shrinking in. Help to release the tool by pulling it gently. Place the removed tool on a heat-resistant surface and protect other persons from touching the tool and hot chuck by mistake. Immediately fit the matching cooling adaptor and place the tool with tool holder and cooling adaptor on one of the cooling stations. There are no cooling adapters available for TSF chucks! 6.2.3 Tool change Once a tool has been shrunk out, it is possible to replace the old tool with a new one in the same shrinking cycle. First, shrink the tool out as described under 6.2.2. In this case, do not stop the heating process with the Start/Stop-button. Wait until the coil has moved up again and insert the new tool. Place the removed tool and a heat-resistant surface and protect other persons from touching the tool and hot chuck by mistake. Immediately fit the matching cooling adaptor and leave the chuck on the fan until it has cooled down or place the tool together with the tool holder and cooling adaptor on the optional cooling station. There are no cooling adapters available for TSF chucks! April 2010 ISG2200 15
6. Shrinking 6.3 Shrink-fitting operating modes 6.3.1 Shrinking of ThermoGrip chucks : automatic mode For ThermoGrip clamping chucks, all necessary parameters such as power and time are preprogrammed into the ISG2200. Depending on the configuration of the ISG2200, the diameters of standard chucks, TSF chucks or both will be displayed in automatic mode for selection purposes. In order to differentiate them from standard chucks, both decimal points are switched on for the TSF chucks. Dependant on the type of chuck (standard or TSF) and the tool diameter, the parameters are set automatically. When the ISG2200 has been switched on, the unit is in automatic mode. The AUTO-LED is lit up. The following tools can be shrunk in this mode: Standard Chucks TSF Chucks Tool Type Ø range in mm Carbide 3 20 HSSE 6 20 Tool Type Ø range in mm Carbide 3 20 HSSE not suitable! The tool diameter required (and, depending on the configuration, the chuck type) can be selected by using the + or button on the right hand side of the keypad. Insert the appropriate cover plate into the coil. This is dependant on the type and clamping diameter of the chuck. An overview can be found in Appendix A2 of this operating manual. Move the coil downwards over the chuck, so that the bottom edge lies on the metallic cover disc of the coil on the chuck. After having reached the coil position, the coil is stopped by pressing the green button on the linear unit. When coil is stopped, the green LED of the start-button lights up (generator ready). The shrink process can now be started by using the START/STOP button. When shrinking in or out, it will usually be possible to insert or remove the tool before the programmed time, which is based on the least favourable tolerance ratios of the tool and chuck. If a tool can be inserted or removed more quickly, the heating process can be interrupted with the START/STOP button to avoid using any more energy than necessary on the chuck and the tool. This also means that the cooling time is considerably reduced. Use the appropriate cooling adaptor immediately after operation and leave the chuck on the fan until it has cooled down or place the tool together with the tool holder and cooling adaptor on the optional cooling station. Note! There are no cooling adapters available for TSF chucks! April 2010 ISG2200 16
6. Shrinking 6.3.2 Shrinking of other chucks: manual mode Use the manual mode to shrink other chucks. Press the AUTO button so that the AUTO-LED light goes out. You are now in manual mode. In the 2-digit display you can see the shrink power set. The figure "99 indicates 100% shrink power. By pressing the + and buttons on the right hand side of the keypad, the required shrink power between 100% and 50% can be selected. Insert the appropriate cover plate into the coil. This is dependant on the type and clamping diameter of the chuck. An overview can be found in Annex A2 of this operating manual. Move the coil down to the chuck so that the bottom edge of the metal plate is resting on the chuck. After the coil has reached its position, it is be locked by pressing the green button on the linear unit. The green LED on the start key will light up when the coil is locked (generator ready). The shrinking operation can now be carried out by means of the Start/Stop button. As long as this button is pressed, the chuck will be heated with the pre-selected power. Use the appropriate cooling adaptor immediately after operation and leave the chuck on the fan until it has cooled down or place the tool together with the tool holder and cooling adaptor on the optional cooling station. Note! There are no cooling adapters available for TSF chucks! April 2010 ISG2200 17
7. Cleaning and maintenance 8. Service 7. Cleaning and maintenance The machine is to be cleaned regularly. To do so, disconnect it from the power (pull the main plug). The machine can be cleaned on the outside using a damp cloth and commercially available (solvent-free) cleaning agent. Protect the guide rod from rust by greasing it occasionally. Do not use compressed air and no cleaning agents! Opening the machine and repairing it is only allowed by Bilz service staff! 8. Service This operating manual can only provide a general description of the functions and control of the ThermoGrip induction generator. For special solutions and for carrying out repairs and any modifications not described in this manual, Bilz Werkzeugfabrik GmbH & Co. KG is gladly available. In case of problems or queries, please note the machine serial number and the software status. you can find the serial number either on the nameplate on the back of the machine, or together with the serial number as display text in the control display after switching on the machine, also in the menu service under the version number. Contact: Bilz Werkzeugfabrik GmbH & Co. KG Vogelsangstrasse 8, DE-73760 Ostfildern P.O.B. 1155, DE-73747 Ostfildern Tel. ++49/7 11/3 48 01-0 Fax ++49/7 11/3 4812 56 e-mail: info@bilz.de Latest news about ThermoGrip on the Internet pages www.bilz.de and www.thermogrip.de. April 2010 ISG2200 18
Appendix Appendix A 1. Troubleshooting Fault message Possible cause Action/Remedy E1 CURRENT FAULT - current monitoring of the coil diagnoses over/under current - try again E2 END LEVEL RUNNING - Generator program running - wait a minute before next input E3 SAFETY CIRCUIT OPEN - coil temperature >60 - let coil cool down - check cause E5 IDENTIFICATION ERROR - unsuitable shrinking geometriy for shrinking process EF TELEGRAM FAULT - please contact the manufacturer If the above malfunctions prevent the ISG2200 from being operated, please contact the supplier or customer services. Transport of the machine only with transport lock screwed into the coil A 2. Selection table for shrinking plates Standard Chucks TSF Chucks Ø Range in mm Plate Ident No. 3 5,9 ISGS2201-1 6725758 6 12 ISGS2201-2 6725759 12,1 20 ISGS2201-3 6725760 Ø in mm Plate Ident No. 3 ISGS2201-TSF03 9102727 4 ISGS2201-TSF04 9102728 5 ISGS2201-TSF05 9102749 6 ISGS2201-TSF06 9102750 8 ISGS2201-TSF08 9102752 10 ISGS2201-TSF10 9102753 12 ISGS2201-TSF12 9102754 14 ISGS2201-TSF14 9102755 16 ISGS2201-TSF16 9102756 18 ISGS2201-TSF18 9102757 20 ISGS2201-TSF20 9102758 April 2010 ISG2200 19
Appendix A 3. Technical data Voltage: Maximum current: Nominal power 3*400 V/ 50 Hz 3*16 A 8 kw Weight: Dimensions: Depth: Width: Transport height: Max. usage height: 25 kg 390 mm 310 mm 730 mm 880 mm A 3.1 Overview Shank Tolerances The following shank tolerances are required for the different shank diameters: Shank Ø 3mm 4mm 5mm 6mm Shank Tolerance h4 h4 h5 h6 April 2010 ISG2200 20
Appendix A 4. Scope of supply Processor controlled induction generator ISG2200 Safety gloves Operating manual A 4.1 Optional extras Tool holder for HSK-32 T3-W/HSK32 6725939 HSK-40 T3-W/HSK40 6725940 HSK-50 T3-W/HSK50 6725941 HSK-63 T3-W/HSK63 6725942 HSK-80 T3-W/HSK80 6725943 HSK-100 T3-W/HSK100 6725938 SK-40 T3-W/SK40 6725944 SK-50 T3-W/SK50 6725945 Cooling adaptor for ThermoGrip Ø 6.0-9 T3-K/6-9 6725955 standard Ø 9.1-12 T3-K/9,1-12 6725956 Ø 12.1-16 T3-K/12,1-16 6725951 Ø 16.1-22 T3-K/16,1-22 6725953 Measuring adaptor 6 mm T3-M 0600 6725959 8 mm T3-M 0800 6725962 10 mm T3-M 1000 6725963 12 mm T3-M 1200 6725964 14 mm T3-M 1400 6725966 16 mm T3-M 1600 6725967 18 mm T3-M 1800 6725968 20 mm T3-M 2000 6725969 Cooling grid T3-Z/WZ 6726004 Transportation trolley ThermoGrip chuck with various holders and further cooling adaptors, please see brochure for details. April 2010 ISG2200 21
Appendix A 5. EC STATEMENT OF CONFORMITY In accordance with the EC Machine Directive 2006/42/EG, Appendix II A We herewith declare BILZ Werkzeugfabrik GmbH & Co. KG that the machine designated below corresponds to the pertinent health and safety requirements of the EC 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 ISG2200 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 DE- 73760 Ostfildern Phone: ++49/7 11/3 48 01 0 Fax: ++49/7 11/3 48 12 56 E-Mail : vertrieb@bilz.de Internet : www.bilz.de Register of companies: HRA 210313, Amtsgericht Stuttgart Year founded: 1919 Ostfildern, September 30, 2009 General manager Michael Voss April 2010 ISG2200 22
Appendix A 6. Instructions Safety Glove Description: 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: Warning: yellow JUTEC GmbH, Mellumstr. 23-25, DE-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 your 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. 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. April 2010 ISG2200 23
Appendix A 7. Connection socket for ISG2200 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. April 2010 ISG2200 24
Appendix A 8 Transformer for ISG2200 In order to guarantee an accurate handling of your Shrinking device, a power supply according to the enclosed description is necessary. Please ensure in your installation that all 3 phase voltages are within the required limits it is an IT-system so that there is a mid-point wire, neutral (N) and a protected earth wire (PE) In case your power supply differs from the described form, we can offer you various transformers as solutions for a smooth adaption: Your power supply BILZ-Designation of the transformer article-no. mostly used in 3 x 200V with / without neutral wire 3 x 230V with / without neutral wire 3 x 380V with / without neutral wire 3 x 380V or 3 x 440V with / without neutral wire 3 x 220V to 600V with / without neutral wire 3 x 400V without neutral wire (N) ISGTR/3x200V/3x400V/8300VA/N10% 6726113 Japan ISGTR/3x230V/3x400V/8300VA/N10% 6726123 France ISGTR/3x380V/3x400V/8300VA/N10% 6726117 France ISGTR/3x380+440V/3x400V/8300VA/N10% 6726118 USA ISGTR/3x200-600V/3x400V/8300VA/N10% Multiple transformer with 16 different input voltages ISGTR/3x400V/N10% Transformer to create the neutral mid-point conductor (N) 6726114 USA 6726116 France Italy Prices for transformers for further input voltages will be quoted on request. April 2010 ISG2200 25
Appendix A 9. Wiring diagram cooling fan Lüfter overtemperature switch Übertemperaturschalter S2 induction coil Induktionsspule heat sink Kühlkörper S4 Übertemperaturschalter overtemperature switch X8 S3 X7 ISGG2xxx-400V STL101 STL102 Klemmung STL104 clamping Bedienfeld control panel ISBF 2200 TxD RxD Gnd Gnd 24V STL105 STL106 PE-point at sliding guide PE-Punkt an der Führungseinheit clamping magnet Klemmmagnet1 X4 induction generator Induktionsgenerator Gnd TxD RxD X5 3 *Ferraz Shawmut G200750 F3 16A/500V F F2 16A/500V F F4 F1 Lü N PE N L3 L2 L1 16A/500V F X13 X12 X11 1,6A/250V T X6 Netzschalter S1 NETZKABEL mainscable Netzteil / power supply 24V/1,8A F5 3A/250V LED1 X2 24V Gnd PE N L PE-point on generator plate PE-Punkt Generatorblech Bodenblech PE bottom plate X10 PE ISG2200_400V.T2001 Bilz GmbH&Co.KG 3*400V / 50Hz 7kW 16A PE-point at cabinet PE-Punkt am Gehäuse X9 PE L1 schwarz, black L2 braun, brown L3 N mainswitch grau, grey blau, blue gr-ge, gr-ye PE R. Bader N PE Rückwand ISG 2200 (400V-Version) L1 L2 L3 backplane 1/1 April 2010 ISG2200 26