Deprag SENSOMAT-ULTRA 347S-228-31 User manual

011878 EN
Operating Instruction Booklet
Stationary Screwdriver Spindle
347S-228-31 391488 A
347S-328-31 391488 B
347S-528-31 391488 C
SENSOMAT®-ULTRA

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Dear Customer:
This toolis the result of more than70years of experiencein thedesignand
manufacturing of pneumatic tools forthe industrial market.
Wekindlyask that you read theseoperatinginstructions carefullysothat you
will be able touse this toolsafelyandfor manyyears tocome. If you need
additionalinformation, please contact your DEPRAG Representative, one of
our internationalsupport offices orus direct at DEPRAG. Wewill be happyto
answer anyquestions. Pleasevisit our web site: www.deprag.com
Content
1SAFETY TIPS................................................................................................................3
1.1. General SafetyTips....................................................................................................3
1.2. General SafetyTips for StationaryScrewdriver Spindles...........................................4
1.3. Owner Obligation........................................................................................................4
1.4. Operator Obligation....................................................................................................5
1.5. Warrantyand Liability.................................................................................................5
1.6. Symbol Description.....................................................................................................6
1.7. Observe Environmental Regulations..........................................................................8
2DESIGNATED EQUIPMENTUSE.................................................................................8
3INSTALLATION..............................................................................................................9
4OPERATION................................................................................................................11
4.1. Range and Exchange ofClutch Spring.....................................................................12
4.2. Torque Adjustment...................................................................................................14
4.3. Connection-Possibilities ofthe Function Control.......................................................15
4.4. To adjust the sensor finder.......................................................................................15
4.5. Change of Bits..........................................................................................................17
5ASSEMBLY - DISASSEMBLY......................................................................................18
5.1. Correct AssemblyofShut-Off Function on Clutch....................................................20
5.2. Spare Parts Drawing.................................................................................................21
5.3. Installation Tips for Screwdriver Spindle...................................................................24
6MAINTENANCE AND UPKEEP...................................................................................25
6.1. Wear Parts................................................................................................................25
7TROUBLE SHOOTING................................................................................................26
8DELIVERY CAPACITY.................................................................................................27
9ACCESSORIES – OPTIONAL EQUIPMENT...............................................................28
10 STORAGE..................................................................................................................29
11 TECHNICAL DATA.....................................................................................................29
12 DISPOSAL..................................................................................................................30
13 DECLARATION OF MANUFACTURER.....................................................................31
14 SERVICE LOCATIONS AND AUTHORIZED PARTNERS.........................................32

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1SafetyTips
1.1. General SafetyTips
Before operating tool makesureto carefullyread and
observe this operating instruction.
Generally, the operatorof the equipment and/ormachinery is responsible for
the equipment’s perfect condition and operation, while observing all necessary
safetyregulations. The equipment and/or machineryhas been constructed in
accordance with the newest level of technologywhile recognizingall
necessarysafety-relatedrequirements. Nevertheless, while operatingthe
equipment and/or machinerythereis a risk of bodilyharm totheoperatoras
well as damageto equipment and/or machineryand other property.
Operatethe equipment and/ormachineryonlyif equipment/machinery
• Is used forthe task it was designed for
• is in perfect working condition and safe touse.
It is important toobserve thetechnicaldata of the equipment, especiallyin
regards to theenvironmentaltemperatures. Thedesignated areaof useforthis
equipment is clearly describedinchapter DesignatedEquipment Use and
those requirements have to be observed as well. Prerequisite forthesafe
conduct andthe uninterruptedoperation of the equipment, is the knowledge of
the basic safetytips and thesafetyregulations. Additionally, all current
regulations for asafe operationalarea, foraccident-preventionguidelines of
electrical and mechanicalinstallations, as well as noisesuppressiondemands
must beobserved. During anymaintenanceor repairwork, acleanwork
surfaceis recommended. Also, it is not recommendedtoeithereat orsmoke
during repairor maintenance. Arbitrarychanges made to the equipment, which
alters its designated use, voids the warrantyand cancels the manufacturers
liability.
• The toolis not insulated toprotect against anelectricalpower surge.
• It is not recommended to usethis tool in explosive hazardous
environments, unless it was specifically designed forsucha use.
• During the disconnection orreconnection of the toolfrom the
compressedair, aninjuryis possible because of a whipping pressure-
hose.
The operatinginstruction booklet, especiallythesafetysymbols and safetytips
attachedto theequipment or included in thedocumentation, must beobserved
at all times byall persons gettinginto contact withtheequipment.

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1.2. General SafetyTips for StationaryScrewdriver Spindles
•
Disconnect thetoolfromthe air supply, when changingbits or
when re-adjustingclutch.
• Do not wear wide clothingorjewelry, for theycan beseized by
movable parts. Wear ahairnet if operator has longhair.
• Keep hands off theinstalledScrewdriver Spindle.
• Injuryis possible, if the driver reacts with an unexpectedmotionor when
usedwith brokenbit orfixture.
• Whenusing toolwith bit-adapter or bit-extension (i.e. Magnetic Bitholder)
make sure, that those items are ingood condition and well suitedf
or forthe
applicationwith this tool.
• Do not exceed themaximum allowable airpressure.
Apressure
regulator has tobeinstalled, which regulates pressurebefore
reachingthe tool.
• After turning-off thetool, thebit will continuetorotate (inertia).
1.3. Owner Obligation
The owner is obliged toonlylet persons operate theequipment, who
• are familiarwith basic work environment safetyrules and accident-
preventing regulations. Also, those persons must have been instructedin
the correct useof the equipment.
• have read andunderstood all safetyand warning notifications in the
Operating Instruction Booklet, as well as all otherdocumentation
pertaining to this equipment.
• check andconfirmat regularintervals, that a safetyoriented operationis
guaranteed.
Onlyqualifiedandauthorizedpersonnel is allowed to operate, maintainand
repair this equipment. Amalfunction, whichimpairs operator safety, must be
immediatelyremoved.

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1.4. Operator Obligation
Personnel, who is engaged inthe operationof the equipment, must always be
committed to
• observe thebasic safetyandaccident preventing regulations,
• read andobserve the safetyand warning notifications of this operating
instructionbooklet.
1.5. Warrantyand Liability
Unless otherwise specified, our “General Sales and DeliveryConditions”
apply.Warrantyand liabilityclaims in regardstopersons or equipment
damages areinvalid, if one or several of thefollowing causes apply:
• Use of theequipment inanon-designated application.
• Improperinstallation, operation, service ormaintenanceof themachine.
•
Operationofthemachine with either defectiveor removed safetyand
protection devices.
• Non-
observance ofthe requirements stated in the operating instruction
booklet
,in regardsto transportation, storage, mounting, installation,
operation, maintenanceand serviceof theequipment.
• Structural change or adjustmenton the equipmenttoanon-
designated
use.
• Inadequatesupervisionof wear parts.
• Improperrepair, inspection or maintenance.
•
Catastrophiccases because ofawar, acts of god or other reasons which
are beyond ourcontrol.

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1.6. Symbol Description
Read andobserve the OperatingInstruction Booklet, prior to
and during operation of tool.
DANGER
Reference toan immediate dangertoa person. Mayleadto
serious injuries or even death, if unobserved!
Properlyrecycle environmentallydamaging grease, cooling
agents or detergents.
RECOMMENDATIONS
Important oradditional information on the equipment or in the
documentation.
Use eye protectionor wear safetygoggles.
Wearhearing protection.
Warning against hand-injuries.
Attention: Keepawayyour hands fromareas, which are marked
with this symbol!
Hands maybe crushed, seizedorotherwise injured.
Waste Oil

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ESD-protected area
Equipment maybe damaged ordestroyed byan electrostatic
discharge.
Maintenance and repair onhydraulic and pneumatic equipment
mayonlybe performed byspeciallytrained personnel!
Disconnect equipment fromairsupply, priortorepair of
pneumatic or hydraulic equipment.
Provide regular preventive maintenance on hoses andairlines.
Exchange hose lines, even if there is no visible damage!
(Observe corresponding requirements of the manufacturer!)
After repair and maintenance, check the following items:
• make surealldetached andre-attached connections are
solid.
• confirm that removed covers, screens or filters were re-
installed
• During disconnecting orreconnecting of anair-operated
equipment, injurymayoccurduetoawhipping air-hose
After conclusion of maintenance or repair andpriorto start of
operation, makesure to
• remove all materials, tools andothersupplies needed forthe
maintenance or repair from work area of theequipment
• remove leaking liquid oroils
• make sureallsafetydevices onthe equipment work perfectly!

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1.7. Observe Environmental Regulations
Whenworking on or with the equipment, it is imperative to
observe all requirements inregards towaste-disposal and
proper recycling.
Especiallyduringinstallation, repairormaintenance, water
damaging agents such as
• lubricatinggreaseand oil
• hydraulic fluid
• coolingagents
• solvent-containing cleaningagents
must not leak into the ground orinto the sewage system!
Suchmaterials must bestored, transported, containedand
recycled insuitablecontainers.
2Designated Equipment Use
Screwdriver Spindles are constructedfor thestationaryuse in:
•Lever OperatedSingle Spindle Screwdriving Stations
•ConstructionUnits
•Multi-Spindle Screwdriving Stations
•Robot End-Of-Arm Tooling
•X-Y-Z Screw-AssemblyStations
These Spindles assemble screws totorque andmeasure that torque more
accuratelythan any subsequent testingmethod. Theytighten andtest the
assemblyin one operation.
DEPRAG SENSOMAT-ULTRA screwdrivers are mostlyused forthread-
ridging, thread-cutting orself-drillingthrough bolts.

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3Installation
•
Blowout airlineand pressure hose, prior to connection it to thetool.
• Make sure, that all air lines have a sufficient cross-section(see technical
data)andhoses must befree of bends and kinks. The hose lengthshould
not exceed2 meters.
• All DEPRAGScrewdrivers, maybe operatedeither withor without
lubricatedair. (seeparagraph: Maintenanceand Upkeep)Whenoperating
with oilfreeair, a performance reduction of upto20% occurs and
maintenance requirements increases!
• Connect the equipment as follows:
a) for theuse with minimal lubrication connect to afilter-regulator
consistingof Filter with condensationreservoir andpressure regulator
Air ConsumptionThread Size Part No.
0,05 - 0,5m³/h ¼” 820454 A
0,15 – 1,5m³/h ½” 820455 A
0,8 –6,0 m³/h ¾” 821608 A
b) for standardoperation connect equipment toa maintenance unit,
consistingof Filter with condensationreservoir, Regulatorand Oiler.
Whenchoosing amaintenance unit, observe air consumption ratefor
the tool(see TechnicalData).
Air ConsumptionThread Size Part No.
0,05 - 0,5m³/h ¼” 822408 A
0,15 – 0,9m³/h 3/8” 826981 A
0,5 –1,5 m³/h ½” 822409 A
0,8 –6,0 m³/h ¾” 826982 A
Eachin connectionwith a Point-of-UseOiler (Part No. 378077 A)
c)for oilfree operation, connect to Filter/Regulator, consistingof Filter
with condensationreservoir andPressure Regulator.
Air ConsumptionThread Size Part No.
0,05 - 0,5m³/h ¼” 822408 A
0,15 – 0,9m³/h 3/8” 826981 A
0,5 –1,5 m³/h ½” 822409 A
0,8 –6,0 m³/h ¾” 826982 A

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OUR RECOMMENDATION: The preferred lubricatingmethod for the
screwdriver spindles mountedinfixtures, brackets, machines, etc., eachin
connection with acontroller, is methodb) withPoint-of-Use Oiler.
• Check pressureat directlyon the machine. The Regulator needs tobe
adjusted toanairflow between 5.0 (71 PSI)and6.3bar(90 PSI). Ahigher
pressureleads toincreased wear and tear. A lower pressure maylead to
clutchnot being able tocorrectlyshut-off the motor.
In regards toair-qualityaccordingtoISO8573-1, we recommend:
CLASS
RESIDUE
OF OIL RESIDUE OF DUST RESIDUE OF WATER
Content
mg/m³ Particle
Size µm
Concentration
max. mg/m³ Dew Point oC
Pressure
Concentration
max. g/m³
Lubricated Air 4515 8+3 6
DryAir 3155-20 0,88

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4Operation
Unless otherwise requested thedriver is presetto max.torquewith the
strongestclutchspring.
Adjustclutch to the requiredtorquevalue.Ifnecessary,exchangeclutch
spring.
Operatingtheclutch using a clutchspring whichexceeds
its allowable torque,leads to areductionofthe torque
accuracy.
The necessarytorque adjustment canbe tested,using aDEPRAG Torque
Wrenchor Dynomameter (seeDEPRAG catalogs D3020andD3022).This
equipmentcanalsobeusedto re-adjust the torque of the Screwdriver
Spindle.
Attention:
Push-to- start-screwdriver!
Theflowpressure shouldnot dropbelow 5 bar (71PSI)!
The installationandconnectionofthe Screwdriver Spindle requires the
following steps:
1. Adjust clutch to requiredtorquesetting(seeparagraph: Torque
Adjustment)
2. Install Screwdriver spindleaccordingtopicture: „Installation Tips for
screwdriverspindle“.If several Spindles are being installed, refer tothe
screwdriver arrangementonconstruction sheet(if you donot havethis
constructionsheet, pleasecall us)
3. Connectmainair hose.
4. Connectpneumatic functioncontrol hose.This functioncontrol is under
pressureof 2,5 bar during actual screw-driving. Ifthe functioncontrolis
not needed,the port hasto be closed, otherwise thereis aloss of power
of about 15%.
Pleasemake surenot toexceed the driver stroke(see Installation Tips for
screwdriver spindle) duringScrewdriving. Thenoiselevel can befurther
reduced, whenan exhaust connection with connectedFilter/Silenceris used.

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4.1. Range and Exchange of Clutch Spring
The torque range of theDEPRAG Screwdriver is adjustable. Please seea
listing forthe torque ranges of the color
-
coded springs below.
Torque Range of the individual clutch spring:
PART NO.
WIRE-∅
COLOR TORQUE "MIN." TORQUE "MAX."
326391 3,4 mm Black appx. 3,0 Nm / 26 in.lbs. appx. 5,0 Nm / 44 in.lbs.
323034 3,2 mm Violet appx. 2,0 Nm / 18 in.lbs. appx. 4,0 Nm / 35 in.lbs.
323035 2,8 mm Green appx. 1,4 Nm / 12 in.lbs. appx. 2,4 Nm / 21 in.lbs.
323036 2,2 mm Red
appx. 0,4 Nm / 3,5 in.lbs.
appx. 1,5 Nm / 13 in.lbs.
323037 1,6 mm Yellow appx. 0,3 Nm / 3 in.lbs appx. 0,6 Nm / 5,3 in.lbs.
All torquevalues are based on 90-PSI (6,3bar)airpressure. Torque values
are estimateddata which maydiffer– dependingon thetype of screwjoint.
Exchange of Clutch Spring
To avoid loosingindividual small parts, it is recommended
to onlydisassemble themachineon top of aflat work
surface.
1. Disconnect Screwdriver from airsupply prior tochangingclutchsprings.
2. Unscrewclutchbearing. (left-hand thread)
3. Remove complete clutch.
ATTENTION:
The Ball802181forbit location canfallout.
4. Insert handscrewdriver into thehalf-round boreof thelock ring and turn
hand screwdriver in clockwise direction, untilthe adjustment nut comes
off.
5. Remove lock ring.
6. Remove clutchspring, replace with required clutchspringand reassem-
bled inreverse order.
7. Placeclutchintoclutchbearing and tightenclutch bearing tothe
DEPRAG Screwdriver. (left-handthread)

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The clawof the intermediateringhas to engagewith the clawin
the spindle.
Make surethat ball802181 forbit locating is assembled.
Check the start-stroke at theclutchshaft (2–3 mm).
7. The clutch canbeadjusted again externally(see Torque Adjustment).
Picture: Changeof ClutchSpring
Make sureto screw adjusting nut ontoclutchbearing untilone line
of thethread is visible.
Adjustment Nut
326111
ClutchSpring Ball
802181

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4.2. Torque Adjustment
Setting theshut off-torque
For setting theshut off-torqueyou have tounlock theshut off-
clutch.
Thereforepush thesensor finder bythe handtothe clutchand
hold it.
For a simplersetting you canuse the adjustment bushing
461319 (Optional Equipment).
For fineadjustment of the shut off-torque you canheldthe
springsleeve byhand.
After unlockingthe clutchbypushback of thesensor finder the screwdriver
can be adjustedbysupport of a suitable torque measuringdevice (seeleaflet
D3020).
The requiredtorque for thedriver canbe adjusted externallyas follows:
1. Disconnect Screwdriver from airsupply.
2. Insert handscrewdriver throughtheslot of theclutchbearing into the
half-round bore of the lock ring. (If necessary, turnclutchusingbit)
3. Byturning thehandscrewdriver clockwise, the torque is reducedandby
turningit counter-clockwise, thetorqueis increased.
For theverificationof thefinal torqueadjustment we would like to recommend
a screwjoint analysis. We offerthescrewjoint analysis as a service toyou.
Picture: TorqueAdjustment
Adjustment Nut
326111
ClutchSpring Ball
802181
Lock Ring
326110/2

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4.3. Connection-Possibilitiesof the Function Control
•
Use as air pressure outletduring screw-assembly:
- to controldriver start and stop, as well as shut-off control of clutch;
- as cycle counterof the completeprocess;
eachin connectionwith a PE-Switchor similar.
• Use as air pressure inlet:
- if 6,3bar(90PSI) air pressure is given to thefunctioncontrol port,
the driver starts rotatingat about 15 %of its speed. This will
simplifytheengagement of bit/socket to fastener(for example
when driving hexscrews, nuts, etc.)
4.4. To adjust thesensor finder
See picture Toadjust the sensorfinder
Coarse Adjustment:
Sensorfinderexceeds thebit tipbyapprox. 2 mm.
Fine Adjustment:
Test-drive the SENSOMAT screwdriver for finaladjustment.
1. In case thescrewis not tightened allthe way(SENSOMAT-clutchshuts-
off too early, despite preset torque), loosenthecounter nut and slightly
tighten sensorfinder (left-hand thread).
2. In case thescrewstrips (SENSOMAT-clutchdoes not shut-off despite
preset torque), loosen counter nut andslightlyunscrewsensorfinder (left
hand thread).

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Picture: To adjust the sensor finder

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4.5. Change of Bits
Attention:
Disconnect driver from air supply.
To get areliablebit-locationthescrewdriver has aquick-change-chuck in
standard.
1. Disconnect driver from air supply.
2. Unscrewspringsleeve (left-hand thread).
3. Pull bothshank screws 828756 totheback andput out the bit.
4. Pushin thenewbit into thehex. femaleof the clutchshaft.
5. Let go thebothshank screws 828756 and the bit is fixed.
2 Shank Screw
828756

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5Assembly- Disassembly
Disassembly: (see SpareParts Drawing)
Prior todisassembly, disconnect equipment from air
supply! Onlyexperiencedmaintenance personnel may
assembleor disassemble thisequipment.
After repair or maintenance, verifythat equipment runs tospecification!
Principally, useonly DEPRAG originalspare parts. Otherwise, a reduction
in equipment power-output and anincreasedmaintenance-requirement
occurs. If NON-DEPRAG parts areinstalled, DEPRAG is justifiedto void
anyexisting warrantyand liabilityobligations.
Attention:
Motor- and gearingparts maybe damaged if dropped!
Attention:
Never clamp motorhousinginto avice, without theusage of the
protective chuckingjaws, sincedamage tomotor-housing and
internalparts isunavoidable.
For disassemblyproceedin thesequence described below:
1. Disconnect driver from air supply.
2. Unscrewclutchbearing together withspring sleeve.
3. Remove complete clutch.
4. Disassembleguidebolt byremoving hex. nut 826715.
5. Clamp thedriver into a vice, utilizingthe flats of theflangeand unscrew
the sleeve 384494(right-hand thread).
6. Hold motorhousingusing a24-mmwrenchand usethe key462122 to
remove the valve housing384469(right-handthread).
7. Remove valve pin.
8. Clamp mountingtube 460566intovice and usethe provided arborto
pushthemotor- and gearparts out of the motor housingin direction of
the air inlet. Anyother suitable arbormaybe usedtocarefullypushthe
motor- and gearingparts out of the motor housing(without mounting
tube)

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Assembly:
Use the DEPRAG Grease807293 (100-g tube) to grease the
ball bearing, needle bearing and gearing partsprior to
reassembly.
Reassemblyoccurs logicallyin reverseorder!
Special Repair Tools (Optional Equipment)
NAME PART NO.
Fixing device (for rotorcylinder) 460474
Arbor (todisassemblybearing cover with groove ball bearing) 462330
Chucking jaws (formotor housing) 462048
Pin wrench (forvalve housing 384469) 462122
Spanner AF 24(formotorhousing) 800406
Assemblytube (formotor- and gearingparts) 460566

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5.1. CorrectAssemblyof Shut-Off Function on Clutch
ATTENTION
If thestop-pin isinstalledincorrectly,the clutch will NOT
shut -off.
In between the two curves, thetaperof thestoppinhas topoint towards
the outside(as illustrated inthe pictures below).
Curves
Taper on
StopPin
Taper on
StopPin