Diebold Hs 1100-p User manual

Bedienungsanleitung

User Manual

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Horizontal-Schrumpfgerät

Horizontal Shrinking Device

HS 1100-P

Helmut Diebold GmbH & Co.

An der Sägmühle 4

D-72417 Jungingen (Germany)

Tel.: + 49 (0)7477-871-0 Fax: + 49 (0)7477-871-30

E-Mail: [email protected]

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HS 1100-P

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Information zum Hersteller / Manufacturer

Helmut Diebold GmbH & Co.

Goldring Werkzeugfabrik

An der Sägmühle 4

D-72417 Jungingen (Germany)

Tel.: + 49 (0) 74 77-871-0

Fax: + 49 (0) 74 77-871-30

Web: www.diebold-hsk.de

Mail: [email protected]

Weitergabe sowie Vervielfältigung und Nutzung dieser Unterlage ist nur mit

Genehmigung der Helmut Diebold GmbH & Co. Goldring Werkzeugfabrik gestattet.

Änderung

Die Firma Helmut Diebold GmbH & Co. behält sich inhaltliche und technische

Änderungen vor.

Gewährleistung

Für Schäden, die durch Nichtbeachtung dieser Anleitung entstehen, wird keine Haftung

übernommen.

This manual is property of Helmut Diebold GmbH & Co. Goldring Werkzeugfabrik and

may not be copied without the approval of Diebold.

Changes

Helmut Diebold GmbH & Co. reserves the right to modify the specifications of this

device to reflect technical advances.

Warranty

All Diebold devices are warranted to be free from manufacturing and / or material

defect. Misuse of the devices will void warranty.

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English..................................................................................................................... 33

14. Foreword........................................................................................................... 33

14.1. Outline ........................................................................................................ 33

14.2. Note............................................................................................................ 33

15. Symbols and pictograms ................................................................................... 34

16. General Safety instructions ............................................................................... 35

16.1. Operating location ...................................................................................... 35

16.2. Hazards from electric components ............................................................. 36

16.3. Hazards from hot parts ............................................................................... 36

16.4. Avoid overheating “ThermoGrip” Chucks.................................................... 37

16.5. Hazards from electromagnetic radiation..................................................... 37

17. General information about ThermoGrip ® Shrink technology............................. 38

17.1. Micro processor controlled Induction generator HS 1100-P........................ 38

17.2. Advantages of ThermoGrip ® Shrink technology at a glance:...................... 38

17.3. Quality of the tools and chucks ................................................................... 39

17.3.1. Tool shanks .......................................................................................... 39

17.3.2. Shrink fit chuck holes ........................................................................... 39

18. Initial Set-Up of the HS 1100-P........................................................................... 40

18.1. Connecting the device ................................................................................ 40

18.2. On-site socket and fuse............................................................................... 40

18.3. Controls of the HS 1100-P ........................................................................... 40

19. Operating the HS 1100-P ................................................................................... 41

19.1. Ferrite Interchangeable Discs..................................................................... 41

19.2. Shrinking Process....................................................................................... 41

19.3. LCD-Messages............................................................................................ 42

19.4. Shrinking with Parameters.......................................................................... 43

19.5. Shrinking without Parameters with indicating the power level .................... 44

19.6. Changing Standard Parameters.................................................................. 45

19.7. Reset to Factory Settings............................................................................ 46

20. Handling tool holders ........................................................................................ 47

20.1. Tool holder HSK-40 to HSK-100 .................................................................. 47

20.2. Tool holder SK / BT 30 to SK / BT 50 ............................................................ 48

20.3. Universal Adaptor for Clamping range Ø12 to Ø100 ................................... 48

21. Operation of the Length Setting Unit (Optional) ................................................. 49

21.1. Assembly .................................................................................................... 49

21.2. Measuring................................................................................................... 49

21.3. Shrink on length.......................................................................................... 49

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22. Appendix ........................................................................................................... 50

22.1. Technical data ............................................................................................ 50

22.2. Block diagram............................................................................................. 50

22.3. Wiring diagram ........................................................................................... 51

22.4. Scope of delivery and accessories.............................................................. 52

22.5. Expansion options and optional accessories............................................... 52

22.5.1. Tool Adaptor......................................................................................... 52

22.5.2. Length Setting Unit............................................................................... 53

22.5.3. Chiller Unit ........................................................................................... 53

23. Cleaning and maintenance ................................................................................ 54

24. Service and repair / Contact the Manufacturer .................................................. 54

24.1. Repair process ........................................................................................... 54

25. EC Declaration of Conformity ............................................................................ 55

26. 5 Finger-Safety-Glove........................................................................................ 56

26.1. Instructions for use ..................................................................................... 56

26.2. EC Declaration of Product Conformity ........................................................ 57

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English

14. Foreword

This user manual is part of the technical documentation for the Horizontal Shrinking

Device HS 1100-P manufactured by Helmut Diebold GmbH & Co..

This user manual contains all information necessary for proper use of the unit.

The contents correspond to the stage of construction of the Horizontal Shrinking

Device HS 1100-P at the time of preparation of this manual. Due to continuous

development and customization, design and specifications are subject to change.

Data, diagrams, drawings, descriptions, and etc. included in this manual are for

informational purposes only, and are not to be used for manufacture.

The intent of this operation is to familiarize you with the Horizontal Shrinking DeviceHS

1100-P and facilitate its proper use.

Please inform us if you should find any errors in this manual.

All Diebold products are manufactured according to the current standards for quality

products. We recommend to service the units periodically as recommended in this

manual. The manual contains all data to enable the user to use the units according to

the manufacturers recommendations.

14.1. Outline

This user manual contains important instructions for the safe operation of the

Horizontal Shrinking DeviceHS 1100-P, for reducing repair costs and downtime, and for

increasing the reliability and service life of the induction unit.

The foot line shows the name of the unit on the left, the date of compilation in the middle

and the page number on the right.

14.2. Note

Please store the original packaging of the Horizontal Shrinking Device HS 1100-P in

case the unit needs to be returned to Diebold for service or maintenance.

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15. Symbols and pictograms

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: Are marked by circles with hazard symbol or square with instructions,

and describe an activity or the use of certain items or objects.

Wear goggles

Wear safety gloves

Notes: Are marked by the information pictogram and contain recommendations

or other additional information.

Example:

Detailed instructions for the chemical test method are available from

your supplier.

Lists: Are marked by the symbol 

Example:

Can be used for high speeds

Highest clamping forces

Slim body chuck

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

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16. General Safety instructions

For shrink fit chucks a new technique is used, which allows the tool change with the

matching shrink chuck in a convenient, efficient and energy saving method. The

induction generator is built using state of the art technology at the time of delivery and

is reliable. Nevertheless, the equipment may pose a hazard if it is not used by trained or

at least instructed personnel and / or for the intended use. Therefore, please note:

Read the operating manual carefully before initial set-up and operation

of the unit, and become well acquainted with the control elements.

The operating manual is an integral part of the unit, and must be

accessible and understood by all persons working with the unit.

Only trained individuals should be allowed to operate this unit.

The unit may only be operated as specified for and under good working

conditions.

This unit is designed and programmed for the use of Diebold “ThermoGrip” chucks.

When other shrink chuck forms and designs are used, problems may occur, because

shrink parameters are set for Diebold shrink chuck contours.

Only use Diebold shrink fit chucks! For other shrink fit chucks no

warranty can be given.

Unauthorized modifications or repairs to the unit will void warranty. Such modifications

lead to damage of the unit.

16.1. Operating location

The Horizontal Shrinking Device HS 1100-P is a table-top unit.

Place the unit on a clean, dry workbench, in a dust and vibration-free

environment.

Avoid direct sunlight on LCD display.

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16.2. Hazards from electric components

The unit contains components with dangerous voltages. Please observe the following

for your own safety:

This unit is to be serviced ONLY by trained personal authorized by the

manufacturer.

Do not allow metal chips or liquids to enter the unit.

Unit should be cleaned regularly.

Only ThermoGrip chucks and quality cutting tools should be used.

16.3. Hazards from hot parts

The very effective form of heating only heats the relevant boundary zones of the shrink

fit chuck with low heat input.

The surface of the shrink fit chuck can heat up to approx. 400°C.

Caution! Risk of burns!

For your own safety, comply with the following safety rules when working with the unit:

Ensure that hot parts cannot be touched by mistake.

Never leave hot “ThermoGrip” chucks uncovered. Remove hot tools

from the coil and place them in their respective cooling positions or in

the Chiller Unit.

Do not place hot tools on flammable surfaces.

When shrinking tools in and out, always wear the supplied gloves for

protection from burns and cuts.

Remove all metallic objects from the environment of the inductive coil!.

During operation, remove all jewelry and keep hands clear of coil.

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16.4. Avoid overheating “ThermoGrip”Chucks

The chuck and tool can overheat as a result of incorrectly entered shrink parameters

and repeated heating of a “ThermoGrip” chuck in a short period of time. This is why the

shrink parameters must be entered with particular care. Use a lower setting if in doubt.

Repeated heating the chuck is to be avoided. Before heating chucks again, make sure

to cool it down to room temperature first.

Avoid the use of excessive shrinking energy and long shrink times.

Do not keep flammable substances in the vicinity of the unit.

Do not use flammable cleaning agents.

16.5. Hazards from electromagnetic radiation

When the unit is used properly, there is no magnetic radiation to the immediate

surroundings. The radiation safety of the unit has been tested and verified by

EN 55011:2007+A2:2007 category A group 2. If the Inductive heating is started up

without a tool holder in the coil, the magnetic field affects only the immediate vicinity of

the coil.

For your own safety, please comply with the following rules:

Do not run any other units into the vicinity of the unit to avoid electrical

interference.

If you have a cardiac pacemaker, please consult the manufacturer or

your doctor. In certain cases, interference is possible.

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17. General information about ThermoGrip ®

Shrink technology

Shrinking has been known as a technique for achieving non-

detachable connections, and offers remarkable advantages for

chucking tools. By the inductive heating with high energy density,

tools can be changed in a matter of seconds.

A 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 any conventional clamping

techniques.

Only shrink using clean tools in cleaned chucks!

17.1. Micro processor controlled Induction generator HS 1100-P

With the help of special coils, only the specific clamping area of the chuck is heated.

This means it is possible to shrink out carbide tools as well as tools with the same

temperature expansion behavior as the tool holder (e.g. HSS tools).

A special housing / shield surrounding the coil prevents magnetic flux to a large extent.

The control components and the high frequency generator are integrated in the

housing.

17.2. Advantages of ThermoGrip ® Shrink technology at a glance:

Quick shrinking times in and out

High clamping forces

Higher tool and spindle life due to small run-out (< 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 localized yet homogeneous heating of the chuck

Clamping of carbide and HSS tools (see 4.3.1 Werkzeugschäfte)

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

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17.3. Quality of the tools and chucks

Tool shafts and shrink fit chucks must have the following characteristics to guarantee a

easy on- or unshrinking process.

17.3.1. Tool shanks

must be smooth

must be free of oil and grease

preferably should not have a clamping face

must not have any marking with raised areas

must have the necessary tolerance quality

The following shank tolerances are required for the various shank diameters:

Shank-Ø

Shank tolerance

Tool type

3 mm

Carbide

4 mm

Carbide

5 mm

Carbide

≥ 6 mm

Carbide or HSS

17.3.2. Shrink fit chuck holes

must be smooth

must be free of oil and grease

must have the necessary quality of tolerance

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18. Initial Set-Up of the HS 1100-P

18.1. Connecting the device

To ensure that the unit is not damaged during the unpacking process,

unload the unit with the top facing up. Do not hold the unit housing by

the coil.

Connect the power cord to the power supply. Make sure that the main power switch

while the unit is off. Through the operation of the main switch, the device is now ready

for operation. The LC display will show "Diebold".

18.2. On-site socket and fuse

Picture

Pin designation

Pin name

Wire colour

Phase L1

brown

Phase L2

black

Phase L3

black / grey

Neutral wire

blue

Protective earth

green-yellow

The rated voltage between the phases is 3x400V (-10/+10%)

Always connect the neutral wire N and protective earth PE !

If a ground fault circuit-breaker is used to secure the CEE socket, it

must be a 4-pin model and according to DIN VDE 0100 (part 530) for

frequency converters of type B (all-current-sensitive).

18.3. Controls of the HS 1100-P

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19. Operating the HS 1100-P

19.1. Ferrite Interchangeable Discs

Ferrite interchangeable discs are used for the effective heat shrinking process and are

necessary for shrinking of Carbide and HSS tools. The discs will concentrate the

magnetic field in a way so the tool holder will open up faster. The interchangeable discs

are inserted in the RH side of the coil and locked in place with a clockwise turning

motion. They will serve as a limiter for the toolholder.

A complete set of interchangeable discs comes with the unit.

19.2. Shrinking Process

The shrinking and un-shrinking of a tool works as:

Clamp the shrink chuck in the tool adaptor

Move the induction coil to the required shrink position and lock it by turning the

lock handle

Select shrinking parameters (see 19.4)

Start the heating process by pressing the “Start/Stop” button. When the heating

cycle is completed, push the tool in or pull out the tool.

The induction coil may now be pushed back and the (hot) shrink fit chuck may be

removed for cool down.

Always use the gloves supplied with the unit.

ATTENTION! To prevent damage to the device, the induction coil

should never be moved relative to the chuck during the shrinking

process.

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19.3. LCD-Messages

After switching on the device the

Software version (in picture "v02.1")

and the

Number of shrink cycles (in picture "82")

will be displayed for approx. 3 seconds.

The following messages may appear in the LC display:

ATTENTION! Heating time too long !!

the maximum permissible heating time has been exceeded. Heating of the shrink

chuck will automatically be stopped

•Max. temp. coil, please wait -

the maximum permissible coil temperature has been exceeded. Please wait a few

minutes until the inductor has cooled down

•Max. temp. IGBT, please wait -

the maximum permissible IGBT temperature (transistors in the generator) has

been exceeded. Please wait a few minutes until the IGBTs have cooled down

Fault !! -

a fault has occurred

Overload -

the generator is overloaded

IGBT Error -

an IGBT error has occurred

If error messages continue even after switching the unit off and back on, please contact

the manufacturer.

(Observe the cool down of the generator!)

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19.4. Shrinking with Parameters

21. Turn on the unit with the main switch

22. Select the shrink chuck type using the ”Menü“ button

Menu and the shrink chuck types will appear:

Manual: Shrinking without parameters

Standard: DIN holder contour (without grooves)

II TSF: Slim holders (2 grooves)

(To shrink Carbide tools only, not HSS shanks!)

IIII Pyroquart: Holders with Pyroquart contour (4 grooves)

TER 11 to 32: Shrink Collet TER / ER 11 to ER 32

23. Select the tool shank-Ø with the „+“ or „–“ button

24. Insert the correct ferrite interchangeable disc in the coil

Disc selection:

Ø3-5

Ø6-12

Ø14-22

Ø25-32

25. Set the induction coil in the position over the heat shrink tool so that the shrink

chuck is in contact with the ferrite interchangeable disc

26. Start the shrinking process with the “Start/Stop“ button

27. At the end of the shrink cycle, shrink or un-shrink the tool

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19.5. Shrinking without Parameters with indicating the power level

28. Turn on the unit with the main switch

29. Press the “Menü“ button until “Manuell“ is shown in the display

30. Select the Power level with the “+“ or “–“ button

Power level:

30%

40%

50%

75%

100%

Full power (100%):

When shrinking HSS tools, full power must be applied, otherwise

releasing of the tool will not work. Most carbide tools may also be

heated at full power.

Reduced power (30% - 75%):

When shrinking carbide tools in holders with thin nose type or slim

chucks (especially shrink extensions), it is recommended to heat

with reduced power to avoid overheating of the shrink chuck

Shrink chucks with D1<17 mm should always be heated with

reduced power

If it is not possible to shrink a carbide tool using reduced power,

then the shrink process with full power may be used

31. Insert the correct ferrite interchangeable disc

Disc selection:

Ø3-5

Ø6-12

Ø14-22

Ø25-32

32. Set the induction coil in the position over the heat shrink tool so that the shrink

chuck is in contact with the ferrite interchangeable disc

33. Press and hold the “Start/Stop“ button until shrink or un-shrinking the tool

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19.6. Changing Standard Parameters

34. Turn on the unit with the main switch

35. Select the shrink chuck type with the ”Menü“ button

Menu and the shrink chuck type will appear:

Manual: Shrinking without parameters

Standard: DIN holder contour (without grooves)

II TSF: Slim holders (2 grooves)

IIII Pyroquart: Holders with Pyroquart contour (4 grooves)

TER 11 to 32: Shrink Collet TER / ER 11 to ER 32

36. Select the tool shank-Ø with the ”+“ or ”–“ button

37. Press the ”+“ and ”–“ button simultaneously

38. The power level flashes in the display when you release the buttons:

Select the required power level with the ”+“ and ”–“ button and confirm by pressing

the ”Menü“ button

39. The time flashes in the display:

Select the required time with the ”+“ and ”–“ button and confirm by pressing the

”Menü“ button

40. Parameter is successfully stored

ATTENTION!

The shrink fit chucks can be damaged by overheating through

changing the default parameters.

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19.7. Reset to Factory Settings

41. Turn on the unit with the main switch

42. Hold down the ”+“ and ”–“ button simultaneously and press the ”Menü“ button

43. When releasing the ”+“ and ”–“ button the display shows:

44. Confirm by pressing the “Start/Stop“ button

when released, the display shows:

45. Confirm by pressing the ”Menü“ button

when released, the display shows:

46. Turning off and turning back on the unit with the main switch

47. The factory settings are being restored

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20. Handling tool holders

The different tool holders are inserted up to the stop on the receiving rail and secured

with the clamping screw against displacement.

The tool holders for HSK and SK / BT have a Ejector pin to push the cutting tools during

unshrinking from the clamping bore.

Clamping the Ejector pin with the clamping bolt for Ejector pin you will get a length stop

of the tools while shrinking.

20.1. Tool holder HSK-40 to HSK-100

Shrink fit chucks with HSK taper are inserted into the tool holder and the clamp handle

is swung down. By this means the shrink fit chuck is clamped by an internal cam.

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