Hainbuch TOPlus mini User manual

Operating instructions
[incl. installation manual]
TOPlus mini / TOPlus premium pull-back
EN

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Translation of the original operating instructions
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Contents
1General.................................................................................................................8
1.1 Information about this manual......................................................................8
1.2 Key to symbols.............................................................................................8
1.3 Definition of terms........................................................................................9
1.3.1 Release setting...............................................................................9
1.3.2 Complete clamping reserve............................................................9
1.4 Limitation of liability....................................................................................10
1.5 Copyright....................................................................................................10
1.6 Scope of delivery .......................................................................................10
1.7 Spare parts and accessories......................................................................11
1.8 Warranty terms ..........................................................................................11
2Safety.................................................................................................................12
2.1 Responsibility of the operator.....................................................................12
2.2 Personnel requirements.............................................................................13
2.3 Intended use..............................................................................................14
2.4 Personal protective equipment...................................................................16
2.5 Particular hazards......................................................................................17
2.6 CFRP products ..........................................................................................19
2.7 Other safety instructions ............................................................................19
2.8 Screws.......................................................................................................21
2.9 Functionality...............................................................................................22
2.10 Environmental protection ...........................................................................22
3Technical data....................................................................................................23
3.1 General information....................................................................................23
3.2 Performance values...................................................................................23
3.3 Balancing quality........................................................................................24
3.4 Speed.........................................................................................................25
3.5 Clamping force diagram.............................................................................25
3.5.1 Size 26 .........................................................................................26
3.5.2 Size 40 .........................................................................................26
3.5.3 Size 52 .........................................................................................27
3.5.4 Size 65 .........................................................................................27
3.5.5 Size 80 .........................................................................................28
3.5.6 Size 100 .......................................................................................28
3.6 Operating conditions..................................................................................29
3.7 Type designation........................................................................................29
4Layout and function............................................................................................30
4.1 Overview and brief description...................................................................30
4.2 Accessories required..................................................................................31
4.2.1 Spindle flange...............................................................................31
4.2.2 Drawtube adapter.........................................................................31

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4.2.3 Clamping head .............................................................................31
4.2.4 Workpiece end-stop......................................................................31
4.2.5 Test kit..........................................................................................31
4.3 Optional accessories..................................................................................31
4.3.1 Jaw module ..................................................................................31
4.3.2 Magnet module.............................................................................32
4.3.3 MANDO Adapt..............................................................................32
4.3.4 Morse taper adaptation.................................................................32
4.3.5 Face driver adaptation..................................................................32
4.3.6 Swarf baffle ring............................................................................33
4.3.7 Base end-stop with swarf baffle ring.............................................33
4.3.8 vario flex end-stop system............................................................33
4.3.9 vario part end-stop system...........................................................33
4.3.10 vario quick end-stop system.........................................................33
4.4 Special aids................................................................................................34
4.4.1 Manual changing fixture ...............................................................34
4.4.2 Pneumatic changing fixture ..........................................................34
4.4.3 Screwdriver bit with tip guide........................................................34
5Use and limits of use..........................................................................................35
5.1 Use.............................................................................................................35
5.2 Limits of use...............................................................................................35
5.2.1 Nomenclature...............................................................................35
5.2.2 First limit [workpiece length] .........................................................38
5.2.3 Second limit [workpiece mass] .....................................................38
5.2.4 Third limit [clamping length]..........................................................39
5.2.5 Fourth limit [forces].......................................................................39
5.2.6 Sample calculation .......................................................................51
5.2.7 Permitted maximum speed...........................................................54
6Transport, packaging, storage............................................................................55
6.1 Safety, transport, packaging, storage ........................................................55
6.2 Symbols on the packaging.........................................................................56
6.3 Transport inspection...................................................................................56
6.4 Unpacking and internal transportation........................................................57
6.5 Packaging..................................................................................................57
6.6 Storage ......................................................................................................58
6.7 Preservation...............................................................................................58
6.8 Return to storage .......................................................................................58
7Installation..........................................................................................................59
7.1 Installation safety .......................................................................................59
7.2 Preliminary remarks...................................................................................61
7.3 Screw tightening torques............................................................................61
7.4 Preparation of the machine for installation.................................................63

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7.5 Installation of the product...........................................................................63
7.5.1 Compatibility check.......................................................................64
7.5.2 Preparation of the product............................................................64
7.5.3 Installation of the drawtube adapter..............................................66
7.5.4 Installation of a spindle flange that cannot be aligned ..................67
7.5.5 Installation of a spindle flange that can be aligned.......................69
7.5.6 Installation of the functional unit of an alignable clamping device 71
7.5.7 Installation of the functional unit of a non-alignable clamping
device...........................................................................................74
7.6 Installation of the clamping element...........................................................77
7.7 Installation of the changing parts ...............................................................79
7.7.1 Installation of the variant, screwed directly...................................80
7.7.2 Installation of the variant x-times with axial screw connection......80
7.7.3 Installation of the variant x-times with bayonet axial screw
connection....................................................................................81
7.7.4 Installation of the central variant with axial screw connection.......83
7.7.5 Installation of the radially clamped variant....................................84
7.8 Aligning the clamping device with the test specimen .................................86
8Commissioning...................................................................................................87
8.1 Commissioning safety................................................................................87
8.2 Checking the total stroke............................................................................89
8.3 Tests..........................................................................................................89
8.4 Workpiece..................................................................................................90
8.5 Procedure after a collision..........................................................................91
9Activities after end of production ........................................................................92
10 Removal.............................................................................................................93
10.1 Safe removal..............................................................................................93
10.2 Preparing the machine for removal............................................................95
10.3 Removal of the changing parts ..................................................................95
10.3.1 Removal of the variant with direct screw connection....................96
10.3.2 Removal of the variant x-times with axial screw connection.........96
10.3.3 Removal of the variant x-times with axial screw connection
bayonet.........................................................................................97
10.3.4 Removal of the central variant with axial screw connection..........99
10.3.5 Removal of the radially clamped variant.....................................100
10.4 Removal of the clamping element............................................................101
10.5 Removal of the product............................................................................103
10.5.1 Removal of the functional unit ....................................................103
10.5.2 Removal of the spindle flange ....................................................105
10.5.3 Removal of the drawtube adapter...............................................106
11 Maintenance.....................................................................................................107
11.1 Maintenance safety..................................................................................107
11.2 Maintenance schedule.............................................................................107

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11.3 Cleaning...................................................................................................108
11.4 Visual inspection......................................................................................111
11.5 Lubricating the product.............................................................................111
11.6 Use of lubricants ......................................................................................112
12 Disposal............................................................................................................113
13 Faults................................................................................................................114
13.1 Procedure with faults................................................................................114
13.2 Fault table................................................................................................114
13.3 Commissioning after a fault has been remedied......................................116
14 Annex...............................................................................................................117
14.1 Contact.....................................................................................................117
14.2 Manufacturer certification.........................................................................117

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Directory of tables
Table 1: Technical data...............................................................................23
Table 2: Operating conditions .....................................................................29
Table 3: Nomenclature application limits.....................................................37
Table 4: Maximum workpiece mass............................................................38
Table 5: Scatter widths of clamping force....................................................42
Table 6: Contact forms / scenarios..............................................................42
Table 7: Contact factor................................................................................43
Table 8: Specific cutting forces ...................................................................44
Table 9: Friction coefficient for steel workpieces.........................................45
Table 10: Clamping head mass and distance of mass center of gravity of
clamping head segments to the rotational axis..............................46
Table 11: Maximum permitted tailstock force................................................48
Table 12: Maximum permitted cutting force ..................................................49
Table 13: Maximum permitted transverse force ............................................50
Table 14: Maximum permitted torque due to transverse force ......................50
Table 15: Screw tightening torques, metric control threads...........................62
Table 16: Screw tightening torques for aluminum components.....................62
Table 17: Maintenance table.......................................................................108
Table 18: Selection of lubricants .................................................................112
Table 19: Fault table....................................................................................116

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General
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1 General
1.1 Information about this manual
This manual enables you to work safely and efficiently with
the product.
This manual is part of the product and must be kept in a lo-
cation directly beside the product that is accessible to the
personnel at all times. The personnel must have read this
manual carefully and understood its contents before starting
any work. The basic requirement for safe work is compliance
with all stipulated safety notices and work-related instruc-
tions in this manual.
If the product is passed onto a third party, this manual must
accompany it.
Illustrations in this manual are there to facilitate a basic un-
derstanding, and may differ from the actual design configu-
ration of the product.
WARNING
Serious injuries caused by individual products or
by inappropriate combinations of them!
Read and pay attention to all operating instruc-
tions for individual products and combinations of
them.
1.2 Key to symbols Safety instructions in this manual are designated by sym-
bols. The safety notices are invoked by signal words that ex-
press the level of hazard involved.
Always comply with safety notices and exercise caution to
avoid accidents, injury to people and damage to materials.
Safety notices
DANGER
… indicates an immediate and hazardous situation
that can lead to death or serious injury if not avoided.
WARNING
… indicates a potentially hazardous situation that can
lead to death or serious injury if not avoided.
CAUTION
… indicates a potentially hazardous situation that can
lead to moderate or slight injuries if not avoided.
NOTE
… indicates a potentially hazardous situation that can
lead to damage to materials if not avoided.

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Tips and recommenda-
tions
INFORMATION
… highlights useful tips and recommendations as well
as information for efficient and problem-free opera-
tion.
… refers to other documents relating to personal and
general safety.
Warning symbols may appear on the product or its compo-
nents.
Always pay attention to warning symbols, and exercise cau-
tion to avoid accidents, injury to people and damage to ma-
terials.
… warns of stored energy [for example involving springs].
… warns of hand injuries.
… draws attention to the fact that the operating instructions
of the product must be read.
1.3 Definition of terms
1.3.1 Release setting Release setting means that the clamping device is released.
If the clamping device is released, this also releases the
workpiece.
1.3.2 Complete clamping reserve
Complete clamping reserve means that the clamping device
is clamped without a workpiece. The complete stroke has
been used up, which means that the clamping device is
therefore at the limit position for clamping reserve.

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1.4 Limitation of liability All details and notices in this manual were compiled with due
reference to applicable standards and specifications, state-
of-the-art technology and our many years of expertise and
experience.
The manufacturer accepts no liability for damage arising
from any of the following:
Non-compliance with this manual
Unintended use
Use of untrained personnel
Autonomous conversion work
Technical modifications
Use of non-approved spare parts
Use of non-approved accessories
Installation and use of clamping elements not made by
the manufacturer
Subject to any commitments agreed to in the supplier con-
tract, the General Terms & Conditions of Business and the
delivery terms of the manufacturer and all legislative stipula-
tions valid at the time of conclusion of this contract.
1.5 Copyright This manual is protected by copyright, and are only intended
for internal use.
The dissemination of this manual to third parties, reproduc-
tions in any shape or form - even in part - as well as com-
mercial use and/or communication of their contents are pro-
hibited for anything other than internal use, except with the
written consent of the manufacturer.
Infringements oblige the offending party to pay compensa-
tion. Without restriction on further claims.
1.6 Scope of delivery The scope of delivery of this product includes:
TOPlus mini / TOPlus premium
The operating instructions
Additionally needed and included as optional items in the
scope of delivery:
Spindle flange
Drawtube adapter
Clamping head
Workpiece end-stop
Changing fixture
Screwdriver bit with tip guide
Test kit [for TOPlus premium]