Hainbuch vario flex User manual

Operating instructions
[incl. installation manual]
vario flex
EN

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Translation of the original operating instructions
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Contents
1General.................................................................................................................6
1.1 Information about this manual......................................................................6
1.2 Key to symbols.............................................................................................6
1.3 Definition of terms........................................................................................8
1.3.1 Release setting...............................................................................8
1.3.2 Complete clamping reserve............................................................8
1.4Limitation of liability......................................................................................8
1.5 Copyright......................................................................................................8
1.6 Scope of delivery .........................................................................................8
1.7 Spare parts and accessories........................................................................9
1.8 Warranty terms ............................................................................................9
2Safety.................................................................................................................10
2.1 Responsibility of the operator.....................................................................10
2.2 Personnel requirements.............................................................................10
2.3 Intended use..............................................................................................12
2.4 Personal protective equipment...................................................................14
2.5 Particular hazards......................................................................................15
2.6 Other safety instructions ............................................................................16
2.7 Screws.......................................................................................................17
2.8 Functionality...............................................................................................18
2.9 Environmental protection ...........................................................................18
3Technical data....................................................................................................19
3.1 General information....................................................................................19
3.2 Performance values...................................................................................20
3.3 Speed.........................................................................................................21
3.4 Operating conditions..................................................................................21
3.5 Type designation........................................................................................21
4Layout and function............................................................................................22
4.1 Overview and brief description...................................................................22
4.2 Accessories required..................................................................................22
4.2.1 Clamping device...........................................................................22
4.3 Optional accessories..................................................................................22
4.3.1 Workpiece end-stop......................................................................22
5Use and limits of use..........................................................................................23
5.1 Use.............................................................................................................23
5.2 Limits of use...............................................................................................23
6Transport, packaging, storage............................................................................24
6.1 Safety, transport, packaging, storage ........................................................24
6.2 Symbols on the packaging.........................................................................25
6.3 Transport inspection...................................................................................25
6.4 Unpacking and internal transportation........................................................25

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6.5 Packaging..................................................................................................26
6.6 Storage ......................................................................................................27
6.7 Preservation...............................................................................................27
6.8 Return to storage .......................................................................................27
7Installation..........................................................................................................28
7.1 Installation safety .......................................................................................28
7.2 Preliminary remarks...................................................................................29
7.3 Screw tightening torques............................................................................30
7.4 Preparation of the machine for installation.................................................31
7.5 Installation of the product...........................................................................31
7.5.1 Compatibility check.......................................................................32
7.5.2 Preparation of the product............................................................32
7.5.3 Installation of the product on the clamping device........................35
8Commissioning...................................................................................................36
8.1 Commissioning safety................................................................................36
8.2 Tests..........................................................................................................37
8.3 Workpiece..................................................................................................38
8.4 Procedure after a collision..........................................................................38
9Activities after end of production ........................................................................39
10 Removal.............................................................................................................40
10.1 Safe removal..............................................................................................40
10.2 Preparing the machine for removal............................................................41
10.3 Removal of the product..............................................................................42
10.3.1 Removal of the product from the clamping device........................42
11 Maintenance.......................................................................................................43
11.1 Maintenance safety....................................................................................43
11.2 Maintenance schedule...............................................................................43
11.3 Cleaning.....................................................................................................44
11.4 Visual inspection........................................................................................45
11.5 Use of lubricants ........................................................................................46
12 Disposal..............................................................................................................47
12.1 Disposal of the gas pressure spring...........................................................48
13 Faults..................................................................................................................49
13.1 Procedure with faults..................................................................................49
13.2 Fault table..................................................................................................50
13.3 Commissioning after a fault has been remedied........................................50
14 Annex.................................................................................................................51
14.1 Contact.......................................................................................................51
14.2 Manufacturer certification...........................................................................51

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Directory of tables
Table 1: Technical data...............................................................................20
Table 2: Operating conditions .....................................................................21
Table 3: Screw tightening torques, metric control threads...........................31
Table 4: Screw tightening torques for aluminum components.....................31
Table 5: Maintenance table.........................................................................43
Table 6: Selection of lubricants ...................................................................46
Table 7: Fault table......................................................................................50

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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
recommendations
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.

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General
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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.
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
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:
vario flex
The operating instructions
Additionally needed and included as optional items in the
scope of delivery:
Clamping device

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1.7 Spare parts and accessories
WARNING
Serious injuries can be caused by incorrect or de-
fective spare parts!
Always use genuine spare parts made by the orig-
inal manufacturer.
WARNING
Serious injuries can be caused by incorrect or
missing clamping devices!
Only use genuine clamping devices from the
manufacturer.
NOTE
Damage, malfunctions or total failure of the prod-
uct or the machine tool caused by an incorrect or
defective spare parts!
Always use genuine spare parts made by the orig-
inal manufacturer.
NOTE
Damage, malfunctions or total failure of the prod-
uct or machine tool caused by incorrect or miss-
ing clamping devices!
Only use genuine clamping devices from the
manufacturer.
Spare parts and accessories can be sourced from contract
dealers or directly from the manufacturer [see »Contact«
chapter].
Without exception, wearing parts and components in contact
with the workpiece are not covered by warranty.
1.8 Warranty terms The warranty terms are included in the manufacturer's Gen-
eral Terms & Conditions of Business.
The gas pressure spring used in the product is a wearing
part. Deviating from the warranty in the General Terms &
Conditions of Business, it can perform a maximum of 30,000
strokes, or one year from delivery, whichever occurs first.

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Safety
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2 Safety This section provides an overview of all the important safety
aspects for optimum protection of personnel, and for safe
and problem-free operation.
2.1 Responsibility of the operator
The product is used in the industrial sector. The operator of
the product is therefore governed by the provisions of Health
& Safety at Work legislation.
As well as the safety notices in this manual, the area of use
of the product must also comply with locally applicable
safety, accident prevention and environmental protection
specifications as well as those in the manual for the machine
tool.
No modifications must be made to the product. The operator
is wholly and solely responsible for any resultant personal
injury and/or damage to materials.
DANGER
Serious injuries caused by parts being ejected
centrifugally due to a drop in actuating force / sup-
ply pressure!
On the machine, ensure that the actuating force /
the supply pressure do not drop while the product
is in use.
If no precautions have been taken onthe machine
to maintain the actuating force / the supply pres-
sure, it is prohibited to use this product on the ma-
chine.
Pay attention to the operating instructions for the
machine tool.
2.2 Personnel requirements
WARNING
Serious injuries caused by incorrect handling of
the product by insufficiently skilled or trained per-
sonnel!
All activities must be performed by skilled staff
from the relevant specialist field.