HANSA Press VKA-110 User manual

Operating Instructions
VKA-110 Four-Ball Tester
In compliance with DIN 51350
1. Safety (from Page 5)
1.1 General information
1.2 Intended use
1.3 Safeguards of the VKA-110 four-ball tester
1.4 Transport
1.5 Occupational health and safety
1.6 Cleaning and maintenance
1.7 Electrics
1.8 Emergency stop
1.9 What to do if there is a fire
1.10 Environmental protection
2. Operation / “Option 4” Control Unit, Page 8
2.1 Switching on the machine
2.2 Switching off the machine
2.3 “Option 4” control unit
2.3.1 Options
2.3.1.1 USB interface
2.3.1.2 Zero-point weight
2.3.1.3 Additional options
2.3.1.4 Temperature control unit (TC)
1

2.3.1.5 More data points
2.3.1.6 Calibration
2.3.1.7 Testing without additional options
2.3.1.8 FTP server
2.3.1.9 WebVisu and web interface
2.3.2 Measuring
2.3.2.1 Measuring
2.3.2.2 Time-delayed recording
2.3.2.3 Stop parameter: measurement
2.3.2.4 Maximum torque
2.3.2.5 Unregulated / regulated
2.3.2.6 Step control
2.3.3 Status
2.3.3.1 Status
2.4 Jockey weight setting
2.5 Mounting additional weights
2.6 Ball holder
2.6.1 Inserting and loading the ball holder
2.6.2 Removing the ball holder
2.7 Standard ball cup and temperature-adjustable ball cup
2.7.1 Applying a load to the ball cup
2.7.2 Taking a load off the ball cup
2.7.3 Measuring microscope
2

2.8 Types of tests
3. Test Description, Page 22
3.1 Types of tests
3.1.1 What to do prior to each test
3.1.2 Standard short-time tests
3.1.3 Long-time tests
3.1.4 Testing materials
3.2 How to perform the tests
3.2.1 Conditions if the loads applied are low
3.2.2 Conditions if the loads applied are high
3.2.2.1 The wear scar diameter
3.2.2.2 The 2.5-second wear and tear delay time
3.2.3 Conditions if the loads applied are extremely high
4. Maintenance, Page 29
4.1 Spindle bearing
4.2 Ball holder
4.3 Standard ball cup and temperature-adjustable ball cup
4.4 Cutter holder
5. Installation, Page 30
5.1 Choosing a location
5.2 Floor requirements
5.3 Space requirements
5.4 Mechanical installation
3

5.4.1 Installation of the housing (pos. 1)
5.4.2 Installation of the writing utensil holder (pos. 19)
5.4.3 Balance scale bar (pos. 24)
5.4.3.1 Installation of the balance scale bar
5.4.3.2 The balance scale bar
5.4.4 Installation of the push rod (pos. 22), the plunger (pos. 20), the bearing
(pos. 64) and the rotary plate (pos. 21)
5.4.5 Mounting the stand for the “Option 4” control unit
5.4.6 Mounting the “Option 4” control unit
5.5 Electrical installation
6. Spare Parts and Wear Parts / Assembly Drawing, Page 33
7. Electrics/ Circuit Diagram, Page 33
8. VKA Training, Page 33
4

1. Safety
1.1 General information:
The VKA-110 four-ball tester incorporates state-of-the-art technology. It is safe to operate
if it is used as intended and the safety requirements are adhered to.
Though the design of the machine is state-of-the-art and safe to operate, there may still be
risks if:
the operating personnel is not properly trained or has not been properly instructed;
the machine is not used as intended;
the machine is not properly maintained or serviced.
Each person involved in installing, operating, maintaining, repairing and servicing the
VKA-110 must have read and understood these operating instructions and the safety
requirements.
The operator of the VKA-110 must properly train and instruct the operating personnel to
protect their health and safety. In addition the operator must train and instruct the
operating personnel in operating, servicing and maintaining the machine properly and
safely.
1.2 Intended use
The VKA-110 four-ball tester is used to mechanically test lubricants.
Permissible ambient temperature +5 to +40 ° C
Working temperature +5 to +150 ° C
Any use beyond this scope is considered improper. The operator / user of the machine is
liable for any damage caused by improper use.
Intended use includes observing the
safety information
operating information
servicing and maintenance information
provided in these operating instructions.
If you modify the electrics or mechanics of the VKA-110 four-ball tester, you will
forfeit the warranty.
5

1.3 Safeguards of the VKA-110 four-ball tester
Main switch Q1 0 = machine is OFF.
I = machine is ON.
Circuit breaker F3 0 = overload at power point 1 + 2 + ventilator
I = voltage at power point 1 + 2 + ventilator ON
Circuit breaker F1 0 = overload of the control voltage
1 = control voltage is ON.
Circuit breaker F2 0 = overload of the supply voltage for frequency converter/motor
I = supply voltage for frequency converter/motor is ON.
1.4 Transport
Unpack the VKA-110 four-ball tester immediately upon delivery and check for potential
transport damage. Check the separately supplied accessories for completeness.
You must notify us of any damage or missing parts within 10 days.
Only use sufficiently dimensioned transport and lifting slings and equipment (fork lift,
crane, belts).
1.5 Occupational health and safety
The VKA-110 four-ball tester has been designed and built in compliance with the EC
Machinery Directive, the relevant occupational health and safety regulations, and the
accident prevention regulations.
Caution! Spilled oil and lubricants make the floor slippery. If you slip while holding heavy
parts or sharp tools, you may sustain severe injuries.
Ensure that the workplace is well lit.
Keep your workplace tidy and clean to avoid accidents.
Beware of warm and/or hot objects (warning: the ball cup is extremely hot after wear tests
and weld tests have been carried out).
Wear protective gloves at all times.
Never reach into machinery and keep hands and fingers away from the moving spindle.
Loose clothing, long hair, necklaces, rings, bracelets, watches and ties may get caught up
in the spindle and/or ball holder.
6

1.6 Cleaning and maintenance
Clean and maintain the VKA-110 four-ball tester at regular intervals to ensure the
operational safety of the machine.
Switch off the main switch (Q1) of the four-ball tester before you start any cleaning and
maintenance works.
Ensure that the main switch (Q1) cannot be operated by unauthorised persons (padlock).
Even if the main switch (Q1) is turned off, some parts of the electrical system are live.
Always keep the control cabinet locked.
Do not clean the interior of the control cabinet. Risk of electrocution!
Warning: risk of explosion!
Oil mist-air mixtures may cause an explosion! Do not use compressed air or ozone to blow
off the VKA-110 four-ball tester.
Avoid open fire (smoking).
Take precautions to ensure that a fire can be extinguished quickly.
Do not use cleaning agents that attack synthetic material, rubber or varnish. They may
damage cables/wires, power points and displays.
Note that caustic cleaning agents such as, e.g., ethanol damage varnished coatings. Only
use cleaning agents suitable for varnish.
Cleaning agents may contain harmful substances.
Read the manufacturer’s information carefully.
1.7 Electrics
Only qualified electricians and/or persons properly trained in accordance with electro-
technical regulations are permitted to work on, maintain or repair the electrical system.
Even if the main switch (Q1) is turned off, some parts of the electrical system are live.
7

1.8 Emergency stop
Hitting the emergency stop button (kill switch) will slow the motor down to a complete
stop.
To re-start the VKA-110, click the "Acknowledging Emergency Stop" button on the
Touchdisplay under "Options". The VKA-110 is ready to start operating.
1.9 What to do if there is a fire
Use the circuit breakers to cut off the power supply.
Call the fire brigade.
Only use CO2 (carbon dioxide) to extinguish the fire.
1.10 Environmental protection
Make sure that the used-up testing and operating materials are properly disposed of.
2. Operation / “Option 4” Control Unit
The control unit has a Touchdisplay to operate and control certain functions. To operate
the control unit, lightly touch the Touchdisplay.
2.1 Switching on the machine
To switch on the VKA-110, turn the main switch (Q1) to ON/“I”.
Caution: risk of injury!
Keep hands and fingers away from the rotating spindle while the VKA-110 is in
operation.
If you need to work in the spindle operating range, make sure that the main switch (Q1) is
in the OFF/“0” position.
2.2 Switching off the machine
To switch off the VKA-110, turn the main switch (Q1) to OFF/"0".
8

2.3 “Option 4” control unit
The runtime system of the VKA-110 is based on Windows CE 5.0. It starts automatically
when the main switch (Q1) is turned to ON.
The “Option 4” control unit standard package comprises the following functionalities:
Evaluation of short-time test data at 0.1-second intervals
Weld point tests at rotational speeds of up to 6000 r/min
Motor torque display (numerical and graphic display)
Step control (freely programmable testing process)
Switch-off parameters: time or number of revolutions
Changing the rotational speed during the runtime
Automatic calibration of the rotational speeds
WebVisu + web interface (external operating option via PC, Ethernet interface)
FTP server (measuring data can be retrieved directly from a USB interface)
USB and Ethernet interface to evaluate data (e.g. in Excel)
The following additional options are available for the VKA-110 control unit:
Temperature display
Torque display for various ball cups
Test force display (assembly, see 5.4.4)
Vibration sensor
Additional options 1 - 3 are displayed numerically and graphically.
Additional option 4, vibration sensor, is displayed numerically.
The test data are transmitted via Ethernet or USB interface for evaluation in Excel.
Setting up the tester:
The VKA-110 comes default-configured.
You will only need to configure the network settings under the “end PLC” option if you
want to use the network functions of the VKA control unit.
Go to the Windows start menu, click on “Programs” and then “Control Panel”.
Enter the settings in “Network”.
Disconnect from the network before you start the VKA-110.
Connect the network cables only after the VKA-110 has been fully powered up to ensure
that your test results will be recorded.
Warning!
The “Option 4” control unit has copy protection.
Any attempt to copy the software will disable the control unit.
9

Operating panel:
You can control all the VKA-110’s functions via the three windows listed below.
2.3.1 Options
Here you’ll find all the relevant control unit options.
2.3.1.1 USB interface
The “USB Stick Status” field indicates whether the control unit has recognised a USB
stick. If the field is green, a measurement protocol will automatically be stored on the USB
medium when you start the VKA-110.
The system creates a file titled “VKA” on the connected USB medium and a sub-file for
each measurement, including date and name.
You can evaluate the data stored on the USB medium on an external computer.
Open an Excel file to automatically evaluate the data. If macros are activated, CVS (a file
format) will be automatically read in and diagrams will be created simultaneously. You
can adjust the macros individually to meet your company’s specific and format-specific
requirements.
The template is stored under \USBStorage\VKA\ in the control unit.
2.3.1.2 Zero-point weight
If various ball cups are used, the weight display may show deviations (due to the different
weights of the ball cups, temperature deviations or a deviating position of the push rod).
If you upgrade to additional option 3, we recommend you always click the “Zero-Point
Weight” (under options) when you chuck a new ball cup.
10
about WebVisu anInformationd FTP server
Selection of the measurand, progress
display (available if upgrade to additional
options)
Start/activation of the temperature control unit
(only when buying a circulation thermostat)
Step control activation
Safe working load in the “limited” mode
Switch-off limit if a vibration sensor is
used for the measurements (available with
additional option 4 only)
Control temperature before and after start

2.3.1.3 Additional options
Use the “Display Temperature”, “Display Torque” and “Display Weight” buttons
under “Options” to select the respective diagram display.
The diagram including progress is displayed under “Status”.
To make use of the function, you must have installed the respective additional options.
If you have not clicked a field, the display will show the torque or the rotational speed of
the motor (depending on the control mode of the frequency converter (FC)).
The respective measurand selected will be scaled automatically.
Temperature: 1°C * scaling factor/scale division (additional option 1)
Force transducer torque: 1nm *scaling factor/scale division (additional option 2)
Weight: 1kg * scaling factor/scale division (additional option 3)
FC torque: 1% * scaling factor/scale division (included in the standard package)
2.3.1.4 Temperature control unit (TC)
If the Julabo circulation thermostat is connected and switched on, the “Option” field will
display the “Start TC” and “Activate TC” buttons.
In “Activate TC” the temperature control unit starts operating when you click the start
button.
The motor will only power up when the temperature has reached the tolerance range
stated. There are two settings.
Temperature before engine start (e.g. 50°C) and Temperature after engine start (e.g. 60°C).
That is, the Taper roller bearing Holder (or Ball Cup) is heated to 50°C and then the
engine starts. The temperature is then further increased to 60 ° C control temperature.
2.3.1.5 More data points
If you set more data points, you will have more logging points per time unit in the
evaluation. When you measure the torque in short-time tests, you can set more
measurement points (0.1 seconds) under “More Data Points”.
2.3.1.6 Calibration
The VKA-110 comes default-calibrated.
You only need to carry out a calibration when you exchange the motor.
11

2.3.1.7 Testing without additional options
If you have not selected any option, the Touchdisplay will show the rotational speed or the
torque of the motor.
Regulated = display shows the torque
Unregulated = display shows the rotational speed
2.3.1.8 FTP server
You can retrieve measurement data from the USB interface via the FTP server.
Note:
To retrieve data directly, we recommend you use Excel (version 2007 and higher). If you
use a different table calculation programme, you must export the data to a PC to be able to
read them.
2.3.1.9 WebVisu and web interface
“WebVisu” displays the buttons on your PC.
You can then use “Web Interface” to start and stop the VKA-110 via the PC.
If the VKA-110 is not connected to your in-house network, you will need an additional
router to be able to work with “WebVisu” and “Web Interface” (the router is not
included in the scope of delivery).
Note:
To work with “WebVisu” and “Web Interface”, click the following buttons:
“End PLC” / “START” / “Programs” / “Control Panel” / “Network” /
“ONBOARD”
A window “SEC Ethernet Driver” opens. In this window, enter your own IP address
under “IP Address” and confirm with “OK”. In the desktop select “MS DOS Restart” to
return to the VKA control unit.
12

2.3.2 Measuring
2.3.2.1 Measuring
The “Measurement” window allows you to enter the measurement settings.
Use “Measurement Name” to enter a new name. When you click the start button, the
suffix “@01” will be added to the name. If you do not assign any new name following the
last measurement, the name of the previous measurement will be counted up.
Warning!
If you do not assign any name, the USB storage medium will not record any
measurements.
2.3.2.2 Time-delayed recording
You can time-delay the start of the recording of a test run by clicking ON/OFF.
If the motor is running, you can start the current recording prior to the time set by clicking
the “Status” and “Recording Status” buttons. However this has no impact on the
measurement time that has already passed and the duration of the measurement.
2.3.2.3 Stop parameter: measurement
Use the “Stop Parameter: Measurement” field to set the switch-off requirements.
You can choose between two methods: switch-off after a pre-defined period of time or
switch-off after a pre-defined number of revolutions has been reached.
You can change the values (e.g. switch-off after 1,000 revolutions) by touching the
numerical values.
13
Pre-defined standard rotational speeds
Step control
Freely settable rotational speed
Mode of operation

2.3.2.4 Maximum torque
Go to “Maximum Torque” to limit the torque threshold for switch-off at the weld point.
You can limit the torque threshold as follows:
Under “limited” the motor switches off once the value of the motor’s torque set
under options has been reached.
Under “unlimited” the motor switches off only after 100% of its torque has been
reached. This function replaces the motor protection circuit breaker.
When you perform long-time tests always set the maximum torque to “limited”.
In tests at < 1200 r/min it is best to use the “regulated” mode (with frequency converter
(FC)) as otherwise the torque of the motor will be too high.
2.3.2.5 Unregulated / regulated
Under rotational speed you can select the “unregulated” button (without FC) or the
“regulated” button (with FC) to set the frequency converter control method.
In the “unregulated” mode (without FC) the FC does not supply any frequency and
voltage to the motor.
In this case the motor behaves as if it were connected to power without FC. The motor slip
is not compensated for and it may be necessary to readjust manually as the motor’s
rotational speed depends on the load in the ball cup.
In the “regulated” mode (with FC) the FC uses vector control to compensate for load
cases at the motor. Here, the FC increases voltage and power to maintain the rotational
speed.
The “regulated” mode is not suitable to perform weld tests.
You have three options available to set the motor’s rotational speed for the FC:
Touch the speedometer in the “Status Window” (also possible during a test run)
In the “measurement” window using the freely settable rotational speed field
In the “measurement” window using the standard rotational speed buttons
14

2.3.2.6 Step control
The VKA-110 permits you to change the rotational speed in steps.
Click on the “Step 2” to “Step 5” buttons to add additional steps.
Depending on the switch-off parameter chosen you can set step points based on the time
passed or the number of revolutions done. The system will carry out a plausibility test after
all settings have been made.
You can hide the entire “Step Control” field under “Options” by clicking the “Activate
Step Control” button.
You can use step control to perform one test at different rotational speeds. E.g. if you
select the stop parameter “Time”, you can run the VKA-110 for one hour at 1000 r/min,
followed by another hour at 1500 r/min and another 30 minutes at 2000 r/min.
You can also do this using the stop parameter “Revolutions”.
Setting:
Enter the starting rotational speed (under “Freely settable Rotational Speed”) and
the stop parameter (time or no. of revolutions).
Step 2: enter the time or no. of revolutions + rotational speed (r/min)
Step 3: enter the time or no. of revolutions + rotational speed (r/min)
Step 4: like step 2 and 3, continue until maximally step 5.
Example:
Step 1: Select the stop parameter “Revolutions”. Enter 5000 revolutions in the
field to the right. Enter 1000 r/min in the “Freely settable Rotational Speed”
field directly below.
Step 2: Enter 1500 revolutions / 1500 r/min
Step 3: Enter 3000 revolutions / 2000 r/min
Step 4: Enter 4000 revolutions / 3000 r/min
Description:
Step 1: The motor powers up at 1000 r/min.
Step 2: After 1500 revolutions the rotational speed increases to 1500 r/min.
Step 3: After another 1500 revolutions (total: 3000 revolutions) the rotational speed
increases to 2000 r/min.
Step 4: At 4000 revolutions the motor runs an additional 1000 revolutions at 3000 r/min.
Once 5000 revolutions have been reached, the motor switches off automatically.
15

2.3.3 Status
2.3.3.1 Status
The “Status” window displays the current values while the motor is running. The torque
is displayed in % of the maximum torque of the motor.
When you click the start button, the control unit automatically jumps to that window.
You cannot select the “Option” and “Measurement” windows while the motor is
running.
The lower diagram shows the progress of the measurand selected under “Option”.
The progress display is automatically scaled to the duration of the measurement.
When you click “Speedometer” on the Touchdisplay, a window will open that allows you
to change the rotational speed while the machine is in operation.
Attention!
After completion of a test or abort a test, a restart is possible only after pressing the
"Reset" button.
2.4 Jockey weight adjustment
You can set the load by moving the jockey weight on the balance scale bar (pos. 24).
Jockey weights are available in 1, 2, 2.5, 5, 7 or 10kg.
Make sure that the indexing lever (pos. 31) points away from the housing.
Use the indexing lever to lock the load required.
Warning:
Before you mount the 10kg jockey weight, you must remove the “cylinder screw”
(pos. 91). For safety reasons, put the screw back after you have mounted the weight.
16
Speedometer
Progress display
Scaling factor
Motor load

2.5 Mounting additional weights
If you mount additional weights, the load range will be increased.
To mount them, push them onto the 10kg jockey weight (pos. 30). Use a fixing screw to
fasten and/or position the additional weights (pos. 15).
The following additional weights are available:
40kg additional weight consisting of 4 rings (each ring weighs 10kg);
40kg additional weight with grab handles to move it
Note: When you unscrew the fixing screw, you must remove it far enough out of the test
weight to avoid damage to the test weight.
You can find the relevant load sequences on a separate sheet supplied together with the
VKA-110 documentation.
Information about the test weights:
For control purposes note that the jockey weights including indexing lever and all rings of
the additional weights with screws as well as the 40kg additional weight including grab
handles have been manufactured to the weight stated (tolerance = 0.5%).
17

2.6 Ball holder
2.6.1 Inserting and loading the ball holder
Caution: risk of injury!
Feed balls into the spindle ball holder only when the motor is switched off.
Keep hands and fingers away from the rotating spindle.
Switch off the VKA motor. Make sure that the spindle does not rotate.
Press the new test ball tightly into the ball holder and/or hit the ball holder lightly with a
copper hammer (e.g. 500gr copper hammer) to fix it.
Press the ball holder with one test ball tightly into the spindle. Hit it lightly with a copper
hammer to ensure that it sits tight.
Feeding test balls into the ball holder:
To avoid damaging the test balls, fix them on a copper plate to feed them into the ball
holder (copper plate dimensions e.g. 10cmx10cmx2cm).
Warning:
When you insert the ball holder ensure that it is maximally 0.75mm and at least
0.50mm above the spindle.
Remove any foreign bodies from the clamping surface of the ball holder before
inserting it into the spindle as otherwise the ball will run out (maximally 0.03mm)
and the results will be inaccurate.
Replace unusable holders immediately with new ball holders.
18

2.6.2 Removing the ball holder
Caution: risk of injury!
Remove the ball holder only when the motor is switched off. Make sure that the spindle
does not rotate.
Switch off the VKA motor.
When the spindle has come to a complete stop, press down the release lever (pos. 32) to
release the ball cup.
Use the drill drift supplied (pos. 9) to loosen the ball holder in the spindle as well as the
clamped ball. To loosen the ball holder, insert the drill drift into the crossways slot of the
spindle and then bend it downwards.
Warning:
Don’t hit the ball holder to remove it from the spindle; hitting it will damage the
spindle bearing.
Use the drift punch (pos. 18) to remove the ball on the mounting plate opening from the
ball holder.
2.7 Standard ball cup and temperature-adjustable ball cup
Feed three test balls into the standard ball cup (item no. 002.00426) and the temperature-
adjustable ball cup (item no. 002.00145) by using the pressed pressure plate (pos. 12).
Place the clamping ring (pos. 11) on the balls in the ball cups with the polished conical
surface pointing downwards. The conically shaped clamping ring centres the test balls in
the ball cup.
Tighten the clamping nut (pos. 13) to fix the three test balls. To do so, insert the square of
the ball cup into the mounting plate. Use the HANSA Press wrench (pos. 16) to tighten the
ball cup clamping nut to ensure that the balls are fixed and cannot move.
The high forces occurring during the welding process would destroy the pressure plate and
the clamping ring as the balls rotate too.
Afterwards fill test lubricant into the ball cup.
Fill only as much test lubricant into the ball cup as you need to ensure that the lubricant
level is about 3mm above the three clamped-in test balls (about 75ml)
19

Test balls:
Preferably use SKF test balls, 12,700 G 20 DIN 5401, made of 100Cr6(W3) rolling
bearing steel with a hardness of HRC 64+/-1 (item no. VKA-00020).
In addition, you can also use the following test balls from Hansa Press
RB 12.7 MM / G10 / Material: 1.3505 (B1) 100Cr6 / hardness HRC 64 +/- 1
(item no. VKA-00136)
Balls made from other materials or with a different hardness will not produce comparable
and hence inaccurate test results.
You must use a new set of 4 steel balls for each test.
2.7.1 Applying a load on the ball cup
Place the ball of the ball holder on top (in the centre) of the three balls of the ball cup that
holds the test balls and the test lubricant.
Afterwards place the tip (pos. 34) of the ball cup into the pan (pos. 41) of the rotary plate
(pos. 21).
Swivelling the release lever upwards (pos. 32) will apply the load (weight).
When you apply the load, swivel the release lever upwards slowly and carefully to
avoid damage to the balls that is worse than the wear scars visible after a test run.
This is especially important when it comes to loads of between 500kg and 1000kg as the
strain on the individual parts, in particular the cutter holder, is already quite high.
After applying the load, clamp the release lever into the holder mounted at the housing
(pos. 47).
Prior to powering up the motor ensure that the ball cup measuring arm is coupled to the
carrying arm via the support supplied (pos. 38) to prevent the ball cup measuring arm from
swerving during a test run.
Warning:
A test only starts after the motor has been switched on and the load has been applied.
20