Index Traub ABC User manual

DAA007EN - 11.05.2021
0521/Ku (Sicherheitshinweise und Technische Angaben) - 20081220
Safety Precautions and
Technical Details
CNC Lathes
OPERATING INSTRUCTIONS
Safety instructions

Note on applicability
Illustrations in this publication may deviate from the product supplied. Errors and omissions due to technical
progress expected.
A word on copyright
This document is protected by copyright and was originally compiled in German.
The duplication and distribution of this document or parts thereof is prohibited without prior consent of
the copyright owner, and any violators will be prosecuted. All rights, including the right to translate, are
reserved.
©Copyright by INDEX-Werke GmbH & Co. KG
Englisch

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Safety Precautions and Technical Details
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TABLE OF CONTENTS
1 Explanation of symbols ............................................................................................................................... 5
1.1 Symbols used in the user documentation ................................................................................................... 5
1.2 Information and safety instructions on the machine ................................................................................... 5
2 General instructions for safe operation ................................................................................................... 6
2.1 Obligations of the operator/owner................................................................................................................ 6
2.2 Personnel obligations.................................................................................................................................... 6
2.3 Requirements for personnel selection and qualifications .......................................................................... 7
2.3.1 Definition of “qualified employee”/“qualified personnel”................................................................. 7
2.3.2 Personal selection and qualifications.................................................................................................. 7
2.4 Intended use of the machine........................................................................................................................ 9
2.5 Reasonably foreseeable misuse of the machine........................................................................................10
2.6 Modifications to the machine......................................................................................................................10
2.7 Spare parts and accessories .......................................................................................................................11
2.8 Repairs..........................................................................................................................................................11
2.9 Workspace of the operator..........................................................................................................................12
2.9.1 Spatial allocation in the workspace....................................................................................................13
2.10Personal protective equipment ...................................................................................................................14
2.11 Climbing aids ...............................................................................................................................................14
2.12IT and data security......................................................................................................................................15
3 Safety functions and safety equipment................................................................................................. 16
3.1 Main switch ..................................................................................................................................................16
3.2 EMERGENCY STOP ....................................................................................................................................17
3.3 Work area enclosure and work area door ...................................................................................................18
3.4 Window pane(s) ...........................................................................................................................................19
3.5 Splinter protection film on the design pane ................................................................................................19
3.6 Clamping conditions.....................................................................................................................................19
3.7 Pneumatic safety valve (optional) ............................................................................................................... 20
3.8 Warning signals/indicators.......................................................................................................................... 20
3.9 Keys and password protection .................................................................................................................. 20
3.10Confirmation mode ..................................................................................................................................... 20
3.11 Pressure tanks............................................................................................................................................. 21
4 Instructions for safety-conscious work.................................................................................................. 22
4.1 Handling of workpieces ............................................................................................................................ 22
4.1.1 Clamping the workpiece ................................................................................................................... 22
4.1.2 Clamping pressure and clamping force............................................................................................ 23
4.1.3 Chuck and jaws ................................................................................................................................. 24
4.1.4 Machining of bar stock...................................................................................................................... 25
4.2 Handling of tools ......................................................................................................................................... 26
4.2.1 Changing tools................................................................................................................................... 26
4.2.2 Mechanical interface......................................................................................................................... 26
Note on applicability
Illustrations in this publication may deviate from the product supplied. Errors and omissions due to technical
progress expected.
A word on copyright
This document is protected by copyright and was originally compiled in German.
The duplication and distribution of this document or parts thereof is prohibited without prior consent of
the copyright owner, and any violators will be prosecuted. All rights, including the right to translate, are
reserved.
©Copyright by INDEX-Werke GmbH & Co. KG
Englisch

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TABLE OF CONTENTS
4.3 Chip conveyor.............................................................................................................................................. 27
4.3.1 Machine without chip conveyor ....................................................................................................... 28
4.4 Work on electrical components ................................................................................................................. 29
4.5 Prevention of burns and scalds .................................................................................................................. 30
4.6 Conduct around noise................................................................................................................................. 30
4.7 Conduct around laser radiation................................................................................................................... 30
4.8 Handling of operating fluids and auxiliary materials................................................................................... 31
5 Fire protection............................................................................................................................................. 32
5.1 Fire risks....................................................................................................................................................... 32
5.1.1 Combustible working materials and by-products ............................................................................ 32
5.1.2 Minimal quantity lubrication system or dry machining.................................................................... 32
5.1.3 Combustible cooling lubricants......................................................................................................... 32
5.2 General fire safety measures .................................................................................................................... 33
5.2.1 Use of CO2as an extinguishing agent ............................................................................................. 33
5.3 Fire extinguishing system for cooling lubricant fires ................................................................................. 34
5.3.1 Intended use of the fire extinguishing system ................................................................................ 34
5.3.2 Foreseeable misuse of the fire extinguishing system..................................................................... 34
5.4 Central extraction system........................................................................................................................... 35
6 Safety instructions for different life phases .......................................................................................... 36
6.1 Transport and packing................................................................................................................................. 36
6.2 Setup, installation, and commissioning...................................................................................................... 37
6.3 Setup mode................................................................................................................................................. 38
6.4 Operation (production mode) ..................................................................................................................... 39
6.5 Maintenance, service, and repair ............................................................................................................... 40
6.6 Storage and decommissioning....................................................................................................................41
6.7 Disposal ........................................................................................................................................................41
7 Product monitoring .................................................................................................................................... 42
8 Certificate of conformity ........................................................................................................................... 43
9 Technical details ......................................................................................................................................... 44
9.1 Approved ambient conditions..................................................................................................................... 44
9.2 Noise emission............................................................................................................................................ 45

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EXPLANATION OF SYMBOLS
1 Explanation of symbols
1.1 Symbols used in the user documentation
This chapter explains the symbols that are used in the user documentation to call
attention to dangers and important notes.
This symbol warns against a direct imminent danger to the life
and health of individuals.
Failure to observe this danger warning may result in severe
health impairment such as perilous injury and even death.
These symbols indicate important notes for the proper operation of
the machine.
Failure to observe this information may result in damage to or mal-
function of the machine or its components.
This symbol warns against a direct imminent danger from elec-
tricity.
Failure to observe this danger warning may result in severe health
impairment such as perilous injury and even death.
1.2 Information and safety instructions on the
machine
All information and safety instructions directly on the machine must be observed
and must be kept in a fully legible condition.
Various symbols and warnings may be found on the machine, depending on the
design of the machine and its intended use.

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GENERAL INSTRUCTIONS FOR SAFE OPERATION
2 General instructions for safe operation
2.1 Obligations of the operator/owner
The operator/owner must ensure that all the specified limits, ambient conditions,
and clearances in the vicinity of the machine are observed at the place of installation.
Prior to commencing operation of the machine:
• The machine operator must understand the dialog language of the control sys-
tem user interface.
• The personnel responsible must be sufficiently qualified to perform the work
assigned to them. This applies particularly to commissioning, maintenance and
servicing, as well as any working on electrical equipment and components.
• All safety equipment must be properly attached and functional; it must not be
tampered with or disabled.
• Devices and measures to override the restricted access to the controller (e.g.,
keys for switches, passwords) must be accessible only by authorized personnel.
• The machine must be in proper functional condition. Any damaged or defective
parts must be replaced immediately. This applies particularly to all safety equip-
ment.
2.2 Personnel obligations
The personnel responsible must read and understand the user documentation in-
cluding the caution labels. This applies particularly to the safety labels and warnings.
Before starting work, all those operating the machine or who are assigned work on
the machine must commit to do the following:
• Follow the basic regulations on occupational safety and accident prevention.
• Comply with the safety chapter and the warnings in the user documentation.
This requires them either to read the relevant sections or to receive instruction
about their content.
All those carrying out work on the machine must use the required personal protec-
tive equipment.

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GENERAL INSTRUCTIONS FOR SAFE OPERATION
2.3 Requirements for personnel selection and
qualifications
2.3.1 Definition of “qualified employee”/“qualified personnel”
A qualified employee is capable, on the basis of their relevant professional educa-
tion, training and/or experience, to recognize risks and to avoid possible hazards that
arise when using the product.
Depending on the activities to be carried out, these qualified employees may be
from various fields, e.g. qualified transport personnel for machine transport or quali-
fied electricians for work on the electrical equipment of a machine.
2.3.2 Personal selection and qualifications
The personnel responsible must be sufficiently qualified to perform the work
assigned to them. Individuals undergoing training must not work on the machine
without constant supervision by a person having the required qualifications.
Qualified personnel must meet the following requirements:
Transport personnel
• Qualified employees/trained individuals with knowledge of the relevant load
securing and approval for the means of transport of the relevant type.
Installation/commissioning personnel
• Qualified employees/technically trained individuals with experience of installing
and commissioning machines of this type.
Setup personnel
• Trained and qualified employees
• Specialized training by the machine manufacturer
Programming personnel
• Trained and qualified employees
• Specialized training for the machine or programming system by the machine
manufacturer
Operating personnel
• Trained skilled employees or semi-skilled employees
• Comprehensive instruction on the machine
• Operator training by machine manufacturer
Maintenance personnel
• Trained skilled employees or semi-skilled employees
• Specialized training by the machine manufacturer

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GENERAL INSTRUCTIONS FOR SAFE OPERATION
Service and repair personnel
• Trained and qualified employees
• Specialized training by the machine manufacturer
Decommissioning/storage personnel
• Trained and qualified employees
Disposal personnel
• Trained and qualified employees
Expert
• A person who has sufficient knowledge of the machine based on professional
training and experience and who is familiar with all regulations, thereby enabling
evaluation of the inspected machine with regard to occupational safety.
The following also applies:
• Work on the machine may only be carried out by reliable persons who are able
to cope with the physical demands involved.
• Key switches may only be operated by instructed and authorized persons. The
key must be removed after use and stored in such a way that unauthorized per-
sons do not have access.
• Work on the electrical equipment of the machine may only be carried out by
qualified electricians or by instructed persons under the direction and supervision
of a qualified electrician in accordance with the electrical/electronic regulations.
• Work on the hydraulic system may only be carried out by trained and authorized
persons.

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GENERAL INSTRUCTIONS FOR SAFE OPERATION
2.4 Intended use of the machine
The machine has been designed mainly for cold working of common metallic mate-
rials without requiring access to the work area during machining.
The machine is intended exclusively for use in an industrial environment.
The machine has been designed and constructed in accordance with current best
practices and generally recognized safety rules. All the required safety equipment
and protective apparatus are present.
The operational safety of the machine is only ensured if it is used as intended. If it is
not used as intended, risks may arise.
Residual risks exist even when the machine is used as intended.
For this reason, the safety notices and warnings in the operating instructions and on
the machine must be observed.
All the safety notices and warnings on the machine must be kept in a legible condi-
tion and must be replaced if necessary.
The limits specified in the technical data (e.g., maximum rotational speed or maxi-
mum turning length) must be observed.
The machine must not be operated in an explosive atmosphere.
Only one person at a time may work on the machine.
If more than one person is required in exceptional cases, the operator/owner must
appoint one person as the person responsible for coordinating the work and comply-
ing with the occupational safety regulations.
Do not walk on the machine or its auxiliary units.
If in exceptional cases it is necessary to be on the machine, this is expressly permit-
ted only when the machine is switched off.

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GENERAL INSTRUCTIONS FOR SAFE OPERATION
2.5 Reasonably foreseeable misuse of the machine
Reasonably foreseeable misuse includes:
• Bypassing protective apparatus during operation
• Operating the machine in ambient conditions other than the approved ambient
conditions
Machining of the following materials is not permitted:
• Explosives
• Materials releasing hazardous substances during the machining process (e.g.,
toxic or radioactive substances)
• Materials that produce explosive dust during machining
• Combustible materials
This does not apply to titanium alloys if appropriate fire-safety measures are met
when dealing with the collection of chips.
• Materials without sufficient inherent stability
2.6 Modifications to the machine
Modifications to the machine may result in a safety risk. This applies particularly to
all safety equipment, electrical circuits, and the machine control system software
and parameters.
Significant modifications to the machine may lead to non-conformance with the
applicable directives for product safety.
Therefore, the operator/owner must not make any modifications or additions to the
hardware or software of the machine without the written approval of INDEX-Werke
GmbH & Co. KG.
Modifications approved by the manufacturer must be documented in a retraceable
manner.

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GENERAL INSTRUCTIONS FOR SAFE OPERATION
2.7 Spare parts and accessories
The use of unapproved products may change the structural characteristics of the
machine and negatively affect its active or passive safety.
The use of original spare parts and accessories is recommended. For damages
caused by the use of parts from third-party providers, liability and warranty are
excluded.
If you have any questions or doubts, contact INDEX-Werke GmbH & Co. KG. Doing
so could prevent major damage.
2.8 Repairs
The operator/owner's employees may only carry out maintenance and repair work
to the extent described in the user documentation. The instructions for it must be
followed in all particulars.
INDEX-Werke GmbH & Co. KG assumes no liability or warranty for damage and
operational malfunctions as a result of non-compliance with these instructions or
improper repairs by the operator/owner's personnel.
Please consult INDEX-Werke GmbH & Co. KG if any uncertainties or complications
arise. Doing so could prevent major damage.
The information and instructions in this document and in the accompanying techni-
cal documents must be observed.

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GENERAL INSTRUCTIONS FOR SAFE OPERATION
2.9 Workspace of the operator
It is recommended that a working area of at least 1 m is kept free around the ma-
chine (including attached units) for operator activities.
Workspaces can vary depending on the activity.
The following activities, among others, can occur during production:
• Operating the machine from the operating panel
• Loading and unloading workpieces
• Refilling bar stock in the loading magazine, if one is present
• Removing chips in the work area and on the chip conveyor, as needed
• Emptying the chip container
• Observing and maintaining the process at the operating panel and in the work
area
• Removing and measuring workpieces
• Checking operating fluids (such as hydraulic fluid, lubricant, cooling lubricant) and
refilling if necessary
• Changing tools on the tool magazine or in the work area
• If needed: making adjustments for tool wear in the machine control system
A different workspace may apply during the following activities:
• Setup
• Inspection and testing
• Cleaning work
• Maintenance work

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GENERAL INSTRUCTIONS FOR SAFE OPERATION
2.9.1 Spatial allocation in the workspace
Spatial allocation of a multi-spindle lathe, example
Spatial allocation of a single-spindle lathe, example
Spatial allocation of a sliding headstock automatic lathe, example
Left Bar feeder Multi-spindle lathe Right
Rear
Front
Left Bar feeder
Single-spindle lathe
Right
Rear
Front
Left Bar feeder
Sliding headstock machine
Right
Rear
Front

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GENERAL INSTRUCTIONS FOR SAFE OPERATION
2.10 Personal protective equipment
The machine operator/owner must provide personal protective equipment.
The operator/owner's safety representative should be consulted regarding the use
of personal protective equipment.
Personal protective equipment required depending on the specific activity:
• close-fitting workwear
• safety shoes
• safety glasses (suitable eye protection)
• hairnet
• safety helmet
• safety gloves
• hearing protection
• skin barrier cream
Additional personal protective equipment required if combustible cooling
lubricants are used:
• flame-retardant work clothes
Work clothes contaminated with oil must be removed immedi-
ately.
2.11 Climbing aids
If climbing aids (ladders or steps) are used to carry out certain activities, be sure to
observe the safety regulations and instructions for the intended use published by
the respective manufacturer.

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GENERAL INSTRUCTIONS FOR SAFE OPERATION
2.12 IT and data security
Direct access to the production network should be protected by a firewall and hence
according to the current IT security standards. Nevertheless, it is the operator’s
responsibility to verify that the measures taken in the existing network are sufficient.
External data storage media as well as maintenance and service devices represent
basic security risks. These devices should be scanned for viruses before they are
used.
Only software that is required for production is installed on the controller. Installation
of additional software is not permitted.
Only network connections that are necessary, secure, and have been selected for
the production process (e.g., for remote maintenance) may be set up on the control-
ler. Unrestricted internet access to the controller must be prevented.
Additional protection can be achieved by network segmentation (e.g., by separating
the production network from the office network) to prevent mutual interference.
Modifications to the operating system are not permitted.

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SAFETY FUNCTIONS AND SAFETY EQUIPMENT
3 Safety functions and safety equipment
Some machine components, aside from their technical functions, also fulfill a safety
function that is designed to protect personnel from dangers at the machine.
For this reason, safety functions must not be tampered with, disabled or removed.
In case of damage to or failure of safety functions or equipment, the machine must
be shut down immediately.
Removal of safety functions is only allowed during repair work on the machine.
Once the repairs are finished, all safety equipment must be reinstalled and checked
for proper functioning.
3.1 Main switch
OFF
ON
Main switch, example
Turning the main switch to the “O” position (OFF) switches off the power supply to
the machine.
Danger!
Exception: lines that are specially marked. These can be live even
when the main switch is switched off and can be potentially
lethal if not handled properly.
Before all installation and repair work, if applicable:
– Switch off the relevant area switch and lock it out
– Remove the relevant fuses
For more details, see the electrical documentation of the ma-
chine.
The main switch can be secured with a safety lock to prevent it being switched back
on without authorization.

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SAFETY FUNCTIONS AND SAFETY EQUIPMENT
3.2 EMERGENCY STOP
EMERGENCY STOP device, example
EMERGENCY STOP devices are located at every operator position and should be
actuated when human life is in danger.
When actuated, all hazardous movements are switched off as quickly as possible
and a safe state is established.
However, the machine is not disconnected from the power supply.
A fault message is displayed on the screen.
Unlocking the EMERGENCY STOP does not cause the machine to restart automat-
ically.
Ensure the EMERGENCY STOP devices are accessible and
visible at all times.

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SAFETY FUNCTIONS AND SAFETY EQUIPMENT
3.3 Work area enclosure and work area door
The work area enclosure and work area door are safety partitions.
During setup and production of workpieces, it is possible for machine parts or work-
pieces to accidentally come loose and be thrown around.
If this happens, the safety partition protects the personnel at the machine against
dangers resulting from this situation. For this reason, no modifications may be made
to the safety partition.
The specified impact resistance of the safety partition must be observed. Detailed
specifications for the resistance classes can be found in the applicable standards.
The impact resistance is rated based on the forces expected, but it may be exceed-
ed due to special process parameters.
This applies, in particular, when specially adapted clamping devices are used. For
the selection and adaptation of clamping devices not provided as standard, the
technical limits and impact resistance of the machine and the instructions for the
clamping devices must be observed.
The protective measures were implemented according to the applicable type C
standard for the machine, although a residual risk always remains.
During production, always maintain a distance of at least
20cm from the work area door, which must always be closed.
In setup mode, the possible movements are severely restricted (e.g., by reduced
axis speeds) when the work area door is open.
Automatic work area doors do not have handles, in order to prevent people from
getting caught during movements of the door.
The interlock on the work area door must not be tampered with or disabled.

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SAFETY FUNCTIONS AND SAFETY EQUIPMENT
3.4 Window pane(s)
The work area door is fitted with window panes. These window panes have the
required resistance class and provide:
• A view of the machining process
• Protection from objects that may be thrown out, e.g., chips, tools, or broken-off
parts of workpieces
• Protection from splashed coolant
The window panes must be inspected for damage, such as cracks, in accordance
with the maintenance instructions.
The window panes must be replaced every time they are damaged (e.g. if they
become cloudy or cracked) because their protective effect is no longer guaranteed.
The year of manufacture is indicated on the window panes.
When the interval specified in the maintenance instructions expires, the window
panes must be replaced even if they are not damaged.
3.5 Splinter protection film on the design pane
For additional safety, one1) special highly transparent splinter protection film is af-
fixed to the outside of the design pane.
Danger from flying splinters!
The splinter protection film affixed to the design pane to pro-
tect against splinters must never be removed!
1) On some machine types, two safety films are used.
3.6 Clamping conditions
A description of clamp stroke monitoring is included in the respective user docu-
mentation.
The monitoring measures designed to ensure the clamping conditions (e.g. clamp-
ing stroke monitoring, clamping pressure monitoring) must not be bypassed.

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SAFETY FUNCTIONS AND SAFETY EQUIPMENT
3.7 Pneumatic safety valve (optional)
If compressed air is used in the machine, the machine will feature a compressed
air maintenance unit with pressure regulating valve, including a pressure gauge to
display the system pressure (for setting the operating pressure), an electric switch-
on and shut-off valve, and a manual switch-on and shut-off valve to separate the
machine from the compressed air supply (customer's air network).
A system pressure sensor to monitor the customer's network is also installed.
3.8 Warning signals/indicators
Various indications, alerts, and fault/error messages are displayed on the screen.
They are usually self-explanatory.
The machine status is signaled by an LED multi-indicator lamp.
3.9 Keys and password protection
Access to the various operating modes and settings is protected using keys and
passwords.
Do not allow keys or passwords to come into the hands of unauthorized persons.
Setup mode is safeguarded by a key.
The key must be pulled out again once setup mode is finished.
Machine programs and other safety-critical settings can only be accessed after
entering the corresponding passwords.
The passwords are linked to a number of protection levels.
The protection levels available are determined by the customer's requirements and
the configuration used by the manufacturer.
3.10 Confirmation mode
In setup mode with the work area door open, hazardous movements can only be
started when both the confirm key and the action key are pressed.
If one of the keys is released, the movement is stopped.