joke EL 380 User manual

Single-disc Flat Lapping and Polishing Machine
EL 380

Instruction Manual
for
Single-disc Flat Lapping and Polishing
Machine
Type: EL 380
Sold by:
joke Technology GmbH
Asselborner Weg 14-16
D-51429 Bergisch Gladbach
Telephone [phone] / 8 39 - 0
Telefax: +49 (0) 22 04 / 8 39 - 60
Internet: www.joke.de
Email: [e-mail]
joke 02/2011
Subject to changes due to technical progress and improvements.
Page I
EL 380

1 List of contents
List of contents..........................................................................1-1
Notes on the manual............................................................... 2-1
Safety instructions .................................................................. 3-2
Warranty / identification ......................................................... 4-1
Machine overview ................................................................... 5-2
Technical data......................................................................... 6-1
Operation / control ................................................................. 7-23
Troubleshooting ...................................................................... 8-1
Care and maintenance .............................................................9-1
Consumables ..........................................................................10-1
11
Spare parts list .......................................................................11-1
Annex ...................................................................................12-12
Page 1 - 1
EL 380

2 Notes on the manual
This manual has been written for the device user to ensure a problem-free
operation, care and maintenance.
Important instructions and information concerning safety and operational
reliability have been highlighted.
The symbols used in the manual have the following meanings:
RSICHT!
Working and operating processes which must be observed to the letter to
exclude any risk to persons. .
Working and operating processes which must be observed to the letter to
avoid any damage to the machine.
Technical information to which the device operator must give special
attention.
The illustrations and diagrams are numbered in sequence within each chap-
ter. Some of these illustrations have keys. References to illustrations within
the text e. g. (5.1/2) have the following meaning:
5.1 = Figure 5.1
2 => Position 2 in the key to the figure.
Please feel free to call our customer service department at any time
should you encounter technical problems which are not dealt with in this
manual:
Telephone [phone]
Telefax +49 (0) 2204/839-60.
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VO
joke operating manual EL 380
CAUTION!

3 Safety instructions
This machine has been built according to the latest technical standards
and generally accepted safety regulations. Nevertheless, it can
constitute danger to life and limb for operator or third parties and a
hazard to the device itself or other equipment during use.
Only use the device if in perfect working order and for its intended pur-
pose. You must always pay attention to the instruction manual and
safety instructions therein and be aware of the risks! Repair any faults
which could affect the device’s safety immediately by yourself or have
these repaired.
The device is designed exclusively for lapping, polishing or honing
according to the disc type used. Any other use will be deemed to be
contrary to its intended purpose. The manufacturer cannot be held lia-
ble for any resulting damages. The risk is borne solely by the user.
Correct use also includes compliance with the instruction manual and
observation of the care and maintenance conditions.
Keep the instruction manual handy at the device’s place of use.
Pay attention to and observe generally applicable statutory and other-
wise binding regulations relating to accident prevention and environ-
mental protection in addition to the information provided in the
instruction manual!
RSICHT!
(5) All personnel commissioned to work on or with the machine must have
read this instruction manual, and particularly the safety instructions
chapter, before starting work. This applies especially for personnel who
only work with the device occasionally.
Observe safety instructions on the machine and keep them legible.
Stop the device immediately should you notice changes to the device or
its operating behaviour that are relevant to its safety. Have these
remedied by suitable specialists before restarting work.
Page 3 - 1
VO
EL 380
CAUTION!

3 Safety instructions
Do not carry out yourself or have carried out any modifications,
additions or conversions to the device!
Spare parts must meet the technical requirements specified by the
manufacturer. This can only be guaranteed with original JOKE®spare
parts.
Any work on/with the device may only be carried out by qualified,
appropriately trained and authorised personnel. Pay attention to mini-
mum statutory age limits!
Personnel undergoing training or in a general apprenticeship should
only be allowed to work with the machine under the constant supervi-
sion of an experienced operator!
Restrain from any type of work that could jeopardise your safety.
The machine may only be used if all protective and safety equipment is
in place and in proper working order.
Do not leave the machine unattended when switched on!
Stop and secure the machine immediately in the event of malfunctions!
Faults must be remedied at once by suitable specialists!
Pay attention to adequate ventilation of the workroom when using the
polishing and lapping system!
Install air extraction if necessary in case of small rooms!
Page 3 - 2
EL 380

4 Warranty / identification
Joisten & Kettenbaum warrants the correct manufacture of every Joisten &
Kettenbaum product which is delivered in accordance with the terms of
contract and delivery.
This warranty does not cover damages caused by normal wear and tear,
incorrect handling, negligent use, the fitting of non-original spare parts, ina-
dequate care and/or a failure to comply with this technical manual.
The machine may only be used by appropriately trained and
commissioned personnel. If it is not, all warranty claims will be
forfeited according to the terms of delivery.
Machine identification
The manufacturer’s code, type code,and series number can be found on the
rear of the machine.
Page 4 - 1
joke operating manual EL 380

5 Machine overview
Purpose
The joke single-disc flat lapping and polishing machines are intended for
lapping, polishing or flat honing.
Depending on the application, the machines are fitted with a lapping disc,
polishing and lapping disc, solid grit disc or a carrier disc for stick-on
polishing cloths.
Discs in conjunction with various different lapping and polishing media are
tailored to the desired result of the processing method.
The machines are suitable for achieving flat surfaces with low surface
roughness values on workpieces made of almost all materials.
The main applications are in production of mechanical components and
components for electronics and optics.
joke operating manual EL 380
Page 5 - 1

5 Machine overview
Structure of a single-disc flat lapping and polishing machine
Structure of a single-disc flat lapping and polishing machine
##hier ist noch das falsche Bild drin##
Fig. 5.1 Machine overview
1 –Table plate
2 - Dressing rings
3 - Control cabinet and control box
4 – Screws for lapping disc fixting
5 - Machine table
6 - Screws for table height adjustment
7 - Roller yoke and guide rail
EL 380
Page 5 - 2

6 Technical data
Technical data for EL 380
Number of dressing rings .......................................................3 items
Dressing ring internal Ø ........................................................140 mm
Lapping disc Ø .......................................................................380 mm
Lapping disc speed.................................................................60 rpm
Machine length without pneumatics......................................725 mm
Machine height without pneumatics.........................................400 mm
Machine height with pneumatics............................................1075 mm
Supply voltage ........................................................ 230 volts, 1~50 Hz
Supply load............................................................400 volts, 3~50 Hz
Fuse ...........................................................................16 A, slow-blow
Drive motor............................................................................ 0.55 kW
Pump motor........................................................................... 0.08 kW
Weight
Weight without pneumatics............................................ approx. 150 kg
Weight with pneumatics................................................. approx. 200 kg
Page 6 - 1
EL 380

7 Operation / control
Unpacking the machine
Remove all packaging materials.
Dressing rings, weights and lapping discs are precision parts!
Handle them carefully and protect against damage.
Securely grasp the machine by the bottom crossmembers and
position the machine at the machine location.
Figure 7.1
Page 7 - 1
EL 380

7 Operation / control
EL 380 layout plan
Dimensions in millimetres
Fig. 7.2
joke operating manual EL 380 Page 7 - 2

7 Operation / control
Machine location
Refer to layout plan in Fig. 7.2. for spatial requirements.
The machine location must not be exposed to any emissions caused
by other machines (dust, vibrations)!
Align the machine using a spirit level; the lapping disc represents the
reference surface.
Starting up the machine
Remove the dressing rings and hand weights from the lapping disc.
If a pneumatic contact pressure device is present, establish the air connection via the
maintenance unit
Figure 7.3
(3)Move the contact pressure weights to the top end position by
operating the control valves (see Fig. 7.7).
Plug the male connector on the machine connecting cable into a socket
with the supply voltage specified in the tech. data.
Pay attention to correct earthing!
Page 7 - 3
joke operating manual EL 380
Maintenance unit
Air max. 4 bars

7 Operation / control
Check direction of rotation of the lapping disc
Set the main switch on the side of the control console to the on position.
Press the „START“ pushbutton (7.6/1).
RSICHT!
It is essential for the dressing rings to be removed from the lapping
disc.
The rings slip off the machine if the direction of rotation is incorrect!
Risk of injury!
The lapping disc must rotate anticlockwise.
Bild 7.4
Figure 7.4
If the direction of rotation is incorrect, correction can be made by changing a
phase of the electrical connection.
SICHT! Only have this work performed by a skilled electrician!
Further tasks for starting up
Degrease the dressing rings and lapping disc with a suitable medium.
Apply the dressing rings to the lapping disc in the "neutral" position.
Install the lapping medium tank with the pump and waste tank (see Fig.
7.5).
Page 7 - 4
VOR
joke operating manual EL 380
CAUTION!
CAUTION!
Direction of rotation

7 Operation / control
Figure 7.5
Page 7 - 5
joke operating manual EL 380
Sight glass
Guide wire
Socket for
spraying unit
Socket for lapping
medium pump
Dispensing screw
Dispensing unit
Flow from pump
Return flow to
lapping
medium pump
Drain
Lapping
medium tank
with pump

7 Operation / control
Control elements of lapping machine
8
10
Figure 7.6
1 - Mains
2 - Machine ON
3 - Machine OFF
4 – Pump start
5 - Timer
6 - Indicator light: LAPPING TIME END
7 - 230 V socket for pendulum arm (permanent voltage in "ON"
position of the main switch)
8 - 230 V socket for dispensing unit and pulse device activated via pump
start (switched by means of "PUMP" start)
9 - Main switch
joke operating manual EL 380 Page
7 - 6

7 Operation / control
Contact pressure device (optional equipment)
The pneumatic contact pressure device is available for joke lapping
machines of series „EL“ or as a retrofitting unit.
Structural diagram
Figure 7.7
– Pneumatc cylinder
- Clamping screws for cylinder retaining plate
3 – Contact pressure plate
4 - Fixing flange for pneumatic contact pressure device
Page 7 - 7
joke operating manual EL 380

7 Operation / control
On the pneumatic contact pressure device, the three contact pressure
cylinders (7.7/1) can be moved to their working and end position by
operating the control valve.
After loosening two locking screws (7.7/2), the the pneumatic contact
pressure cylinders can be adjusted in position in relation to the position of
the lapping machine dressing rings by means of a guide.
The necessary working pressure can be adjusted for all three contact
pressure cylinders by means of a pressure relief valve.
The necessary contact pressure depends on the size of the surfaces to be
processed and the type of machining process selected. It is generally
determined empirically. (see chapter 12, annex 4.)
Reduce travel speed for safety reasons!
The cylinder travel speed is cut back to < 10cm/sec. for safety reasons.
Page 7 - 8
joke operating manual EL 380

7 Operation / control
General advice on lapping
Fig. 7.8
The dressing rings serve to holding the lapping disc flat and guiding and
receiving the workpieces in addition to distributing the lapping or polishing
medium.
The dressing rings run at three positions against machine jokes which are
capable of transferring shearing force.
The means of transmitting force to the workpiece is either the dressing ring
itself (with the ring fully loaded) or a mask corresponding to the
workpiece(s).
The mask is generally a hard paper disc with the internal dimension of the
sealing ring and recesses for receiving the workpieces.
Fig. 7.9
Page 7 - 9
joke operating manual EL 380
Lapping or polishing disc
Dressing ring
Working receptacle bore
Hard paper mask

7 Operation / control
This mask should have approx. 1 - 2 mm of play in relation to the dressing
ring; the workpieces should have approximately the same play in the mask
in order to ensure flat contact between the workpiece surface and the
lapping disc.
The hard paper masks are to be provided with suitable spacers (e.g.
commercially available U washers) in order to limit the lapping process to
the workpieces and the dressing rings.
Fig. 7.10
The height "H" must be less than the height of the workpieces to be
processed.
The dressing rings are fitted with workpieces after the lapping disc displays
an adequate film of lapping medium.
This is achieved by a brief period of machining with the lapping machine
running idle but with the lapping medium supply system activated.
When the dressing rings are equipped with workpieces, the contact pressure
required for machining is created by applying the hand weights or, if the
machine is equipped with a pneumatic system, by charging the contact
pressure cylinder.
Compensation washers (soft rubber material) should be placed between the
workpieces and the contact pressure weights to compensate for any
differences in dimensions of the individual workpieces/ring.
Page 7 - 10
joke operating manual EL 380
Working receptacle bore Spacer
Lapping disc