KELCH KENOVA set line V9 Series User manual

05.09.2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
KENOVA set line V9xx(-S)
Translation of the Original Operating Instructions
KENOVA set line V9xx(-S)
BA - Version 1.0
Document No. / Article No.: 1066307
© KELCH GmbH 2013
All rights reserved. Subject to technical changes

Translation of the original operating instructions
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page I
Table of Contents
Table of Contents ........................................................................................................ I
List of Figures ............................................................................................................ III
1Product liability and warranty............................................................................... 1
1.1 General.................................................................................................... 1
1.2 Warranty .................................................................................................. 2
1.3 Servicing.................................................................................................. 2
1.4 Intended Use ........................................................................................... 3
1.5 Disposal of the appliance......................................................................... 4
2Safety .................................................................................................................. 5
2.1 Warnings and hazard symbols................................................................. 5
2.2 Fundamental safety rules ........................................................................ 7
2.3 Spare parts, accessories ......................................................................... 7
2.4 Requirements on the operating and maintenance personnel .................. 7
2.5 Safety measures...................................................................................... 9
2.6 Safety decals on the appliance.............................................................. 10
2.7 Dangerous areas on the appliance and during operation ...................... 11
2.8 Danger from electrical power /voltage ................................................... 13
2.8.1Danger from electromagnetic radiation ....................................... 14
2.9 Pneumatic supply .................................................................................. 14
2.9.1Dangers arising from hydraulic and pneumatic power ................ 14
2.9.2Danger from lubricants................................................................ 15
2.10 Opening the housing.............................................................................. 15
3Commissioning .................................................................................................. 16
3.1 Transportation / Packaging / Storage .................................................... 16
3.2 Scope of delivery: .................................................................................. 16
3.3 Securing for transport ............................................................................ 17
3.4 Installation ............................................................................................. 18
3.5 Pneumatic connection ........................................................................... 20
3.6 Electrical connection.............................................................................. 20
3.6.1Connecting cables for the peripheral devices.............................. 21
3.6.2Procedure when cabling up ......................................................... 21
3.7 Acceptance test ..................................................................................... 21
4Operating........................................................................................................... 22
4.1 General remarks on operating the electronic measuring equipment...... 22
4.2 Components .......................................................................................... 22
4.3 Measuring.............................................................................................. 23
4.3.1Operating panel........................................................................... 23
4.3.2Axis travel.................................................................................... 23
4.3.3Travel to reference points ........................................................... 24
4.3.4Clamping and releasing the tool.................................................. 24
4.3.5Camera carrier ............................................................................ 25
4.3.6Camera ....................................................................................... 25
4.3.7Measurement preparation ........................................................... 26

Translation of the original operating instructions
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page II
4.4 Shrinking and setting (only with V9xx-S) ............................................... 27
4.4.1Length adjustment with end-stop pin........................................... 28
5Maintenance and care ....................................................................................... 29
5.1 Safety measures.................................................................................... 29
5.2 Inspection .............................................................................................. 30
5.3 Cleaning ................................................................................................ 30
5.4 Maintenance .......................................................................................... 30
5.4.1Servicing Schedule ..................................................................... 31
6Technical Data................................................................................................... 32

Translation of the original operating instructions
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page III
List of Figures
Figure 1: Left: KENOVA set line V9xx with base frame and peripherals carrier, right:
KENOVA set line V9xx-S with base frame and peripherals carrier...........................3
Figure 2: Transport securing, counterweight .................................................................17
Figure 3: Transportation securing, axes ........................................................................17
Figure 4: (1) Transport securing means of the shrink tower for the
KENOVA set line V9xx-S........................................................................................18
Figure 5: Base frame KENOVA set line V9xx(-S) ..........................................................18
Figure 6: Schematic representation of KENOVA set line V9xx(-S)................................19
Figure 7: Maintenance unit with pressure reducer.........................................................20
Figure 8: Components KENOVA set line V9xx(-S) ........................................................22
Figure 9: Operating elements of KENOVA set line V9xx(-S) .........................................23
Figure 10: Camera components ....................................................................................25
Figure 11: Insertion of the tool (here an adjustment mandrel)........................................26
Figure 12: Length adjustment with end-stop pin ............................................................28

Translation of the original operating instructions
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page IV
List of Tables
Table 1: Dangerous areas on the appliance..............................................................12
Table 2: Technical data of KENOVA set line V9xx(-S) ..................................................32

1. Product liability and warranty
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page 1
1 Product liability and warranty
1.1 General
These Operating Instructions are important in order to operate the appliance safely, cor-
rectly and efficiently. Observance of them assists in avoiding hazards, reducing repair
costs and down times and increase the reliability and service life of the complete ma-
chine.
The Operating Instructions, in particular the Chapter “Safety”, must be read and applied
by all persons who are commissioned to work with and on the appliance:
Operating
including setting up, fault rectification during the operating cycle, disposal of pro-
duction waste, care, disposal of operating and consumable materials
Servicing
Maintenance, inspection, overhaul
Transport
In addition to the applicable regulations for accident prevention in the Operating
Instructions and country of use, also observe the recognized technical regula-
tions for safety and correct operation, as well as the respective workshop-specific
regulations.
If uncertain, the company KELCH GmbH are gladly at your disposal for queries:
KELCH GmbH
Werkstrasse 30
D-71384 Weinstadt-Endersbach
Telephone: [phone] switchboard
640 Service
Fax: 613
E-Mail: [email protected]
Internet: www.kelch.de

1. Product liability and warranty
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page 2
1.2 Warranty
It is anticipated that the appliance will remain efficient, safe to operate and operate ac-
curately for many years. However, this can only be ensured when the rules for opera-
tion, maintenance and servicing are maintained.
During the warranty period, malfunctions that occur will be rectified by KELCH GmbH in
accordance with the warranty conditions. All consequences of unauthorized conversions
and modifications shall be incurred by the operating company. This is particularly appli-
cable to modifications that impair the safety of the unit.
Warranty is exclusively accepted for original spare parts.
Contravening this results in KELCH GmbH declining all liability.
Immediately check the completeness of the delivery on receipt, according to the order
confirmation / delivery note.
These Operating Instructions do not broaden the scope of the KELCH GmbH Terms
and Conditions of Purchase and Delivery!
1.3 Servicing
It is highly recommended to keep a stock of the most important spare and expendable
parts (refer to the Spare Parts List in the documentation file) at the location of use to
maintain operational readiness of the appliance.
For comprehensive repair and overhaul tasks on the appliance, KELCH GmbH are at
your disposal. For all written or telephone inquiries or orders, state:
The module affected
Serial number and year of manufacture of the appliance:
This data is located on the appliance nameplate.

1. Product liability and warranty
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page 3
1.4 Intended Use
The tool setting device KENOVA set line V9xx is used for the gauging of tools. If you
have decided on a KENOVA set line V9xx(-S), the device can also be used to shrink
tools in the shrink chuck provided for this purpose and cool this by means of a cooling
system. With ‘tool’, we mean in the following the complete tool, i.e. a tool in its adapter.
The temperature of tools must correspond roughly to the room temperature. Especially
tools, which have been previously heated up, must be cooled down before the gauging.
Use for any other purpose is considered to be an improper use. KELCH GmbH accept
no liability for damage resulting from this. The risk shall be borne solely by the operator.
Intended use also includes observance of the Operating Instructions, as well as adher-
ence to the inspection and maintenance intervals prescribed by KELCH GmbH.
Figure 1: Left: KENOVA set line V9xx with base frame and peripherals carrier, right: KENOVA set line
V9xx-S with base frame and peripherals carrier

1. Product liability and warranty
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page 4
1.5 Disposal of the appliance
Where possible, during the design of the appliance it was ensured that no composite
materials were used. This design concept permits a high degree of hardware recycling
after reaching the end of its service life. Thus, we also offer to take back the appliance
for correct disposal at a fee. Moreover, we wish draw attention to the fact that the re-
quirements of the electronic scrap provisions for disposal must be adhered to.

2. Safety
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page 5
2 Safety
2.1 Warnings and hazard symbols
The following designations and symbols are used in these Operating Instructions for
particularly important tasks:
Warning! Danger of death or serious bodily injury!
By non-observance, risk of possible or direct serious injury or
death.
Caution! Risk of light bodily injury or damage to property!
By non-observance, low risk of bodily injury or damage to proper-
ty!
Warning! Warning of non-ionizing electromagnetic radiation!
Do not expose interference-sensitive appliances and persons
with active and, in certain cases, also passive medical implants
to the system electromagnetic field.
Warning! Warning of hazardous electric voltage!
The appliance must not be used if damage occurs such as: loose
cable connections, defective insulation, burnt cables and other
damage that impairs the electrical safety of the appliance.
Warning! Warning of toxic substances!
During shrinking, residual cooling lubricants, oils or greases can
vaporize. Do not inhale oil mist! Oil mist is harmful to health and
can contain carcinogenic substances.
Warning! Warning of hot surface!
During the shrinking procedure, do not reach into the induction
coil or take objects into the vicinity of the coil. Risk of injury due
to burns from hot parts!

2. Safety
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page 6
Warning! Warning of explosive and combustible substances!
The shrink fit device (if present) must not be operated in potential
fire or explosion environments or in the vicinity of combustible,
flammable or explosive substances.
Warning! Warning of being drawn in by rotating equipment!
Care has to be taken that no loose objects such as jewellery are
worn when operating the machine. When filling the cooling sys-
tem with cooling water, loose items can get caught up in the rotor
of the cooling unit. The same applies to the rotational axis of the
setting device.
Prohibited! Prohibited for persons with medical implants!
Staff with active medical implants are not permitted to work with
this appliance and, for safety reasons, must not go nearer than
3 m to the appliance.
Note! Particular information as a reminder or something taken from our
experience. For example as a tip, in order to carry out an action
with particular efficiency.

2. Safety
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page 7
2.2 Fundamental safety rules
The appliance is designed in accordance with state-of-the-art technology and applicable
safety regulations.
All linear axes are fitted with Uhing shafts to prevent crushing as the linear axes slip at a
force of approx. 80 N. For this reason, no particular protection measures such as auto-
matic linear axis travel are necessary to prevent crushing.
Nevertheless, the appliance can pose special hazards if insufficiently trained personnel
carry out the installation, the appliance is incorrectly used, or not used as intended.
Observe the following accident prevention regulations:
The company accident prevention regulations
UVV accident prevention regulations
VDE safety regulations
2.3 Spare parts, accessories
Only accessories and spare parts authorized by KELCH GmbH must be used.
Such parts have been checked and released by KELCH GmbH. Otherwise the active
and passive safety of the appliance can be impaired!
KELCH GmbH excludes all liability and warranty claims for damage that occurs if origi-
nal parts and accessories are not used.
2.4 Requirements on the operating and maintenance personnel
Before carrying out tasks, every person engaged with the setting up, installation, com-
missioning, operation and servicing of the appliance must have read and understood
these Operating Instructions, in particular the Chapters; “Safety” “Commissioning”
and “Operating and setting the language”. This applies in particular to persons who
only occasionally carry out tasks on the appliance.
The operating company is obliged to instruct the operating and servicing personnel
about operating and servicing the appliance, taking all safety regulations into considera-
tion.

2. Safety
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page 8
Only persons can be deployed to operate and service the appliance who have had the
appropriate training for such tasks. This applies particularly to tasks on the electrical,
pneumatic and mechanical equipment of the appliance.
Persons being trained, instructed or personnel within the framework of general training
are permitted to carry out tasks on the appliance but only under constant supervision of
an experienced person!
If more than one person carries out a task on the appliance, the responsibilities of the
individual tasks must be clearly defined and adhered to. From a safety viewpoint,
spheres of responsibility must be clearly defined!
Note! Before carrying out special and servicing tasks, inform the
operating personnel. Nominate a supervisor!

2. Safety
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page 9
2.5 Safety measures
To avoid accidents, it is mandatory to observe the company regulations!
For operating personnel who work with the appliance, the following safety measures are
mandatory:
Hands Wear hand protection!
Possible sharp edges or swarf deposited on the tool can cause
cuts. Furthermore, burns can come from the heated shrink chuck
(if present).
Risk of injury due to crushing when inserting the tool.
Thus, wear protective gloves!
Feet Wear foot protection!
A possible falling tool can cause injuries to the feet. Thus, wear
safety shoes with steel toe caps!
Head Wear head protection!
Fundamentally, if there is a risk of head injuries, in particular from
falling objects, for assembly and disassembly procedures over-
head, as well as for tasks using the crane, wear a safety helmet.
Eyes Wear eye protection!
If there is a possibility of harmful influences, such as strong light,
chemicals, swarf, oil or dirt, it is always recommended to wear
safety goggles.
Hair Wear a hair net!
Long hair can get caught, just as easily as necklaces, in rotating
machinery such as the spindle of rotor of the cooling unit. So al-
ways wear a net to keep hair put of the way and remove any
loose items such as jewellery.

2. Safety
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page 10
2.6 Safety decals on the appliance
All safety and hazard instructions on the appliance must be maintained in a legible con-
dition and be observed!
Warning! Warning of non-ionizing electromagnetic radiation!
Do not expose interference-sensitive appliances and persons
with active and, in certain cases, also passive medical implants
to the electromagnetic field of the system.
Prohibited! Prohibited for persons with medical implants!
Staff with active medical implants are not permitted to work with
this appliance and, for safety reasons, must not go nearer than
3m to the appliance.
Warning! Indirect danger to life in the switch cabinet!
The switch cabinet is constructed to current standards, also in
terms of contact safety within the cabinet. Nevertheless, it would
be possible with the help of suitable tools (e.g. measuring probes,
screwdrivers) to make contact with voltages of 90 to 260 VAC!
The switch cabinet may therefore only be opened, when the de-
vice has been made potential free by opening the main switch. A
key is necessary to open the safety lock.
Note! The switch cabinet contains no operating elements or manually
operable fuses. Opening the cabinet is therefore not necessary in
the normal case.

2. Safety
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page 11
2.7 Dangerous areas on the appliance and during operation
Item Dangerous area Hazard Safety instructions
1 Tool Cuts Wear gloves
2 Take-up spindle
Crushing,
danger of being
drawn in
Avoid getting fingers jammed when insert-
ing and loosening the tool! Wear clean
gloves. No loose objects such as neck-
laces or other hanging jewellery may be
worn as they can become jammed and
draw the operator into the machine.
3
Induction coil
(only with
V9xx-S)
Electro-
magnetic
radiation
Do not permit persons with active (e.g.
pacemaker) and, in certain cases, also
passive medical implants, to work on this
appliance, or allow interference-sensitive
appliances to be exposed to the electro-
magnetic field of the system. For safety
reasons, these persons must not go
nearer than 3 m to the appliance.
4
Induction coil
(only with
V9xx-S)
Vapours
harmful to
health
During shrinking, residual cooling lubri-
cants, oils or greases can vaporise or
create dust. These vapours can contain
carcinogenic substances and are harmful
to heath. Therefore keep a safe distance
and do not inhale these!
5
Shrink chuck
(only with
V9xx-S)
Burns Wear thermally insulating gloves
6
Cooling unit,
motor housing,
refrigerant
pressure lines
(only with
V9xx-S)
Burns
Continuous operation can give rise to high
temperatures on the motor housing and
the refrigerant pressure lines. So always
wear protective gloves when filling the
unit.

2. Safety
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page 12
Item Dangerous area Hazard Safety instructions
7
Induction coil
(only with
V9xx-S)
Burns
Do not reach into the coil during heating.
Do not allow objects (e.g. metal parts) to
get into the induction coil.
Table 1: Dangerous areas on the appliance

2. Safety
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page 13
2.8 Danger from electrical power /voltage
Warning! Indirect danger to life if the appliance is incorrectly handled!
The appliance may not be operated if the housing is open.
The appliance housing must only be opened by specialists from KELCH GmbH!
The appliance must not be operated in a potentially explosive environment.
The appliance may not be exposed to condensation or liquids.
The device must be switched off immediately when damage such as the following
occurs;
- loose cable connections,
- defective insulation,
- burnt cables,
- other damage that impairs the safety of the device.
Pull out the main connector of the tool setting device / cooling unit (only with the
V9xx-S) before performing any maintenance, cleaning or repair work!
Electric shock still possible when the device is switched off. Wait for five minutes
after switching off on all poles (capacitor charge!) before touching the equipment.
Only operate again after all damage has been rectified.
Electrical connection of the appliance to the mains supply, as well as carrying out
tasks on the electrical equipment, must only be carried out by a qualified special-
ist. Thereby, observe the corresponding VDE guidelines and guidelines and
regulations applicable at the location of installation.

2. Safety
KENOVA set line V9xx(-S) © Kelch GmbH 2014
Kelch GmbH · Werkstraße 30 · D-71384 Weinstadt-Endersbach · Tel. [phone] · Fax [phone] · [e-mail]
Page 14
2.8.1 Danger from electromagnetic radiation
When the system is used as intended, there are no electromagnetic radiation effects on
the environment. If the induction heating is started with no shrink chuck in the coil, the
magnetic field affects the immediate area in the coil.
Caution! Risk of damage to property!
Do not bring any interference-sensitive devices into the vicinity of
the system!
Prohibited! Danger of injury!
Staff with active medical implants are not permitted to work with
this appliance and, for safety reasons, must not go nearer than
one metre to the appliance.
Warning! Warning of toxic substances!
During shrinking, residual cooling lubricants, oils or greases can
vaporize. Do not inhale oil mist! Oil mist is harmful to health and
can contain carcinogenic substances.
2.9 Pneumatic supply
Work on the pneumatic system may only be carried out by specialists, taking the guide-
lines and regulations which apply at the installation site into consideration. If this is not
complied with, Kelch GmbH will decline any liability.
2.9.1 Dangers arising from hydraulic and pneumatic power
Caution! Risk of damage to property!
If damage to pressure hoses and pipes as well as screwed con-
nections is detected (e.g. abrasion marks or leaks), the tool pre-
setter with combined shrink fit must be switched off immediately
and may not be brought into operation again till the defects have
been remedied.
Caution! Danger of injury!
Danger of injury from leaks of high-pressure media