Microtap Microtap II User manual

Operating Instructions Thread tapping units/ Accessoriesr 01/09, Software 4.9 © 01.1994-2016 microtap GmbH
Operation Instructions
microtap II megatap II
jobtap

Operating Instructions Thread tapping units/ Accessoriesr 01/09, Software 4.9 © 01.1994-2016 microtap GmbH
© copyright microtap GmbH 05.1994 - 2016
All information, know-how and illustrations contained in these operating instructions
are the sole property of microtap GmbH.
Without expressed permission from microtap GmbH neither the entire operating
instructions nor any parts thereof may be communicated directly or indirectly to third
parties, nor may they be copied or used other than for the purpose for which they
are supplied.
General information, list of contents, 1
SAFETY INSTRUCTIONS
Technical data 2
Description
Assembly, 3
Commissioning
Operation machine 4
Maintenance 5
Trouble shooting 6
Spare parts 7
Integration of optional 8
Accessories
Product overview 9
Date of original issue: Version 01.94
Date of this issue: Version 01.16

Operating Instructions Thread tapping units/ Accessoriesr 01/09, Software 4.9 © 01.1994-2016 microtap GmbH 1
TABLE OF CONTENTS
1. GENERAL INFORMATION.......................................................................4
1.1. Declaration of EC-conformity......................................................................................... 4
1.2. Warranty-/Operating procedure Certificate................................................................... 5
1.3. Operating conditions....................................................................................................... 6
1.4. Definitions......................................................................................................................... 6
1.4.1. Viewing definitions .............................................................................................................6
1.4.2. Validity of the operating instructions .................................................................................. 6
1.5. Definition of pictograms.................................................................................................. 7
1.6. Safety instructions........................................................................................................... 8
1.7. Specific operating instructions for the operator.......................................................... 9
1.8. Possible risks to health and safety.............................................................................. 10
2. TECHNICAL DATA, DESCRIPTION.......................................................11
2.1.1. Dimensions megatap II .................................................................................................... 14
2.1.2. Dimensions microtap II .................................................................................................... 15
2.1.3. Dimensions base plate..................................................................................................... 16
2.2. Short description of the machine................................................................................. 17
2.2.1. The automatic thread tapping machine has the following distinguishing features: ......... 18
2.2.2. Rear side of machine head megatap II / microtap II ........................................................ 19
2.3. Thread tapping terms .................................................................................................... 20
2.4. Static fracture torque of taps........................................................................................ 23
3. ASSEMBLY, COMMISSIONING AND RELOCATION............................24
3.1. Off-loading and unboxing ............................................................................................. 24
3.2. Commissioning .............................................................................................................. 25
3.2.1. Location............................................................................................................................ 25
3.2.2. Assembly and commissioning.......................................................................................... 26
3.3. Relocating the machine................................................................................................. 27
3.4. Interfaces, pin-out.......................................................................................................... 28
3.4.1. Connector for lubricating system (receptacle, 4-pins female) ......................................... 28
3.4.2. Serial interface RS 232, SUB-D, 9-pin female................................................................. 28
3.4.3. I/O user interface connector (SUB-D, 15-pins) ................................................................ 29
3.4.4. I/O wiring diagramm (internal wiring of the machine) ...................................................... 30
3.4.5. I/O Samples (external wiring of the machine).................................................................. 32

Operating Instructions Thread tapping units/ Accessoriesr 01/09, Software 4.9 © 01.1994-2016 microtap GmbH 2
3.5. Link between PC and thread tapping machine........................................................... 34
3.5.1. Set of parameters forwarding to the machine.................................................................. 34
3.5.2. Feedback messages of the thread tapping machine....................................................... 35
3.5.3. How to request for specific values ................................................................................... 35
3.5.4. Quality monitoring ............................................................................................................ 36
3.5.5. Remote control mode....................................................................................................... 36
4. OPERATING THE MACHINE..................................................................37
4.1. Changing taps................................................................................................................ 37
4.2. Power Up / working menu............................................................................................. 38
4.3. System Setup ................................................................................................................. 39
4.4. Setting / changing the parameter................................................................................. 40
4.4.1. Operating menu ............................................................................................................... 40
4.4.2. Parameter Menu .............................................................................................................. 40
4.5. Manual operation ........................................................................................................... 48
4.6. Thread tapping with option „ZAP“ via remote control .............................................. 49
4.7. Thread tapping with ZAP-option via RS232................................................................ 50
5. MAINTENANCE ......................................................................................51
5.1. Periodic routine maintenance....................................................................................... 51
5.1.1. Replacing the dust filter (only megatap II, jobtap / labtap): ............................................. 51
6. TROUBLE SHOOTING ...........................................................................52
6.1. General information....................................................................................................... 52
6.2. Fault report form.......................................................................................................... 53
6.3. Quality, error indications............................................................................................... 54
6.4. Opening and closing the machine ............................................................................... 57
6.5. Repairs............................................................................................................................ 58
6.5.1. Replacing the fuse ........................................................................................................... 58
6.5.2. Changing the suspension wires....................................................................................... 58
7. SPARE PARTS .......................................................................................60
7.1. General information....................................................................................................... 60
7.2. Ordering spare parts...................................................................................................... 60
7.3. Spare parts list ............................................................................................................... 61

Operating Instructions Thread tapping units/ Accessoriesr 01/09, Software 4.9 © 01.1994-2016 microtap GmbH 3
8. INSTALLATION OF OPTIONAL EQUIPMENT.......................................62
8.1. MMS Minimum – quantity – lubricant unit.................................................................. 62
8.1.1. MMS with blow out unit .................................................................................................... 64
8.1.2. MMS with impulse control ................................................................................................ 65
8.2. Installation / commissioning the pneumatic feed system (ZAP) to megatap II....... 66
8.3. Depth stop ......................................................................................................................69
8.3.1. Setting of the depth stop .................................................................................................. 70
8.3.2. Working in ZAP mode with depth stop............................................................................. 70
8.4. DSK double spindle head.............................................................................................. 71
8.4.1. Installing double spindle head onto the machine............................................................. 71
8.4.2. Adjusting the hole centres................................................................................................ 71
8.4.3. Installing of collet and tool................................................................................................ 72
8.4.4. Maintenance.....................................................................................................................72
8.5. LSM Air seal for exit of motor spindle......................................................................... 73
8.5.1. Mounting of air seal.......................................................................................................... 73
8.6. Air Blast unit................................................................................................................... 75
9. PRODUCT OVERVIEW...........................................................................76
9.1. Options and accessories for the thread tapping machine ........................................ 77
9.2. Quick change inserts..................................................................................................... 78
9.3. Collets – Accessories.................................................................................................... 79

Operating Instructions Thread tapping units/ Accessoriesr 01/09, Software 4.9 © 01.1994-2016 microtap GmbH 4
1. General information
1.1. Declaration of EC-conformity
in view of EC-standard machines 2006/42/EG (89/392/EWG, appendix II A)
89/392/EWG
We, microtap GmbH
Rotwandweg 4
82024 Taufkirchen / München
Germany
declare that the machine, described in the following, is due to its concept and design and in
the form and version distributed by us conforms to all relevant safety- and health related EC-
regulations.
This declaration is void if alterations are performed on the machine without prior agreement
with microtap GmbH.
machine term: Tapping machine
machine type: microtap II / megatap II / labtap / jobtap
machine serial No.: xxxxxx - x
Applied EC-standards: EC-machine regulation 2006/42/EG (89/392/EWG)
EC-low voltage regulation 2006/95/EG (73/23/EWG)
EC-regulation electromagnetic compatibility 2004/108/EG
(89/336/EWG)
Applied harmonized standards: EN 60 204-1; 1997 1992
DIN EN 292 T1,T2
DIN EN ISO DIN EN 294
DIN EN 349
DIN 8418
Date / signature of producer/legal representative: January 2016
Information to the undersigner: Company owner/president: Klaus M. Müller

Operating Instructions Thread tapping units/ Accessoriesr 01/09, Software 4.9 © 01.1994-2016 microtap GmbH 5
microtap GmbH
Service department Tel.: [phone]
Rotwandweg 4 Fax: [phone]
82024 Taufkirchen
Germany
1.2. Warranty-/Operating procedure Certificate
With your torque controlled thread cutting machine
and together with the operating instructions as well as our delivery- and payment-
conditions you are receiving this confirmed manufacturer warranty document.
Hereby microtap GmbH, Taufkirchen, will be liable as manufacturer to grant a 12
month warranty according to the product-liability law dated 01.01.89 and in the
range of our own delivery conditions provided that the copy of this warranty-
certificate will be returned to us immediately after taking the a.m. machine into
operation.
By sending this certificate with your signature back to us, you acknowledge the
receipt of a.m. machine including operating instructions and CE-certificate in good
condition.
Received goods:
Machine-type: ............................. Serial-Nr.: .............................
Invoice-/Delivery Note No.:................ Software Version: .............................
Buyer/Company name with legal form:
Name .............................................Stamp:
Street: .............................................
Address: .............................................
Taking a.m. machine into operation acc. to delivered instructions:
Name: ............................................. Signature: .............................
Date: .............................................

Operating Instructions Thread tapping units/ Accessoriesr 01/09, Software 4.9 © 01.1994-2016 microtap GmbH 6
1.3. Operating conditions
The „microtap II“ versions G2, G5 and jobtap G5 and “megatap II” versions G8, G14,
-G16, jobtap G8, -G14, -G16 and labtap G5, -G8 automatic thread tapping machine
and its optional accessories are state-of-the-art design and meet all relevant safety
regulations.
All versions of the thread tapping machine must be used only in the upright position
unless specifically equipped for horizontal operation for the following purposes:
- for thread tapping operation in low- or high volume batches
- as a reference machine for establishing optimum tapping process parameters
- for thread inserts (ENSAT, HELICOIL)
- for torque controlle screwing
Any other utilisation is contrary to its purpose and not allowed.
The manufacturer expressly excludes all responsibility for damage or injury caused
by improper use or failure to observe these operating rules; in such event the user
shall bear full responsibility.
The machine must be assembled, operated, maintained and repaired only by
authorised and trained personnel allocated to the task.
The safety equipment attached to the machine must not be modified or disabled.
Retrofits or modifications of the machine may be carried out only following prior
agreement with and in accordance with instructions issued by microtap GmbH. The
user shall bear full responsibility for any unauthorised retrofits or modifications.
1.4. Definitions
In these operating instructions various types of information is provided. The type of
information provided is identified by the following symbols, whose purpose must be
adhered to under all conditions.
1.4.1. Viewing definitions
The terms front, back, left, right, top and bottom refer to the parts of the machine as
seen from the operating position. The operating lever, for instance, is on the right
side of the machine.
1.4.2. Validity of the operating instructions
Unless otherwise stated, these operating instructions are valid for the „microtap II“
versions G2, G5 and jobtap G5 and “megatap II” versions G8, G14, -G16, jobtap
G8, -G14, -G16 and labtap G5, -G8 automatic thread tapping machines and their
listed optional accessories.

Operating Instructions Thread tapping units/ Accessoriesr 01/09, Software 4.9 © 01.1994-2016 microtap GmbH 7
1.5. Definition of pictograms
The following pictograms are used in these operating instructions.
Danger! High voltage!
Disconnect mains power supply!
Wear breathing protection!










Protect the environment!
NOTE
This symbol identifies technical features which, if disregarded, can result in machine
errors.
CAUTION
This symbol identifies operating instructions which must be followed exactly to avoid
damage to the machine, its control system or peripheral system components.
WARNING
This symbol identifies operating instructions which must be followed exactly to avoid
risks of injury to personnel; it includes the definition of CAUTION.
Failure to observe such instructions may lead to death or severe injury.
Manufacturer’s hint
This symbol identifies hints and tips offered by the manufacturer, which the operator
may find useful.


Operating Instructions Thread tapping units/ Accessoriesr 01/09, Software 4.9 © 01.1994-2016 microtap GmbH 8
1.6. Safety instructions
The thread tapping machine and its optional accessories are state-of-the-art design
and conform to all relevant safety regulations.
They may however due to their nature give rise to safety risks if they are operated
incorrectly by untrained personnel or not in accordance with the operating
instructions.
Operating risks can only be eliminated by proper operation.
All relevant general safety regulations (in Germany VBG ...) must be observed and
complied with.
• Risk of electric shock
- through contact with conducting components through assembly of the
machine (EN 60204/VDE 0113)
- through contact with conducting components following inexpert maintenance
(VBG 4).
• Risk of thermal shock
- by touching the tap immediately after the tapping process.
• Risk from materials of components or work materials
- through contact with liquids, oils and greases or by inhaling gases, vapours
and dusts.
- The relevant instructions for use by manufacturers of lubricants and cleaning
materials must be complied with.
- See also the relevant safety data sheets.
• Risk due to not following operating instructions.
- do not carry out unauthorised work on or with the machines.