Nakanishi Sheenus ZERO User manual

25
English
Thank you very much for your purchase of Sheenus ZERO ultrasonic polishing system. This product
can be used to grind, polish, and mirror-finish various types of molds, from aluminum molds to
cemented carbide molds. We also have a wide variety of tools available for all types of machining.
Please read this manual carefully before use, and we hope you will enjoy using this product for many
years to come. Please keep this manual in a place where the user can read it at all times.
CONTENTS
1. Safety precautions ........................................... 26
2. Product information ......................................... 29
2–1 Bundled items ................................................29
2–2 Names of parts ...............................................30
3. Preparation before use .................................... 33
3–1 Connecting the main power cord ...........................33
3–2 Connecting the foot switch ..................................33
3–3 Connecting the handpiece ..................................33
3–4 Tool installation ..............................................34
4. How to use ...................................................... 36
4–1 Basic operation ..............................................36
4–2 The essentials of ultrasonic finishing operations ..........37
4–3 A simple method of vibration verification using the test
horn ...........................................................38
5. Maintenance ................................................... 39
5–1 Fuse replacement ............................................39
5–2 Care ...........................................................39
6. Setup .............................................................. 41
6–1 User setting operations ......................................41
6–2 Setting the forced stop time when not in use .............41
6–3 Setting the notification volume .............................41
6–4 Setting the amplitude display and WATT Display ..........41
6–5 Setting the foot switch ......................................42
6–6 Setting the handpiece heat protection function ...........42
6–7 Initializing Settings ...........................................42
7. Troubleshooting ............................................... 43
7–1 Error code ................................................................. 43
7–2 Failure causes and countermeasures ......................44
8. After sales service ........................................... 46
8–1 Warranty ......................................................46
8–2 Contact for inquiries .........................................46
8–3 Product disposal .............................................46
9. Specifications ................................................. 47
9–1 Specifications ............................................................ 47
9–2 Conforming standards .......................................47
9–3 Protection sircuitry ...........................................48
9–4 Symbol ..................................................................... 48
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1 Safety Precautions
Please read the operation manual thoroughly, make sure you understand all warnings and cautions prior to operating
the system and only use the system in the manner intended.
These warnings and cautions are intended to avoid potential hazards that could result in personal injury or damage to
the device. These are classified as follows in accordance with the seriousness of the risk.
Class Degree of Risk
WARNING A hazard that could result in bodily injury or damage to the device if the safety
instructions are not properly followed.
CAUTION A hazard that could result in light or moderate bodily injury or damage to the
device if the safety instructions are not followed.
NOTICE Keep this manual in a safe place for future reference.
ŠGROUNDING INSTRUCTIONS
ƔIn the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to
reduce the risk of electric shock. This tool is equipped with a power cord having an equipment grounding conductor
and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in
accordance with all local codes and ordinances.
ƔDo not modify the plug provided-if it will not fit the outlet, have the proper outlet installed by a qualified electrician.
ƔImproper connection of the equipment-grounding conductor can result in a risk of electric shock. The conductor with
insulation having an outer surface that is green with or without yellow stripes is the equipment grounding conductor.
If repair or replacement of the power cord or plug is necessary, do not connect the equipment-grounding conductor
to a live terminal.
ƔCheck with a qualified electrician or service personnel if the grounding instructions are not completely understood, or
if in doubt as to whether the tool is properly grounded.
ƔUse only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool's
plug.
Ɣ(120V) This tool is intended for use on a circuit that has an outlet that looks like the one illustrated in Sketch A in
Figure (below). The tool has a grounding plug that looks like the plug illustrated in Sketch A in Figure (below). A
temporary adapter, which looks like the adapter illustrated in Sketches B and C, may be used to connect this plug to
a 2-pole receptacle as shown in Sketch B if a properly grounded outlet is not available. The temporary adapter should
be used only until a properly grounded outlet can be installed by a qualified electrician. The green-colored rigid ear,
lug, and the like, extending from the adapter must be connected to a permanent ground such as a properly grounded
outlet box.
Ɣ(240V) This tool is intended for use on a circuit that has an outlet that looks like the one illustrated in sketch D in
figure.
ƔNOTE: Adapter in (Figure B) is not for use in Canada.
GROUNDING
PIN GROUNDING
CONTACT
METAL
SCREW
(A)
COVER OF GROUND
OUTLET BOX
(B)
(C)
(D)
ADAPTER
GROUNDING
MEANS
ƔUse proper extension cord. Make sure your extension cord is in good condition. When using an extension cord, be
sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line
voltage resulting in loss of power and overheating. Table (below) indicates the correct size to use depending on cord
length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the
heavier the cord.
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Safety Precautions
English
Ampere Rating
Volts Total length of cord
120V
240V
7.5m (25ft.)
15m (50ft.)
15m (50ft.)
30m (100ft.)
30m (100ft.)
60m (200ft.)
45m (150ft.)
90m (300ft.)
More Than Not More
Than
0 6 18 16 16 14
6 10 18161412
10 12 16 16 14 12
12 16 14 12 Not Recommended
Use the table above for your correct voltage.
WARNING
ƔFor safety reasons, wear protective gloves, goggles, and a dust-proof mask when using this product.
ƔDo not drop or impact the product. Strong impacts may result in deformation or damage.
ƔDo not modify or disassemble this product in any way that is not described in the instruction manual. This can
have a significant impact on performance and safety. If the controller is disassembled, you may receive an electric
shock due to the high voltage section inside. In the event of malfunction or repair, please contact the place of
purchase for repair.
ƔBe sure to ground the grounding wire of the power cord before use. Failure to do so may result in a malfunction,
fire or electric shock.
ƔDo not use this product in a room where there is a risk of explosion or near flammable materials. Especially if the
tool is in contact with flammable materials for a long time in an oscillating state, it may ignite.
ƔUse the controller at room temperature in the range of 10 - 40°C (75 - 104ºF), with no condensation.
Condensation may cause a short circuit or an electric shock.
ƔAvoid installing the controller in the vicinity of high temperature, high humidity, condensation, corrosive or
explosive gases, flammable gases, salt damage, and direct sunlight. Failure to do so may result in a malfunction,
fire or electric shock.
ƔThe bottom of the controller also serves as a heat sink. Install it so that the space between it and the work desk
is not blocked. A temperature increase can occur inside the controller, causing failure.
ƔIf there is any dust or damage to the threaded part of the tool, handpiece, or tool mountings, normal oscillation
will not be possible. It can also cause the handpiece to heat up.
ƔMake sure the tool is securely installed. If it is not secured firmly, it can cause a loss of power and heat in the
handpiece.
ƔEven under normal conditions, the tool and tip holder will be heated by ultrasonic vibration. Grabbing it hard or
pressing it against the skin may cause burns.
ƔIf oil or other contaminants get into the handpiece, they may cause a failure. Do not pour abrasive oil or lubricate
the handpiece.
ƔDo not touch the tool, tip holder or ultrasonic horn during ultrasonic vibration. Parts and tools may become hot,
which could cause injury or burn.
ƔDamaged main power cord must be replaced with new cord as they may cause fires or electric shock due to a
short circuit. Please contact us or your local distributor for details.
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Safety Precautions
CAUTION
ƔThe operating environment for this product is 10 - 40°C (75 - 104ºF),, humidity is 30 - 75% RH,, and air
pressure is 700 - 1,060 hPa. Also, use the controller in a non-condensing environment. If used beyond this
range, it may cause malfunctions or damage.
ƔStore the product in a place where the temperature is between 10 - 50°C, degrees Celsius, the humidity is
between 30 - 75% RH, the air pressure is between 500 and 1,060 hPa, and there is no dust, sulfur or salt air.
When installing the controller, provide a space of 10 cm behind the controller to allow for smooth insertion and
removal of the power cord in the event of an emergency.
ƔBefore starting to use the product, please inspect it in advance and make sure that there is nothing wrong. If you
notice any abnormality, contact your dealer for repair.
ƔIf the tool, tip holder or handpiece becomes hot or if a strange noise occurs suddenly during use, stop using it
immediately and check the entire system. If the tool is damaged, do not continue to use it and replace it with a
new tool.
NOTICE
ƔThis product uses an ultrasonic oscillator. The proximity of computers and LAN cables may affect them. Also, if
there is a radio receiver nearby, there may be noise.
ƔWhen in use, if the operation sounds peculiar to ultrasonic vibration is generated. We recommend that you wear
earplugs.
ƔSet the power switch to OFF after use. Also, unplug the power cord when not in use for long periods of time.
ƔThe user is responsible for operation and maintenance.
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English
2 Product Information
2–1 Bundled items
After opening the package, please check that the contents of "Table - 1 List of Contents " are inorder.
In the unlikely event that any of the contents of the package are inadequate, please contact " 8–2
Contact for inquiries " or the dealer from whom you purchased the product.
10
10
ྲྀᢅㄝ󰩣᭩
OPERATION MANUAL
Table - 1 List of Contents
No. name Product
Number quantity Note
Main power cord - 1 2m
Foot switch - 1 FC-24
Controller - 1 -
Handpiece - 1 Cord 3m
Wrench - 2 10mm
Hexagon wrench - 1 2.5mm
Tip holder 60902 1 For 3.0mm dia
Tip holder 60922 1 For flat t = 1.0mm
Ceramic fiber grindstone #800 60519 1 Flat 6 x 50mm t=1
Electroplated diamond file
#200 60101 1 Flat taper 4 x 50mm t=0.4
Fuse - 2 T1.6AH 250V
Tool case - 1 -
Operation manual - 1 -
The above items are included in the "standard set". When purchasing a controller, only 1, 3, 11 and 13 are included in the
package.
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Product Information
2–2 Names of parts
Overall Structure
Handpiece
Main power switch
Controller
Control panel
Pedal
Handpiece
socket
Foot switch socketInlet with power
supply fuse
㸺Back of controller㸼㸺Foot switch㸼
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Product Information
English
Control panel
AB
C
G
EF
D
H
I
No. indication name function
APower level
indicator Displays the power level.
BIndicator
Displays the amplitude, WATT, and ERROR
values.
Indication display of amplitude
The maximum amplitude is displayed in 50
divisions. Please use this as a guide for
processing.
CUP key
Increase the power level.
Pressing and holding the UP key raises the
output level continuously.
DDOWN key
Reduce the power level.
Pressing and holding down the DOWN key
allows you to continuously lower the Power
level.
EWATT
This is displayed when W units are set.
(See "6–4 Setting the amplitude display and
WATT Display")
FERROR This is displayed in case of an error.
GUNCLAMP Key
UNCLAMP mode setting
When using an integrated tool, set it to
UNCLAMP mode.
HCLAMP Key
CLAMP mode setting
Set to CLAMP mode when using the tip holder
with the tip in place.
ION / OFF Key Start and stop the handpiece.
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Product Information
Handpiece
1
2
34
No. name Note
1 Test horn
A test horn is installed at the end of the handpiece at the factory.
This test horn is used to check if the ultrasonic vibration is
properly output from the handpiece. When using the handpiece,
remove the test horn and install the No. 3 and No. 4 tools before
use.
2 Protector sleeve
The protector sleeve prevents direct contact with the tool
connection. Always make sure that the protector sleeve is
installed before using the handpiece, as using the handpiece
without it may result in burns.
3 Tip holder This is the holder to which the special tip tool is attached.
4 One piece tool (M6 x 0.9) The One piece tool (M6 x 0.9) is used directly on the handpiece.
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33
English
3 Preparation before use
3–1 Connecting the main power cord
1 Make sure the main power switch is in the OFF
position. 2 Insert the main power cord into the Inlet with power supply fuse. Then plug it into a commercial power
outlet.
3–2 Connecting the foot switch
When using a foot switch, insert the foot switch plug into the foot switch socket with the plug in place.
3–3 Connecting the handpiece
Align the plug of the handpiece with the handpiece socket on the back of the controller, and insert it
firmly into the socket until you hear a click. Pull lightly to make sure it doesn't come off.
To remove it, pinch the plug and pull it straight out.
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Preparation before use
3–4 Tool installation
1 A test horn is attached to the handpiece when it is
shipped. Turn the protector sleeve and remove it.
①
②
2 Remove the test horn using the two wrenches
(10mm).
ŠOne piece tool (M6 x 0.9)
1 Attach the One piece tool (M6 x 0.9) to the
handpiece and tighten firmly using two wrenches
(10mm).
2 Insert the protector sleeve into the handpiece and
turn it to install it.
①
②
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Preparation before use
English
ŠCeramic fiber grindstone, tip type
1 Attach the tip holder to the handpiece and tighten
firmly with two wrenches (10mm).
2 Insert the ceramic fiber grindstone wheel and tip into
the tip holder and tighten the set screw firmly with
the attached hexagon wrench.
①
②
3 Insert the potector sleeve into the handpiece and
turn it to install it.
①
②
CAUTION
ƔIf the tool and tip holder are loosely tightened, not only does it not produce enough vibration, but it can also cause
abnormal noise and abnormal heat generation. Be very careful to make sure it is securely tightened.
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4 How to use
4–1 Basic Operation
1, 5
2
3
4
1 Power ON
The LED on the control panel lights up.
2 Mode Selection
The LED of the selected key lights up.
UNCLAMP mode
CLAMP mode
3 Power level adjustment
Press and hold down the key
to activate the key repeat function.
UP key DOWN key
4 Startup / Stop
You can start and stop the program in one of the following two ways
(1) Manual ON / OFF (2) When using the foot switch
Press the ON / OFF key to activate
and Stop.
It is activated by pressing the
pedal.
Release the pedal to stop.
(See "6–5 Setting the foot switch")
If it is started by the ON / OFF key, it can only be
stopped by the ON / OFF key.
If activated by a footswitch, it can only be stopped
by a footswitch.
The ON / OFF key and the LED on the handpiece light up when starting up.
As long as the LED is on, it is vibrating.
5 Power off
CAUTION
ƔWhen using the tip holder, be sure to use it in CLAMP mode.
ƔWhen using the One piece tool , it can be used in UNCLAMP or CLAMP mode (low power).
ƔThe thread of the One piece tool is M6 x 0.9. Do not install screws of different size.
ƔSetting the WATT display (see "6–4 Setting the amplitude display and WATT Display."), use 8W or less for
continuous use.
ƔUsing the handpiece at high power can cause the tool and tip holder to become very hot, which can cause
handpiece failure and injury.
ƔDo not plug or unplug the handpiece and foot switch while the foot switch is depressed. Failure to do so may
result in failure or malfunction.
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37
How to use
English
4–2 The essentials of ultrasonic finishing operations
ŠBasic usage
The basic way to use the tool is to place it on the surface and press down lightly while sliding it. The
figure below shows the direction of ultrasonic vibration and the effective sliding direction pattern. The
ultrasonic vibration greatly reduces the resistance to machining, which is more effective in getting the
tool to bite the surface of the workpiece and the tool rather than the machining pressure.
Do not press down on the tool more than necessary and be careful to ensure that the tool touches the
work surface.
Modify the face of the tool as necessary to get a better bite. It is useful to correct the tool by using a
diamond file/sandpaper to create weak vibrations in the tool.
Use the side of the tool Use the tool at an angle Use the end face of the tool
Beware of tool bites. The best angle is about 30r. Use it while correcting the tool
surface.
= direction of vibration
= direction of sliding
ŠOptimal tip length
When using the tip holder with a tip in between, use it within the range of optimum length as shown in
the table below.
Also, please note that it may not vibrate normally due to a defective (or loose) tip holder or tip
installation.
Tools for Sheenus ZERO Cross-sectional dimensions
(mm) Optimum length (mm)
Ceramic fiber grindstone
4 x 1.0
10 - 506 x 1.0
ȭ3
ŠHow to use lapping brass tips
When using the lapping brass tips, select the CLAMP mode and adjust the output to the extent that the
protection circuit (see "9 – 3 Protection circuitry ") is not activated. If the output value is too high, it may
stop due to overload.
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38
How to use
4–3 A simple method of confirming vibration using a test horn
1 Prepare a small amount of water and attach the test
horn securely.
2 Select the UNCLAMP mode (1) and set the output to
MIN using the DOWN key (2).
①
②
3 With the ON / OFF key in the OFF position, put a
small amount of water on the tip of the test horn.
Water
4 Turn the ON / OFF key to ON. It can be confirmed
that water is attracted by the ultrasonic vibration.
Water
5 Gradually raise the UP key to MAX and the water will
be vaporized by ultrasonic vibration.
If the operation can be verified in this way, the transducer is working properly.
If no vibration is output or the vapor is not sufficiently high in UNCLAMP mode, tighten the test horn
again to check. (See "7–2 Failure causes and countermeasures")
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English
5 Maintenance
5–1 Fuse replacement
1 The fuse box is set in a Inlet with power supply fuse.
Push the claws on both sides of the cap inward and
pull it out.
②
①
2 Two fuses are used. When replacing them, replace
both with the specified fuses.
3 Push the claws of the cap firmly into the inlet box.
WARNING
ƔWhen replacing the fuses, turn off the controller's power switch and then unplug the power cord from the power
fused inlet.
ƔUse fuses specified by us.ࠉDesignated fuses T1.6AH 250V
5–2 Care
When the controller and handpiece are dirty, wipe them up well with a dry cloth.
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6 Setup
Various settings can be made for your use from below.
6–1 User setting operations
1 Set the Main power switch to OFF.
2 While holding down the ON / OFF key (1), turn on the
Main power switch (2).
Press the UP key (3) during the 2 seconds when "
" is displayed.
With a "beep" sound, " "*1 will appear on the
display.
①
③
②
3 Press the UP key to select the item you want to set.
The display unit will display the following order*2: "
" Ѝ" " Ѝ" " Ѝ" " Ѝ
"" Ѝ" " Ѝ... When the settings are
complete, turn the power off and then on again to
complete the settings.
6-2 Setting the forced stop time
when not in use 6-5 Setting the foot switch
6-3 Setting of notification volume 6-6 Setting the handpiece heat
protection function
6-4 Setting the amplitude display
and WATT Display
NOTICE
ƔMemory function
When the power is turned off and then on again, the settings before the power was turned off are retained. (For
mode settings, return to CLAMP mode (low output).
ƔPressing the foot switch does not activate the controller during the 6–1 User setting operations.
*1 " " is displayed only when it is first set up.
After the second time, " ", " ", " ", " ", " ",
" ", or "oA", which are stored by the "memory
function", will be displayed.
*2 Display order " " Ѝ " " Ѝ " " Ѝ " " Ѝ
" " Ѝ " " Ѝ ... is displayed only at the initial
setting.From the second time onwards, the settings are
retained by the "memory function".
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41
Setup
English
6–2 Setting the forced stop time when not in use
This function forces the handpiece to stop if the handpiece has been left unused with the ON / OFF
key turned on.
Press the DOWN key to change the setting value.
The Indicator shows the following order
" " Ѝ " " Ѝ " " Ѝ " " Ѝ " " Ѝ " " Ѝ " " Ѝ ...
No setup time 3 minutes. (factory setting)
one minute 5 minutes.
2 minutes. 10 minutes.
6–3 Setting the notification volume
Press the DOWN key to change the setting value.
The Indicator shows the following order
" " Ѝ " " Ѝ " " Ѝ " " Ѝ...
No sound.
Notification tone.
Loud notification (default setting)
6–4 Setting the amplitude display and WATT display
The LED display can be switched between "Amplitude" and "WATT".
Press the DOWN key to change the setting value.
The Indicator shows the following order
" " Ѝ " " Ѝ " " Ѝ " " Ѝ ...
Amplitude display (default
setting)
Displayed in 1W increments
0.Displayed in 1W increments
The "WATT" will be displayed when the " " and " " are set to
display in W units.
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42
Setup
6–5 Setting the foot switch
The setting can be changed from pressing the foot switch to start (ON) or release to stop (OFF), to
pressing the foot switch to start (ON) or pressing it again to stop (OFF).
Press the DOWN key to change the setting value.
The Indicator shows the following order
" " Ѝ " " Ѝ " " Ѝ ...
Motion operation (depressing the foot switch turns ON
and releasing the foot switch turns OFF) (factory default
setting)
Alternate operation (press the foot switch to start up,
press it again to stop off)
6–6 Setting the handpiece heat protection function
The heat protection function can be set to work if an abnormal heat is detected on the tip of the tool.
Press the DOWN key to change the setting value.
The Indicator shows the following order
" " Ѝ " " Ѝ " " Ѝ ...
unprotected
Protected (default setting)
6–7 Initializing Settings
You can restore the factory default settings.
While pressing the UP key and the DOWN key (1) at the same time, turn on the power switch (2).
Release the UP key and DOWN key after "beep" and a beep sounds to initialize the user settings. The
output display is set to MIN and the unit starts in normal mode.
②
①
Factory Default Settings
Forced stop time when not
in use 3 minutes.
Notification volume Notification Sound Loud
Amplitude display and
WATT display amplitude indication
Foot switch
Motion operation
(depressing the foot switch
turns ON and releasing it
turns OFF)
handpiece heat protection
function protected species
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43
English
7 Trouble-shooting
7–1 Error code
If a problem occurs with the product, an error code will be displayed on the display unit on the
operation panel.
1 Stop the operation at once.
2 Press the ON / OFF key, or step on the footswitch again or turn it back on and see if the
error is resolved.
3 If the error appears again, please refer to the following table for solutions.
error code Error Description how to deal with it
system error Please send it to us.
Amplifier error (overcurrent/heat) Check for loose One piece tool, tip holder and tip. If
it's loose, tighten it firmly.
handpiece overload error Do not put excessive load on the tool.
Excessive input voltage Please send it to us.
Under Input Voltage Please send it to us.
Amplitude feedback residual voltage
error Please send it to us.
Handpiece fever abnormality Check for loose One piece tool, tip holder and tip. If
it's loose, tighten it firmly.
Start frequency confirmation error Please send it to us.
resonance frequency search timeout
(This is an error if the resonant frequency
of the integral tool, tip holder, or tip that is
installed is not found.)
Check for loose One piece tool, tip holder and tip. If
it's loose, tighten it firmly..
frequency pull-back anomaly
(This is an error when the resonance
frequency changes significantly during
operation.)
Check for loose One piece tool, tip holder and tip. If
it's loose, tighten it firmly.
memory failure Please send it to us.
Forced deactivation when not in use The factory default setting is "3 minutes". (See "6-2
Setting the Forced Stop Time When Not in Use".)
Excessive amplitude of the oscillator
feedback signal Please send it to us.
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