SCHUNK ELKE 24/2F User instructions

02/ELKE/en/2010-04-12/SW Document last updated: 2010-04-12
Electrical Control Unit
Type ELKE 24/2F with RSS
Assembly and Operating Manual

202/ELKE/en/2010-04-12/SW
Dear Customer,
Congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have
opted for the highest precision, top quality and best service.
You are going to increase the process reliability of your production and achieve
best machining results –to the customer's complete satisfaction.
SCHUNK products are inspiring.
Our detailed assembly and operation manual will support you.
Do you have further questions? You may contact us at any time –even after purchase.
You can reach us directly at the mentioned addresses in the last chapter of these
instructions.
Kindest Regards,
Your SCHUNK GmbH & Co. KG
Precision Workholdind Systems
Bahnhofstr. 106 –134
D-74348 Lauffen/Neckar
Tel. [phone]
Fax [phone]
[email protected]
www.schunk.com

Table of contents
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Table of contents
1 About this manual.................................................................................................5
1.1 Purpose/validity..........................................................................................5
1.2 Target groups.............................................................................................5
1.3 Applicable documents................................................................................5
1.4 Symbols in this manual ..............................................................................6
2 Basic safety notes ................................................................................................7
2.1 Intended use ..............................................................................................7
2.2 Environmental and operating conditions ....................................................7
2.3 Controlled production.................................................................................8
2.3.1 Constructional changes, attachments, or modifications.................8
2.4 Personal qualification.................................................................................8
2.5 Safety-conscious working...........................................................................8
3 Warranty................................................................................................................9
4 Scope of delivery..................................................................................................9
5 Technical Data ....................................................................................................10
6 Description of the unit........................................................................................11
6.1 Configuration............................................................................................11
6.2 Function ...................................................................................................12
7 Assembly.............................................................................................................13
7.1 Mechanical connection.............................................................................13
7.2 Electrical connection ................................................................................14
7.3 Air connection ..........................................................................................16
7.4 Assembly example...................................................................................17
8 Commissioning and operation ..........................................................................18
8.1 Overview of operation ..............................................................................18
8.2 Power-up messages ................................................................................19
8.3 Selecting the operating mode...................................................................21
8.4 Teach-in mode.........................................................................................28
9 Troubleshooting..................................................................................................39
9.1 Electric signals are not transmitted ..........................................................39
9.2 Compressed air is not conveyed..............................................................39

Table of contents
402/ELKE/en/2010-04-12/SW
9.3 End of the clamping or opening procedure is not correctly detected........39
9.4 End of the clamping procedure is detected too early ...............................40
9.5 End of the clamping procedure is detected too late or not at all...............40
9.6 End of the opening procedure is detected too early.................................41
9.7 End of the opening procedure is detected too late or not at all ................41
9.8 Error messages........................................................................................42
10 Maintenance and care ........................................................................................44
10.1 Maintenance intervals ..............................................................................44
10.2 Dismantling the module............................................................................44
10.3 Maintaining the module............................................................................44
11 Transport, storage and disposal .......................................................................45
11.1 Transport..................................................................................................45
11.2 Packaging ................................................................................................45
11.3 Storage.....................................................................................................45
11.4 Disposal ...................................................................................................45
12 Assembly drawing..............................................................................................46
13 Contact ................................................................................................................47

About this manual
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1 About this manual
1.1 Purpose/validity
This manual is part of the module and describes the safe
and proper use during all phases of operation.
This manual is valid only for the module specified on the
front page.
1.2 Target groups
Target group
Task
Manufacturer, operator
Keep this manual available for the personnel at all
times.
Require personnel to read and observe this manual and
the applicable documents, especially the safety notes
and warnings.
Skilled personnel, fitter
Read, observe and follow this manual and the
applicable documents, especially the safety notes and
warnings.
Tab. 1
1.3 Applicable documents
You can find the following documents on our homepage:
Document
Purpose
Catalog
Technical data or application parameters of the module
and information on accessories. The last version is always
valid.
General terms of
business
Including notes on the warranty.
Tab. 2

About this manual
602/ELKE/en/2010-04-12/SW
1.4 Symbols in this manual
To give you quick access to information, the following
symbols will be used in this guide:
Symbol
Meaning
WARNING
Dangers for persons.
Nonobservance can cause death or serious injuries.
NOTICE
Information on avoiding material damage.

Prerequisite for a handling instruction.

Handling instruction, also measures in a warning or note.
1.
2.
3. ...
Step-by-step handling instruction.
Observe the order.
Component/spare part represented in a graphic.
Part/detail shown in a graphic which is part of a spare part or which
must be provided by the customer.
(10), (/10/)
Reference in the text or in a handling instruction to a part that is
represented in a graphic.
Tab. 3

Basic safety notes
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2 Basic safety notes
2.1 Intended use
The (ELKE 24-2F) electrical control unit is not a safety
component. The electrical control unit is used to control
max. two pneumatic chucks for lathes.
The module is intended for installation in a machine. The
requirements of the applicable guidelines must be observed
and complied with.
The module may be used only in the context of its defined
application parameters.
Any other use or use exceeding that specified is an
infringement of use for intended purpose. The manufacturer
bears no liability for damage resulting from such use.
2.2 Environmental and operating conditions
The module may be used only in the context of its
defined application parameters (see chapter 5, page 10
and catalog).
Make sure that the environment is clean and the ambient
temperature corresponds to the specifications per the
catalog. Maintenance and lubrication intervals (see
chapter 10.1, page 44).
Make sure that the environment is free from splash
water and vapors as well as from abrasion or processing
dust. Excepted are modules that are designed specially
for contaminated environments.

Basic safety notes
802/ELKE/en/2010-04-12/SW
2.3 Controlled production
The module represents the state of the art and the
recognized safety rules at the time of delivery. However, it
can present risks if, for example:
•The module is not used in accordance with its intended
purpose.
•The module is not installed or maintained properly.
•The EC Machinery Directive, the VDE directives, the
safety and accident-prevention regulations valid at the
usage site, or the safety and installation notes are not
observed.
2.3.1 Constructional changes, attachments, or modifications
Additional drill holes, threads, or attachments that are not
offered as accessories by SCHUNK may be attached only
with permission of SCHUNK.
2.4 Personal qualification
The assembly, initial commissioning, maintenance, and
repair of the module may be performed only by trained
specialist personnel.
Every person called upon by the operator to work on the
module must have read and understood the complete
Assembly and Operating Manual, especially chapter 2
"Basic safety". This applies particularly to occasional
personnel such as maintenance personnel.
2.5 Safety-conscious working
Avoid any manner of working that may interfere with the
function and operational safety of the module.
Observe the safety and accident-prevention regulations
valid at the usage site.

Warranty
02/ELKE/en/2010-04-12/SW 9
3 Warranty
The warranty is valid for 24 months from the delivery date to
the production facility under the following conditions:
•Intended use in 1-shift operation
•Observation of the maintenance and lubrication intervals
(see chapter 10.1, page 44)
•Observation of the ambient conditions and operating
conditions (see chapter 2.2, page 7)
Parts touching the workpiece and wearing parts are not part
of the warranty. Also observe our general terms of business.
4 Scope of delivery
The scope of delivery includes:
•Electrical Control Unit ELKE 24/2F with RSS
The following accessories are required for the module:
•Connection cable with Harting plug in the version
ordered:
–Ölflex Classic 110 cy 18 G 0.75, length 5 m
–Ölflex Classic 110 cy 18 G 0.75, length 10 m
–Ölflex Classic 110 cy 18 G 0.75, length 15 m
–Ölflex Classic 110 cy 18 G 0.75, length 20 m
The following accessories are available for the module:
•2 WEH maintenance units
•2 FSC foot switches with Harting plugs
Order accessories separately.
For additional accessories, see catalog.

Technical Data
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5 Technical Data
Further technical data can be found in our catalog. The
most recent version applies.
Type
ELKE 24/2F with RSS
weight [kg]
20
dimension
see chapter 12 page 46
power supply [V DC]
24 (stabilized) ±10%
Current input during idle running [mA]
2.30
Current input (rated value) [mA] without
digital outputs
700
Digital outputs
max. permissible output current
for each output Imax [mA]
Resistance RL[Ω]
25
≥1000
Digital inputs
1 signal input current
Imax [mA]
25
pressure medium
compressed air,
standard for quality of the compressed air
according to ISO 8573-1: 6 4 4
Maximal pressure [bar]
8
IP rating
42
interface
digital control inputs and outputs
External protection for power supply
(provided by the customer)
Electronic circuit breaker with rated current
1 A (e.g.: ETA, type ESX10T)
Tab. 4

Description of the unit
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6 Description of the unit
6.1 Configuration
/1/ Key switch for "Teach in" function
/8/ Button for controlling chuck 2
/2/ Bicolor display
/9/ Pilot lamps for chuck 2 (1x red, 2x green)
/3/ Key switch for all five operating modes
/10/ Connections for the foot switch
/4/ Pilot lamps for chuck 1 (1x red, 2x green)
/11/ Power supply and PLC
/5/ Button for controlling chuck 1
/12/ Outputs for four RSS units
/6/ Pneumatic connection for chuck 1
/13/ Stainless steel housing
/7/ Pneumatic connection for chuck 2
Figure 1 Connections and operating devices of the module
/2/
/1/
/12/
/11/
/10/
/3/
/4/
/9/
/5/
/7/
/6/
/8/
/13/

Description of the unit
12 02/ELKE/en/2010-04-12/SW
6.2 Function
ELKE 24/2F is an electrical control unit for controlling
pneumatic chucks for lathes. The control unit can be used
for all chuck sizes. A maximum of two chucks can be
controlled.
There are five possible operating modes:
•Synchronous clamping
•Separate O.D. clamping
•Separate I.D. clamping
•Sequential clamping chuck 1, chuck 2
•Sequential clamping chuck 2, chuck 1
Synchronous clamping
This operating mode is used for the simultaneous control of
the two chucks, irrespective of which button or foot switch is
currently being actuated.
Separate O.D. clamping
This operating mode is used for the O.D. clamping of
workpieces in the lathe. The chucks are controlled
independently of each other.
Separate I.D. clamping
This operating mode is used for the I.D. clamping of
workpieces in the lathe. The chucks are controlled
independently of each other.
Sequential clamping chuck 1, chuck 2
In this operating mode, the chucks are controlled one after
the other. For the clamping procedure, chuck 1 is tightened
first and then chuck 2. The opening procedure takes place
in the reverse sequence, i.e. chuck 2 opens first and then
chuck 1.
Sequential clamping chuck 2, chuck 1
In this operating mode, the chucks are controlled one after
the other. For the clamping procedure, chuck 2 is tightened
first and then chuck 1. The opening procedure takes place
in the reverse sequence, i.e. chuck 1 opens first and then
chuck 2.

Assembly
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7 Assembly
7.1 Mechanical connection
WARNING
Risk of injury when the machine/system moves
unexpectedly!
Switch off power supply.
Figure 2
Install the module onto the lathe using the four fixing
brackets.
The customer must provide the following mounting material:
•4 x M8 mounting screws and applicable washers
Mounting

Assembly
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7.2 Electrical connection
WARNING
Risk of injury when the machine/system moves
unexpectedly!
Switch off power supply.
Note
•Observe the requirements for the power supply
(see chapter 5, page 10).
Observe the pin assignment.
/10/-1 Connections for foot switch 1
/11/ Power supply and PLC
/10/-2 Connections for foot switch 2
/12/ Outputs for four RSS units
Figure 3 Electrical interfaces
/12/
/11/
/10/-1
/10/-2

Assembly
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Pin allocation for the simple Harting plug connectors
(Han-Modular®Compact)
Pin
Allocation
1
+24 V
2
+24 V
3
"Foot switch connected" signal
4
"Foot switch stop / open" signal
5
"Foot switch stop / closed" signal
Table 1 Allocation terminal block A for the foot switch
Pin allocation for the double Harting plug connectors
(Han-Modular®Series with two Han® EE modules)
Pin
Allocation
1
+24 V
2
0 V
3
n.c.
4
Signal for "Emergency stop" ("active low")
5
Signal for "Spindle has stopped"
6
0 V
7
n.c.
8
n.c.
Table 2 Allocation for terminal block A
Pin
Allocation
1
"Clamping procedure for chuck 1 active" signal
2
"Clamping procedure for chuck 1 ended" signal
3
"Clamping procedure for chuck 2 active" signal
4
0 V
5
"Clamping procedure for chuck 2 ended" signal
6
"Clamping procedure for chucks 1 and 2 active"
signal
7
"Clamping procedure for chucks 1 and 2 ended"
signal
8
0 V
Table 3 Allocation for terminal block B

Assembly
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7.3 Air connection
WARNING
Risk of injury when the machine/system moves
unexpectedly!
Switch off power supply.
Note
•Observe the requirements for the air supply
(see chapter 5, page 10).
Use separate compressed air lines for each chuck.
Figure 4 Air connection chuck 1 and chuck 2
Item
Designation
Function
/1/
Line A C1
Connection A for chuck 1 (pressure chamber for closing
together)
/2/
Line B C1
Connection B for chuck 1 (pressure chamber for opening out)
/3/
Line A C2
Connection A for chuck 2 (pressure chamber for closing
together)
/4/
Line B C2
Connection B for chuck 2 (pressure chamber for opening out)
/5/
Feed line C1
Compressed air supply (2 - 8 bar) for chuck 1
/6/
Feed line C2
Compressed air supply (2 - 8 bar) for chuck 2
/7/
Exhaust air C1
A sound absorber, for example, can be connected here.
/8/
Exhaust air C2
Table 4 Allocation for the compressed air lines
/1/
/2/
/5/
/7/
/3/
/4/
/6/
/8/

Assembly
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7.4 Assembly example
Figure 5
Item
Designation
/1/
Chuck 1
/2/
Chuck 2
/3/
ELKE 24/2F electrical control unit
/4/
Feed line with pressure control for chuck 1
/5/
Feed line with pressure control for chuck 2
/6/
Foot switch for chuck 1
/7/
Foot switch for chuck 2
/8/
Connection to machine control system 24 V
Table 5 Compressed air lines
/1/
/3/
/2/
/4/
/5/
/6/
/7/
/8/

Commissioning and operation
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8 Commissioning and operation
8.1 Overview of operation
Figure 6 Sequence of operation diagram
Power-up messages
- Version & Date
- Foot switch mode
- RSS mode
Power up
Select operating mode
Left key switch
Execute operating mode
- Open chuck
- Tighten chuck
- Stop chuck
Buttons: "open", "stop",
"clamp", foot switch
Teach-in mode part 2: execute measurements
- Measure clamping procedure
- Measure opening procedure
Right key switch "Teach In"
Buttons: "open", "clamp"
Teach-inmodepart3:Changeparameters:
- Select parameter
- Reduce/increase parameter value
Buttons: "stop"
Buttons: "stop"
Teach-in mode part 1: prepare messages
- Open chuck
Buttons: "stop"
Buttons: "open", "clamp"
Buttons: "open"

Commissioning and operation
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8.2 Power-up messages
Power-up messages are shown on the LCD display of the
ELKE 24/2F when the power supply is switched on.
Power-up message 1 displays information on the firmware
for three seconds:
•Version number (release)
•Date of the firmware
•Serial number of the device
Figure 7 Example for power-up message 1
Power-up message 1 can be displayed for longer, e.g. so
that the version information can be noted down:
Keep one of the "stop" keys pressed down.
If the "stop" key is released, then the next power-up
message follows in the LCD display.
Power-up message 2 displays the status of the foot switch
for three seconds:
•Status of the connection (connected "yes" or "no") of the
foot switch for the respective chuck (1 = chuck 1; 2 =
chuck 2)
•Current status (not connected "-", left switch actuated
"L", or right switch actuated "R") of the foot switch
•Mode ("stay" or "tap") of the foot switch
Figure 8 Example for power-up message 2
Power-up message 1
Module version
Power-up message 2
Status of the foot
switches
Foot switch 1 2
Connected: no no
Status: - -
Mode: stay
ELKE 24/2F firmware
- Release: 1.0.1.7
- Date: 2009-04-28
- Serial no.: 2

Commissioning and operation
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In the "stay" mode, the operator has to remain stood on the
foot switch for as long as it takes for the ELKE 24/2F to
recognize the end of the movement.
In the "tap" mode, the operator only has to actuate the foot
switch once to release the movement.
Power-up message 2 can be displayed for longer, e.g. so
that the function of the connected foot switches can be
checked:
Keep one of the "stop" keys pressed down, the
displayed information in the second and third lines is
constantly updated.
If the "stop" key is released, then the next power-up
message follows in the LCD display.
Power-up message 3 displays the status of the four RSS
(1-4) for three seconds:
•Status of the watchdog output (WD)
•Current status of the level control output (LC)
•Actual data output Data Out 2 (DO2)
Figure 9 Example for power-up message 3
Power-up message 3 can be displayed for longer, e.g. so
that the function of the outputs can be checked:
Keep one of the "stop" keys pressed down, the
displayed information is constantly updated.
If the "stop" key is released, then the message for the
teach-in mode follows in the LCD display (for initial
commissioning) or the "general readiness for operation
display" (for reconnection).
Power-up message 3
Status of the RSS
RSS 1:- 2:- 3:- 4:-
WD: 0 0 0 0
LC: 0 0 0 0
DO2: 0 0 0 0