STEINEL S-Former E User manual

Assembly instructions
for S-Former E

2 Assembly instructions Version 12.2022
Legal notices
This documentation is intended solely for the owners and their personnel.
The contents of this documentation (texts, figures, drawings, graphics, plans, etc.) may not be reproduced or distributed, whether fully or
partially, without our written consent, or, for the purpose of competition, be given or made available to third parties.
(English translation of the original German text).
Responsible for content
STEINEL Normalien AG .Winkelstraße 7 .78056 Villingen-Schwenningen .Germany
Phone [phone] .Fax [phone] [e-mail] .www.steinel.com
Copyright STEINEL Normalien AG .All rights reserved.
Assembly instructions
Edition 1 English
Date of issue 12/2022
Changes to the design and product that serve to improve the product remain reserved.

Version 12.2022 Assembly instructions 3
Table of contents
1 Introduction 7
1.1 Preface 7
1.2 Product identification/product information 7
1.3 Scope of supply 7
1.4 Warranty and liability 8
1.5 Symbols in these operating instructions 9
1.5.1 Danger warning levels 9
1.5.2 Danger symbols 10
1.5.3 Command symbols 10
1.5.4 General symbols 11
1.6 Demarcation from the superordinate complete machine 11
2 Safety 12
2.1 Safety measures 12
2.2 Intended use 12
2.3 Foreseeable misuse 13
2.4 Owner obligations 13
2.5 Obligations of the personnel 13
2.6 Dangers when handling the S-Former E 14
2.7 S-Former E identification 15
3 Function 16
3.1 Functional description 16
3.2 S-Former E control unit 16
3.3 S-Former E control unit with the STEINEL S-Former E control unit 17
4 Design according to type 18
4.1 S-Former E types 18
4.1.1 S-Former E0 18
4.1.2 S-FormerE1.1 19
4.1.3 S-FormerE1.1 SSP 20
4.1.4 S-FormerE1.2 21
4.1.5 S-Former E2 22
4.1.6 S-Former E3 23

4 Assembly instructions Version 12.2022
Table of contents
5 Transport, storage 24
5.1 Transport information 24
5.2 Storage information 24
6 Electrical installation 25
6.1 Safety instructions 25
6.2 Connecting the S-Former E to the STEINEL S-Former E control unit 25
6.3 Connecting the S-Former E to an external control unit 25
6.4 Connecting the AC Servodrive 26
6.4.1 General procedure 26
6.4.2 Kollmorgen AKM1 to AKM7 type 26
6.4.3 Beckhoff Am802x type 27
6.4.4 Beckhoff AM803x to Am807x type 27
6.5 Coding for the operation of a STEINEL S-Former E control unit 28
7 Assembly 29
7.1 Safety instructions 29
7.2 Requirements 29
7.3 Forces and torques 29
7.4 S-Former E0 30
7.5 S-FormerE1.1 30
7.6 S-FormerE1.1 SSSP 31
7.7 S-Former E1.2 31
7.8 S-Former E2 32
7.9 S-Former E3 32
8 Setup, putting into service 33
8.1 Safety instructions 33
8.2 Connecting to a STEINEL S-Former E control unit 33
8.3 Connecting to another manufacturer’s servo amplifier or servo controller 33
9 Tool change 34
9.1 Safety instructions 34
9.2 S-Former E0 34
9.2.1 Changing the tool 34
9.2.2 Changing the tool size 34

Version 12.2022 Assembly instructions 5
Table of contents
9.3 S-Former E1.1 35
9.3.1 Changing the tool 35
9.3.2 Changing the tool size 36
9.4 S-Former E1.1SSP 37
9.4.1 Changing the tool 37
9.4.2 Changing the tool size 37
9.5 S-Former E1.2 38
9.5.1 Changing the tool 38
9.5.2 Changing the tool size 39
9.6 S-Former E2 40
9.6.1 Changing the tool 40
9.6.2 Changing the tool size 40
9.7 S-Former E3 41
9.7.1 Changing the tool 41
9.7.2 Changing the tool size 42
10 Maintenance, repair 43
10.1 Safety instructions 43
10.2 Maintenance schedule 43
10.2.1 Regular inspections 43
10.2.2 Maintenance, cleaning 43
10.2.3 Repairs 43
10.3 Maintenance work on the S-Former E0 45
10.3.1 Cleaning 45
10.3.2 Retightening of the toothed belt 46
10.4 Maintenance work on the S-Former E1.1 48
10.4.1 Cleaning 48
10.4.2 Retightening of the toothed belt 49
10.5 Maintenance work on the S-Former E1.1SSP 50
10.5.1 Cleaning 50
10.5.2 Retightening of the toothed belt 51
10.6 Maintenance work on the S-Former E1.2 52
10.6.1 Cleaning 52
10.6.2 Retightening of the toothed belt 53
10.7 Maintenance work on the S-Former E2 54
10.7.1 Cleaning 54
10.7.2 Retightening of the toothed belt 55
10.8 Maintenance work on the S-Former E3 56
10.8.1 Cleaning 56
10.8.2 Retightening of the toothed belt 57
10.9 Sensor calibration 58

6 Assembly instructions Version 12.2022
Table of contents
11 Disposal 59
12 Technical data 60
12.1 Performance data, limits, lifetime 60
12.1.1 S-Former E0 60
12.1.2 S-Former E1.1 62
12.1.3 S-Former E1.1SSP 64
12.1.4 S-Former E1.2 66
12.1.5 S-Former E2 68
12.1.6 S-Former E3 70
12.2 Drawings and parts lists 72
12.2.1 S-Former E0 72
12.2.2 S-Former E1.1SSP 78
12.2.3 S-Former E1.2 81
12.2.4 S-Former E2 85
12.2.5 S-Former E3 88

Version 12.2022 Assembly instructions 7
1 Introduction
1.1 Preface
Dear technical supervisor,
You are facing the task of operating the S-Former E. These assembly instructions will assist you in per-
forming this responsible job.
Please read these assembly instructions carefully and pay particular attention to the safety instructions!
If you have questions about this product, our employees are available to assist you.
Your STEINEL Normalien AG
1.2 Product identification/product information
Legal classification
The S-Former E is an incomplete machine in accordance with Machinery Directive 2006/42/EC Article
1 Paragraph (1) g.
Validity
These assembly instructions describe the conditions that must be fulfilled in order for the S-Former E to
be properly assembled into a complete machine using other components and without endangering the
health and safety of the personnel.
Only commission the S-Former E unit after you have read and understood the assembly instructions.
By installing and using the S-Former E, you confirm that you are aware of the unit’s intended use and any
potential dangers, have read and fully understood the safety instructions, and are aware of the required
maintenance and servicing measures in order to ensure sustained safety and functionality.
Storage
Always store these assembly instructions in a location the maintenance personnel can access at any time.
1.3 Scope of supply
The S-Former is supplied without a control unit or operating elements.
The following components are included in the scope of supply:
S-Former E, consisting of an AC servodrive, belt drive, pneumatic cylinder, pneumatic valve, cylinder
position sensor and spindle
Assembly instructions and declaration of incorporation

8 Assembly instructions Version 12.2022
1 Introduction
1.4 Warranty and liability
For the use of the S-Former E, our “General Terms and Conditions” always apply.
The “General Terms and Conditions” are accessible via our homepage.
Warranty or liability claims in case of damage to persons or property are precluded if they were the result
of one or several of the following causes in particular:
non-intended use of the S-Former E
improper assembly, commissioning, operation, maintenance and inspection of the S-Former E
operating the S-Former E with defective safety equipment or protective devices that were not
installed properly or protective devices and/or safety equipment that does not work.
non-observance of the notices contained in these assembly instructions regarding safety, putting
into service, operation, setting, maintenance and inspection of the S-Former E
unauthorised structural alterations of the S-Former E
insufficient monitoring and maintenance of parts that are subject to wear.
improperly performed repairs
disaster situations caused by external elements or force majeure
In order to maintain functional reliability, only original spare parts from the manufacturer may be used.

Version 12.2022 Assembly instructions 9
1 Introduction
1.5 Symbols in these operating instructions
1.5.1 Danger warning levels
Various signal words and colours are used depending on the level of risk.
DANGER
DANGER indicates danger which, if not avoided, has a high chance of
resulting in death or serious injury.
WARNING
WARNING indicates danger which, if not avoided, has a medium chance
of resulting in death or serious injury.
CAUTION
CAUTION indicates danger which, if not avoided, has a low chance of
resulting in minor or moderate injury.
ATTENTION
Obligation to specific conduct or a task for the safe handling of the
manifold plate in order to avoid property damage.
This symbol points to texts that contain important instructions/comments.

10 Assembly instructions Version 12.2022
1 Introduction
1.5.2 Danger symbols
Warning of a danger area
Warning of automatic start
Warning of hand injuries
Warning of hot surface
Warning of dangerous electrical voltage
1.5.3 Command symbols
Observe instructions for use
General warning signs

Version 12.2022 Assembly instructions 11
1 Introduction
1.5.4 General symbols
This arrow identifies the descriptions of tasks that you must perform.
This square identifies enumerations.
This arrow identifies cross references.
If cross references to other chapters occur within the text, notations are abbre-
viated for reasons of clarity.
Example: (OI, 2 Safety)
This means: Refer to operating instructions, Chapter 2 Safety
If the cross reference refers to a page, figure or position number, then this
information will be added at the end of the cross reference.
Example: (Fig. 4 - 4, Pos. 1
)
This means: Refer to (in chapter 4 of this manual)
position number 1 of figure 4.
Numbers in a square with a red frame refer to positions in the figures.
1.6 Demarcation from the superordinate complete machine
We, STEINEL Normalien AG, expressly demarcate ourselves from the direct and indirect dangers posed
by the superordinate machine in which The S-Former E is installed.
Providing information on dangers that may be posed by the superordinate machine is the responsibility
of the manufacturer and the owner.



3

12 Assembly instructions Version 12.2022
2 Safety2 Safety
2.1 Safety measures
The following information serves to recognise and avoid dangers in
order to ensure a handling of the S-Former E that is as safe as possible.
The S-Former E is a quality product manufactured according to accepted tech-
nological standards and left the production site in excellent condition with
regard to safety.
However, its use may endanger the life and limb of operators or third parties, or
cause damage to the S-Former E itself as well as other property.
The prerequisite for the safe handling and failure-free operation of the S-Former E
is knowledge of the safety instructions and regulations. Observe the general and
regional regulations regarding accident prevention and environmental protection,
the assembly instructions of the S-Former E and the manufacturer documents
for the components.
Integrate the assembly instructions into the technical documentation of the
machine in which the S-Former E has been installed. The assembly instructions
must be readily accessible for all operating and maintenance personnel.
2.2 Intended use
The S-Former E is exclusively intended to be installed in a superordinate complete machine.
It is designed for
the non-machining manufacture of internal threads in designated, prepared threaded holes,
use in superordinate machines such as punching presses, punching tools and progressive
stamping tools,
use as a self-sufficient unit.
The manufacturer of the superordinate complete machine must provide a control unit with a frequency
converter and servo control technology for controlling the AC Servodrive, as well as the operating ele-
ments and safety equipment, in accordance with the relevant standards.
The fixtures for the installation of the S-Former E must be sufficiently stable and bend-resistant to meet
the anticipated maximum output and the resulting torques.
Only designated components and accessory parts that have been approved by the manufacturer may
be used.
Putting the S-Former E into service is prohibited until it has been determined that the machine in which
the S-Former E has been installed fulfils all the fundamental requirements of the Machinery Directive.

Version 12.2022 Assembly instructions 13
2 Safety
Intended use also includes:
observing all notices in the assembly instructions
adhering to and monitoring the mechanical, thermal and electrical limits as well as limiting or
switching off when the limits have been either reached or exceeded,
adhering to inspection and maintenance cycles,
assigning only qualified and authorised professionals and operators to the respective tasks,
the exclusive use of original parts.
2.3 Foreseeable misuse
Operating the S-Former E beyond the defined mechanical and electrical limits
Powering the S-Former E with a type of drive that is different from the one defined
Operating the AC Servodrive with an unsuitable drive control unit
Operating the AC Servodrive without software limit monitoring (torque, rotation speed, temperature)
Unauthorised modifications or changes to the cylinder, gear, motor
Operating the S-Former E without attachment/installation on a holding device or in a tool
Operating the S-Former E without the required protective device to prevent access to moving parts
Operating the S-Former E in the immediate vicinity of magnetic fields or magnetised parts
Operating the S-Former E in explosive environments
Electrical and mechanical limits can be found in the MA, 12 Technical data
2.4 Owner obligations
The owner commits to only allow persons to work with the S-Former E who
are familiar with the basic regulations concerning occupational safety and accident prevention,
have been fully instructed in working with the S-Former E,
have read and understood these assembly instructions.
The owner also commits to complying with the EC directive for the use of work equipment 2007/30/EC
as well as the pertinent national regulations.
2.5 Obligations of the personnel
Prior to beginning work, all personnel tasked with working at the S-Former E are obligated to
observe the basic regulations concerning occupational safety and accident prevention.
read and observe the safety instructions and warning notices in these assembly instructions.

14 Assembly instructions Version 12.2022
2 Safety
2.6 Dangers when handling the S-Former E
DANGER
Life-threatening voltages of up to 400 VAC can occur at the motor.
Check the electrical connections, plugs and cables before use as well
as regularly during operation.
In the event of damage, immediately stop the S-Former E until it has
been repaired properly.
The repairs and inspection must be carried out by electrotechnical experts!
WARNING
There is a risk of injury from moving machine parts.
Before carrying out any work, secure the S-Former E against starting
unexpectedly.
WARNING
There is a danger of injury from malfunctions and unexpected starts.
Make sure that nobody is in the danger area prior to starting the
movements.
Do not modify mechanical or electrical parts in any way.
WARNING
The gear, AC Servodrive, pneumatic cylinder and S-Former E may reach
temperatures of over 80°C during operation.
There is a risk of burns.
Do not touch the components or wear safety gloves. Allow the com-
ponents to cool down to room temperature prior to touching them.

Version 12.2022 Assembly instructions 15
2 Safety
ATTENTION
The S-Former E may become electrically, mechanically or thermally
destroyed as a result of overloading and an incorrect/faulty limit mon-
itoring.
Operate the S-Former E within the product-specific limits, MA, 12
Technical data.
Ensure that the limits are electronically monitored.
2.7 S-Former E identification
The S-Former E’s identification data is laser-engraved on the front of the housing.
1Company name
2Internet address
3Year of construc-
tion (MMYY)/
consecutive serial
number
4Part number
www.steinel.com
1
2
3
4

16 Assembly instructions Version 12.2022
3 Function3 Function
3.1 Functional description
The S-Former E is an electrically powered tapping unit head.
It has been designed for the non-machining manufacture of internal threads through tapping or
thread grooving.
The S-Former E consists of an AC Servodrive, belt drive, pneumatic cylinder, pneumatic valve
(not pictured), position sensor and spindle.
The AC Servodrive rotates the spindle in which the tool is fixed, while the pneumatic cylinder moves
it axially.
The position sensor mounted on the cylinder determines the position of the spindle and feeds it
back as an analogue 0...10V signal.
The valve for retracting and extending the pneumatic cylinder can be controlled via digital signals.
1Belt drive
2AC Servodrive
3Spindle with tool
4Pneumatic cylinder
with position sensor
In principle, machining operations other than tapping may also be carried out, e.g. thread cutting, drilling,
screw mounting (also torque-controlled), torque tests for mounted elements etc.
The S-Former E can be used for practically all applications for which rotational and free axial movements
are required. However, it is not suitable for applications that require the spindle to be moved in an axial
direction via a defined feed rate.
3.2 S-Former E control unit
Before operating the S-Former E, it must be combined with a control unit featuring a frequency converter
and servo control technology for controlling the AC Servodrive.
Using a correctly designed and programmed control unit enables all rotation speeds and torques to be
controlled and monitored within the permissible mechanical and electrical limits for each AC Servodrive.
The position sensor enables switching points to be created depending on the feed movement of the
pneumatic cylinder.
1
2
4
3

Version 12.2022 Assembly instructions 17
3 Function
3.3 S-Former E control unit with the STEINEL S-Former E control unit
The STEINEL S-Former E control unit was specially developed to be used with the S-Former E.
A control unit can be used to control up to four S-Former E units regardless of their size (E0, E1.1, E1.2, E3).
Each S-Former E can be individually parametrised, and the settings can be saved in programs. You can
therefore switch from one production series to the next without incurring a time delay. The multilingual
menu instructions and touch display allow all relevant menus to be navigated and provide all important
system information.
Information on the STEINEL S-Former E control unit can be found in our current
control unit manual. For additional information and ordering options, please go to:
www.steinel.com » Service » Operating instructions
Example of a tapping movement in a punching or bending tool with a STEINEL S-Former control unit:
Movement
S-Former
Material
Material feed
S-Former E at a standstill
Material clamped
Start signal from press
Unit accelerates to rotation speed
and compressed air extends the
spindle
The S-Former E goes to the
threaded hole, the compressed
air is switched off, the S-Former E
automatically rotates itself into the
material
S-Former
Material
After the set number of revolutions
has been reached, the direction is
reversed: the S-Former E rotates
itself out of the thread
The S-Former E is out of the thread,
the compressed air is switched on
and the spindle is moved back to
the upper end position, while the
drive is braked until it comes to a
standstill
Spindle in upper end position and
drive at a standstill, monitoring OK
Ready signal to press
123
456

18 Assembly instructions Version 12.2022
4 Design according to type
4.1 S-Former E types
The S-Former E product series consists of 4 basic sizes (E0, E1, E2 and E3) for thread sizes of 1 to 26 mm.
Size E1 is available in the variants E1.1, E1.1SSP (not shown here) and E1.2. The S-Former E can also be
operated as an independent production unit.
S-Former E E0 E1.1 E1.2 E2 E3
Ø thread [mm] 1-4 4-8 4-8 8-16 8-26
Ø tap shaft [mm] 1-4 4-8 4-8 8-12 8-16
Max. tap path [mm] 20 30 30 40 50
Number of strokes [stroke/min]* Up to 160 Up to 110 Up to 80 Up to 70 Up to 50
Max. torque MF[Nm] 2 8 14 20 40
Rotation speed nF[t/min] Up to 5 000 Up to 3 250 Up to 2777 Up to 2500 Up to 1 000
* 240° thread form angle), steel < 600 N/mm²; F = roll tap
4.1.1 S-Former E0
The S-Former E0 (part number SZ2701-00005) is operated with a single-stage toothed belt gear. The AC
Servodrive has an output of 0.77 kW, while the pneumatic cylinder has a stroke of 20 mm.
The tool is clamped with a collet.
1Pneumatic cylinder with piston diameter = 16 mm and stroke = 20 mm as well as with the
analogue position sensor and compressed air connections for nominal width D = 6 mm
2AC Servodrive with an output of 0.77 kW, rotation speed 8 000 rpm
3Gear stage with AT5 toothed belt
4Spindle/spline shaft with tool clamping nuts and collets (type ERG08)
21
4 3
4 Design according to type

Version 12.2022 Assembly instructions 19
4 Design according to type
4.1.2 S-FormerE1.1
The S-Former E1.1 (part number SZ2701-00001) is operated with a double-stage toothed belt gear.
The AC Servodrive has an output of 0.93 kW, while the pneumatic cylinder has a stroke of 30 mm.
The tool is clamped with a collet.
A reducer enables a length compensation and the square wheel driver.
1Pneumatic cylinder with piston diameter = 16 mm and stroke = 30 mm as well as with the
analogue position sensor and compressed air connections for nominal width D = 6 mm
2Gear stage 1 with AT3 toothed belt
3AC Servodrive with an output of 0.93 kW, rotation speed 8 000 rpm
4Spindle/spline shaft with tool clamping nuts and collets (type ER11)
5Gear stage 2 with AT3 toothed belt
2 31
4 5

20 Assembly instructions Version 12.2022
4 Design according to type
4.1.3 S-FormerE1.1 SSP
The S-Former E1.1 SSP (part number SZ2701-00004) is operated with a double-stage toothed belt gear.
The AC Servodrive has an output of 0.93 kW, while the pneumatic cylinder has a stroke of 30 mm.
The tool is picked up by a high-speed clamping system with clamps, length compensation and a square
wheel driver.
The high-speed clamping system enables tool-free tool changes.
1Pneumatic cylinder with piston diameter = 16 mm and stroke = 30 mm, with the analogue
position sensor and compressed air connections for nominal width D = 6 mm
2Gear stage 1 with AT3 toothed belt
3AC Servodrive with an output of 0.93 kW, rotation speed 8 000 rpm
4Gear stage 2 with AT3 toothed belt
5Spindle/spline shaft with clamping nuts and high-speed clamping inserts
21
5 4
3