STEINEL S-Former E3 User manual

Instruction manual
Tapping unit
S-Former E3
Original instruction manual

Instruction manual
Tapping unit
S-Former E3
Original instruction manual

by Steinel Normalien AG, 07/2013
Diese Dokumentation ist ausschließlich für den Betreiber und dessen
Personal bestimmt.
Der Inhalt dieser Dokumentation (Texte, Abbildungen, Zeichnungen,
Grafiken, Pläne etc.) darf ohne unsere schriftliche Zustimmung weder
vollständig noch teilweise vervielfältigt oder verbreitet werden oder zu
Zwecken des Wettbewerbs unbefugt verwertet oder an Dritte ausge-
händigt oder zugänglich gemacht werden.
Steinel Normalien AG
Winkelstrasse 7
D – 78056 Villingen-Schwenningen
Telefon: + 49/(0) 77 20 / 69 28-0
Telefax: + 49/(0) 77 20 / 69 28-70
e-mail: [email protected]
Internet: http://www.steinel-normalien.de
Handbuch: Informationshandbuch
Ausgabe 1.0 Deutsch
Ausgabedatum: 07/2013
Design- und Produkt-Änderungen, die der Verbesserung des Produktes
dienen, bleiben vorbehalten.

Structure of the product manual
IM Tapping unit S-Former E3 I
Structure of the product manual
The overall documentation of the tapping unit comprises:
Product manual
– Information manual (IM)
– for the owner of the tapping unit
– Operating instructions (OI)
– for the operator and
– for the technical supervisor of the tapping unit
Overview of the structure of the overall documentation
Overview of the structure of the information manual (for the owner)
Index Content
I Information manual (IM)
Chapter Content
1 Introduction
2 Technical data
3 Disposal
4 List of signatures
Overview of the structure of the operating instructions
(for the operator and technical supervisor)
Index Content
II Operating instructions (OI)
Chapter Content
1 Introduction
2 Safety instructions
3 Functional description
4 Device description
5 Installation manual
6 Shipping, storage and assembly
7 Operation
8 Maintenance
9 Technical data
10 Main parts list and drawings
11 Error messages
12 Disposal

Table of contents (IM)
II IM Tapping unit S-Former E3
Table of contents (IM)
Chapter Topic Page

1Introduction
IM Tapping unit S-Former E3 1
1 Introduction
1.1 Preface
Dear owner,
With the purchase of a tapping unit from the company STEINEL Normalien AG
you now own a new generation product. In established STEINEL tradition, the tap-
ping unit sets new standards with regard to performance, quality and application
fields.
In order to permanently guarantee the technical capabilities of the product, it is
necessary to instruct operators and maintenance personnel in its assembly,
commissioning and decommissioning, maintenance, etc.
This technical briefing is carried out via this product manual.
In order to eliminate malfunctions and damages to the product as much as possi-
ble, give the respective personnel an opportunity to use these operating instruc-
tions to familiarise themselves with the functions of the product.
Your
STEINEL Normalien AG
1.2 Product identification/product information
Validity
The descriptions in this product manual solely refer to the tapping unit as it is de-
scribed in Chapter 2, Technical Data and as it was designed and built by the
manufacturer.
Product information
The tapping unit of the company STEINEL Normalien AG is suited for installation
in a press in order to tap threads into punched parts.
Storage
This information manual is part of the tapping unit product manual, it is meant for
owners and explains their obligations to them.

1Introduction
2 IM Tapping unit S-Former E3
1.3 Owner obligations
The owner commits to only allow those qualified persons to work with this tapping
unit who
received sufficient training to perform the respective functions.
are familiar with the basic regulations concerning occupational safety and acci-
dent prevention and who were instructed in the handling of the tapping unit by
qualified persons.
read and understood the safety instructions and warnings contained in the op-
erating instructions.
In the interest of everybody involved, please observe the following instructions:
Supplement the operating instructions with general, statutory and otherwise
binding regulations on occupational safety, accident prevention and environ-
mental protection and make sure that all personnel working with the tapping unit
are briefed accordingly!
Supplement the operating instructions with orders that take into account special
operational features, e.g. with regard to work plans, workflow, deployed person-
nel (including obligatory supervision and obligation to register)!
Clearly define the responsibilities of personnel regarding operation, cleaning,
maintaining, etc.!
Periodically check that personnel work in a manner conscious of safety and po-
tential dangers!
Take steps to ensure that the tapping unit is only used in a safe and functioning
condition!
Make sure that the tapping unit is cleaned and maintained within the specified
intervals (OI, Chapter 8, Maintenance and cleaning)!
Without the expressed written consent of the manufacturer, do not allow struc-
tural or other program changes (with the exception of those described in the
operating instructions)!
Make sure that no persons enter the danger area near the tapping unit that
have not, through the safety instructions, been briefed on the dangers accom-
panying working at and with the tapping unit!
Providing a safe working environment is solely the responsibility of the owner.
(OI, Chapter 2, Safety instructions)

1Introduction
IM Tapping unit S-Former E3 3
1.4 Definition of qualified persons/authorised personnel
Unqualified handling of the tapping unit can result in bodily harm or material dam-
ages. Only qualified personnel may therefore operate the tapping unit or commis-
sion, decommission, clean and maintain it.
Those persons are considered to be qualified personnel who
– are familiar with the safety concepts applying to the tapping unit.
– have been briefed on how to handle the tapping unit and are familiar with the
contents of the operating instructions related to running and operating it.
– have received the respective technical briefing from qualified personnel.
– based on their training, experience and instruction as well as their knowledge of
relevant standards, regulations, accident prevention rules and operating condi-
tions, were authorised by the person responsible for the safety of the tapping
unit to perform the necessary functions and are able to recognise and avoid
possible dangers.
Qualification
Assembly
Installation
Commissioning
Operation
Maintenance
Repair
Completed professional training
machine engineering/technician x x - x x x
Completed professional training
electrical
engineering/mechatronics
x x x x x x
Qualified person - - - x x -
Worker (trained and briefed) - - - x - -
[x] Permitted
[-] Not permitted/prohibited

1Introduction
4 IM Tapping unit S-Former E3
ATTENTION!
1.4.1 Intended use
The following illustrations may deviate from the actual configuration of the tapping
unit due to customer-specific adjustments.
The tapping unit is used to tap threads in prefabricated (pre-cut) boreholes.
The tapping units may only be operated with approved control unit components (
OI, Chapter 7.3, Control unit).
The tapping unit is an incomplete machine/partial machine. Additional components
must be installed or be made available and other expenditures must be made.
The owner is responsible for the integration of the customer-side expenditures as
well as the integration of the completed tapping unit into an operational process or
an entire system.
The owner is responsible for integrating the tapping unit into an operational pro-
cess and/or an entire system.
The tapping unit may only be operated by authorised qualified personnel and in
combination with appropriate protective devices. The protective devices must meet
the provisions of the Machinery Directive 2006/42/EC.
Commissioning the tapping unit is not permitted until it was determined that the in-
tegration of the tapping unit into the entire system was completed according to the
EC machine directive and that it conforms to national standards in its current condi-
tion.
Fig. 1 - 1 Tapping unit S-Former E3

1Introduction
IM Tapping unit S-Former E3 5
WARNING!
WARNING!
The intended use of the tapping unit also includes observing the instruction manual
as well as inspections and maintenance operations.
Another use or one that exceeds the intended use is considered to be a non-
intended use. The manufacturer is not liable for resulting damages. The owner
bears the entire risk.
1.4.2 Foreseeable misuse
Non-intended uses that can possibly be expected to occur are:
1.4.2.1 Operation of the device without separating safety equipment
Never operate the device without housing.
Fig. 1 - 2 Example 1 Protective device
Risk of injury from the rotating tapping tool
Risk of injury from flying chips following breakage of a tapping tool.
Never operate the device without appropriate protective devices.
The protective devices must meet the provisions of the Machinery Directive
2006/42/EC.
Fig. 1 - 3 Example 2 Protective device

1Introduction
6 IM Tapping unit S-Former E3
ATTENTION!
1.4.2.2 Operating the device in close proximity to external magnetic fields
Malfunction of the position recognition due to external magnetic fields.
Make sure that no external magnetic fields are present that could influence
the function of the magnetic monitoring on the cylinder piston.
Keep a distance of at least 1 m to all possible magnetic fields.
Fig. 1 - 4 External magnetic fields

1Introduction
IM Tapping unit S-Former E3 7
ATTENTION!
1.4.2.3 Operating the device with incorrect tapping tools
Malfunction during operation as a result of breakage of tapping tools.
Only operate the device with approved tapping tools.
Minimum: M8
Maximum: M20
1 min. M8/max. M20
Fig. 1 - 5 Application field tapping tool
1.4.2.4 Operating the device with faulty connected loads
Only operate the system with approved connected loads.
See Chapter 2, Technical data

1Introduction
8 IM Tapping unit S-Former E3
1.5 Complaints
Claims for damages related to damage in transit can only be claimed when the
manufacturer and the shipping company were notified right away.
Immediately complete a damage protocol for return shipments (because of
damage in transit/repairs) and return the parts, in their original packaging if pos-
sible, to the manufacturer.
During the receipt of goods, record all possible damages in transit on the freight
documents.
Add the following information to the return shipment:
– The name and address of the sender and recipient
– Type and serial number of the tapping unit
– Description of the defect
– For damages in transit: Name of the shipping company and, if possible,
Delivery date and time, name of the driver and license plate number of the
delivery vehicle.
1.6 Guarantee and liability
For the use of the tapping unit, our general terms and conditions of sale and deliv-
ery always apply.
Deviating agreements have to be agreed upon in writing and must be confirmed by
us!
The "General Terms and Conditions of Sale and Delivery" are delivered to the
owner with the quote.
Guarantee or liability claims in case of damage to persons or property are preclud-
ed if they were the result of one or several of the following causes:
– non-intended use of the tapping unit.
– operating the tapping unit with defective safety equipment or safety equipment
and/or protective devices that were not installed improperly or do not work.
– failure to observe notes contained in these operating instructions regarding
safety, shipping, storage, assembly, commissioning, operation, maintenance
and repairs of the tapping unit.
– improper assembly, commissioning, operation, maintenance and repair of the
tapping unit.
– insufficient monitoring and maintenance of parts that are subject to wear.
– unauthorised constructional changes to the tapping unit.
– disaster situations caused by external elements or force majeure.
In order to maintain functional reliability, only original spare parts from the manu-
facturer may be used.

1Introduction
IM Tapping unit S-Former E3 9
1.7 Declaration of incorporation
EC declaration of incorporation according to EC directive 2006/42/EC (machines),
Annex II B
The manufacturer:
STEINEL Normalien AG
Winkelstraße 7
78056 Villingen-Schwenningen - Germany
hereby declares that the following product (the incomplete machine/
partial machine):
Designation STEINEL Normalien Art. number
Tapping unit, S-Former E3 SZ8871.03
if the scope of delivery allows it, conforms to the following basic requirements of
the Machinery Directive 2006/42/EC:
Annex 1, article 1 1.1.1; 1.1.2; 1.1.3; 1.1.5;
1.3.2; 1.3.4;
1.5.1; 1.5.4;
1.7.4; 1.7.4.1; 1.7.4.2
The incomplete machine also conforms to the following directives:
Directive 2004/108/EC of the council from 15 December 2004 on the approxima-
tion of the laws of the member states relating to electromagnetic compatibility.
Directive 2006/95/EC of the council from 12 December 2006 on the harmonisation
of the laws of member states relating to electrical equipment designed for use with-
in certain voltage limits.
The technical documents were prepared according to annex VII part B and can be
submitted electronically to national offices in response to a well-founded request.
List of some of the applied harmonised standards:
DIN EN ISO 12100
The commissioning of the incomplete machine (tapping unit) delivered by us is not
permitted until it has been determined that the integration of the tapping unit into
the entire system conforms to the basic safety and health protection requirements
as per annex I of the EC directive 2006/42/EC that is referenced above.
Name of the authorised representative: Gerd Roggatz, CE representative
Address of the authorised representative: see address of manufacturer
Villingen-Schwenningen, in February 2013 ppa. Heinz Elfers
(Division manager Engineering)

1Introduction
10 IM Tapping unit S-Former E3
ATTENTION!
1.8 Definition of terms
The following illustrations may deviate from the actual configuration due to cus-
tomer-specific adjustments.
Tapping element
The tapping element contains the gear with lead screw, the motor and the tapping
tool and it is the core component of the tapping process.
Fig. 1 - 6 Tapping element
Tapping unit
The entire system is referred to as "tapping unit".

2Technical data
IM Tapping unit S-Former E3 11
ATTENTION!
2 Technical data
2.1 Tapping unit S-Former E3
Tool data
Max. rotation speed at the tool: 1,150 rpm
Max. driving torque at the tool 40 Nm
Min. thread size: M8
Max. thread size: M20
Drive
Motor: AC servomotor
Type: AKM 52K
Nominal speed 5,500 rpm
Nominal torque: 3.90 Nm
Torque constant: 0.93 Nm/A
Nominal power: 2.25 kW
Mains voltage: 400 VAC
Pneumatic system
Max. piston stroke 50 mm
Cylinder feed force at 6 bar: 754 N (extending)
686 N (retracting)
Air connection: for externally calibrated hose PUN 6
Air consumption: 0.2 Standard litre (extending)
0.2 Standard litre (retracting)
Typical switching time (at 6 bar) ≤ 120 ms (extending)
≤ 150 ms (retracting)
Cylinder end position monitoring: 1 analogue position sensor
Dimensions and Weight
Main dimensions (L x W x H) (356 x 125 x 248) mm
Weight: 20 kg
Ambient conditions
Ambient temperature: +5 °C to + 40 °C at an installation
height
up to 1,000 m AMSL
Airborne noise emitted: 70 db(A)

2Technical data
12 IM Tapping unit S-Former E3
The nominal power of the tapping unit has to be reduced if the temperature is
higher or at installation heights above 1,000 m above sea level because otherwise
the motor will reach the temperature limit.

3Disposal
14 IM Tapping unit S-Former E3
3 Disposal
The tapping unit can be taken apart following the removal of the conveyed medium
and possibly remaining lubrication remnants. The individual parts can be recycled
depending on the used materials.
If the tapping unit has been contaminated with chemical, poisonous or other substances
that are a danger to people or the environment, the tapping unit must be disposed of
according to the respective valid regulations!
The owner can recycle or dispose of the system as long as legal requirements are
adhered to. Expertise in differentiating waste materials is needed in order to ap-
propriately disassemble the system and sensibly separate materials.
If hazardous materials according to directive 2006/12/EC must be disposed of, the
disposing person also requires expertise in the following areas:
– Risks and dangers
– Disposal regulations
– Accident prevention regulations
– First aid measures
– Safety regulations
Prior to disposing of the system, read the chapter Safety Observe all warning no-
tices it contains and also read the technical documents of the OEM components in
the annex.
3.1 Legal bases
3.1.1 Liability
According to directive 2006/12/EC, the owner is responsible for the disposal of the
machine/component according to regulations. The owner can hand over the sys-
tem to a licensed private or public waste collector or carry out recycling or removal
on their own.
Note: If a waste collector disposes of the device, the owner must provide that com-
pany with operating instructions. The operating instructions contain important in-
structions regarding the disposal of the system.
3.1.2 Notification requirement
Companies that remove or recycle their own waste are subject to local approval
and oversight. The licensing requirement may be waived if certain conditions are
met as long as the companies take into account environmental protection require-
ments. These companies are subject to the notification requirement. You can get
detailed information from the authority in charge of environmental protection. Out-
side of the EU, comparable legal requirements generally apply.

3Disposal
IM Tapping unit S-Former E3 15
3.1.3 Environmental protection requirements
Waste materials must be recycled or disposed of in a way that does not threaten
the health of people. Only those procedures and methods may be applied that do
not harm the environment. In particular, it must be ensured that
– air, water and soil are not contaminated,
– flora and fauna are not endangered,
– noises and smells do not cause any inconvenience,
– the surroundings and the landscape are not harmed.
3.1.4 Sorting
Once the device has been disassembled, the individual components must be sepa-
rated into waste categories according to the index of the European waste cata-
logue (EWC) or similar regulations. The EWC catalogue applies to all waste mate-
rials, regardless of whether they are to be disposed of or recycled.
3.1.5 Waste management
Waste management must be carried out according to governmental waste man-
agement plans. These particularly include:
– Type, amount and origin of the waste materials
– General technical regulations
– Special provisions for certain waste materials
– Suitable areas for landfills or other waste disposal sites
Among others, the plans contain the following information:
– Natural or legal persons authorised to perform waste management functions
– The estimated cost of recycling and disposal
– Measures to streamline the collection, sorting and treatment of waste materials
– Labelling of hazardous waste materials