Traub TNL12.2 User manual

DTE070EN - 15.09.2021
09.21/Ru (Transport, Aufstellung, Inbetriebnahme) - 20187889
Transport,
Installation,
Commissioning
TNL12. 2
OPERATING INSTRUCTIONS
Transport and installation

Note on applicability
Illustrations in this publication may deviate from the product supplied. Errors and omissions due to technical
progress expected.
A word on copyright
This document is protected by copyright and was originally compiled in German.
The duplication and distribution of this document or parts thereof is prohibited without prior consent of
the copyright owner, and any violators will be prosecuted. All rights, including the right to translate, are
reserved.
©Copyright by INDEX-Werke GmbH & Co. KG
Englisch

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Table of Contents
SafetySafety .............................................................................................................................................................................................................................................................................................. 77
Explanation of symbols ..................................................................................................................... 7
Safety instructions documentation .................................................................................................... 7
Installation planInstallation plan ............................................................................................................................................................................................................................................................ 99
Installation plan TNL12.2, simplified .................................................................................................. 9
Installation items - load distribution TNL12.2 ..................................................................................... 10
GeneralGeneral .......................................................................................................................................................................................................................................................................................... 1111
Information for transporting the machine ......................................................................................... 11
Lifting device ................................................................................................................................. 11
Information on where the machine is installed ................................................................................. 12
Space requirements .......................................................................................................................... 12
Environmental conditions .................................................................................................................. 12
Subsoil, foundation ............................................................................................................................ 12
Floor trough ....................................................................................................................................... 13
Compressed-air supply ...................................................................................................................... 13
Operating material to be provided ..................................................................................................... 13
Pumps and tanks ............................................................................................................................... 13
Customer site attachment of a local extraction system .................................................................... 13
Power supply ..................................................................................................................................... 14
Main circuit breaker ........................................................................................................................... 14
External data transfer ........................................................................................................................ 14
Chip disposal ..................................................................................................................................... 15
Disposal of used operating materials ................................................................................................ 15
Observing the ground and wastewater regulations ........................................................................... 15
Transporting the machineTransporting the machine .......................................................................................................................................................................................................................... 1717
Delivery of the machine ..................................................................................................................... 17
Dimensions and weights ................................................................................................................... 18
Machine TNL12.2 .......................................................................................................................... 18
Cooling lubricant unit ..................................................................................................................... 18
Machine center of gravity (S) ............................................................................................................. 19
Transport by crane (min. 3 t capacity) ................................................................................................ 20
Attaching the lifting device components ....................................................................................... 21
Attaching the machine to the lifting device ................................................................................... 22
Transporting the machine ............................................................................................................. 23
Transporting with a forklift ................................................................................................................. 24
Technical requirements – forklift ................................................................................................... 24
Transporting with transport casters ................................................................................................... 27
Technical requirements – transport casters ................................................................................... 28

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Table of Contents
Installing the machineInstalling the machine ........................................................................................................................................................................................................................................ 3333
Electrical connection ......................................................................................................................... 33
Aligning and doweling the machine ................................................................................................... 33
Spirit level and support surface ..................................................................................................... 33
Installation items ........................................................................................................................... 33
Aligning .......................................................................................................................................... 34
Fastening to the floor .................................................................................................................... 34
Removing the transport locks from the machine ............................................................................. 36
Locations of the transport locks on the machine .............................................................................. 36
Transport lock at main spindle ....................................................................................................... 37
Transport lock at counter spindle and back working attachment .................................................. 38
Upper tool carrier and front working attachment .......................................................................... 39
Transport lock at operating panel .................................................................................................. 39
Transport lock at work area door ................................................................................................... 40
Connecting the machine to central suction unit ................................................................................ 41
Shutoff valve for fire protection .................................................................................................... 41
Indicator lamp ................................................................................................................................... 43
Installing configuration levels and additional equipmentInstalling configuration levels and additional equipment .................................................................................................................. 4545
Transporting and installing the cooling lubricant unit ......................................................................... 45
Installing the cooling lubricant unit ................................................................................................... 46
Sealing of cooling lubricant unit / machine .................................................................................... 47
Connecting the cooling lubricant unit ............................................................................................ 48
Electrical connectionElectrical connection ............................................................................................................................................................................................................................................ 4949
Important notes ................................................................................................................................. 49
Pneumatic connectionPneumatic connection ........................................................................................................................................................................................................................................ 5151
Provision of compressed air .............................................................................................................. 51
Air consumption ............................................................................................................................ 51
CommissioningCommissioning .............................................................................................................................................................................................................................................................. 5353
Cleaning the machine ........................................................................................................................ 53
Check the operating fluid levels and replenishing, if necessary ........................................................ 54
Data loss due to prolonged downtime .............................................................................................. 54
Switching on the machine ................................................................................................................ 55

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Table of Contents
Relocation of the machineRelocation of the machine .......................................................................................................................................................................................................................... 5757
Preparing the machine for transport .................................................................................................. 57
Transport locks on the machine ........................................................................................................ 57
Locations of the axes for attaching the transport locks ................................................................ 57
Drain the hydraulic tank before transport .......................................................................................... 58
Seal disconnected hose lines or pipelines ......................................................................................... 58
Corrosion protection .......................................................................................................................... 58
Transporting the machine with a truck .............................................................................................. 59
Loading guard ................................................................................................................................... 60

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Table of Contents

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Safety
Explanation of symbols
This section explains the symbols that are used in the user documentation to
call attention to dangers and important notes.
This symbol warns against a direct, imminent danger to the life and
health of individuals. Failure to observe this danger warning may
result in severe health impairment such as perilous injury and even
death.
This symbol warns against a direct, imminent danger from electric-
ity. Failure to observe this danger warning may result in severe
health impairment such as perilous injury and even death.
This symbol indicates important notes for the proper operation of
the machine. Failure to observe this information may result in dam-
age to or malfunction of the machine or its components.
Safety instructions documentation
The user documentation and, in particular, the safety instructions
must be observed.
The safety instructions, as a separate document, are part of the
TRAUB user documentation.

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Safety

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Installation plan
Installation plan TNL12.2, simplified
The corresponding installation and layout plan must be requested before the machine is installed.
Example shown
10011216412

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Installation plan
DD
A
A
CC
B
B
Installation items - load distribution TNL12.2
Installation items A B C D
Max. static load (kN) 5.0 9.7 3.5 6.9

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General
Information for transporting the machine
Danger from falling machine/parts
No persons are allowed to remain under suspended loads!
Transporting the machine
Means of transport approved for transporting the machine:
• Crane (requires lifting device)
• Transport casters
• Forklift
Shipping of the machines to countries with extreme climatic condi-
tions is carried out by specialized logistics companies.
Be sure to carefully plan the delivery, unloading, and transporting of the ma-
chine from the unloading site to the installation site.
Take the size (dimensions) and weight of each unit into consideration.
Any obstacles along the transport route from the unloading site to the installa-
tion site must be eliminated before the machine is delivered.
Check the transport route for load capacity, levelness, damaged pavement,
traverse grooves, slopes, gradients, etc.
Lifting device
Lifting devices are either packed separately or included with other units.
The lifting device required for proper transport of the machine is
supplied with the machine and must be returned to INDEX-Werke
after the machine has been installed.
The lifting device must not be disassembled further.
1
23
1 Load beam, top
2 Load beam, side
3Spacer

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General
Information on where the machine is installed
Risk of crushing
The installation site must be chosen such that moving parts of the
machine, including hand-operated doors, flaps, etc., do not create
risks of being crushed against walls, columns, or hall installations.
In any case, the machine, including the bar loading magazine, must
be doweled to the floor.
Space requirements
The following must be ensured:
• Sufficient free space around the machine.
• Sufficient movement space for the operator.
• Sufficient space for maintenance and repair.
• It must be possible to open all doors of the machine completely.
• Space for placing blank and workpiece pallets, workpiece containers, chip
trolleys, tool trolleys, etc.
Use the installation plan to determine the required space.
Environmental conditions
See Environmental Conditions in the safety instructions.
If the actual conditions at the installation site differ from these
specifications, be sure to contact the machine manufacturer or its
representative..
Subsoil, foundation
The load capacity and strength of the floor must be suitable for the machine
weight based on constructional aspects.
There must be no expansion joints in the area of the machine footprint.
Bar guides, bar feeders, and bar loading magazines must generally be anchored
in the foundation (for information, see the associated operating instructions and
the installation plan).

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General
Floor trough
If a floor trough is required, it must be designed according to the
specifications “Information on floor trough drawing” so that exten-
sion of the corresponding chip conveyor is ensured.
The floor in the area of the floor trough must only be max. 5 mm convex, as flat
or concave as possible. Exceeding the allowable unevenness may cause the
floor trough to contact the machine base / machine components.
Compressed-air supply
See Chapter Pneumatic connection
Operating material to be provided
See Chapters Commissioning and Information on operating material
Pumps and tanks
A simple pump is sufficient to extract the used cooling lubricant. The same
pump may be used to fill the cooling lubricant tank; however, it must be thor-
oughly flushed with fresh cooling lubricant.
A robust container is required for collecting the extracted fluids. Suitable con-
tainers are metal barrels of sufficient capacity and with proper labels, which can
be tightly closed.
Customer site attachment of a local extraction system
If a local extraction system is attached to the machine, any existing
fire extinguishing system available on the machine must be adjusted
accordingly.

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General
Power supply
The directives and regulations applicable in the country of use must
be followed.
The power supply cord to the machine should be as short as pos-
sible.
Use a sufficient wire size.
The power supplies for the programmable logic controller (PLC) and the numeri-
cal control (NC) require stable mains conditions; the max. allowed operating
voltage fluctuations are +10% or -10%.
The mains line must comply with the regulations of the local electricity supplier
and the IEEE directives.
Main circuit breaker
Check that the building connection has sufficient capacity to cover
the additional load to be protected.
Discuss any unclear conditions with your local electricity supplier.
The main circuit breaker is not included in the delivery of the machine.
It must be installed outside the machine according to DIN EN 60204-1.
If a pre-transformer is required, the main circuit breaker must be installed be-
fore the pre-transformer, i.e., on the primary side.
The loads to be protected depend on the existing operating voltage.
For the information on machine connection, operating voltage, main fuse, see
the electrical diagrams or Chapter Electrical connection.
External data transfer
Data cables must not be routed directly next to live cables.
For data transfer to/from external computers or servers/storage devices, suit-
able metal conduits must be installed for the data lines.
The connection to the internal network (DNC) requires an RJ45 network cable.
An additional connection to the external network (IoT) must be made with a
separate RJ45 network cable.

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General
Chip disposal
If the machine is equipped with a chip conveyor, a chip trolley, its height match-
ing the chip conveyor's discharge height, is required.
The chip trolley should have a device for draining the accumulating cooling lubri-
cant so it can be returned to the cooling lubricant tank.
Chip conveyor without discharge chute
The customer must provide a cover for the collection bin for the
discharged chips when using a chip conveyor without a discharge
chute.
The cover must be designed such that it is not possible to reach into
the discharge chute.
Disposal of used operating materials
The directives and regulations applicable in the country of use must
be followed.
Decide in advance on how to dispose of used operating fluids such as hydraulic
fluid, lubricating oil, and cooling lubricant in an environmentally friendly manner.
Observing the ground and wastewater regulations
The directives and regulations applicable in the country of use must
be followed.
The machine contains water-polluting substances such as water-miscible cool-
ing lubricants and mineral oils. These substances may leak from the machine in
case of adverse events.
Therefore, the machine must be installed in a place that excludes any harm by
these substances to waters or groundwater.
Possible preventive measures
• Place the machine inside a tight steel trough (floor trough).
• Seal the floor of the factory hall.

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General

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Transporting the machine
Delivery of the machine
The machine is delivered by truck.
The machine is in the following condition when delivered:
– Machine incl. control cabinet mounted on the adjustable feet
– Certain moving parts on the machine, such as the work area door and the
swiveling operating panel, are secured by transport locks or were removed.
– Protruding machine parts hampering the transport may have been removed.
– All blank parts of the machine were treated by spray-covering with an anti-
rust agent.
– For operating material, see Chapter Commissioning.
Other separate units
Certain equipment levels or add-on equipment such as chip conveyor, bar feed-
er, bar loading magazine, etc., are usually separate units.
Chip conveyors usually rest on a transport base for shipping. The bar feeder and
bar loading magazine are delivered in a special shipping crate.
Loose parts, such as keys, tools, and fittings, are supplied in a separate box,
which may be included with a separate unit.
Before unloading, check the machine, the enclosed accessories, and any sepa-
rate units for external damages and completeness (compare bill of lading with
delivery form).
Have the carrier confirm any damages or missing parts on the bill of lading or
delivery form.
In case of damages during transport, it is recommended to take photos of the
damages for evidence.
Notify the machine manufacturer or the machine manufacturer's representative.

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Transporting the machine
The control cabinet houses:
• The necessary logs such as geometry or safety log
• Installation plan
• Key for the operating panel
• Key for the fire extinguishing system
(depending on the machine equipment)
On a separate pallet are:
• Accessories box
- Screw-on brackets with threaded rods and mortar cartridge (2x)
- Operator tools ( such as special keys)
• User documentation
Dimensions and weights
Machine TNL12.2
The weight specifications refer only to the basic machine, i.e.,
without cooling lubricant unit and workpieces.
Length
- Basic machine mm 1900
Depth
- Basic machine mm 110 0
Height
- Basic machine (without signal lamp) mm 1600
Weight, approx.
(with control cabinet and max. equipment)
- Basic machine kg 2500
Cooling lubricant unit
Length mm 3500
Width mm 1235
Height mm 1700
Weight approx. (with max. equipment) kg 900

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Transporting the machine
Machine center of gravity (S)
Center of gravity S*
Basic machine
mm
S1 S2 S3
875 805 505
* Values may vary slightly
S3
SS
S2
SS
S1

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Transporting the machine
Transport by crane (min. 3 t capacity)
Danger from falling machine/parts
No persons are allowed to remain under suspended loads!
The lifting device required for proper transport of the machine is
supplied with the machine and must be returned to INDEX-Werke
after the machine has been installed.
Illustrations show examples
t