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HANSA Press VKA-110 Operating Instructions Manual

Four-ball tester
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1. Safety (from Page 5)
1.1 General information
1.2 Intended use
1.3 Safeguards of the VKA-110 four-ball tester
1.4 Transport
1.5 Occupational health and safety
1.6 Cleaning and maintenance
1.7 Electrics
1.8 Emergency stop
1.9 What to do if there is a fire
1.10 Environmental protection
2. Operation / "Option 4" Control Unit, Page 8
2.1 Switching on the machine
2.2 Switching off the machine
2.3 "Option 4" control unit
2.3.1 Options
2.3.1.1 USB interface
2.3.1.2 Zero-point weight
2.3.1.3 Additional options
2.3.1.4 Temperature control unit (TC)
Operating Instructions
VKA-110 Four-Ball Tester
In compliance with DIN 51350
1

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Summary of Contents for HANSA Press VKA-110

  • Page 1 VKA-110 Four-Ball Tester In compliance with DIN 51350 1. Safety (from Page 5) 1.1 General information 1.2 Intended use 1.3 Safeguards of the VKA-110 four-ball tester 1.4 Transport 1.5 Occupational health and safety 1.6 Cleaning and maintenance 1.7 Electrics 1.8 Emergency stop 1.9 What to do if there is a fire...
  • Page 2 2.3.1.5 More data points 2.3.1.6 Calibration 2.3.1.7 Testing without additional options 2.3.1.8 FTP server 2.3.1.9 WebVisu and web interface 2.3.2 Measuring 2.3.2.1 Measuring 2.3.2.2 Time-delayed recording 2.3.2.3 Stop parameter: measurement 2.3.2.4 Maximum torque 2.3.2.5 Unregulated / regulated 2.3.2.6 Step control 2.3.3 Status 2.3.3.1 Status 2.4 Jockey weight setting...
  • Page 3 2.8 Types of tests 3. Test Description, Page 22 3.1 Types of tests 3.1.1 What to do prior to each test 3.1.2 Standard short-time tests 3.1.3 Long-time tests 3.1.4 Testing materials 3.2 How to perform the tests 3.2.1 Conditions if the loads applied are low 3.2.2 Conditions if the loads applied are high 3.2.2.1 The wear scar diameter 3.2.2.2 The 2.5-second wear and tear delay time...
  • Page 4 5.4.1 Installation of the housing (pos. 1) 5.4.2 Installation of the writing utensil holder (pos. 19) 5.4.3 Balance scale bar (pos. 24) 5.4.3.1 Installation of the balance scale bar 5.4.3.2 The balance scale bar 5.4.4 Installation of the push rod (pos. 22), the plunger (pos. 20), the bearing (pos.
  • Page 5 VKA-110 must have read and understood these operating instructions and the safety requirements. The operator of the VKA-110 must properly train and instruct the operating personnel to protect their health and safety. In addition the operator must train and instruct the operating personnel in operating, servicing and maintaining the machine properly and safely.
  • Page 6 Only use sufficiently dimensioned transport and lifting slings and equipment (fork lift, crane, belts). 1.5 Occupational health and safety The VKA-110 four-ball tester has been designed and built in compliance with the EC Machinery Directive, the relevant occupational health and safety regulations, and the accident prevention regulations.
  • Page 7 1.6 Cleaning and maintenance Clean and maintain the VKA-110 four-ball tester at regular intervals to ensure the operational safety of the machine. Switch off the main switch (Q1) of the four-ball tester before you start any cleaning and maintenance works.
  • Page 8 To switch on the VKA-110, turn the main switch (Q1) to ON/“I”. Caution: risk of injury! Keep hands and fingers away from the rotating spindle while the VKA-110 is in operation. If you need to work in the spindle operating range, make sure that the main switch (Q1) is in the OFF/“0”...
  • Page 9 2.3 “Option 4” control unit The runtime system of the VKA-110 is based on Windows CE 5.0. It starts automatically when the main switch (Q1) is turned to ON. The “Option 4” control unit standard package comprises the following functionalities: ...
  • Page 10 Operating panel: You can control all the VKA-110’s functions via the three windows listed below. 2.3.1 Options Here you’ll find all the relevant control unit options. about WebVisu anInformationd FTP server Start/activation of the temperature control unit (only when buying a circulation thermostat) Step control activation Safe working load in the “limited”...
  • Page 11 When you measure the torque in short-time tests, you can set more measurement points (0.1 seconds) under “More Data Points”. 2.3.1.6 Calibration The VKA-110 comes default-calibrated. You only need to carry out a calibration when you exchange the motor.
  • Page 12 2.3.1.9 WebVisu and web interface “WebVisu” displays the buttons on your PC. You can then use “Web Interface” to start and stop the VKA-110 via the PC. If the VKA-110 is not connected to your in-house network, you will need an additional router to be able to work with “WebVisu”...
  • Page 13 2.3.2 Measuring Mode of operation Freely settable rotational speed Pre-defined standard rotational speeds Step control 2.3.2.1 Measuring The “Measurement” window allows you to enter the measurement settings. Use “Measurement Name” to enter a new name. When you click the start button, the suffix “@01”...
  • Page 14 2.3.2.4 Maximum torque Go to “Maximum Torque” to limit the torque threshold for switch-off at the weld point. You can limit the torque threshold as follows:  Under “limited” the motor switches off once the value of the motor’s torque set under options has been reached.
  • Page 15 You can use step control to perform one test at different rotational speeds. E.g. if you select the stop parameter “Time”, you can run the VKA-110 for one hour at 1000 r/min, followed by another hour at 1500 r/min and another 30 minutes at 2000 r/min.
  • Page 16 2.3.3 Status Speedometer Motor load Progress display Scaling factor 2.3.3.1 Status The “Status” window displays the current values while the motor is running. The torque is displayed in % of the maximum torque of the motor. When you click the start button, the control unit automatically jumps to that window. You cannot select the “Option”...
  • Page 17 You can find the relevant load sequences on a separate sheet supplied together with the VKA-110 documentation. Information about the test weights: For control purposes note that the jockey weights including indexing lever and all rings of the additional weights with screws as well as the 40kg additional weight including grab handles have been manufactured to the weight stated (tolerance = 0.5%).
  • Page 18 2.6 Ball holder 2.6.1 Inserting and loading the ball holder Caution: risk of injury! Feed balls into the spindle ball holder only when the motor is switched off. Keep hands and fingers away from the rotating spindle. Switch off the VKA motor. Make sure that the spindle does not rotate. Press the new test ball tightly into the ball holder and/or hit the ball holder lightly with a copper hammer (e.g.
  • Page 19 Tighten the clamping nut (pos. 13) to fix the three test balls. To do so, insert the square of the ball cup into the mounting plate. Use the HANSA Press wrench (pos. 16) to tighten the ball cup clamping nut to ensure that the balls are fixed and cannot move.
  • Page 20 HRC 64+/-1 (item no. VKA-00020). In addition, you can also use the following test balls from Hansa Press RB 12.7 MM / G10 / Material: 1.3505 (B1) 100Cr6 / hardness HRC 64 +/- 1 (item no.
  • Page 21 2.7.2 Taking a load off the ball cup The weight is taken off the ball cup and/or the test balls after the motor (spindle) has come to a stop and you have pressed down the release lever. Take out the ball cup. Use the square in the mounting plate to dismount the ball cup. 2.7.3 Measuring microscope for standard ball cup and temperature-adjustable ball The measuring microscope (item no.

  • Page 22: Test Description

    2.8 Types of tests The runtime depends on the purpose of the test, i.e. whether it is a long-time test or a short-time test (weld test). When the balls weld together, an electronic automatism will switch off the machine if the load corresponds to the weld limit.
  • Page 23 3.1.2 Standard short-time tests Lubricants will usually be tested in 1-minute short-time tests. Short-time tests allow you to test the lubricant fast and  apply specific contact pressure which, e.g., is present at the mating teeth of gears subjected to heavy wear; ...
  • Page 24 3.1.3 Long-time tests Long-time tests are performed to get an idea of the gradual wear and tear (abrasion) of parts subjected to light wear with different lubricants used. In long-time tests a lower load on the ball cup is preferable whereby the test may last for several hours.
  • Page 25 3.2 How to perform the tests 3.2.1 Conditions if the loads applied are low If the loads are low, the balls show hardly any wear. The result is the same when you measure and record the friction torque, i.e. the friction coefficient. The friction coefficient will remain constant here and usually range from 0.05 to 1.0.
  • Page 26 3.2.2.1 The wear scar diameter Fig 2 shows the wear surface if a medium load is applied. The wear scar diameter is in accordance with the static deformation rate. Fig 2 If during the test a state of equilibrium occurs, in other words there is no further wear, the balance scale bar will stop going down.
  • Page 27 Results obtained with SPIRAL BEVEL GEARS have revealed that only those lubricants in spiral bevel gears work satisfactorily that show a 2.5-second welding load of at least 140kg-150kg in the VKA-110.
  • Page 28 320kg, but fails the test at 340kg where welding occurs. The VKA weld point cannot always be based on to determine the suitability of a lubricant for gears subjected to extremely heavy wear. If required, the anti-wear properties of the lubricant must be tested with the VKA-110.

  • Page 29: Maintenance

    HIGH-PRESSURE GREASE. Use a grease gun to lubricate the spindle bearing every six months with high-pressure grease (small grease nipple is located at the back of the VKA-110). We recommend you use Klüber grease, Isoflex NBU 15, item no. 004026.

  • Page 30: Installation

    If in doubt, consult a structural engineer. 5.3 Space requirements If the VKA-110 comes with a table, you will need a floor area of about 1200mm x 700mm. The front of the VKA-110 must be freely accessible and provide sufficient space to load the balance scale bar.
  • Page 31 The cutters at the balance scale bar have very sharp edges that can cause severe cuts. Always wear protective gloves to install and/or transport the balance scale bar. 5.4.3.2 The balance scale bar The VKA-110 comes with adjusted balance scale bar. The adjustment is a life-long adjustment. Warning! Only the manufacturer can do adjustments!
  • Page 32 In the middle of the two-section push rod there is a load cell. Guide the red plug of this load cell through the lower rear bore hole (with thread) at the VKA-110 and connect it to the control cabinet before you install the balance scale bar. Now carefully screw in the grey-coloured cable guide (grey stopper) from the inside of the VKA housing.
  • Page 33 Warning! Insert the push rod with the longer upper section pointing upwards to avoid damage to the connecting cable. Oberteil = upper section Make sure that the cable of the load cell is not within the operating range of the balance scale bar.
  • Page 34 6. List / Drawing of the Spare Parts and Wear Parts / Assembly Drawing The scope of delivery of the VKA-110 includes a list (4 pages) with an associated drawing (no. H1-2.367/1) of all spare parts and wear parts as well as a drawing (no. H1-2.367) of the VKA-110 group compilation.