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joke EL 380 Instruction Manual

Single-disc flat lapping and polishing machine
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Single-disc Flat Lapping and Polishing Machine
EL 380

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  • Page 1 Single-disc Flat Lapping and Polishing Machine EL 380...
  • Page 2 Instruction Manual Single-disc Flat Lapping and Polishing Machine Type: EL 380 Sold by: joke Technology GmbH Asselborner Weg 14-16 D-51429 Bergisch Gladbach Telephone +49 (0) 22 04 / 8 39 - 0 Telefax: +49 (0) 22 04 / 8 39 - 60 Internet: www.joke.de...

  • Page 3: Table Of Contents

    Warranty / identification ............4-1 Machine overview ..............5-2 Technical data ................. 6-1 Operation / control ..............7-23 Troubleshooting ..............8-1 Care and maintenance ............. 9-1 Consumables ................10-1 Spare parts list ............... 11-1 Annex ................... 12-12 Page 1 - 1 EL 380...

  • Page 4: Notes On The Manual

    Please feel free to call our customer service department at any time should you encounter technical problems which are not dealt with in this manual: Telephone +49 (0) 2204/839-77 Telefax +49 (0) 2204/839-60. joke operating manual EL 380 Page 2 - 1...

  • Page 5: Safety Instructions

    Observe safety instructions on the machine and keep them legible. Stop the device immediately should you notice changes to the device or its operating behaviour that are relevant to its safety. Have these remedied by suitable specialists before restarting work. EL 380 Page 3 - 1...
  • Page 6 Spare parts must meet the technical requirements specified by the manufacturer. This can only be guaranteed with original JOKE ® spare parts. Any work on/with the device may only be carried out by qualified, appropriately trained and authorised personnel.

  • Page 7: Warranty / Identification

    If it is not, all warranty claims will be forfeited according to the terms of delivery. Machine identification The manufacturer’s code, type code,and series number can be found on the rear of the machine. joke operating manual EL 380 Page 4 - 1...

  • Page 8: Machine Overview

    Machine overview Purpose The joke single-disc flat lapping and polishing machines are intended for lapping, polishing or flat honing. Depending on the application, the machines are fitted with a lapping disc, polishing and lapping disc, solid grit disc or a carrier disc for stick-on polishing cloths.
  • Page 9 2 - Dressing rings 3 - Control cabinet and control box 4 – Screws for lapping disc fixting 5 - Machine table 6 - Screws for table height adjustment 7 - Roller yoke and guide rail EL 380 Page 5 - 2...

  • Page 10: Technical Data

    Technical data Technical data for EL 380 Number of dressing rings ............3 items Dressing ring internal Ø ............140 mm Lapping disc Ø ...............380 mm Lapping disc speed..............60 rpm Machine length without pneumatics........725 mm Machine height without pneumatics.........400 mm Machine height with pneumatics..........1075 mm Supply voltage ............

  • Page 11: Operation / Control

    Dressing rings, weights and lapping discs are precision parts! Handle them carefully and protect against damage. Securely grasp the machine by the bottom crossmembers and position the machine at the machine location. Figure 7.1 EL 380 Page 7 - 1...
  • Page 12 Operation / control EL 380 layout plan Dimensions in millimetres Fig. 7.2 Page 7 - 2 joke operating manual EL 380...
  • Page 13 (see Fig. 7.7). Plug the male connector on the machine connecting cable into a socket with the supply voltage specified in the tech. data. Pay attention to correct earthing! joke operating manual EL 380 Page 7 - 3...
  • Page 14 Degrease the dressing rings and lapping disc with a suitable medium. Apply the dressing rings to the lapping disc in the "neutral" position. Install the lapping medium tank with the pump and waste tank (see Fig. 7.5). joke operating manual EL 380 Page 7 - 4...
  • Page 15 Socket for Guide wire spraying unit Socket for lapping medium pump Dispensing screw Dispensing unit Flow from pump Return flow to lapping medium pump Lapping Drain medium tank with pump Figure 7.5 joke operating manual EL 380 Page 7 - 5...
  • Page 16 7 - 230 V socket for pendulum arm (permanent voltage in "ON" position of the main switch) 8 - 230 V socket for dispensing unit and pulse device activated via pump start (switched by means of "PUMP" start) 9 - Main switch Page joke operating manual EL 380 7 - 6...
  • Page 17 Operation / control Contact pressure device (optional equipment) The pneumatic contact pressure device is available for joke lapping machines of series „EL“ or as a retrofitting unit Structural diagram Figure 7.7 – Pneumatc cylinder - Clamping screws for cylinder retaining plate 3 –...
  • Page 18 It is generally determined empirically. (see chapter 12, annex 4.) Reduce travel speed for safety reasons! The cylinder travel speed is cut back to < 10cm/sec. for safety reasons. Page 7 - 8 joke operating manual EL 380...
  • Page 19 The mask is generally a hard paper disc with the internal dimension of the sealing ring and recesses for receiving the workpieces. Working receptacle bore Hard paper mask Fig. 7.9 joke operating manual EL 380 Page 7 - 9...
  • Page 20 Compensation washers (soft rubber material) should be placed between the workpieces and the contact pressure weights to compensate for any differences in dimensions of the individual workpieces/ring joke operating manual EL 380 Page 7 - 10...
  • Page 21 Observe max. lapping medium height. Lapping medium pump Maximum lapping medium filling level Lapping medium tank Impeller housing with partial flow holes for raising and mixing abrasive and carrier fluid Figure 7.11 joke operating manual EL 380 Page 7 - 11...
  • Page 22 Other time ranges 30 sec. - 3 min. - 30 min. - 3 hrs. may be set. Time range adjustable Time range adjustable Figure 7.12 Set the timer indicator to the desired lapping time. The indicator runs back to "0" and the machine switches off automatically. Page 7 - 12 joke operating manual EL 380...
  • Page 23 Selection of the appropriate polishing and lapping disc in conjunction with the diamond suspension (grit size) is made based on the desired process results. Our application technology department, tel. 02204/ 839 - 77 is at your disposal for recommendations concerning processing. Page 7 - 13 joke operating manual EL 380...
  • Page 24 Screw the glass vessel under the dispensing device. Dispensing device Diamond emulsion Figure 7.13 Connect the dispensing device to air and electric power. Input air (from Maintenance unit) max. 4 bars To control cabinet Figure 7.14 Page 7 - 14 joke operating manual EL 380...
  • Page 25 Solenoid valves are activated via timers and the compressed air initiates the spraying process by means of the spray arm equipped with 2 jets. Page 7 - 15 joke operating manual EL 380...
  • Page 26 Projecting burrs on the workpiece result in corresponding grooves in the polishing and lapping disc coating. Ensure burr-free workpieces joke operating manual EL 380 Page 7 - 16...
  • Page 27 All traces of the previous grinding medium must be removed when changing the polishing and lapping discs and the diamond suspension. Polishing and lapping discs must be stored flat (level). Page 7 - 17 joke operating manual EL 380...
  • Page 28 The operating pressure for the spraying unit is 0.5 - 1.0 bars. Tip: Flush the diamond suspension line with fluid in case of more prolonged stoppage! joke operating manual EL 380 Page 7 - 18...
  • Page 29 Flatness testing by means of a workshop flat ruler and thin paper • (e.g. cigarette paper): Flat ruler Paper Lapping disc Figure 7.17 joke operating manual EL 380 Page 7 - 19...
  • Page 30 Plane glass Test block Test block Light band Figure 7.18 Light band This test block is This test block is 3 light bands, convex. 1 light band, concave. joke operating manual EL 380...
  • Page 31 "Interference testing devices". Dressing the polishing and lapping disc using the diamond dressing block Lapping machine dressing block Diamond dressing block Polishing and lapping coating Figure 7.20 joke operating manual EL 380 Page 7 - 21...
  • Page 32 • over the edge of the lapping disc during dressing. If this is not observed, the pellets may become detached or a recess may occur on the polishing and lapping disc! Page 7 - 22 joke operating manual EL 380...
  • Page 33 When the surface of the part to be tested is absolutely flat, the bands are uneven. straight and parallel. If the bands are curved, the surface is - Details: see brochure. For detailed information, see special information on "Interference testing ". devices Page 7 - 23 joke operating manual EL 380...

  • Page 34: Troubleshooting

    Troubleshooting See annex: Observe manufacturer’s instructions for geared motor and control unit. joke operating manual EL 380 Page 8 - 1...

  • Page 35: Care And Maintenance

    During machine stoppage, it is expedient to cover the lapping plate (e.g. with film) in order to avoid contamination. Do not cover polishing cloths with film. Contamination on the lapping disc results in scratches on the lapped surface. joke operating manual EL 380 Page 9 - 1...

  • Page 36: Consumables

    Consumables Detailed documents concerning Lapping and polishing media, Lapping and polishing discs, Dressing rings and similar refer to joke polishing and lapping system brochure. Page 10 - 1 joke operating manual EL 380...
  • Page 37 Three-phase motor 0.55 KW, 1500 l/min 32003670 Worm gear ZAE-E63/30:1 32004223 Immersion pump KTA 25/220 3635113 Pump mounting 517-205-3 3635114 Lapping medium tank 517-204-2 3635114 Waste tank 517-204-2 3635116 Castor, cpl. 517-032-4 31730955 O-ring OR28.00-3.00 Page 11 - 1 joke operating manual EL 380...
  • Page 38 Spare parts Spare parts for EL 380 Pos. Sach-Nr. Bezeichnung Menge 32003622 31730206 Flanschlager FLCTE 17 32003623 31730009 Rillenkugellager 6000 2RS 32004218 32004219 32003647 Dosierblock 517-202-2 3635132 31730950 O-Ring, Dosierschraube OR 5.00-1,20 32002825 Schlauch, klar PVC-NW8x2 31722531 Schlauch, schwarz PU-6...
  • Page 39 Hex spud Dispensing block, cpl. Dispensing screw O-ring, dispensing screw Hose, transparent Hose, black Sealing washer Dripper Guide wire Dispensing block, cpl. Clamping lever Pneum. cylinder Star handle screw Yoke Yoke holder, standard Yoke holder, pneumatic joke operating manual EL 380...
  • Page 40 Spare parts Figure 11.1 Page 11 - 3 joke operating manual EL 380...

  • Page 41: Annex

    Annex Dispensing device (option) Spraying unit 1a - old version 809-B Spraying unit new version S1-08 Control unit (Lenze) Gear ZAE Lapping pressure EL 380 with contact pressure device Page 12 - 1 joke operating manual EL 380...
  • Page 42 Fuse holder - stirrer motor Fuse holder - control circuit Compressed-air connection, 3 bars Compressed-air hose connection for diamond emulsion Compressed-air hose connection for fluid Connecting hose to spray arm Connecting hose to spray arm Page 12 - 2 joke operating manual EL 380...
  • Page 43 Annex Enclosure 1 Figure 12.1 Page 12 - 3 joke operating manual EL 380...
  • Page 44 Time for spraying Syrelec JDR process Diamond emulsion 31710844 Circular plug, old Voltage supply Spannungsversorgung 32005358 Square plug, new permanently 31710844 Circular plug, old Voltage supply 32005358 Square plug, new activated via Machine joke Technology GmbH EL 380 Page 12 - 4...
  • Page 45 Illuminated pushbutton, yellow 3645828 Illuminated pushbutton, red with scale 32005358 Plug connector 250 V, 10A 32005358 Plug connector 250 V, 10A 3645835 Solenoid valve for spraying unit 3645835 Solenoid valve for spraying unit Page 12 - 5 joke operating manual EL 380...
  • Page 46 Annex Enclosure 1a – Spraying unit 809B Bild 12.2 Page 12 - 6 joke operating manual EL 380...
  • Page 47 Annex Enclosure 1b – Spraying unit S1-08 Page 12 - 7 joke operating manual EL 380...
  • Page 48 Annex Enclosure 1 Bild 12.3 Control unit (Lenze) The speed of the drive motor is infinitely adjustable in conjunction with a frequency converter. Page 12 - 8 joke operating manual EL 380...
  • Page 49 EL 380 Series 8200; type 8202E.V002 2005318 The frequency converters are optimally configured by JOKE and are maintenance-free. Speed control is performed by a potentiometer incorporated in the control cabinet. The operating module of the frequency converter displays an error message in case of a failure.
  • Page 50 More   t han   8   e rror   m essages   w ithin   According   t o   t he   e rror   m essage   reset   10   m inutes   displayed   EL 380...
  • Page 51 In   c ase   o f   m ore   t han   8   a uto   T RIP   r esets   w ithin   1 0   m inutes,   t he   d rive   c ontroller   s ets   TRIP   w ith   t he   m essage   r ST   ( timer   e xceeded).   Page 12 - 10 joke operating manual EL 380...
  • Page 52 Low-voltage motors are components for installation in machinery in the sense of the Machinery Directive 89/392/EEC. Commissioning is forbidden until compliance of the final product with this directive has been established (observe EN 60204-1). Page 12 - 12 joke operating manual EL 380...
  • Page 53 The connection must ensure a continuous and safe electrical connection (no protruding wire ends); use appropriate cable terminals. Establish a safe protective earth connection. Page 12 - 13 joke operating manual EL 380...
  • Page 54 Pay particular attention in this case to: unusual noises or temperatures loss of seal loose attachment elements the condition of the electrical leads. If the fault cannot be remedied, please inform the JOKE customer service department. Page 12 - 14 joke operating manual EL 380...
  • Page 55 Tel. +49 (0) 22 04 / 8 39 – 0 Fax +49 (0) 22 04 / 8 39 – 60 info@joke.de www.joke.de Lapping pressure EL 380 with contact pressure device Calculation example: Workpiece to be polished 85x85mm: area 8.5x8.5cm theor. contact pressure: 200g/cm²...

This manual is also suitable for:

El 380/n3635021-2

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