STEINEL S-Former E1 Instruction Manual
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STEINEL S-Former E1 Instruction Manual

STEINEL S-Former E1 Instruction Manual

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Tapping unit
S-Former E1
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Summary of Contents for STEINEL S-Former E1

  • Page 1 Instruction manual Tapping unit S-Former E1 Original instruction manual...
  • Page 3 Instruction manual Tapping unit S-Former E1 Original instruction manual...
  • Page 4  by Steinel Normalien AG, 08/2013 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.

  • Page 5: Table Of Contents

    (for the operator and technical supervisor) Index Content Operating instructions (OI) Chapter Content Introduction Safety instructions Functional description Device description Installation manual Shipping, storage and assembly Operation Maintenance Technical data Main parts list and drawings Error messages Disposal IM Tapping unit S-Former E1...
  • Page 6 Table of contents (IM) IM Tapping unit S-Former E1...

  • Page 7: Introduction

    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.
  • Page 8  Providing a safe working environment is solely the responsibility of the owner. ( OI, Chapter 2, Safety instructions) IM Tapping unit S-Former E1...
  • Page 9 Qualification Completed professional training machine engineering/technician Completed professional training electrical engineering/mechatronics Qualified person Worker (trained and briefed) [x] Permitted [-] Not permitted/prohibited IM Tapping unit S-Former E1...
  • Page 10 EC machine directive and that it conforms to national standards in its current condi- tion. Fig. 1-1 Tapping unit S-Former E1 IM Tapping unit S-Former E1...
  • Page 11 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 IM Tapping unit S-Former E1...
  • Page 12 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 IM Tapping unit S-Former E1...
  • Page 13 Only operate the device with approved tapping tools. Minimum: Maximum: 1 min. M4/max. M8 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 IM Tapping unit S-Former E1...
  • Page 14 – 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. IM Tapping unit S-Former E1...
  • Page 15 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) IM Tapping unit S-Former E1...
  • Page 16 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". IM Tapping unit S-Former E1...

  • Page 17: Technical Data

    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. IM Tapping unit S-Former E1...
  • Page 18 2 Technical data IM Tapping unit S-Former E1...

  • Page 19: Disposal

    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. IM Tapping unit S-Former E1...
  • Page 20 – 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 IM Tapping unit S-Former E1...
  • Page 21 – Plastics (cover plates, films) Disposal of cleaning agents Cleaning agent residues or soaked rags must be disposed of in an environmentally friendly manner according to the local regulations and laws that apply at the time of disposal. IM Tapping unit S-Former E1...
  • Page 22 3 Disposal IM Tapping unit S-Former E1...

  • Page 23: List Of Signatures

    Per- sons who do not confirm this with their signature are not authorised to work with the product!  Then file the list with your other documents. IM Tapping unit S-Former E1...
  • Page 24 – the function, – operation, – maintenance, cleaning, – and the installation of the tapping unit and that they have read and understood the safety instructions and operating instructions. Participant Date Instructor Name Signature (Date, Signature) IM Tapping unit S-Former E1...
  • Page 25 Instruction manual Tapping unit S-Former E1 Original instruction manual...
  • Page 26  by Steinel Normalien AG, 08/2013 Diese Dokumentation ist ausschließlich für das Bedienungs- und Wartungs- 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.

  • Page 27: Operating Instructions (Oi)

    (for the operator and technical supervisor) Index Content Operating instructions (OI) Chapter Content Introduction Safety instructions Functional description Device description Installation manual Shipping, storage and assembly Operation Maintenance Technical data Main parts list and drawings Error messages Disposal OI Tapping unit S-Former E1...
  • Page 28 Table of contents (OI) OI Tapping unit S-Former E1...
  • Page 29 Table of contents (OI) OI Tapping unit S-Former E1...
  • Page 30 Table of contents (OI) OI Tapping unit S-Former E1...

  • Page 31: Introduction

     Commissioning: only by qualified personnel with wide-ranging expertise in the areas of electrical engineering/drive technology. The qualified personnel must have knowledge of and observe the following stand- ards:  IEC 60364 or IEC 60664.  national accident prevention regulations. OI Tapping unit S-Former E1...
  • Page 32  Shut down the tapping unit as soon as a safety threat emerges! Make sure the machine cannot be restarted and immediately notify the owner! OI Tapping unit S-Former E1...
  • Page 33 OI Tapping unit S-Former E1...
  • Page 34 1 Introduction Qualification Completed professional training machine engineering/technician Completed professional training electrical engineering/mechatronics Qualified person Worker (trained and briefed) [x] Permitted [-] Not permitted/prohibited OI Tapping unit S-Former E1...
  • Page 35 EC machine directive and that it conforms to the respective national standards in its current condition. Fig. 1-1 Tapping unit S-Former E1 OI Tapping unit S-Former E1...
  • Page 36 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 Machinery Directive 2006/42/EC. Fig. 1-3 Example 2 Protective device OI Tapping unit S-Former E1...
  • Page 37 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 OI Tapping unit S-Former E1...
  • Page 38 Only operate the device with approved tapping tools. Minimum: Maximum: 1 min. M4/max. M8 Fig. 1-5 Application field tapping tool 1.7.2.4 Operating the device with faulty connected loads Only operate the system with approved connected loads. See  Chapter 10, Technical data OI Tapping unit S-Former E1...
  • Page 39 It is imperative that you pay attention to these texts and carry out the preven- tative countermeasures! OI Tapping unit S-Former E1...
  • Page 40 Specific danger symbols Warns of dangerous voltage or dangerous electrical current! Warns of mechanical movements or injuries to the hand! Warns of risk of being drawn in! Warns of hot surfaces! Warns of injuries through cuts! OI Tapping unit S-Former E1...
  • Page 41  Use ear protection!  Pull the plug to the mains power supply!  Use safety gloves for protection against mechanical risks according to EN 388 Category II!  Use protection class S1 safety footwear! OI Tapping unit S-Former E1...
  • Page 42 Operation of the tapping unit as well as maintenance and repair tasks may only be performed by authorised personnel (1.6 Definition qualified person/ authorised personnel). The operator must ensure that they are the only ones operating the tapping unit and that it is safeguarded against use by third parties. OI Tapping unit S-Former E1...
  • Page 43 Please refer to  Chapter 2.5, Personal protective equipment for the specifica- tions of the protective equipment. OI Tapping unit S-Former E1...
  • Page 44 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) OI Tapping unit S-Former E1...

  • Page 45: Safety Instructions

    We – the manufacturer – fulfil this obligation with the descriptions contained in this product manual in general and with this chapter in particular. Products from other manufacturers that are needed for operation are installed in this tapping unit. These third-party instructions must therefore also be observed! OI Tapping unit S-Former E1...
  • Page 46 – that all parts and fixings are firmly secured! – the tightness of pneumatic valves and connections!  Do not commission a tapping unit if its operational reliability/safety can- not be guaranteed! OI Tapping unit S-Former E1...
  • Page 47  Use the appropriate personal protective equipment (e.g. safety goggles) for all tasks!  Never remove pressurised tubes! Fig. 2-1 Danger areas OI Tapping unit S-Former E1...
  • Page 48 Only perform work at the tapping unit when compressed air and electric power have been switched off and the device has come to a complete stand- still. Fig. 2-2 Risk of injury from the tapping tool OI Tapping unit S-Former E1...
  • Page 49 The toothed belt can catch body parts and cause severe crushing injuries. Only perform work at the tapping unit when the compressed air and electric power have been switched off and the device has come to a complete stand- still. OI Tapping unit S-Former E1...
  • Page 50  The tapping unit includes mechanisms for disconnecting electrical and/or pneumatic energy.  The disconnection of electrical power is carried out via an electrical main switch.  The disconnection of pneumatic energy is carried out via a ball valve. OI Tapping unit S-Former E1...
  • Page 51 With regard to the recurring inspections, the regulations of the "Operational safety directive (BetrSichV) according to § 10" and the regulations of the "Technical rules for operational safety (TRBS 1201)" must be observed. OI Tapping unit S-Former E1...
  • Page 52  If you did swallow or inhale one of these media or if it has come into contact with your skin or eyes, immediately see a doctor! Immediately notify co-workers and the doctor of how and when you came into contact with the medium.  Please observe the material safety data sheet. OI Tapping unit S-Former E1...
  • Page 53 (e.g. hair net, tight fitting clothing, safety helmet, safety mask, gloves, protective footwear, etc.)!  Do not reach into the danger areas of the tapping unit with an extension piece or other items!  Observe the hazard symbols attached to the tapping unit! OI Tapping unit S-Former E1...
  • Page 54 When, after switching off, the tapping unit continues to operate, the area sur- rounding the tapping unit must be closed off and the person in charge must be notified. Troubleshooting and repairs may only be performed by electrotechnical ex- perts. OI Tapping unit S-Former E1...
  • Page 55  Be aware of your surroundings when working with the tapping unit and immedi- ately stop working and notify the person in charge if such a danger materialises.  If necessary, evacuate the danger area. OI Tapping unit S-Former E1...
  • Page 56 These requirements are laid out in the current mate- rial safety data sheet (MSDS). The owner is legally obligated to implement the respective measures. OI Tapping unit S-Former E1...
  • Page 57 – and during operation, – maintenance, cleaning and repairs, protection class S1 safety footwear according to IEC 61310 must be worn. 2.5.2 Safety gloves When performing tasks, wear safety gloves according to EN 388 Category II! OI Tapping unit S-Former E1...
  • Page 58 2 Safety instructions OI Tapping unit S-Former E1...
  • Page 59 3 Shipping, storage and assembly Shipping, storage and assembly Check the tapping unit for transit damage immediately after delivery. The shipping company, the insurance company and STEINEL Normalien AG must be notified of transit damage immediately. Unpacking Check the unit for transit damage immediately after delivery.
  • Page 60 (e.g. for maintenance purposes or servicing).  Make sure that there is sufficient space for tapping unit maintenance and servic- ing.  Make sure that the tapping unit is only operated in an area without external magnetic fields. OI Tapping unit S-Former E1...
  • Page 61 A Synchronous shaft B Main shaft C Pneumatic lifting cylinder D Analogue position sensor E Roll taps F Belt tensioner G Pneumatic line H AC Servodrive I Toothed belt J Drive shaft Fig. 4-1 Tapping unit OI Tapping unit S-Former E1...
  • Page 62 A tapping unit is connected to the control cabinet as follows: 1 Control cabinet/control unit 2 Connecting cable S-Former E 3 Connection box S-Former E 4 Motor cable 5 Resolver connecting cable 6 Tapping unit Fig. 4-2 Connection of the components OI Tapping unit S-Former E1...
  • Page 63 Roll tap with lubrication grooves ATTENTION! The in-house calculation of STEINEL Normalien AG applies to roll taps with the gating cone shape C (according to DIN 2175). If another type is used, a safe and reliable process cannot be guaranteed. In this case, please contact STEINEL Normalien AG.
  • Page 64 4 Device description OI Tapping unit S-Former E1...

  • Page 65: Functional Description

    The pneumatic cylinder moves into its working position until the tapping tool has reached the borehole. The magnetic valve is vented and the stroke movement switched off. Step 3 The tapping tool forms the thread. OI Tapping unit S-Former E1...
  • Page 66  If a tapping tool is worn out, the unit is stopped and the error message St.X roll tap defect/NOK displayed. Control program design For information regarding the control unit, please consult the control cabinet product manual. OI Tapping unit S-Former E1...

  • Page 67: Installation Manual

    – Make sure that the cover is accessible after the tapping unit has been installed. – Make sure that there is enough space to perform maintenance and servicing tasks. – Make sure that the tapping unit is only operated in an area without external magnetic fields. OI Tapping unit S-Former E1...
  • Page 68 1 Ø 5 mm (8 deep) for cylinder pin ISO 2338 – 5m6 x 16 - St 2 Through hole Ø 5.5 mm for socket-head screw ISO 4762 – M5 x 75 – 8.8 Fig. 6-1 Mechanical integration I OI Tapping unit S-Former E1...
  • Page 69 6 Installation manual 1 5 x M5 (10 deep) 2 3 x Ø 5 mm (10 deep) for cylinder pin ISO 2338 – 5m6 x 20 – St Fig. 6-2 Mechanical integration II OI Tapping unit S-Former E1...
  • Page 70 6 Installation manual OI Tapping unit S-Former E1...

  • Page 71: Operation

    The distance between the tip of the tapping tool and the part should be approx. 2 1 2 mm Fig. 7-1 Distance between the tip of the tapping tool and the part OI Tapping unit S-Former E1...
  • Page 72 Step 1 Fig. 7-2 Step 1  Keep the supporting ring in position with an open ended wrench SW22.  Loosen the clamping set with the hook wrench.  Remove tapping tool, clamping set and reduction. OI Tapping unit S-Former E1...
  • Page 73  Insert reduction (A) into the mounting bore until it reaches the end stop.  Insert tapping tool (C) into clamping set (B & D).  Insert clamping set (B & D) into the reduction (A). OI Tapping unit S-Former E1...
  • Page 74 (as long as the same type of tapping tool is used)! If a tapping tool with a different length is installed, it is important to make sure that the measuring range of the analogue sensor covers the piston stroke. OI Tapping unit S-Former E1...
  • Page 75 30% at 4,000m above sea level 55% at 5,000m above sea level Temperature limiter The maximum permissible The nominal power of activated ambient temperature has the tapping unit must been exceeded. be reduced if OI Tapping unit S-Former E1...
  • Page 76 8 Malfunctions & fault finding temperatures are too high or the installation height is greater than 1,000 m above sea level. OI Tapping unit S-Former E1...
  • Page 77  Mark the entire system (e.g. the press) with a sign to prevent accidental opera- tion.  Secure the entire system against restarting. OI Tapping unit S-Former E1...
  • Page 78 Product manual Disposal of cleaning agents Cleaning agent residues or soaked rags must be disposed of in an environmentally friendly manner according to the local regulations and laws that apply at the time of disposal. OI Tapping unit S-Former E1...
  • Page 79 9 Maintenance and cleaning Maintenance schedule OI Tapping unit S-Former E1...
  • Page 80 Only perform work at the tapping unit when the compressed air and electric power have been switched off and the device has come to a complete stand- still. Medium Identifying information Article IsoFlex Super LDS18 K300-001-1891 OI Tapping unit S-Former E1...
  • Page 81 9 Maintenance and cleaning Fig. 9-1 Step 1  Lubricate spindle with special grease IsoFlex Super LDS18 (K300-001-1891). OI Tapping unit S-Former E1...
  • Page 82 Risk of injury from high surface temperature WARNING! The surface temperature of the motor in operation can exceed 100°C. Allow the components to cool down to the ambient temperature prior to per- forming maintenance tasks at the device. OI Tapping unit S-Former E1...
  • Page 83 9 Maintenance and cleaning Step 1 Fig. 9-2 Step 1  Remove the 4 socket-head screws M5x10 (A) along with the shims.  Remove cover (B). OI Tapping unit S-Former E1...
  • Page 84  Loosen the 4 hexagon head screws M6x20 (C) ATTENTION! In case of a defect, please contact STEINEL Normalien AG. A repair or a replacement of components may only be performed by trained per- sonnel of STEINEL Normalien AG .

  • Page 85: Technical Data

    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. OI Tapping unit S-Former E1...
  • Page 86 10 Technical data OI Tapping unit S-Former E1...

  • Page 87: Main Parts List And Drawings

    Chapter 9, Maintenance and Cleaning without fail. Parts other than those listed here may only be replaced/repaired by skilled person- nel of STEINEL Normalien AG. In this case, please contact STEINEL Normalien AG. ??? (German: view with cover) ??? (German: view without cover) Z Pos.
  • Page 88 11 Main parts list and drawings 11.1 Drawing OI Tapping unit S-Former E1...
  • Page 89 Collet M6 K300-01-1520 Collet M8 K300-001-1180 Clamping nut (M3 – M8) SZ8871.01-1109 Spindle long (M3 – M8) K300-001-1922 Hook wrench (M1 – M4) K300-001-1770 Wrench (M3 – M8) Upon request Roll tap, different versions available OI Tapping unit S-Former E1...
  • Page 90 11 Main parts list and drawings OI Tapping unit S-Former E1...

  • Page 91: Disposal

    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. OI Tapping unit S-Former E1...
  • Page 92 – 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 OI Tapping unit S-Former E1...
  • Page 93 – Steel (bearing, mounting materials such as screws, etc.) – Synthetic material (control units, tubes, casings, etc.) – Rubber (seals, silicone tubes) – Electrical material (cables, components) – Electronic material (circuit boards, PLC) – Plastics (cover plates, films) OI Tapping unit S-Former E1...
  • Page 94 12 Disposal OI Tapping unit S-Former E1...
  • Page 95 Thank you for your suggestions! Chapter Page Comments, suggestions, ideas for improvement Note: Suggestions you send in become the intellectual property of STEINEL Normalien AG Please send a fax to: STEINEL Normalien AG Winkelstrasse 7 78056 Villingen-Schwenningen Germany Tel.:...
  • Page 96 13 Feedback form OI Tapping unit S-Former E1...

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