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- Page 1 OPERATING INSTRUCTIONS Safety instructions Safety Precautions and Technical Details CNC Lathes DAA007EN - 11.05.2021 0521/Ku (Sicherheitshinweise und Technische Angaben) - 20081220...
- Page 2 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...
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Page 3: Table Of Contents
TABLE OF CONTENTS 1 Explanation of symbols ..........................5 1.1 Symbols used in the user documentation ....................5 1.2 Information and safety instructions on the machine ................... 5 2 General instructions for safe operation ....................6 2.1 Obligations of the operator/owner ........................ 6 2.2 Personnel obligations ............................ - Page 4 TABLE OF CONTENTS 4.3 Chip conveyor .............................. 27 4.3.1 Machine without chip conveyor ....................... 28 4.4 Work on electrical components ......................... 29 4.5 Prevention of burns and scalds ........................30 4.6 Conduct around noise ..........................30 4.7 Conduct around laser radiation ........................30 4.8 Handling of operating fluids and auxiliary materials...................
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Page 5: Explanation Of Symbols
ExPLANATION OF SymBOLS 1 Explanation of symbols 1.1 Symbols used in the user documentation This chapter 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. -
Page 6: General Instructions For Safe Operation
GENERAL INSTRUCTIONS FOR SAFE OPERATION 2 General instructions for safe operation 2.1 Obligations of the operator/owner The operator/owner must ensure that all the specified limits, ambient conditions, and clearances in the vicinity of the machine are observed at the place of installation. Prior to commencing operation of the machine: •... -
Page 7: Requirements For Personnel Selection And Qualifications
GENERAL INSTRUCTIONS FOR SAFE OPERATION 2.3 Requirements for personnel selection and qualifications 2.3.1 Definition of “qualified employee”/“qualified personnel” A qualified employee is capable, on the basis of their relevant professional educa- tion, training and/or experience, to recognize risks and to avoid possible hazards that arise when using the product. - Page 8 GENERAL INSTRUCTIONS FOR SAFE OPERATION Service and repair personnel • Trained and qualified employees • Specialized training by the machine manufacturer Decommissioning/storage personnel • Trained and qualified employees Disposal personnel • Trained and qualified employees Expert • A person who has sufficient knowledge of the machine based on professional training and experience and who is familiar with all regulations, thereby enabling evaluation of the inspected machine with regard to occupational safety.
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Page 9: Intended Use Of The Machine
GENERAL INSTRUCTIONS FOR SAFE OPERATION 2.4 Intended use of the machine The machine has been designed mainly for cold working of common metallic mate- rials without requiring access to the work area during machining. The machine is intended exclusively for use in an industrial environment. The machine has been designed and constructed in accordance with current best practices and generally recognized safety rules. -
Page 10: Reasonably Foreseeable Misuse Of The Machine
Therefore, the operator/owner must not make any modifications or additions to the hardware or software of the machine without the written approval of INDEX-Werke GmbH & Co. KG. Modifications approved by the manufacturer must be documented in a retraceable manner. -
Page 11: Spare Parts And Accessories
The use of original spare parts and accessories is recommended. For damages caused by the use of parts from third-party providers, liability and warranty are excluded. If you have any questions or doubts, contact INDEX-Werke GmbH & Co. KG. Doing so could prevent major damage. 2.8 Repairs The operator/owner's employees may only carry out maintenance and repair work to the extent described in the user documentation. -
Page 12: Workspace Of The Operator
GENERAL INSTRUCTIONS FOR SAFE OPERATION 2.9 Workspace of the operator It is recommended that a working area of at least 1 m is kept free around the ma- chine (including attached units) for operator activities. Workspaces can vary depending on the activity. The following activities, among others, can occur during production: •... -
Page 13: Spatial Allocation In The Workspace
GENERAL INSTRUCTIONS FOR SAFE OPERATION 2.9.1 Spatial allocation in the workspace Rear Left Bar feeder Right Multi-spindle lathe Front Spatial allocation of a multi-spindle lathe, example Rear Single-spindle lathe Left Bar feeder Right Front Spatial allocation of a single-spindle lathe, example Rear Sliding headstock machine Bar feeder... -
Page 14: Personal Protective Equipment
GENERAL INSTRUCTIONS FOR SAFE OPERATION 2.10 Personal protective equipment The machine operator/owner must provide personal protective equipment. The operator/owner's safety representative should be consulted regarding the use of personal protective equipment. Personal protective equipment required depending on the specific activity: •... -
Page 15: And Data Security
GENERAL INSTRUCTIONS FOR SAFE OPERATION 2.12 IT and data security Direct access to the production network should be protected by a firewall and hence according to the current IT security standards. Nevertheless, it is the operator’s responsibility to verify that the measures taken in the existing network are sufficient. External data storage media as well as maintenance and service devices represent basic security risks. -
Page 16: Safety Functions And Safety Equipment
SAFETy FUNCTIONS ANd SAFETy EqUIPmENT 3 Safety functions and safety equipment Some machine components, aside from their technical functions, also fulfill a safety function that is designed to protect personnel from dangers at the machine. For this reason, safety functions must not be tampered with, disabled or removed. In case of damage to or failure of safety functions or equipment, the machine must be shut down immediately. -
Page 17: Emergency Stop
SAFETy FUNCTIONS ANd SAFETy EqUIPmENT 3.2 EMERGENCY STOP EMERGENCY STOP device, example EMERGENCY STOP devices are located at every operator position and should be actuated when human life is in danger. When actuated, all hazardous movements are switched off as quickly as possible and a safe state is established. -
Page 18: Work Area Enclosure And Work Area Door
SAFETy FUNCTIONS ANd SAFETy EqUIPmENT 3.3 Work area enclosure and work area door The work area enclosure and work area door are safety partitions. During setup and production of workpieces, it is possible for machine parts or work- pieces to accidentally come loose and be thrown around. If this happens, the safety partition protects the personnel at the machine against dangers resulting from this situation. -
Page 19: Window Pane(S)
SAFETy FUNCTIONS ANd SAFETy EqUIPmENT 3.4 Window pane(s) The work area door is fitted with window panes. These window panes have the required resistance class and provide: • A view of the machining process • Protection from objects that may be thrown out, e.g., chips, tools, or broken-off parts of workpieces •... -
Page 20: Pneumatic Safety Valve (Optional)
SAFETy FUNCTIONS ANd SAFETy EqUIPmENT 3.7 Pneumatic safety valve (optional) If compressed air is used in the machine, the machine will feature a compressed air maintenance unit with pressure regulating valve, including a pressure gauge to display the system pressure (for setting the operating pressure), an electric switch- on and shut-off valve, and a manual switch-on and shut-off valve to separate the machine from the compressed air supply (customer's air network). -
Page 21: Pressure Tanks
SAFETy FUNCTIONS ANd SAFETy EqUIPmENT 3.11 Pressure tanks According to the Pressure Equipment Directive 2014/68/EU, the pressure accumula- tors built into the machine are of category I / module A. They are CE marked by the manufacturer, and a declaration of conformity has been issued. -
Page 22: Instructions For Safety-Conscious Work
INSTRUCTIONS FOR SAFETy-CONSCIOUS wORk 4 Instructions for safety-conscious work All specifications in the user documentation as well as the applicable directives and regulations must always be observed. For integrated com- ponents made by third parties, the user documentation of the respective manufacturers must be observed as well. -
Page 23: Clamping Pressure And Clamping Force
INSTRUCTIONS FOR SAFETy-CONSCIOUS wORk 4.1.2 Clamping pressure and clamping force The required clamping force must be determined based on applicable directives and regulations. The actuation forces of the clamping system and the centrifugal forces acting on the clamping device must be taken into consideration in determining the clamping force required. -
Page 24: Chuck And Jaws
INSTRUCTIONS FOR SAFETy-CONSCIOUS wORk 4.1.3 Chuck and jaws When a part is being placed in a chuck, there is a risk that fingers will be crushed between the jaws and the part. In general: • The original mounting means of the clamping device manufacturer must be used to mount the jaws. -
Page 25: Machining Of Bar Stock
Manual loading of short bars is only permitted if this is carried out through a secured feed opening on the machine side. INDEX offers suitable solutions for this. The machine-specific max. dimensions of the bar stock must be observed. -
Page 26: Handling Of Tools
INSTRUCTIONS FOR SAFETy-CONSCIOUS wORk 4.2 Handling of tools 4.2.1 Changing tools When tools are changed, there is a risk of injury from protruding and sharp-edged tools. In general: • Suitable personal safety equipment must be used. • Tool carriers must be moved to an ergonomically convenient position. •... -
Page 27: Chip Conveyor
INSTRUCTIONS FOR SAFETy-CONSCIOUS wORk 4.3 Chip conveyor The chips resulting from the machining are transported by a chip conveyor from the work area to a collection bin. The chip conveyor has a conveyor belt that transports the chips sideways and upward, so they can be dropped into the collection bin. The chip conveyor does not transport the chips continuously out of the work area, but at (adjustable) intervals. -
Page 28: Machine Without Chip Conveyor
INSTRUCTIONS FOR SAFETy-CONSCIOUS wORk 4.3.1 Machine without chip conveyor Before commissioning a machine without a chip conveyor (e.g., with centralized chip removal), the operator/owner must provide a safe and environmentally friendly option for chip removal. When operating a machine without a chip conveyor, hazards arise at the mechanical interface. -
Page 29: Work On Electrical Components
INSTRUCTIONS FOR SAFETy-CONSCIOUS wORk 4.4 Work on electrical components Improper practices when working on the electrical equipment of the machine may result in death or serious injury. All work on the electrical equipment must be carried out exclusively by properly trained and instructed qualified personnel. -
Page 30: Prevention Of Burns And Scalds
INSTRUCTIONS FOR SAFETy-CONSCIOUS wORk 4.5 Prevention of burns and scalds Before starting work on the machine, disconnect it safely from the power supply, depressurize it, and allow it to cool down, as operating fluids may heat up and parts located under covers may be hot. If necessary, use suitable protective gloves for heated parts. -
Page 31: Handling Of Operating Fluids And Auxiliary Materials
An exhaust system is optionally available and can be obtained—together with the machine—from INDEX. The defined interface to the exhaust system is to be used. Follow the supplier documentation and the drawing provided. Safety Precautions and Technical Details... -
Page 32: Fire Protection
FIRE PROTECTION 5 Fire protection 5.1 Fire risks The operator/owner is generally responsible for preventing fires/explosions. The operator should establish the required measures in consultation with the appro- priate bodies (e.g., occupational health and safety organizations, fire safety engineer, fire brigade). High heat generation, open fire or other ignition sources (e.g. -
Page 33: General Fire Safety Measures
FIRE PROTECTION 5.2 General fire safety measures The operator/owner is responsible for following the applicable regulations and direc- tives for fire safety and to train the personnel for an emergency. A fire extinguishing system does not relieve the operator/owner from the usual pre- ventive or defensive measures in case of fires. -
Page 34: Fire Extinguishing System For Cooling Lubricant Fires
5.3 Fire extinguishing system for cooling lubricant fires After consultation with the customer, INDEX-Werke GmbH & Co. KG will equip machines with a fire extinguishing system to extinguish cooling lubricant fires if this is required for the machine's expected use. -
Page 35: Central Extraction System
FIRE PROTECTION 5.4 Central extraction system If the machine is connected to a central extraction system, the interaction with sub- stances that are processed or used in other connected machines must be checked. For assembly and tolerance reasons, a flexible pipe section is often installed be- tween the central extraction system and the machine. -
Page 36: Safety Instructions For Different Life Phases
SAFETy INSTRUCTIONS FOR dIFFERENT LIFE PhASES 6 Safety instructions for different life phases The phases of the machine's lifecycle are: • Transport and packing • Setup, installation, and commissioning • Setup mode • Operation (production mode) • Maintenance, service, and repair •... -
Page 37: Setup, Installation, And Commissioning
SAFETy INSTRUCTIONS FOR dIFFERENT LIFE PhASES 6.2 Setup, installation, and commissioning The load-carrying capacity of the floor must be observed. It must be chosen such that, when the machine is installed, the machine legs do not rest on openings in the floor (e.g., manhole covers) and there are no crushing or shearing points around the machine. -
Page 38: Setup Mode
SAFETy INSTRUCTIONS FOR dIFFERENT LIFE PhASES 6.3 Setup mode Setup mode allows movements at reduced speeds with the work area door open, which may pose a certain risk. To reduce the risk, the following measures are required: • The work area door should be kept closed as much as possible, especially during workpiece and tool movements. -
Page 39: Operation (Production Mode)
SAFETy INSTRUCTIONS FOR dIFFERENT LIFE PhASES 6.4 Operation (production mode) Operation of the machine requires a detailed analysis and assessment of the planned production process in terms of the risks and hazards that may be caused by it, such as the risks arising from the cooling lubricant or the material. •... -
Page 40: Maintenance, Service, And Repair
SAFETy INSTRUCTIONS FOR dIFFERENT LIFE PhASES 6.5 Maintenance, service, and repair Maintenance and repair work is to be performed only by authorized and trained personnel. This applies particularly to work on motors (spindle motors) or other electrical as- semblies. The instructions in the respective manufacturer documentation must be followed for such work. -
Page 41: Storage And Decommissioning
Flexible, pressurized hydraulic hose lines of INDEX/TRAUB equipment are generally thermoplastic or metal hydraulic hose lines. For the flexible, pressurized hydraulic hose lines used by INDEX/TRAUB, empirical values are available for very different periods of use, some of which exceed 10 years. -
Page 42: Product Monitoring
Therefore, we request that you notify us of any concerns related to the safety of the machine. This applies also to necessary specifications that are not included in the documentation. INDEX-Werke GmbH & Co. KG Hahn & Tessky Plochinger Strasse 92... -
Page 43: Certificate Of Conformity
CERTIFICATE OF CONFORmITy 8 Certificate of conformity The certificate of conformity is issued for each machine in accordance with the requirements of Directive 2006/42/EC Annex II and is provided to the customer as a separate document. Safety Precautions and Technical Details DAA007EN - 11.05.2021... -
Page 44: Technical Details
TEChNICAL dETAILS 9 Technical details 9.1 Approved ambient conditions The following ambient conditions apply: • electromagnetic conditions according to IEC 61000-6-2 and DIN EN 55011 (limit class A) • relative humidity (at 40 °C) max. 50% • max. altitude 1,000 m a.s.l. • ambient temperature at the location of use 10 °C to 40°C •... -
Page 45: Noise Emission
Measurement uncertainty KpA in [dB] All above-mentioned machines The values when idling and machining were determined using the Index acceptance testing workpiece (with a special work cycle with machining according to ISO 8525). The specified noise emission characteristics were determined according to ISO 230-5, incorporating ambient and room correction values. - Page 46 INDEX-Werke GmbH & Co. KG Hahn & Tessky Plochinger Strasse 92 D-73730 Esslingen Phone +49 711 3191-0 +49 711 3191-587 info@index-werke.de www.index-werke.de...