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HAIMER Basic Operating Instructions Manual

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Economic Plus NG2 • Comfort
Induction shrink fit machine
Quality Wins.
POWER-CLAMP
Basic • Economic
Economic NG2 • Economic Plus
Comfort NG2 • Profi Plus NG2
Preset NG2
Haimer GmbH
Weiherstraße 21, 86568 Igenhausen, Germany
Telefon ++49 (0) 82 57 / 99 88-0, Fax ++49 (0) 82 57 / 18 50
eMail haimer@haimer.de, www.haimer.com
Operating instructions

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Summary of Contents for HAIMER Basic

  • Page 1 POWER-CLAMP Basic • Economic Economic NG2 • Economic Plus Economic Plus NG2 • Comfort Comfort NG2 • Profi Plus NG2 Preset NG2 Induction shrink fit machine Operating instructions Haimer GmbH Weiherstraße 21, 86568 Igenhausen, Germany Quality Wins. Telefon ++49 (0) 82 57 / 99 88-0, Fax ++49 (0) 82 57 / 18 50...
  • Page 3 7.2.4 Replacement of the basic unit POWER CLAMP .........................62 8 Disposing of the machine ............................64 9 Technical Data................................64 10 Spare Parts and Accessories ...........................66 11 Circuit Diagrams ................................70 11.1 Power Clamp Basic, Economic, Economic Plus, Comfort, Preset ................. 70 11.2 Power Clamp Profi Plus ..............................71 Quality Wins.
  • Page 4 POWER CLAMP Operating Manual Preface Preface With the POWER-CLAMP, you are the owner of an innovative and simple-to-run device for changing tools on a shrink fit chuck. The long life of this device and more importantly, the safe use of the POWER CLAMP depend on you reading and adhering to the safety information and operating instructions in this manual before commissioning.
  • Page 5 POWER CLAMP Operating Manual Safety Operating manual pictograms Persons with a pacemaker are not allowed to operate the device. Protect the devices from moisture, risk of elec- tric shock. Allgemeine Warnungen vor Person- und/oder Sachschäden. Warning of danger from electric current or an electric shock.
  • Page 6 POWER CLAMP Operating Manual Safety 1 Safety The POWER-CLAMP shrink fit machine is constructed using the latest technology and is depend- able. A function and safety check was carried out. However, the machine can be dangerous if it is not operated by persons who have not been trained or at least instructed. The same applies for improper or non-intended use of the POWER-CLAMP.
  • Page 7 This device is only meant to be used for industrial applications. Franz Haimer assumes no liability for the utilisation of this product for any application other than that described in this operating manual. This also eliminates any guarantee claims.
  • Page 8 POWER CLAMP Operating Manual Safety 1.4 Authorised operators Only operators and personnel that are assigned and authorised by the administration are allowed to perform any operation using the POWER-CLAMP shrink fit machine. The operator is responsible for any other persons located in the working area. The administrator must: •...
  • Page 9 POWER CLAMP Operating Manual Device Description 2 Device Description 2.1 Function description The POWER CLAMP shrink fit machine uses an induction coil, also called an inductor, as its function principle. The coil creates a magnetic alternating field. If a metallic object with iron parts is located inside the coil, it will be heated.
  • Page 10 POWER CLAMP Operating Manual Device Description 2.3.1 Adjustable coils Adjustable coils adapt themselves in diameter and length to suit the relevant tool and chuck. Elements made of a magnetically conductive material (ferrite) can be opened and closed like a camera iris. The coil itself comprises a fixed and a moveable part.
  • Page 11 (coil V 2008) The full range of tools can be shrunk using the POWER CLAMP Basic: HM and HSS from 3 to 32 mm. Cooling can be done with the AIR COOLER (option). No further configuration of the unit is possible.
  • Page 12 POWER CLAMP Operating Manual Device Description POWER CLAMP Economic Plus (coil V 2008), POWER CL AMP Economic Plus NG (coil VS 32 H, VS 32 M or 13kW HD) The POWER CLAMP Economic Plus also has a cooling unit and cooling body for rapid cooling of the shrink fit chuck.
  • Page 13 POWER CLAMP Operating Manual Device Description POWER CLAMP Preset NG (coil VS 32 H or VS 32 M) The adjustable length stop for the tool tip allows tools to be shrink fitted to the ex- act length required. The maximum length ¯18-20 ¯14-16 ¯...
  • Page 14 POWER CLAMP Operating Manual Device Description 2.5 Device overview 2.5.1 Power Clamp Comfort and Profi Plus Mains switch SPEED COOLER Circulation line return Circulation line advance Plug coil Ø 3 - 32 mm Mains switch POWER CLAMP Linear guide Handle with brake Start key Inductor energy cable 10 Spring tensioner...
  • Page 15 POWER CLAMP Operating Manual Device Description 2.5.2 Power Clamp Economic, Economic Plus Plug connector coil Ø 3 - 32 mm Mains switch POWER CLAMP Linear guide Handle with brake Start key Inductor energy cable 10 Spring tensioner 11 Operational display lamp 12 Cooling body 12a Cooling body with quick-change connector...
  • Page 16 42 Chuck holder 43 Stop clamp 44 Measuring head 45 Tool stop 46 Handwheel 47 Clamping lever 48 Stop clamp 2.5.4 Power Clamp Basic Connecting plug Inductor Mains switch Linear guide inductor Handle with brake Start key inductor Energy cable inductor...
  • Page 17 POWER CLAMP Operating Manual Device Description 2.5.5 Optional equipment for Power Clamp Economic, Economic Plus, Comfort, Profi Plus and PRESET 31 Cooling body LED display 32 Motor connection 33 Motor controller for automatic coil VS 32 M 34 Controller for cooling body with temperature display 35 Connecting cable for cooling body with temperature display...
  • Page 18 POWER CLAMP Operating Manual Transport and Packaging 3 Transport and Packaging 3.1 Delivery The POWER-CLAMP shrink fit machine is supplied in suitable packaging so that it can reach its destination in perfect condition during normal transport. Note: The carrier is liable for any transport damage. If any signs of damage are visible on the packaging that indicate damage to the contents, please contact the carrier immediately to make a claim for damages.
  • Page 19 POWER CLAMP Operating Manual Start-up 4 Start-up The start-up procedures for the POWER-CLAMP shrink fit machine are described in the respective sequence of actions required. The operation of the device is relatively simple. You should be familiar with the device before working with it, however. Incorrect operation can cause dangers to the user and the device, in particular, the shrink fit chuck could overheat.
  • Page 20 The transformer must have adequate capacity reserves. Fuses to be provided by the customer: POWER CLAMP Basic, Economic, Economic Plus, Comfort, Preset: 3 x 16 Amps POWER CLAMP Profi Plus: 3 x 32 Amps Attention! Under no circumstances operate the devices with fuses of a higher rating.
  • Page 21 The roller unit may be moved only on level ground. During operation, the devices are not to stand at an angle, be tipped or subjected to vibration. 4.2.1 POWER CLAMP Space required in mm: Type Basic Economic 1000 Economic Plus 1000 Comfort, Profi...
  • Page 22 POWER CLAMP Operating Manual Start-up The POWER CLAMP is almost completely preassembled. Only the linear guide (6) needs to be bolted to the housing and aligned suitably. Important: For safety reasons there must be a con- ductive contact between the linear guide and the housing.
  • Page 23 POWER CLAMP Operating Manual Start-up • Align the linear unit (6) so that the coil (13) is centred over the chuck (52). Tighten the four bolts (50). • Connect the coil with the plug (4) at the housing and close the retaining clip. •...
  • Page 24 POWER CLAMP Operating Manual Start-up Attention! Avoid direct contact with anti-freeze. Sur- plus anti-freeze or water/anti-freeze mixtures must be disposed of properly. They must not be placed in domestic rubbish or released into the drains. • Bleeding the SPEED COOLER: Close the nipple with the hose section (53) (pro- vided as standard) at the inlet (3) of the SPEED COOLER.
  • Page 25 POWER CLAMP Operating Manual Start-up Cooling manager The cooling manager switches the SPEED COOLER on and off automatically. This means the user will not forget to switch the cooler on, nor will he leave it running continuously. This protects the cooler and reduces the need for maintenance.
  • Page 26 POWER CLAMP Operating Manual Start-up 4.2.4 Retrofit cooling body Ø 40 - 50 HD (option) The cooling body Ø 40 - 50 HD (21) can be retrofitted ø14-1 8 ø6-8 ø25-3 2 as an option. The mounting kit contains the following parts: ø10-1 2 ø18-2 0 ø40-5 0 HD...
  • Page 27 POWER CLAMP Operating Manual Start-up • Tilt the rear panel (70) downwards. In order to mount the mounting bracket to the hose cabinet, four mounting holes need to be drilled. • Place the drilling jig (73) on the hose cabinet (74) as shown.
  • Page 28 POWER CLAMP Operating Manual Start-up Connect the cooling body: First of all, the cooling connections need to be provided for the additional cooling body. For this purpose, the rear water distributor (78) needs to be modified. • Loosen screw connection (79) at Pos.1 (SW14) and pull off the end of the coolant hose (80).
  • Page 29 POWER CLAMP Operating Manual Operation 5 Operation 5.1 Switching the devices on • Before switching on, check that the inner wall of the inductor has no evident signs of damage (such as scorched areas or cracks). Attention! The inductor operates at a high volt- age.
  • Page 30 POWER CLAMP Operating Manual Operation 5.2 Menu operation After switching on you find yourself in the Shrink Fit menu. Here you can select the type and size of the shrink fit chuck and start the shrink fit process. A number of setting options are available in the sub-menu. •...
  • Page 31 POWER CLAMP Operating Manual Operation Full menu Shrink Fit menu Shrink fit chuck display Select previous chuck from the list or Automatic Select next chuck from the list or Automatic Select next group keys from the list simultaneously Display shrink fit parameters Shrink fit process Start key or...
  • Page 32 POWER CLAMP Operating Manual Operation 5.2.1 Shrink fit menu The shrink fit chuck being used currently is always shown on the display. Type of shrink fit chuck Standard Size of Ø 10 - 12 shrink fit chuck pos. #4 Setting the Shrinking code coil •...
  • Page 33 POWER CLAMP Operating Manual Operation 5.2.2 Set maximum heating time Back to Heating Time Shrink Fit menu Standard Ø 10 - 12 Heating Time Display the heating time 0 - 20: 4.5 s for the set chuck Select previous / next chuck from list keys Select next group...
  • Page 34 POWER CLAMP Operating Manual Operation 5.2.3 Set languages Back to Shrink Fit menu Languages Save and Back without Language back saving deutsch Save and Back without Language back saving english Save and Back without Language back saving français Save and Back without Language back...
  • Page 35 POWER CLAMP Operating Manual Operation 5.2.5 Read program The software can be updated with this function. The parameters that had been set previously are lost when this is done. The update is done via the USB interface. A PC with suitable software is required to do this. The update should therefore only be carried out by suitably trained persons.
  • Page 36 POWER CLAMP Operating Manual Operation A PC with suitable software is required to do this. The update operation should therefore only be carried out by suitably trained persons. It is essential that you remove the USB cable before starting any new shrinking operations. Window 1 Displayed process (0 to 100) Error code:...
  • Page 37 POWER CLAMP Operating Manual Operation 5.2.8 I-button The induction process can be started by means of the I-button. Depending on the setting in the menu, the I-button can function in various ways. • Setting 0: The I-button functions jus t like t he S t ar t key at t he coil. Heating is applied for as long as the button is pressed and held down, until the maximum heating time is reached.
  • Page 38 POWER CLAMP Operating Manual Operation 5.3 Work procedures 5.3.1 Selecting and changing the coil The POWER-CLAMP was designed in the first in- stance for shrink fit chucks with an outside contour as per DIN 69882 – 8. In addition, there is a large selection of shrink fit chucks and extensions that can likewise be used with the POWER CLAMP.
  • Page 39 (esp. the hole and outside diameter). This is easiest with HAIMER shrink fit chucks via a code, which is visible both on the chuck and on the display. The parameters Standard Ø...
  • Page 40 POWER CLAMP Operating Manual Operation Press the keys simultaneously to jump from one group to the next. Standard Extension S-chuck ..Yo u c a n s w i t c h b e t w e e n t h e i n d i v i d u - al sizes by using t he keys.
  • Page 41 POWER CLAMP Operating Manual Operation 5.3.4 Adjusting the coil 5.3.4.1 Manually adjustable coil VS 32 H The coil is simply adjusted by turning the rotary disk (23) to match the chuck and the tool. The tool Ø is shown on the position No.
  • Page 42 POWER CLAMP Operating Manual Operation T-slot milling cutters When milling T-slots the cutting diameter is greater than the shank. • Rotate the coil into the position shown. • Release the locking pin (27) and lock it by turning it by 90°. •...
  • Page 43 POWER CLAMP Operating Manual Operation Clamping Ø 3 – 5 mm: • Select the parameters for Ø 3 – 5. • Press the key. The coil travels to the desired position. • Press the key . The aperture opens. • Unlock the ferrite ring (30) by turning it clockwise. •...
  • Page 44 POWER CLAMP Operating Manual Operation washer halves can be inserted subsequently. Ultra-short chucks and special shapes Special stop disks are available for use with ultra-short chucks. Please contact the manufacturer regarding chucks of a special shape or construction. 5.3.5 Preparing the shrink fit chuck and the tool Always wear gloves when working with shrink fit chucks and tools.
  • Page 45 POWER CLAMP Operating Manual Operation 5.3.6 Heating the shrink fit chuck Safety notes: The inner wall of the coil is made of a heat-resistant plastic. However, heat radiation and direct contact with the heated chuck can damage the plastic. In an extreme case the coil winding could be exposed as a result.
  • Page 46 POWER CLAMP Operating Manual Operation Clamping the tool: • Hold the tool (57) at the chuck hole with your right hand. • Press the start key (8) or hold the key down until the tool can be inserted. The procedure takes about 5 seconds.
  • Page 47 POWER CLAMP Operating Manual Operation Unclamping the tool: • Hold the tool (57) with your right hand and give it a slight upwards tug. • Press the start key (8) or hold the key down until the tool can be removed. The procedure takes about 5 seconds.
  • Page 48 POWER CLAMP Operating Manual Operation • Shrink fit chuck is defective due to overheating • Shrink fit chuck does not have a suitable shape (wall too thick) • Shrink fit chuck or tool dirty (oil) • Strong voltage drop during the shrinking operation The voltage can drop during the heating procedure with small wire cross sections or if extension cables are being used.
  • Page 49 POWER CLAMP Operating Manual Operation 5.3.7 Cooling the shrink fit chuck The heated shrink fit chucks can be cooled down within a very short time with the aid of the cooling bodies. The prerequisite for this is a good contact between the cooling body and the chuck (surface contact).
  • Page 50 POWER CLAMP Operating Manual Operation Attention! The display is not always reliable. Above all, there can still be residual heat in the chuck even if the LED is green in the case of chucks with a small cooling area, when using cooling adapters and if the cool- ing circuit has been switched off or is blocked.
  • Page 51 POWER CLAMP Operating Manual Operation correction allowance can be found in the table. Clam- mm 4 ping Ø Correcti- mm 0,15 0,18 0,18 0,15 0,14 on value Inch 0,006 0,007 0,007 0,008 0,006 0,006 Clam- mm 14 ping Ø Correcti- mm 0,12 0,14 0,15...
  • Page 52 POWER CLAMP Operating Manual Operation ON/OFF • Swing the tool stop (45) to the rear. ORIGIN ZERO/ABS • Heat up the shrink-fit chuck. in/mm HOLD DATA All other preparations and settings on the POWER CLAMP proceed as normal. The shrink-fit chuck will be heated for the full time until the unit switches off automatically.
  • Page 53 POWER CLAMP Operating Manual Operation • Set the tool stop (45) to the desired length. • Lock the stop grip (48). Use the clamping screw under the measurement head (44) to tighten the stop grip (48). • Push the measurement head (44) upwards by about 100 mm and swing the tool stop (45) to the rear.
  • Page 54 POWER CLAMP Operating Manual Operation 5.5 Switching the devices off In daily use of the units: • Switch off both devices are work, using the mains switch. • Clean the shrink fit machine as required (see section "Service and maintenance“). For longer periods of disuse: •...
  • Page 55 POWER CLAMP Operating Manual Correcting Faults 6 Correcting POWER CLAMP Faults 6.1 Error messages Error Error Possible cause Solution / Correction message code Wrong Wrong selection of shrink fit • Choose the correct setting diameter chuck at the control panel •...
  • Page 56 POWER CLAMP Operating Manual Correcting Faults 6.2 Other errors Problem Possible cause Solution / Correction After switching on, Mains voltage under 350 V • Connect the device to a higher voltage outlet. nothing can be • Use a voltage transformer seen on the display One phase missing in the •...
  • Page 57 POWER CLAMP Operating Manual Correcting Faults Problem Possible cause Solution / Correction Tool or extension One phase missing in the • Check the fuses at the customer’s power supply power supply cannot be unshrunk • Have an electrician check whether all three phases are properly present and connected correctly (socket and plug of the machine)
  • Page 58 POWER CLAMP Operating Manual Correcting Faults 6.3 Correcting SPEED COOLER faults Problem Possible cause Solution / Correction No cooling, or System with cooler has not • Bleed (see below) cooling capacity been bled too low No water or too little water in •...
  • Page 59 POWER CLAMP Operating Manual Correcting Faults 6.3.1 Water pump does not start • Switch off the SPEED COOLER • Move (rotate) the fan wheel (65) of the motor (64) by using a screwdriver placed through the cover (63) and the motor protective cover. •...
  • Page 60 POWER CLAMP Operating Manual Service and maintenance 7 Service and Maintenance Repairs to the POWER CLAMP shrink fit machine or to the SPEED-COOLER may be performed by specialised personnel only. Work that is carried out incorrectly can affect the safety of the devices. The housings are not to be opened by unauthorised personnel.
  • Page 61 POWER CLAMP Operating Manual Service and maintenance • Ensure when doing this that you do not bend the cooling fins. If the dirt sticks firmly then you should have the cleaning done by specialists. Attention! Solvents and liquids can affect the proper functioning and safety of the cooler.
  • Page 62 POWER CLAMP Clamp Basic • Unplug all the electrical cables on the left-hand side of the unit • Remove the screws (69) of the baseplate. The basic unit is now free and can be sent for repair or replaced. Quality Wins.
  • Page 63 (43). • Remove the screws (70) at the back as shown. • Remove the screws (69) of the baseplate. The basic unit is now free and can be sent for repair or replaced. POWER CLAMP Comfort / Profi Plus • Unplug all the electrical cables on the left-hand side of the unit •...
  • Page 64 • Make sure electrical/electronic components are placed in the special processing waste fraction. Recommendation: Please contact a specialised disposal company. 9 Technical Data POWER CLAMP Basic shrink fit machine: Suitable for tools: ..............HM, Ø 3 - 32 mm, h6 HSS + extensions, 3 - 32 mm, h6 Mains connection (the details given on the rating plate shall apply): Nominal voltage ..............
  • Page 65 POWER CLAMP Operating Manual Technical data POWER CLAMP Profi Plus NG shrink fit machine: Suitable for tools: Coil NG ................HM, Ø 3 - 32 mm, h6 HSS + extensions, 3 - 32 mm, h6 Large coil ................HM, Ø 32 - 50 mm, h6 HSS + extensions, 32 - 50 mm, h6 Mains connection (the details given on the rating plate shall apply): Nominal voltage ..............
  • Page 66 POWER CLAMP Operating Manual Spare Parts and Accessories 10 Spare Parts and Accessories 2, 4, 5, 6 10, 11 19, 20 ÿ 18-20 ÿ 14-16 ÿ 25-32 ÿ 6-8 ÿ 10-12 Quality Wins.
  • Page 67 POWER CLAMP Operating Manual Spare Parts and Accessories 2.01-2.14 Mini 3 kW V 2008 Coil V 2008, without stop disks 80.151.00 2.01 Stop disk Ø 3-5 80.152.03 2.02 Stop disk Ø 6-12 80.152.06 2.03 Stop disk Ø 14-16 80.152.14 2.04 Stop disk Ø...
  • Page 68 POWER CLAMP Operating Manual Spare Parts and Accessories 6.01 6.01-6.06 13 kW 6.02 20 kW Coil 13 kW, with stop disks 80.151.30 Coil 20 kW, with stop disks 80.151.40 only for Profi Plus 6.01 Stop disk Ø 16-20 80.151.10.42 for 13 and 20 kW HD coil 6.02 Stop disk Ø...
  • Page 69 Basic / Economic / Stop clamp 113004-0263 Economic Plus / Preset Baseplate 113014-0201 for Economic / Preset Chuck holder for Basic / Economic / Economic Plus 113004-0008 Chuck holder for Basic / Economic / Economic Plus 52.01 SK/BT/CAT 30 80.112.30 52.02 SK/BT/CAT 40 80.112.40...
  • Page 70 POWER CLAMP Operating Manual Circuit Diagrams 11 Circuit Diagrams 11.1 Power Clamp Basic, Economic, Economic Plus, Comfort, Preset Quality Wins.
  • Page 71 POWER CLAMP Operating Manual Circuit Diagrams 11.2 Power Clamp Profi Plus Quality Wins.

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EconomicEconomic ng2Economic plusEconomic plus ng2ComfortComfort ng2 ... Show all
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