Table of Contents
Advertisement
Quick Links
OPERATING MANUAL
ThermoGrip Induction unit
ISG2410 / ISG2430
Software version: 3.5 and higher
5220330
ISG2410-WK
ISG2430-TWK
ISG2430-TLK
Bilz Werkzeugfabrik GmbH & Co. KG • Vogelsangstrasse 8 • 73760 Ostfildern • Germany
Phone +49 (711) 34801-0 • Fax +49 (711) 348-1256
02/2024
ISG2410 / ISG2430 V3.5
1
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for Bilz ThermoGrip ISG2410
Summary of Contents for Bilz ThermoGrip ISG2410
- Page 1 ISG2410 / ISG2430 Software version: 3.5 and higher 5220330 ISG2410-WK ISG2430-TWK ISG2430-TLK Bilz Werkzeugfabrik GmbH & Co. KG • Vogelsangstrasse 8 • 73760 Ostfildern • Germany Phone +49 (711) 34801-0 • Fax +49 (711) 348-1256 02/2024 ISG2410 / ISG2430 V3.5...
-
Page 2: Table Of Contents
Contents Product liability and warranty ............5 1.1 General ........................ 5 1.2 Warranty ......................5 1.3 Intended purpose ....................6 1.4 Service ......................... 8 1.5 Symbols and Pictograms ................... 8 Safety ....................9 2.1 Selection of the installation site ................ 9 2.2 Risks relating to electrical energy .............. - Page 3 5.4.3.2 Setup or change your own parameters externally (option)........29 5.4.3.3 Select your own tool parameters ................29 5.4.4 List of most used tools: FAVORITES ..............30 Configuration ..................31 6.1 Switching between mm/ inch ................32 6.2 Setting up and configuration of cooling time ..........32 6.2.1 Setting up of cooling time ..................32 6.2.2 Configuration of cooling time ................33 Configuration of cooling time for “parameter shrinking”...
- Page 4 10.10.2 ISG2430-TLK-8-FS (400V)................54 10.10.3 ISG2430-TWK-3.2-FS (208V) ................55 10.10.4 ISG2430-TWK-8-FS (400V) ................57 10.10.5 ISG2410-WK-3.2-FS (208V) ................59 10.10.6 ISG2410-WK-8-FS (400V)................61 10.11 Pneumatic plan ISG2410-WK ..............63 02/2024 ISG2410 / ISG2430 V3.5...
-
Page 5: Product Liability And Warranty
Product liability and warranty Product liability and warranty General These operating instructions are part of the technical documentation for the ThermoGrip induction device ISG2410 / ISG2430. These operating instructions are important so that the device can be used safely, correctly and efficiently. -
Page 6: Intended Purpose
Product liability and warranty Intended purpose The ThermoGrip induction device ISG2410 / ISG2430 is used for the thermal engagement and disengagement of tools in shrink chucks. Any other use above and beyond this is deemed not in accordance with the intended use. We will not be liable for any resulting damage. - Page 7 Product liability and warranty Place for ferrite discs and tool holders Guiding unit Tool holder Coil Coolant cooler Control panel Guiding unit Coil Control panel Place for ferrite discs and tool holders Tool holder Air cooler Fig. 3 ThermoGrip Induction unit ISG2430-TLK 02/2024 ISG2410 / ISG2430 V3.5...
-
Page 8: Service
Product liability and warranty Service We will be happy to help solve problems or perform repairs and modifications that are not described in these operating instructions. For problems or queries, make note of the device and generator serial numbers. The device serial number can be found on the type plate on the left side panel, the generator serial numbers is on the right side of the black generator box. -
Page 9: Safety
Safety Safety The induction generator has been built to comply with the state-of-the-art design at the time of delivery and is safe to operate. Nevertheless, there are still risks involved with operating the device if it is used by untrained or unqualified personnel or if it is not used as intended. Therefore, must be observed: Please read the operating instructions carefully and familiarize yourself with the operating elements before commissioning and using the device! -
Page 10: Risks From Hot Parts
Safety Risks from hot parts The very effective heating function only heats the relevant surface zones of the chuck with the lowest heat input possible. The surface of the heated chucks reaches temperatures of up to 400°C. The coil and the cutting tool hardly heats up at all when operated properly. Caution! Risk of injury caused by burns from hot parts! As a result of the shrinking process the heated tool assembly radiates heat. -
Page 11: Risks Relating To Electromagnetic Radiation
Safety Risks relating to electromagnetic radiation If used correctly, the device does not emit any electromagnetic radiation that is dangerous to its environment. The radiation safety of the system is checked and verified through tests performed in accordance with EC Machinery Directive (see 10.6, EC Declaration of Conformity, page 50). The shrinking process must not be operated without the ferrite disc being inserted! If the induction heating is started when there is no ferrite disc being inserted in the coil, the... -
Page 12: Controls And Commissioning Isg2410 / Isg2430
Controls and commissioning ISG2410 / ISG2430 Controls and commissioning ISG2410 / ISG2430 Assembly Caution: Please inspect the unit for shipping damages prior to assembly. Ensure that the unit is not damaged during the unpacking process. In particular, the cable system must not be bent or twisted out of its position of movement! Handle the unit with care. -
Page 13: Mounting The Guide Unit
Controls and commissioning ISG2410 / ISG2430 3.1.2.2 Mounting the guide unit Place the guide unit sub-assembly in the bores and fasten with the two enclosed screws (DIN912 M6x20, see Fig. 5). The PE screws at the side must be fastened tightly. (Fig. 6) Fig. -
Page 14: Connecting The Compressed Air Supply
Controls and commissioning ISG2410 / ISG2430 3.1.2.5 Connecting the compressed air supply Compressed air must be oil-free! The compressed air supply must be connected properly to the unit. The pneumatic connection of the ISG2410-WK is located on the left hand side. Fig. -
Page 15: Operating The Isg2410 / Isg2430
Operating the ISG2410 / ISG2430 Operating the ISG2410 / ISG2430 Operating buttons All the work and adjustment processes are carried out at the operator panel using 7 keys: Button name in Button Function text START Start Start the inductive heating of the shrink-fit chuck Stop the inductive heating of the shrink-fit chuck Acknowledge error messages Stop... -
Page 16: Switching On The Device
Operating the ISG2410 / ISG2430 Switching on the device ➢ Switch on the main switch The display shows the type of the machine. Now you are in the main menu. Shrinking Configuration Service The ISG2430-TWK / ISG2430-TLK is ready for use now. At ISG2410-WK please note: After selecting Shrinking or Service and pressing the OK button, the compressed air is switched The linear unit moves down initially and then upwards. -
Page 17: Shrinking
Shrinking Shrinking Basic shrink-fitting information Only tools with a ground shank and tolerance h4, h5 or h6 should be used. Tools with shank tolerance h7 cannot be securely clamped. The following shank tolerances are required for the various shank diameters: Shank Ø... -
Page 18: Work Sequences When Clamping Or Releasing A Tool
Shrinking Work sequences when clamping or releasing a tool For your own safety, please observe the following rules when working with the ISG2410 / ISG2430: Always observe the safety instructions for all shrink-fit processes! At ISG2430-TWK, after finishing the shrinking procedure, the cooling down must be operated manually through pressing the Cool button. -
Page 19: Clamping
Shrinking 5.2.2 Clamping By pressing on the tool during the subsequent heating phase you assist the clamping process. If the tool has been inserted and the shrinking time has not yet ended, it is helpful to end the heating process with the Stop button, so as not to continue to heat the tool unnecessarily. After the selected shrinking time runs out or the Stop button is pushed, the coil is brought to the upper end position (ISG2430-TWK / ISG2430-TLK) and the cooling device is pulled upwards (ISG2430- TWK). -
Page 20: Shrink-Fit Operating Modes
Shrinking Shrink-fit operating modes Parameter Manual Tool memory Favorites PARAMETER MANUAL TOOL MEMORY FAVORITES …, if you use a …, if you use another …, if you use chuck of …, if you use a table of chuck or tool and want your own with shrinking the most shrunk tools. -
Page 21: Thermogrip Clamping Chucks: Parameter
Shrinking 5.4.1 ThermoGrip clamping chucks: PARAMETER The necessary parameters for the ThermoGrip chuck such as the generator output power, heating period, cooling time and disc sizes for the chuck type are programmed in the factory equipment of the ISG2410 / ISG2430 (see 5.4.1.1, Table of factory defined parameters, page 23). Attention: Special ferrite discs for TSF and TER shrink-fit chucks are necessary (see Fehler! Verweisquelle konnte nicht gefunden werden. - Page 22 Shrinking Step 3: Additional options Select with up ▲ and ▼ down additional options and activate or deactivate with OK. The status (bottom line) shows the type of chuck and the assigned shrinking time and output power. The blinking symbol shows the device is ready for shrinking Following options are possible for ISG2410-WK: Deselecting the automatic cooling, This option is always set active after every...
-
Page 23: Table Of Factory Defined Parameters
Shrinking 5.4.1.1 Table of factory defined parameters T- chucks (Standard Type according to DIN69882-8) Designation of chuck Txxxx -range -range Ferrite disc Shrinking time Shrinking output in sec power in % in mm in inches ISGS2201-1 5/32 ISGS2201-1 3/16 ISGS2201-1 ISGS2201-2 5/16 ISGS2201-2... - Page 24 Shrinking TER Shrink collets, geometry according ER 11 Designation Ferrite disc Time Power Dwell time in sec in % in sec in mm in inches TER0300/11 ISGS2201-TER11-1 TER0400/11 ISGS2201-TER11-1 5/32 TER0600/11 ISGS2201-TER11-1 TER Shrink collets, geometry according ER 16 ...
-
Page 25: Shrinking With Free "Parameter" Selection: Manual
Shrinking Shrinking with free “Parameter” selection: MANUAL 5.4.2 This mode is intended for shrinking special tools or special clamping chucks, which only occur in seldom cases. Furthermore, this mode can be used to set the shrinking parameters for frequently used special chucks or tools. Parameter Manual Tool Memory... - Page 26 Shrinking Following options are possible for ISG2410-WK: Deselecting the automatic cooling, This option is always set active after every shrinking. Other options see Chapter 6.2, Setting up and configuration of cooling time, page 32 Start Delay Delay of the beginning of the shrinking. See Chapter 6.3, Enter Start Delay (ISG2410-WK only), page 34 Stop Delay (Dwell time) Delay of the beginning of the cooling process.
- Page 27 Shrinking ➢ Especially for smaller tools, do NOT increase the heating time by one second at the same power setting. Instead, increase it by 1s and reduce the output power by 20% at the same time. The product of power x time is the energy input. If a cycle at 3s and 100% (3x1=3) is not successful, increase to 4s/ 80% (4*0.8=3.2) and so forth.
-
Page 28: Define Your Own Parameters: Tool Memory
Shrinking 5.4.3 Define your own Parameters: TOOL MEMORY 5.4.3.1 Setup TOOL MEMORY at the machine At the beginning, a similar standard chuck is selected from the existing parameter list. Start with mode PARAMETER similar to standard shrinking (see Chapter 5.4.1, ThermoGrip clamping chucks: PARAMETER, page 21). It is important to define the disc for the new chuck. -
Page 29: Setup Or Change Your Own Parameters Externally (Option)
Shrinking 5.4.3.2 Setup or change your own parameters externally (option) With the PC based program „ToolMemoryEditor“ you can define tools by yourself and read into the control with an USB memory stick. The USB interface is located at the generator module on the right side. Read in the generated file of tools: ➢... -
Page 30: List Of Most Used Tools: Favorites
Shrinking 5.4.4 List of most used tools: FAVORITES A top-ten list of the most used tools is directly available with the function „Favorites“. Select with up ▲ and ▼ down the function "FAVORITES" Activate with OK. A list of the most used tools appears Select with up ▲... -
Page 31: Configuration
Configuration Configuration With multiple pressings of ESC you come to the main menu. Shrinking Configuration Service Select with up ▲ and ▼ down the function Configuration and activate with OK. If the Configuration is protected by a password you have to enter it first. How to activate/ deactivate the password see Chapter 6.6, Password on/ off or change, page 35 You can increase or decrease the numbers with up ▲... -
Page 32: Switching Between Mm/ Inch
Configuration Switching between mm/ inch The diameter of the tool can be shown on the display in mm or in inches. Select the desired unit with up ▲ and ▼ down and confirm with OK. Setting up and configuration of cooling time If only the symbol „cooling“... -
Page 33: Configuration Of Cooling Time
Configuration 6.2.2 Configuration of cooling time The cooling function can be configured differently for the "parameter shrinking" and / or "manual shrinking" functions. Select the functions with up ▲ and ▼ down and activate with OK. The active function is marked with and confirmed with OK. -
Page 34: Enter Start Delay (Isg2410-Wk Only)
Configuration Enter Start Delay (ISG2410-WK only) Around 3 seconds will pass before the generator starts. If this waiting time is too short to insert bulky tools, the Start Delay option can be used to set an additional delay of up to 30s. Select the desired value with up ▲... -
Page 35: Password On/ Off Or Change
Configuration Password on/ off or change Entering "0000" will switch off the password. This is the factory default. Whenever you enter a value unequal to "0000" you switch on the password request. You can enter a password of your choice with up to 4 decimal figures (for e.g.: 3480). -
Page 36: Lock Shrinking Operations
Configuration Lock shrinking operations With the ISG2410 / ISG2430, it is possible to lock the functions “Manual shrinking” and / or “Parameter shrinking” for the operator using a password. The function is only applied when ThermoGrip shrink-fit chucks are used and any overheating occurs as a result of an operating error of the operator must be excluded. -
Page 37: Service
Service Service With multiple pressings of ESC you come to the main menu. Shrinking Configuration Service Select with up ▲ and ▼ down the function Service and activate with OK. Information about the shrink unit Type equipment designation Generator number of the generator installed EEPROM version of the variable memory Software... -
Page 38: Cleaning And Servicing
Cleaning and Servicing Cleaning and Servicing Maintenance / Visual Inspection Every 6 months, check mains cable for damage (visual inspection), the function of protected earth PE and the earth leakage circuit breaker (GFI, GFCI). To check the GFCI, switch on the pump (see Chapter 7, Service, page 37). Cleaning The unit must be cleaned regularly. -
Page 39: Filling/ Draining The Cooling Emulsion
Cleaning and Servicing Filling/ draining the cooling emulsion 1 liter of cooling concentrate (one initial tank filling) is provided with the unit. In general, your plant cooling emulsion with similar contents can be used. Only fill in in an empty and clean tank. 8.3.1 Filling the coolant tank (ISG2430-TWK) Move away flexible cover... -
Page 40: Checking The Float Switch
Cleaning and Servicing Checking the float switch ➢ Whenever the coolant is changed, the function of the float switch must be checked. The float must move freely and it will sag down by its own weight, when the coolant tank is empty. -
Page 41: Contacting The Manufacturer
Service menu beneath the version numbers. Contact us at: Bilz Werkzeugfabrik GmbH & Co. KG Vogelsangstrasse 8 73760 Ostfildern... -
Page 42: Appendix
Appendix Appendix 10.1 Error messages and corrective measures Hints are displayed as follows: <Number> Hints serve as information for the operator and can be acknowledged using the Stop button! Errors are displayed as follows: <Number> After troubleshooting, the displayed error can be acknowledged using the Stop button! Errors must only be rectified by trained personnel! Number Type Message... - Page 43 GFCI switch of pump has Turn on GFCI switch 2.42 defective (Version with been released Replace pump Opto-Coupler) Bilz-Reader not No reader connected Connect reader to USB 2.44 recognized on the USB Wrong or defective interface or change it interface...
- Page 44 Appendix Number Type Message Possible cause Corrective measures No database connected Connect database Connection to database Connection disturbed 2.46 Check Connection failed Defective Ethernet Change hardware interface Data record from data Create data record for Data carrier ID not found 2.47 carrier has not yet been data carrier ID in the...
-
Page 45: Technical Data
Appendix 10.2 Technical data ISG2430-TLK ISG2430-TWK ISG2410-WK Designation of machine types: (short guide unit) Fixed coil 208V ISG2430-TLK-3.2 ISG2430-TWK-3.2 ISG2410-WK1-3.2 Fixed coil 400V ISG2430-TLK-8 ISG2430-TWK-8 ISG2410-WK1-8 El. power supply: 208V: 3 x 208V / 15A / 60 Hz 400V: 3 x 400V + N / 16A / 50 Hz Generator power: 208V: 3,2 kW... -
Page 46: Scope Of Supply
Appendix 10.3 Scope of supply Shrinking Unit ISG2410 / ISG2430 incl. coil and 3 ferrite discs, clamping ring, gloves as well as 1 liter coolant concentrate (corresponds to a complete filling of the coolant tank). Ferrite discs one-piece For an optimal shielding of the magnetic field between coil and tool shank Clamping- Ø... -
Page 47: Available Additions And Optional Accessories
10.3.1 Available additions and optional accessories Expansion options and optional accessories can be found on our homepage or in our product catalogs. www.bilz.de If you have any further questions, please contact your sales representative. 10.3.2 Service pump The service pump can be used to drain the cooling tank of shrink machines with water cooling. -
Page 48: Instructions Safety Glove
Appendix 10.4 Instructions Safety Glove Description: Heat protection glove, outer layer consisting of para aramide yarn (KEVLAR) Fine knitted fabric lined with aramide felt and 100% Nornex knitted fabric Availability: Size 10 Color: yellow Manufacturer: JUTEC GmbH, Mellumstr. 23-25, D-26125 Oldenburg Description: These gloves have been designed to protect your hands. -
Page 49: Mains Connections
Appendix 10.5 Mains Connections Allocation of the CEE socket Pin name Pin designation Wire colour Phase L1 Brown Phase L2 Black/ grey Phase L3 Black Neutral Blue Ground Green-yellow The nominal voltages between the phases are 3x400V (-10/ +10%) The nominal voltage between a phase L1, L2 or L3 and neutral is 230V (-10/ +10%) Further hints: ➢... -
Page 50: Ec Declaration Of Conformity
EC Declaration of Conformity In accordance with the EC Machinery Directive 2006/42/EC Bilz Werkzeugfabrik GmbH & Co. KG declares, that the machine designated below corresponds to the following relevant directives with regard to its design and construction in the version brought into circulation. -
Page 51: Safety Data Sheets
Appendix 10.7 Safety Data Sheets All safety data sheets for the hazardous substances supplied are available on request. 02/2024 ISG2410 / ISG2430 V3.5... -
Page 52: Table Of Fuses For 208V Units
Appendix 10.8 Table of Fuses for 208V units Fuse Phases Rated Voltage Rated Current Frequency Dimensions Tripping Characteristic Location 250V 3.15A 50/60 Hz 5x20 mm fast acting Distribution board 250V 3.15A 50/60 Hz 5x20 mm fast acting Distribution board 250V 3.15A 50/60 Hz 5x20 mm... -
Page 53: Wiring Diagrams
F4A/250VAC distribution board 3*208V / 60 Hz Netzteilplatine power-supply 24V = Firma Maßstab +24VDC 87,48% Zeichner H. Esslinger Blatt 1 von 1 Bilz GmbH & Co. KG +24VDC Änderung +24VDC 15.05.17 12:47 Titel ISG2430TLK-3.2-FS Ausgabe 29.10.18 15:04 Datei ISG2430TLK-3.2-FS.T3001 Projekt... -
Page 54: Isg2430-Tlk-8-Fs (400V)
F4A/250VAC distribution board 3*400V / 50 Hz Netzteilplatine power-supply 24V = Firma Maßstab +24VDC 87,48% Zeichner H. Esslinger Blatt 1 von 1 Bilz GmbH & Co. KG +24VDC Änderung +24VDC 15.05.17 12:22 Titel ISG2430TLK-8-FS Ausgabe 29.10.18 15:04 Datei ISG2430TLK-8-FS.T3001 Projekt... -
Page 55: Isg2430-Twk-3.2-Fs (208V)
24V = Schwimmer- Tauchpumpe schalter pump level F3.15A/250VAC switch Firma Maßstab +24VDC 87,48% Zeichner H. Esslinger Blatt 1 von 2 Bilz GmbH & Co. KG +24VDC Änderung +24VDC 29.10.18 14:59 Titel ISG2430TWK-3.2-FS Ausgabe 29.10.18 15:05 Datei ISG2430TWK-3.2-FS.T3001 Projekt ISG2410 02/2024... - Page 56 Appendix FI - GFP Firma Maßstab 88,21% Zeichner H. Esslinger Blatt 2 von 2 Bilz GmbH & Co. KG Änderung 29.10.18 14:59 Titel ISG2430TWK-3.2-FS Ausgabe 29.10.18 15:06 Datei ISG2430TWK-3.2-FS.T3001 Projekt ISG2410 02/2024 ISG2410 / ISG2430 V3.5...
-
Page 57: Isg2430-Twk-8-Fs (400V)
24V = Schwimmer- Tauchpumpe schalter pump level F3.15A/250VAC switch Firma Maßstab +24VDC 87,48% Zeichner H. Esslinger Blatt 1 von 2 Bilz GmbH & Co. KG +24VDC Änderung +24VDC 29.10.18 14:41 Titel ISG2430TWK-8-FS Ausgabe 29.10.18 15:06 Datei ISG2430TWK-8-FS.T3001 Projekt ISG2410 02/2024... - Page 58 Appendix FI - GFP Firma Maßstab 88,21% Zeichner H. Esslinger Blatt 2 von 2 Bilz GmbH & Co. KG Änderung 29.10.18 14:41 Titel ISG2430TWK-8-FS Ausgabe 29.10.18 15:07 Datei ISG2430TWK-8-FS.T3001 Projekt ISG2410 02/2024 ISG2410 / ISG2430 V3.5...
-
Page 59: Isg2410-Wk-3.2-Fs (208V)
24V = Schwimmer- Tauchpumpe schalter pump level switch F3.15A/250VAC Firma Maßstab +24VDC 87,48% Zeichner H. Esslinger Blatt 1 von 2 Bilz GmbH & Co. KG +24VDC Änderung +24VDC 29.10.18 14:50 Titel ISG2410WK-3.2-FS Ausgabe 29.10.18 15:01 Datei ISG2410WK-3.2-FS.T3001 Projekt ISG2410 02/2024... - Page 60 Out4 I/O-Erweiterung Hubzylinder Futter I/O-Extension lift tool Luftdusche dry air Firma Maßstab 88,21% Zeichner H. Esslinger Blatt 2 von 2 Bilz GmbH & Co. KG Änderung 29.10.18 14:50 Titel ISG2410WK-3.2-FS Ausgabe 29.10.18 15:02 Datei ISG2410WK-3.2-FS.T3001 Projekt ISG2410 02/2024 ISG2410 / ISG2430 V3.5...
-
Page 61: Isg2410-Wk-8-Fs (400V)
24V = Schwimmer- Tauchpumpe schalter pump level switch F3.15A/250VAC Firma Maßstab +24VDC 102,88% Zeichner H. Esslinger Blatt 1 von 2 Bilz GmbH & Co. KG +24VDC Änderung +24VDC 29.10.18 14:37 Titel ISG2410WK-8-FS Ausgabe 29.10.18 15:03 Datei ISG2410WK-8-FS.T3001 Projekt ISG2410 02/2024... - Page 62 Out4 I/O-Erweiterung Hubzylinder Futter I/O-Extension lift tool Luftdusche dry air Firma Maßstab 88,21% Zeichner H. Esslinger Blatt 2 von 2 Bilz GmbH & Co. KG Änderung 29.10.18 14:37 Titel ISG2410WK-8-FS Ausgabe 29.10.18 15:03 Datei ISG2410WK-8-FS.T3001 Projekt ISG2410 02/2024 ISG2410 / ISG2430 V3.5...
-
Page 63: Pneumatic Plan Isg2410-Wk
Appendix 10.11 Pneumatic plan ISG2410-WK ISG2410-WK 02/2024 ISG2410 / ISG2430 V3.5...
Need help?
Do you have a question about the ThermoGrip ISG2410 and is the answer not in the manual?
Questions and answers