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Bilz ThermoGrip ISG4410WK-HL Operating Manual

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OPERATING MANUAL
ThermoGrip Induction unit
ISG4410WK-HL
Software version: 3.5 and higher
5118916
Bilz Werkzeugfabrik GmbH & Co. KG • Vogelsangstrasse 8 • 73760 Ostfildern • Germany
Phone +49 (711) 34801-0 • Fax +49 (711) 348-1256
November 2018
ISG4410WK-HL V3.5
1

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  • Page 1 OPERATING MANUAL ThermoGrip Induction unit ISG4410WK-HL Software version: 3.5 and higher 5118916 Bilz Werkzeugfabrik GmbH & Co. KG • Vogelsangstrasse 8 • 73760 Ostfildern • Germany Phone +49 (711) 34801-0 • Fax +49 (711) 348-1256 November 2018 ISG4410WK-HL 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 ......................... 7 1.5 Symbols and Pictograms ................... 7 Safety ....................8 2.1 Selection of the installation site ................ 8 2.2 Risks relating to electrical energy ..............
  • Page 3 5.5.1.1 Table of factory defined parameters ................25 5.5.2 Shrinking with free “Parameter” selection: MANUAL ..........27 5.5.2.1 Special shrinking: Inverse shrinking (shrinking from the bottom) ......30 5.5.2.2 Inverse shrinking-in ...................... 30 5.5.2.3 Inverse shrinking-out ....................31 5.5.2.4 Inverse shrinking tool change ..................31 5.5.2.5 Shrinking with coil limit stop ISGF3414 ..............
  • Page 4 10.4 Instructions Safety Glove ................. 55 10.5 Mains Connections ................... 56 10.6 EC Declaration of Conformity ................57 10.7 Safety Data Sheets .................... 58 10.7.1 Synergy 905 ......................58 10.7.2 Techniclean MTC 43 ...................62 10.8 Table of Fuses for 400V units ................71 10.9 Table of Fuses for 480V units ................

  • 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 ISG4410WK-HL. These operating instructions are important so that the device can be used safely, correctly and efficiently. Observing these instructions will help to avoid risks, repair costs and downtimes, and will raise the general level of performance and the lifespan of the machine.

  • Page 6: Intended Purpose

    Product liability and warranty Intended purpose The ThermoGrip induction device ISG4410WK-HL 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: 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 8: 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 9: 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 10: 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 57). 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 11: Controls And Commissioning Isg4410Wk-Hl

    Controls and commissioning ISG4410WK-HL Controls and commissioning ISG4410WK-HL 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 12: Mounting The Non-Swiveling Guide Unit

    Controls and commissioning ISG4410WK-HL 3.2.1 Mounting the non-swiveling guide unit Place the guide unit sub-assembly in the bores and fasten with the two enclosed screws (DIN912 M6x20, see Fig. 3). The PE screw at the side must be fastened tightly. (Fig.

  • Page 13: Mounting The Connector Unit

    Controls and commissioning ISG4410WK-HL 3.2.3 Mounting the connector unit Fasten the assembly for the coil receptacle with the cable harness on the coil lift with the enclosed screws (DIN912 M5x25). Attention! The cable harness must not be twisted. Fig. 6 Fastening of the coil receptacle November 2018 ISG4410WK-HL V3.5...

  • Page 14: Mounting The Support Bracket And Aligning The Associated Coil

    Controls and commissioning ISG4410WK-HL 3.2.4 Mounting the support bracket and aligning the associated coil Make sure the coil is centered over the chuck. Use coil #1 with the small disk and a small tool, e.g. 6 mm for alignment. With no air pressure in the system, swivel the coil tower to the shrink position and move the coil manually over the chuck.

  • Page 15: Connecting The Compressed Air Supply

    Controls and commissioning ISG4410WK-HL 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 ISG4410WK-HL is located on the left hand side. Fig. 9 shows a rectangular adaptor G3/8 to 3/8 inch inside screw a threaded adaptor G3/8 to 3/8 NPT as option.

  • Page 16: Operating The Isg4410Wk-Hl

    Operating the ISG4410WK-HL Operating the ISG4410WK-HL Operating buttons All the work and adjustment processes are carried out at the operator panel using 7 keys: Button Button name in text Function START Start Start the inductive heating of the shrink-fit chuck Stop the inductive heating of the shrink-fit chuck STOP Acknowledge error messages...

  • Page 17: Switching On The Device

    Operating the ISG4410WK-HL 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 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 18: 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 19: Work Sequences When Clamping, Releasing Or Changing A Tool

    Shrinking Work sequences when clamping, releasing or changing a tool For your own safety, please observe the following rules when working with the ISG4410WK-HL: Always observe the safety instructions for all shrink-fit processes! The cooling can be operated manually at any time through pressing the Cool button. Use safety gloves! Shrinking chucks should only be handled with gloves and only at the collar and not in the heated area.

  • Page 20: 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 moved to the upper end position and the cooling device is driven upwards.

  • Page 21: Change The Coil

    Shrinking Change the coil Ensure that there is no chuck beneath the coil. Press the Stop button for approx. 1 sec. The linear unit moves into the lower position and it is easier to change the disc. 5.4.1 Dismantle the coil To do this, twist the union nut on the bayonet fixing through approx.

  • Page 22: 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 23: Thermogrip Clamping Chucks: Parameter

    Shrinking 5.5.1 ThermoGrip clamping chucks: PARAMETER The necessary parameters for the ThermoGrip chuck such as the generator output power, heating period, cooling time, coil and disc sizes for the chuck type are programmed in the factory equipment of the ISG4410WK-HL (see 5.5.1.1 Table of factory defined parameters, page 25). Unless otherwise specified, use standard coil #1 (ISGS3400-1-HL, page 50).
  • Page 24 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: Deselecting the automatic cooling, This option is always set active after every...

  • Page 25: Table Of Factory Defined Parameters

    Shrinking 5.5.1.1 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 3 – 5,9 1/8 – 3/16 ISGS3201-0 6 –...
  • Page 26 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 ISGS3201-TER11-1 TER0400/11 ISGS3201-TER11-1 5/32 TER0600/11 ISGS3201-TER11-1 TER Shrink collets, geometry according ER 16 ...

  • Page 27: Shrinking With Free "Parameter" Selection: Manual

    Shrinking Shrinking with free “Parameter” selection: MANUAL 5.5.2 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 28 Shrinking Following options are possible: 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 36 Start Delay Delay of the beginning of the shrinking. See Chapter 6.3, Enter Start Delay, page 38 Stop Delay (Dwell time) Delay of the beginning of the cooling process.
  • Page 29 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 30: Special Shrinking: Inverse Shrinking (Shrinking From The Bottom)

    Shrinking 5.5.2.1 Special shrinking: Inverse shrinking (shrinking from the bottom) ISG4410 enables the shrinking of tools inversely where the cutting edge diameter is larger than the coil diameter and would therefore not go through the coil during a conventional shrinking process.

  • Page 31: Inverse Shrinking-Out

    Shrinking 5.5.2.3 Inverse shrinking-out In order to shrink-out a tool, put the chuck in the suitable tool holder with the unit switched on and the operation “Inverse shrinking” selected. (The coil is located in the lower end position of the cylinder). Proceed as described in the Chapter 5.5.2.2, Inverse shrinking-in.

  • Page 32: Define Your Own Parameters: Tool Memory

    Shrinking 5.5.3 Define your own Parameters: TOOL MEMORY 5.5.3.1 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 5.5.1, ThermoGrip clamping chucks: PARAMETER, page 23). It is important to define the coil and disc for the new chuck.

  • Page 33: Setup Or Change Your Own Parameters Externally (Option)

    Shrinking 5.5.3.2 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 34: List Of Most Used Tools: Favorites

    Shrinking 5.5.4 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 35: 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 39 You can increase or decrease the numbers with up ▲...

  • Page 36: 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 37: 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 38: Enter Start Delay

    Configuration Enter Start Delay 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 39: 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 40: Lock Shrinking Operations

    Configuration Lock shrinking operations With the ISG4410, 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 41: 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 42: 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 0, page 40). Cleaning The unit must be cleaned regularly.

  • Page 43: Filling The Coolant Tank

    Cleaning and Servicing Filling the coolant tank 2 liters of cooling concentrate (one initial tank filling) is provided with the unit. In general, your plant cooling emulsion with similar contents can be used. ➢ Fill 2 liters of coolant concentrate Synergy 905 (approx. concentration of 3%) ➢...

  • Page 44: Contacting The Manufacturer

    Service menu beneath the version numbers. Contact us at: Bilz Werkzeugfabrik GmbH & Co. KG Vogelsangstrasse 8 73760 Ostfildern...

  • Page 45: 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...
  • Page 46 GFCI switch of pump Turn on GFCI switch 2.42 defective (Version with has 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 47 Appendix Number Type Message Possible cause Corrective measures Data reader not No reader connected Connect reader to USB 2.45 recognized on the USB Wrong or defective interface or change it interface reader No database connected Connect database Connection to database Connection disturbed 2.46 Check Connection...
  • Page 48 Appendix Number Type Message Possible cause Corrective measures 3.24 Relay group 1 error Error of generator Change generator 3.25 Relay group 2 error Error of generator Change generator Relay/Fuse/Phase 3.26 Error of generator Change generator Error Relay/Load Resistance 3.27 Error of generator Change generator Error Relay test currently not...

  • Page 49: Technical Data

    Appendix 10.2 Technical data ISG4410WK1-HL ISG4410WK2-HL Designation of machine types: 400V ISG4410WK1-HL-400V ISG4410WK2-HL-400V 480V ISG4410WK1-HL-480V ISG4410WK2-HL-480V El. power supply: 400V 3 x 400 V + N / 16 A / 50 Hz 480V 3 x 480 V / 15 A / 60 Hz Generator power: 400V 11 kW...

  • Page 50: Scope Of Supply

    Appendix 10.3 Scope of supply Shrinking unit ISG4410WK-HL incl. coil and 4 ferrite discs, clamping ring, gloves as well as 2 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 51: Available Additions And Optional Accessories

    Appendix 10.3.1 Available additions and optional accessories Tool holders For the reception and correct positioning of the chuck onto the shrinking unit ISG4410WK-HL Chuck-type Designation Ident No. For HSK chucks HSK-25 T3-WWK/HSK25 9075293 HSK-32 T3-WWK/HSK32 9073950 HSK-40 T3-WWK/HSK40 9073952 HSK-50 T3-WWK/HSK50 9073953 HSK-63...
  • Page 52 Appendix Measuring adapter Clamping-Ø Designation Ident No. 6 mm T3-M0600 6725959 8 mm T3-M0800 6725962 10 mm T3-M1000 6725963 12 mm T3-M1200-SW5 6726111 14 mm T3-M1400-SW5 6726112 16 mm T3-M1600 6725967 18 mm T3-M1800 6725968 20 mm T3-M2000 6725969 25 mm T3-M2500 6725970 32 mm...
  • Page 53 Appendix Ferrite discs TSF The TSF set allows TSF chucks to be shrunk using the shrink machine. The TSF ferrite discs provide optimal shielding of the magnetic field between coil and tool shank. This guarantees safe and reliable shrinking of the TSF chucks.

  • Page 54: Length Pre-Setting For Thermogrip Chucks

    Appendix 10.3.2 Length pre-setting for ThermoGrip chucks On request 10.3.3 Ejecting broken tools The ejection unit provides easy removal of broken tools from chucks. Even tools where the point of breakage is in the tool holder can be removed without difficulty. The basic ejection tool holder can be adapted to all customary machine interfaces (HSK, SK, ABS) by means of different adaptors.

  • Page 55: 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 56: 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 57: 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 58: Safety Data Sheets

    Appendix 10.7 Safety Data Sheets 10.7.1 Synergy 905 November 2018 ISG4410WK-HL V3.5...
  • Page 59 Appendix November 2018 ISG4410WK-HL V3.5...
  • Page 60 Appendix November 2018 ISG4410WK-HL V3.5...
  • Page 61 Appendix November 2018 ISG4410WK-HL V3.5...

  • Page 62: Techniclean Mtc 43

    Appendix 10.7.2 Techniclean MTC 43 November 2018 ISG4410WK-HL V3.5...
  • Page 63 Appendix November 2018 ISG4410WK-HL V3.5...
  • Page 64 Appendix November 2018 ISG4410WK-HL V3.5...
  • Page 65 Appendix November 2018 ISG4410WK-HL V3.5...
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  • Page 69 Appendix November 2018 ISG4410WK-HL V3.5...
  • Page 70 Appendix November 2018 ISG4410WK-HL V3.5...

  • Page 71: Table Of Fuses For 400V Units

    Appendix 10.8 Table of Fuses for 400V 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 72: Wiring Diagrams

    24V = Schwimmer- Tauchpumpe schalter pump level switch Firma Maßstab 89,67% Zeichner H. Esslinger Blatt 1 von 2 F3.15A/250VAC Bilz GmbH & Co. KG Änderung 15.07.16 10:01 Titel +24VDC +24VDC ISG4410WK2-HL-11-WS Ausgabe 15.07.16 11:48 +24VDC Datei ISG4410WK2-HL-11-WS.T3001 Projekt ISG4410 November 2018 ISG4410WK-HL V3.5...
  • Page 73 Luftdusche dry air Positionsschalter unten lower position switch FI - GFP Firma Maßstab 88,94% Zeichner H. Esslinger Blatt 2 von 2 Bilz GmbH & Co. KG Änderung 15.07.16 10:01 Titel ISG4410WK2-HL-11-WS Ausgabe 15.07.16 11:48 Datei ISG4410WK2-HL-11-WS.T3001 Projekt ISG4410 November 2018 ISG4410WK-HL V3.5...

  • Page 74: Isg4410Wk-Hl-480V

    Tauchpumpe 3A/600VAC schalter Trafo pump level transformer switch Firma Maßstab 88,21% Zeichner H. Esslinger Blatt 1 von 2 F3.15A/250VAC Bilz GmbH & Co. KG Änderung 15.07.16 11:36 Titel +24VDC +24VDC ISG4410WK2-HL-15-WS Ausgabe 15.07.16 11:49 +24VDC ISG4410 Datei ISG4410WK2-HL-15-WS.T3001 Projekt November 2018...
  • Page 75 Luftdusche dry air Positionsschalter unten lower position switch FI - GFP Firma Maßstab 88,21% Zeichner H. Esslinger Blatt 2 von 2 Bilz GmbH & Co. KG Änderung 15.07.16 11:36 Titel ISG4410WK2-HL-15-WS Ausgabe 15.07.16 11:50 Datei ISG4410WK2-HL-15-WS.T3001 Projekt ISG4410 November 2018 ISG4410WK-HL V3.5...

  • Page 76: Pneumatic Plan Isg4410Wk-Hl

    Appendix 10.11 Pneumatic plan ISG4410WK-HL ISG4410WK-HL November 2018 ISG4410WK-HL V3.5...

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