sauter BA 892 User Manual

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Operating Instructions

for

Disk-type tool turret

0.5.473.520 107 468

110 660 111 092 111 432 112 862 115 702

BA 892 e

2007-03-27

125 365

Product data as per nameplate on the housing

1. Classification number (series, size)

2. Identification number

3. Order number

4. Gear ratio

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x.x.xxx.x xx

xxx xxx xx-xxx-xx-xx

xxx

Basis-BA: 06-10-23 Manual translation

  



The present manual is part of the product.

The manual should be kept in an easily accessible place during the product’s lifetime.

The manual should be passed on to the next owner/user of the product.

Make sure that any possible supplement received is duly added to the manual.

Table of contents

Interpretation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Use within specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2 Required skills. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.3 Notes on product-specific risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.4 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.5 Liability and warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.1 Designation of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3 Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.3 Maintenance work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.4 Repairs after fault conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.5 Aligning the tool disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.6 Replacing the cooling lubricant valve . . . . . . . . . . . . . . . . . . . . . . . 26

4.7 Adjusting the angular encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.8 Replacing the angular encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.9 Proximity switch S7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.10 Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5 Replacement parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Replacement parts for turrets (without tool drive) Replacement parts tool drive for turret

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Survey: Disk-type tool turret 0.5.480.5..

Table of contents

Appendix

Diagram of functions: Disk-type tool turret . . . . . . . . . . . . . . . . . . . . . . . . . SK - 919

Diagram of functions: Disk-type tool turret . . . . . . . . . . . . . . . . . . . . . . . . . SK - 920

Wiring diagram: Disk-type tool turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EP - 870

Diagram of functions: Tool drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SK - 940

Wiring diagram: Tool drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EP - 855

Contact/Order information

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Interpretatio n o f symbols

Interpretation of symbols

Warning notes

WARNING

This warning de sig n ate s a potentially hazardous sit ua tio n which may lead to serious injuries, or even death.

WARNING

Risk of electric shock due to high voltages!

CAUTION

This caution designates a potentially hazardous situation in which the produ ct or p rop erty in its environment could be damaged.

IMPORTANT

For application notes and other useful information.

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Clearing

Clear machine before carrying out any further work!

1) Classification of signal wo rd s acc. to ANSI Z535.4

Interpretation of symbols

Symbols for action instructions

Designates an a cti on in stru c tion

Designates the result of an action

Designates a c ro ss -ref ere nc e

Tools required: here, hexagonal pin wrench complete with Tgrip

Use M10 bolts, qua lity 1 2. 9; u s e M o S marked, tightening torq ue 7 0 Nm.

M10 - 12.9 MoS

Abbreviations

max. maximum perm. permissible Fig. figure if nec. if necessary approx. approximately acc. according (to) incl. inclusive (of)

to lubricate th e po ints

70 Nm

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1 Safety notes

The turret correspon d s t o th e sta te of the art and the recognized tech nic a l s afe ty rul es. Ne ve rth el ess h a za rds a nd risks can occur.

1.1 Use within specifications

Install and op era te turre t o nl y i n m a ch ines complying with the relevant regulation s for worksp ace pro tecti on.

Operate turret only in perfect condition and in compliance with the Operating Instructions.

1.2 Required skills

Safety note s

• Work may only be pe rfo r me d on the tu rret by qualified staff. These are person s w ho are a ble to id en tif y ri sk s an d t o

prevent possibl e h az ard s on th e b as is o f th ei r sp ec ia l training and their experience (IEC 60 201-1).

• All work on the electrical system is to be carried out by a qualified electrical engineer only.

• Only trained and competent personnel may work on the turret; this personn el m us t h av e be en instructed in accordance with the Operating Instructions and directly on the turret.

1.3 Notes on product-specific risks

Setting tasks require a 24V D C power sup ply.

Clearing required prior to any work:

Switch the machine off.

Push the motor pro te cti on switch for the turret into the OFF po s itio n.

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Safety note s

WARNING

In the event of a fau lt or a collision, unexpected rota tio n of t he tool disk is pos si ble. Injury hazard.

CAUTION

Do not attempt any further switching operations, if the turret is damaged, as otherwise considerable conseq uential damage may be cause d.

Call SAUTER Service.

CAUTION

Functional fau lts m ay b e c a us ed by a n ing r es s of ch ip s and contamination.

Close open too l l oc ations and cooling lubrica nt bo res by means of suitable closing plugs.

For manual operation, turn the motor sha ft with the help of a hexagonal pin wrench, complete with T-grip.

WARNING

A reversal of the m om e nt of the m oto r re su lts in th e acceleration of the mot or shaft . The hexag onal pin wr ench may thus be unexpectedly accelerated. Therefore, in order to avoid the ejection of the hexagonal pin wrench and resu lti ng in ju ries , firmly grip the hexagonal pin wrench.

1.4 Disposal

Comply with all national and regional disposal regulations and laws.

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1.5 Liability and warranty

The information contained in these Operating Instructions is in conformity with the k no wledge at the point of printing . Subject to modifica tio ns wh ich o cc ur with in the fra m ewo rk of continuous further development.

All liability an d w a rran ty sh a ll be excluded if

• the notes and instructions contained in these Operating Instructions are not complied with,

• the product is not used as directed,

Use within specific at ion s, pa ge 7

• the product including accessories is in correctly operated,

• the product including accessories is in competently repaired and maintained,

• conversions and f unctional cha nges are imp lemented witho ut approval by the manufacturer,

• no suitabl e sp in d le uni t s are us e d as st ipulated in SAUTER Product Informat io n PI 14.2, for examp le ,

• no suitable tool disks and tool holders are used,

• no original replacement parts are used.

Liability and warra nt y

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Product description Designation of parts

2 Product description

2.1 Designation of parts

1 Locating disk 2 Tool drive unit: gear housing 3 Tool drive motor

4 Covering hood for electric components 5 Turret housing

1) not included in scope of delivery

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Product description

Designation of parts

6 Solenoid 7 Terminal box:

tool drive motor

8 Flange plate:

tool drive motor

9 Turret motor

10 Electric connection:

turret

11 Angular encoder

12 Proximity switch S7

“Check pre-indexation”

13 Cooling lubricant

cartridge

14 Proximity switch S11

“Tool drive disengaged”

15 Proximity switch S10

“Tool drive engaged” 16 Solenoid 17 Tool drive coupling

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Product description Technical data 0.5.473.520

2.2 Technical data

Number of indexing positions 8 or 12 or 16 Perm. tangential torque

Nm 3,000 (turret locked) at calculated safety

Perm. mass moment of inertia of tool disk,

kgm

1.3

1.8 – 7.5

tool holders, and tools Perm. unbalance (load moment) caused

Nm 63 by tool holders and tools

Indexing times Theoretical cycle time

41 α+

----------------× 017,× 01,+ n

(unlock/turn/lock) at rotating angle α [degrees]

Gear ratio i see turret type plate Motor speed n rpm see motor rating plate

Perm. indexing frequency min

-1

10 – 5.5

Operating voltage/mains frequency see motor rating plate Degree of protection IP 65 Turret mass

kg approx. 70

(without tool disk) Perm. ambient temperature range °C

°F

Operating pressure for cooling lubricant

Cooling lubricant valve – standard version constant supply externally switched suppl y

Medium pressure valve (option)

1) The perm. loads refer to processing without load shocks. Whenever processing is subject to intermittent cuts, shocks or impacts, a significantly reduction in the values needs to be taken into account.

2) Depending on gear ratio and mains frequency

3) In order to achieve an extended service life of the cooling lubricant valve, it is advisable to filter the cooling lubricant by ≤ 100µm. Post-connected loads (spindle units with internal cooling lubricant guide a.o.) may require a higher degree of filter fineness. Note and comply with the manufacturer’s instructions!

bar bar

bar

+10 ... +40 +50 ... + 104

14 25

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Product description

Technical data 0.5.473.520

Tool drive

Mass (without any motor) kg approx. 40

Gear ratio i 41/41 41/31 41/27 41/21

Perm. speed

on tool drive coupling n

Max. perm. torque

2) 3)

perm

rpm 4000

Nm 32

on tool drive coupling Transferable power

perm

kW 10

Suitable for spindle units coupling profile 17 × 14 DIN 5482

1) The data stated here may differ on special versions.

2) M

3) The permissible torque can be utilized for non-pulse machining operations.

is the permissible peak load for the gears.

perm

The torque must be limited on the motor frequency converter to the value

indicated, while adhering to the gear ratio involved! The useful power data depend on the performance characteristic curve of the motor type used.

For strongly pulsed machining operations - e.g. inserted tooth milling cutters and others only a significantly reduced drive torque should be applied to protect the gears against any overloads.

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Manual mode

3 Manual mode

In manual mode, the me chanical functions of the disk-type tool turret will be checked:

• following initial assembly to the machine

• during troubleshooting

• after a renewed setup following fault conditions

Clearing required prior to any work:

Switch the machine off.

Push the motor prote cti on s witc h f or t he tu rret i nto th e OFF p os ition.

1. Undo fixing screws of covering hood, withdraw covering hood to rear. If necessary, use push-off screw.

2. Remove screw plug on motor housing.

Unlock turret

3. Use a hexagonal pin wrench, complete with T-grip, to rotate the motor shaft.

If the disk-type tool turret is locked, the locating disk (or tool disk) does no t co-rotat e; the centre position of t he lock can be felt.

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Manual mode

WARNING

A reversal of the m ome nt o f t he m oto r re su lts in th e acceleration of the motor shaft. The hexagonal pin wrench may thus be unexpectedly accelerated. Therefore, in order to avoid the ejection of the hexagonal pin wrench and resu lti ng in juri es , fi rm ly grip the hexagonal pin wrench.

4. Keep the same direction of rotation, continue to rotate.

The disk-type tool tur ret unlo cks; a r eversal o f the mo ment on the motor shaft can be felt.

Rotate tool di sk

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5. Keep direction of rotation, continue to rotate disk until locating disk (or tool disk) starts to turn as well.

6. Keep direction of rotation, continue to rotate disk until locating disk (or tool disk) has reached the position r equired, then press in the keeper by means of a screwdriver.

The preindexing bolt engages into a hole.

The tool disk cannot be rotated any further.

Manual mode

Lock turret

7. Reverse direction of rotation on the motor shaft whilst simultaneously pressing in keeper.

The disk-type tool turret locks. The lock resistance can be felt when rotation is continued. The locking process ends, if t he centr e pos ition o f the lock can be felt.

On completion of setup or maintenance work:

8. Screw in plug and fit covering hood. Note position of cables in order to avoid any pinching of the same.

Lock turret in position 1

IMPORTANT

For some setup and mai nte nanc e work th e disk -type tool tu rret has to be locked in position 1.

Precondition

• Numeral 1 of the locating disk has reached its 12 o’clock position relative to the turret base area.

• Position 1 of the tool disk is in working position .

1. Use a hexagonal pin wrench, complete with T-grip, and rotate the motor shaft until position 1 has been reached.

2. Press in the keeper by means of a screwdriver and rotate the motor shaft until the disk-type tool turret locks (see above).

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4 Maintenance

Turret maintenance compri ses the followin g tasks:

• Cleaning,

• Checking,

• Setting and

• Repair.

The service life of the turret is approx. 2–3 million switchings or approx. 5 years.

The service life of the tool drive unit is approx. 8000 operating hours.

These values appl y to

• collision-free operation,

Maintenance

Safety note s

• compliance with the specified operating conditions and the permissible loa ds ,

Technical data, page 12

4.1 Safety notes

Page 7

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Maintenance Service intervals

4.2 Service intervals

Plan your tasks car efully in order to provide fo r troublefree o peration an d reduce necessar y downtimes to a minimum.

IMPORTANT

Maintenance intervals must be adapted to the operating conditions involved.

if required

after 4000 operatin g hours of the machine respectively

after 2½ years respectively

after 8000 operating hours of the machine respectively

Clean tool drive coupling. User

Check tool drive coupling for d amage,

User

replace if necessary.

SAUTER Service

Check cooling lubricant valve for wear and leakage. Replace any defective parts.

Check oil of the turret gearbox

User

Page 26

User

chamber;

if necessary, replenish oil.

Check grease condition of tool drive unit; if necessary, replenish grease.

Check all electrical lines and

Page 19

User

Page 21

User connections for mechanical damage as well as embrittlement. Replace any defective parts.

Change the oil of the turret gearbox

Specialist electrical

engineer

User chamber.

Page 19

after approx. 2–3 million indexing operations respectively

The service life of the tool drive unit

SAUTER Service may possibly be reach ed, depend ing on the operating conditions involv ed. A general overhaul is recommende d for further trouble-free operation.

The service life of the turret may

SAUTER Service possibly be reached, depending on the operating conditions involved. A general overhaul is recommende d for further trouble-free operation.

1) These are persons who are able to identify risks and to prevent possible hazards on the basis of their special training and their experience (IEC 60 201-1).

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4.3 Maintenance work

Turret gearbox chamber

The turret gearbox chamber ha s to be service d after 4,00 0 operating hou rs.

Clearing required prior to any work:

Switch the machine off.

Push the motor pro te cti on switch for the turret into the OFF po s itio n.

IMPORTANT

Improperly disposed used oil is a danger for our environment.

Pay attention to the le ga l re gu lat ion s for the waste disposal of used oil.

Maintenance work

Turret gearbox chamber

In line with the setup position of the disk-type tool tur ret, the following apertures (1) for draining or replenishing oil are provided:

Checking the oil

Carefully unsc rew o il dra in plu g and drain the oil (max. 10 cm

) into a suitable co ntainer.

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Maintenance work Turret gearbox chamber

Assess oil condition

Condition Cause Action

Oil black or brow n, w ith ou t metallic abrasi on

Oil black or brown, with metallic abrasi on

Oil white, mixed with cooling lubricant

Natural consum p tion –

Internal parts of turret are damaged

Turret sealings are damage d

None oil left Turret sealings are damaged

Changing the oil

Open oil drai n p lu g, drain waste oil.

Close oil drain plug.

Remove screw plug from oil charging hole.

Fill oil



300cm

Request SAUTER Service!

lubricating oil C acc. to ISO 6743/ 6 viscosity ISO VG 46 acc. to DIN 51562

Screw in screw plug.

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Maintenance work

Tool drive

The tool drive is lubricated with grease. The grease needs t o be checked a fter 4,000 h ours of opera tion of the tool drive.

Clearing required prior to any work:

Switch the machine off.

Push the motor pro te cti on switch for the turret into the OFF po s itio n.

Preparation

Provide access to the ap e rtu re (1) on the tool drive.

Tool drive

Checking the grease condit ion

Unscrew screw plug on aperture (1).

Rotate gear and assess grease condition:

Condition Cause Measure

No grease visible on gear Natural consumption Replenish grease. Grease: blac k or b r own ,

without metallic a bra s ion Grease: blac k or b r own ,

with metallic abra si on

cooling lubrican t

Traces of natural wear – Internal parts of turret are

damaged Turret sealings are damag ed

Request SAUTER Service!Grease: whi te, mixed with

Grease mixe d wi th oil Turret sealings are d am ag ed

Replenishing the grease

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Close aperture (1) by means of screw plug.

ISOFLEX NBU 15max. 20cm

(KLÜBER)

Repairs after fault conditions Possible faults and remedies

4.4 Repairs after fault conditions

Clearing required prior to any work:

Switch the machine off.

Push the motor prote cti on sw itc h f or t he tu rret i nto th e OFF p os ition.

Fault Cause Remedy Who carries out

this task?

Turret

Incorrect center height, tool disk offset relative to locating disk

Tool disk does not rotate

Turret is difficult to operate

(Thermo protection device has responded)

Turret no longer locks or the pre-indexing bolt gets caught

Tool disk does not stop in the selected position

Collision when turret is locked

Gearwheels are defective

Proximity switch S11 does not switch

Insufficient oil in the gearbox chamber

Contactor is defective Check motor drive

Collision during pivoting

Angular encoder is not correctly adjusted or defective

Turn back tool disk in the annular groove and align

SAUTER Service

Check proximity switch S11; if necessary, set or replace

Check oil

SAUTER Service

Check angular encoder, set or replace if necessary

User

Page 25

User

Page 37

User

Page 19

User

Page 27, page 29

Proximity switch S7 does not switch

Check proximity switch S7, set or replace if necessary

User

Page 33

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Repairs afte r fault conditions

Possible fa u lts and remedies

Fault Cause Remedy Who carries out

this task?

Tool disk stops in between two positions

Chips between tool disk and turret

Remove tool disk, remove chips

Leakage oil escapes Seals are defective SAUTER

Service

Cooling lubricant is not being transferred

Cooling lubricant escapes between tool

Cooling lubricant valve is defective

Cooling lubricant valve/ line is blocked

Cooling lubricant valve is defective

Replace cooling lubricant valve

Blow cooling lubricant valve/line clear

Replace cooling lubricant valve

disk and turret

Tangential play of tool disk when turret is

Collision while turret is locked

SAUTER Service

locked

Wear due to lack of oil

User

Page 26

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Repairs after fault conditions Possible faults and remedies

Fault Cause Remedy Who carries out

this task?

Tool drive

Tool drive does not

Tool disk is displaced Align tool disk

engage

Tool drive coupling is defective

Pinion shaft is defective

Solenoid is defective Replace solenoid and

Tool is not driven Gearwheels are

defective

Tool drive motor is defective

Proximity switch S10 does not switch

SAUTER Service

Replace defective part, adjust solenoid

adjust

SAUTER Service

Replace tool drive motor

Check proximity switch S10, set or replace if necessary

User

Page 25

User

Page 36

User

Page 37

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4.5 Aligning the tool disk

Preparation

Clearing required prior to any work:

Switch the machine off.

Push the motor pro te cti on switch for the turret into the OFF po s itio n.

Lock turret.

Manual mode, page 14

Aligning

Repairs a fte r fa u lt conditions

Aligning the tool disk

If necessary, undo screws (1).

Align the locating hole to center height of the machine; use a plug gaug e (2 ) if required.

Tighten screws (1).

M10 - 12.9 77 Nm

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MoS

Repairs after fault conditions Replacing the cooling lubricant valve

4.6 Replacing the cooling lubricant valve

The cooling lubri cant valve is a wearing pa rt and has to be serviced after 4,000 hours of opera tion.

Clearing required prior to any work:

Switch the machine off.

Push the motor prote cti on s witc h f or t he tu rret i nto th e OFF p os ition.

Checking

Check whethe r c oo lin g lub ric ant emerges between tool dis k and turret.

If necessary, replace defective parts or the entire cooling lubricant valve.

Replacing

Undo screw plug (3).

Withdraw coolin g l ub ric ant cartridge complete with screw plug (3).

Check cooling lubricant cartridge; if necessary, replace bushing (1) and O-ring seal (2).

Refit cooling lubricant cartridge complete with screw plug.

1) Customized versions may also differ from the present version.

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Repairs a fte r fa u lt conditions

Adjusting the angular encoder

4.7 Adjusting the angular encoder

IMPORTANT

Setting tasks require a 24V D C power sup ply.

Preparation

Lock disk-type tool turret in position 1.

Manual mode, page14

Undo claws by means of a hexagonal pin wrench.

Adjusting

Rotate angular encoder out of position until illuminated diode lights up.

Clamp in angular encoder by means of the claws.

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Repairs after fault conditions Adjusting the angular encoder

Checking the setup for symmetr y

1. Use hexagonal pin wrench with T-grip for rotating the motor

2. Rotate motor shaft until illuminated diode on the angu lar

shaft.

encoder or the indication “Position 1” on the machine are extinguished.

3. Note the T-grip position.

WARNING

4. Carefully continue to rotate until a moment reversal can be felt on the motor shaft.

5. Note the T-grip position.

The distance between the two grip positions characterizes the angle range.

6. Repeat steps 1 to 5 with reverse direction of rotation. The

α must be the same for both directions of rotation!

angle

By turning the angular encoder out of position, any dissymmetry can be removed.

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Repairs a fte r fa u lt conditions

Replacing the angular encoder

4.8 Replacing the angular encoder

The location of the a ngular encoder depends on t he disk-typ e tool turret version (without /with flui d rotary fee dthrough).

IMPORTANT

Setting tasks require a 24V D C power sup ply.

Angular encoder, centrally positioned

Preparation

Lock disk-type tool turret in position 1.

Manual mode, page 14

1 2

Note the position of the c ab le ou tle t (2 ) on th e angular encoder (1), remove attachment.

Undo cables (3) on te rm ina l s tri p (n ote wh ere th ey a r e connected).

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Undo claws by means of a hexagonal pin wrench.

Repairs after fault conditions Replacing the angular encoder

Replacing

° ° °

Undo setscrew. Carefully withdraw angular encoder. Connect new angular encoder electrically.

Wiring diagram: D is k -t ype too l tu rr et EP - 87 0 in the appendix to these Operating Instructions.

Rotate shaft of the angular encoder until the illumination of the LED on the angular encoder indicates the “Position 1” setting.

This indication must remain whilst the following steps are carried out.

IMPORTANT

The LED is used o nly to in d ica te po sition 1 during the adjustment work. It is no position indicator during operation.

Ensure that the cable outlet is in its correct position.

F:\Sauter\FRAME-AR\TD\0-5-473-\eng\Ba892\IH_Ausw_WPG_480520-25.fm

Repairs a fte r fa u lt conditions

Replacing the angular encoder

Insert the shaft o f th e a ng ul ar enc o de r in to the bore of the flexible shaft an d introduce carefully until the an gu la r encoder is in contact with the plate. Ensure that the claws are in their correct position!

Use setscrew to attach the angular encoder to the shaft.

If necessary, check the adjustment of the angular encoder.

Page 28

Use claws to secure the angular encoder.

Fit covering hood. Note position of cables in order to avoid any pinching of the same.

Angular encoder, in side position

Preparation

Lock disk-type tool turret in position 1.

Manual mode, page 14

Note the position of the cable outlet (2) on the angular encoder (3), remove attachment.

Undo cables (1) on te rm ina l s tri p (n ote wh ere th ey a r e connected).

Replacing

F:\Sauter\FRAME-AR\TD\0-5-473-\eng\Ba892\IH_Ausw_WPG_480520-25.fm

Undo claws by means of a hexagonal pin wrench.

Repairs after fault conditions Replacing the angular encoder

° °

Carefully withdraw angular encoder. On the shaft of the angul ar encoder, a disk is locate d which is

fixed in position by means of a setscrew. Undo setscrew and remove disk. Connect new angular encoder electrically.

Wiring diagram: D is k -t ype too l tu rr et EP - 87 0 in the appendix to these Operating Instructions.

Rotate shaft of the angular encoder until the illumination of the LED on the angular encoder indicates the “Position 1” setting.

This indication must remain whilst the following steps are carried out.

Fit disk in its correct position.

Ensure that the cable outlet is in its correct position.

Insert the angula r en c od er i nto th e op en ing o f th e p la te, note the position of the claws!

If necessary, check the adjustment of the angular encoder.

Page 28

Use claws to secure the angular encoder.

Fit covering hood. Note position of cables in order to avoid any pinching of the same.

F:\Sauter\FRAME-AR\TD\0-5-473-\eng\Ba892\IH_Ausw_WPG_480520-25.fm

4.9 Proximi ty s w it ch S7

IMPORTANT

Setting tasks require a 24V D C power sup ply.

Clearing required prior to any work:

Switch the machine off.

Push the motor pro te cti on switch for the turret into the OFF po s itio n.

Undo fixing screws of covering hood, withdraw covering hood to rear. If necessary, use push-off screw.

Repairs a fte r fa u lt conditions

Proximity s wit ch S 7

Replacing

Undo clip (3) and withdraw proximity switch (1) from

eccentric bushing (2).

F:\Sauter\FRAME-AR\TD\0-5-473-\eng\Ba892\IH_S7_4805xx.fm

Repairs after fault conditions Proximity s wit ch S 7

Checking

Adjusting

brown

24 V

black blue

−

H-Signal ≥ 90% of rated voltage

Apply a voltage of 24 V DC to the proximity sw itc h (1). The proximity switch is energized when the LED lights up.

Insert tested/new proximity switch (1).

Unlock disk-type to ol tu rret.

Manual mode, page14

Move disk-type tool turret into a location between two positions.

If the keeper (M) is operated, the preindexing bolt (4) can be pressed in pa rtia lly o nl y.

Set switching distance x = 0.3 – 0.5 mm.

Determine dimension a.

a = stroke of the preindexing bolt (4) up to the damping ring (5) when the so le no id is op erated manually (corresponds to the press-in depth of the keeper (M)).

F:\Sauter\FRAME-AR\TD\0-5-473-\eng\Ba892\IH_S7_4805xx.fm

Repairs a fte r fa u lt conditions

Proximity s wit ch S 7

Adjust proximity switch (1) on eccentric bushing (2) such that its signal begins to drop after a + 2

+0.5

mm immersion depth

of the preindexing bolt. Any greater immers io n de pth m ay cau se th e mo to r to be

blocked.

Tighten clip (3).

Fit covering hood. Note position of cables in order to avoid any pinching of the same.

Function test

Switch on turret.

Check switch in g process repeatedly.

F:\Sauter\FRAME-AR\TD\0-5-473-\eng\Ba892\IH_S7_4805xx.fm

Repairs after fault conditions Solenoid

4.10 Solenoid

The solenoid deter mines the engagemen t path. The co upling end p ositions are controlled b y mean s of t he prox imity s witches S 10 “Tool drive engaged” and S11 “Tool drive disengaged”.

Clearing required prior to any work:

° °

Preparation

If a tool disk is f itte d, th e tool holder location must be accessible in working position:

Switch the machine off. Push the motor prote cti on s witc h f or t he tu rret i nto th e

OFF p os ition.

If necessary, remove the covering hood on the tool drive unit.

If necessary, disassemble tool ho ld er.

Replacing

Remove screws (1) on the flange plate of the soleno id (2).

Undo setscrew (5).

Replace the solenoid(2) c omplete with adjusting nut(3) and

bushing (4).

Tighten screws (1).

F:\Sauter\FRAME-AR\TD\0-5-473-\eng\Ba892\IH_Mag_WZA073.fm

~1mm

Repairs a fte r fa u lt conditions

Solenoid

Checking

Is the clearance from t he pinion shaft (10) to the edge of the spindle unit coupling (11) 1mm when the keeper is drawn out?

If necessary, adjust final coupling position.

67 8 9

0.3-0.5mm

1011

Adjusting the final coupling position

Undo setscre w (5).

Undo adjusting nut (3) and rotate keeper.

Adjust clearan ce.

Tighten setscrew (5).

Adjusting the proximity switches

Undo screws (8) of clip (7).

Adjust proximity switch S11 (6) to a clearanc e of 0. 3 - 0.5 mm relative to its switching area.

Tighten screws (8) of clip(7 ).

Adjust proximit y s w itc h S10 (9) in the same wa y.

F:\Sauter\FRAME-AR\TD\0-5-473-\eng\Ba892\IH_Mag_WZA073.fm

Replacement parts

5 Replacement parts

IMPORTANT

Only use the order form if you wish to order any replacement parts!

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_Übersicht_473520_BA-892.fm

Replacement parts

A Replacement parts for turrets (without tool drive)

Indexing, page 40

Clamping and angular encoder, page 41

Gear, drive, pre-indexation, page 4 2

B Replacement parts tool drive for turret

0.5.473.520 - 107 468

- 110 660

0.5.473.520 - 111 092

- 111 432

- 112 862

0.5.473.520 - 115 702

Page 44 - 45

Page 46 - 47

Page 48 - 49

Page 50 - 51

Page 52 - 53

Page 54 - 55

- 125 365

Page 56 - 57

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_Übersicht_473520_BA-892.fm

Replacement parts Indexing

Indexing

Setscrew is only applied and secured (LOCTITE 221)

No. Ident No. Designation Qty.

1 058 073

2 102 048

O-ring seal

Replacements parts group Indexing

IMPORTANT Request assembly guideline MR 02.025!

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_480520.fm

Clamping and angular encoder

Replacement parts

No. Ident No. Designation Qty.

1 067586 Disk (for tuning) 1

2 063 358

O-ring seal

Replacements parts group Clamping

IMPORTANT Request assembly guideline M R 02.025!

4 105 500

Angular encoder

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_480520.fm

Replacement parts Gear, drive, pre-indexation

Gear, drive, pre-indexation

12 5364

89 10

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_480520.fm

Replacement parts

Gear, drive, pre-indexation

No. Ident No. Designation Qty.

1 071 904

2 078 218

3 069 340

4 063 365

5 065 718

6Motor

7 004 157

8 070 460

9 067 659

10 064 813

Sealing ring

O-ring seal

1) 2)

Proximity switch

Sealing ring

Compression spring

Solenoid

1) will be supplied complete with housing and bearing

2) data according to motor’s nameplate

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_480520.fm

Replacement parts Tool Drive for turret 0.5.473.520 - 107 468

for turret 0.5.473.520 - 107 468

5 4

Setscrew is only applied and secured

(LOCTITE 221)

11 12

(16) (14)

(15)

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_473520-107468.fm

Replacement parts Tool Drive

for turret 0.5.473.520 - 107 468

0.5.473.520 - 107 468

No. Ident No. Designation Qty.

1036 588

2063 365 3069 657 4068 017 5000 706

Spaghetti hose O-ring seal Wire race ball bearing O-ring seal Deep groove ball bearing

6 058 548 O-ring seal

058 521 O-ring seal 063 461 O-ring seal 065 993 O-ring seal

7076 749 8118 182

Proximity switch Solenoid

9 058 495 O-ring seal

059 932 O-ring seal

1) 2) 3) 4)

1) 2) 3) 4) 6) 7)

0.636m

1 1 1 1 1

1 1 1 2

1 1

10 034 592

11 058 506 12 A 075 508 12 B 101 121

13 103 530 14 065 138 15 038 494 16 060 663

1) for motor SIEMENS 1FT5 072

2) for motor SIEMENS 1FT5 076

3) for motor SIEMENS 1FT6 084

4) for motor FAGOR FXM 55

5) for motor FANUC alpha 22

6) for motor SIEMENS 1FT5 066

7) for motor FANUC 6S

8) standard version

9) version for medium pressure

FU groove ring O-ring seal Cooling lubricant valve, complete Cooling lubricant valve, complete Pinion shaft, complete Radial seal for rotating shaft Deep groove ball bearing O-ring seal

1 1

1 1 1 2 2 2

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_473520-107468.fm

Replacement parts Tool Drive for turret 0.5.473.520 - 110 660

for turret 0.5.473.520 - 110 660

Setscrew is only applied and secured

(LOCTITE 221)

11 12

(16) (14)

(15)

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_473520-110660.fm

Replacement parts Tool Drive

for turret 0.5.473.520 - 110 660

0.5.473.520 - 110 660

No. Ident No. Designation Qty.

1036 588

2067 810 3068 207 4064 594 5000 706

Spaghetti hose O-ring seal Wire race ball bearing O-ring seal Deep groove ball bearing

6 058 075 O-ring seal

058 548 O-ring seal 058 521 O-ring seal 065 993 O-ring seal

7076 749 8118 182

Proximity switch Solenoid

9 058 521 O-ring seal

065 993 O-ring seal

4) 5) 6)

3) 6)

1) 2) 4) 5)

0.636m

1 1 1 1 1

1 1 1 2

1 1

10 034 592

11 058 506 12 A 075 508 12 B 101 121

13 103 778 14 065 138 15 038 494 16 060 663

1) for motor FANUC 2S

2) for motor SIEMENS 1FT5 072

3) for motor FANUC alpha M12

4) for motor SIEMENS 1FT6 064

5) for motor INDRAMAT MDD 93A

6) for motor FANUC alpha M12/4000HVi

7) standard version

8) version for medium pressure

FU groove ring O-ring seal Cooling lubricant valve, complete Cooling lubricant valve, complete Pinion shaft, complete Radial seal for rotating shaft Deep groove ball bearing O-ring seal

1 1

1 1 1 2 2 2

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_473520-110660.fm

Replacement parts Tool Drive for turret 0.5.473.520 - 111 092

for turret 0.5.473.520 - 111 092

Setscrew is only applied and secured

(LOCTITE 221)

11 12

(16) (14)

(15)

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_473520-111092.fm

Replacement parts Tool Drive

for turret 0.5.473.520 - 111 092

0.5.473.520 - 111 092

No. Ident No. Designation Qty.

1036 588

2063 365 3069 657 4068 017 5000 706

Spaghetti hose O-ring seal Wire race ball bearing O-ring seal Deep groove ball bearing

6 058 075 O-ring seal

058 548 O-ring seal 065 993 O-ring seal

7076 749 8118 182

Proximity switch Solenoid

0.636m

9 059 932 O-ring seal 1

10 034 592

11 058 506

FU groove ring O-ring seal

1 1 1 1 1

1 1 2

1 12 A 075 508 12 B 101 121

13 104 127 14 065 138 15 038 494 16 060 663

1) for motor FANUC alpha 3

2) for motor SIEMENS 1FT6 082

3) for motor FANUC alpha 1,5

4) standard version

5) version for medium pressure

Cooling lubricant valve, complete Cooling lubricant valve, complete Pinion shaft, complete Radial seal for rotating shaft Deep groove ball bearing O-ring seal

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_473520-111092.fm

Replacement parts Tool Drive for turret 0.5.473.520 - 111 432

for turret 0.5.473.520 - 111 432

5 4

Setscrew is only applied and secured

(LOCTITE 221)

11 12

(16) (14)

(15)

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_473520-111432.fm

Replacement parts Tool Drive

for turret 0.5.473.520 - 111 432

0.5.473.520 - 111 432

No. Ident No. Designation Qty.

1036 588

2063 365 3069 657 4068 017 5000 706

Spaghetti hose O-ring seal Wire race ball bearing O-ring seal Deep groove ball bearing

6 058 548 O-ring seal

058 521 O-ring seal 063 461 O-ring seal 065 993 O-ring seal

7076 749 8118 182

Proximity switch Solenoid

9 058 495 O-ring seal

059 932 O-ring seal

1) 2) 3)

1) 2) 3) 5) 6)

0.636m

10 034 592

11 058 506 12 A 075 508 12 B 101 121

13 103 530 14 065 138 15 038 494 16 060 663

1) for motor SIEMENS 1FT5 072

2) for motor SIEMENS 1FT5 076

3) for motor SIEMENS 1FT6 084

4) for motor FANUC alpha 22

5) for motor SIEMENS 1FT5 066

6) for motor FANUC 6S

7) standard version

8) version for medium pressure

FU groove ring O-ring seal Cooling lubricant valve, complete Cooling lubricant valve, complete Pinion shaft, complete Radial seal for rotating shaft Deep groove ball bearing O-ring seal

1 1

1 1 1 2 2 2

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_473520-111432.fm

Replacement parts Tool Drive for turret 0.5.473.520 - 112 862

for turret 0.5.473.520 - 112 862

Setscrew is only applied and secured

(LOCTITE 221)

11 12

(16) (14)

(15)

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_473520-112862.fm

Replacement parts Tool Drive

for turret 0.5.473.520 - 112 862

0.5.473.520 - 112 862

No. Ident No. Designation Qty.

1 036 588 Spaghetti hose 0.636 m 2063 365

3069 657 4068 017 5000 706 6 058 075 O-ring seal

058 548 O-ring seal 065 993 O-ring seal

7076 749 8118 182

O-ring seal Wire race ball bearing O-ring seal Deep groove ball bearing

Proximity switch Solenoid

9 059 932 O-ring seal 1

10 034 592

11 058 506 12 A 075 508

FU groove ring O-ring seal Cooling lubricant valve, complete

1 1 1 1 1

1 1 2

1 1 1

12 B 101 121

13 104 127 14 065 138 15 038 494 16 060 663

1) for motor FANUC alpha 3

2) for motor SIEMENS 1FT6 082

3) for motor FANUC alpha 1,5

4) standard version

5) version for medium pressure

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_473520-112862.fm

Cooling lubricant valve, complete Pinion shaft, complete Radial seal for rotating shaft Deep groove ball bearing O-ring seal

1 1 2 2 2

Replacement parts Tool Drive for turret 0.5.473.520 - 115 702

for turret 0.5.473.520 - 115 702

Setscrew is only applied and secured

(LOCTITE 221)

11 12

(16) (14)

(15)

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_473520-115702.fm

Replacement parts Tool Drive

for turret 0.5.473.520 - 115 702

0.5.473.520 - 115 702

No. Ident No. Designation Qty.

1 036 588 Spaghetti hose 0.636 m 2063 365

3069 657 4068 017 5000 706

O-ring seal Wire race ball bearing O-ring seal Deep groove ball bearing

6 058 548 O-ring seal

058 521 O-ring seal 063 461 O-ring seal 065 993 O-ring seal

7076 749 8118 182

Proximity switch Solenoid

9 058 495 O-ring seal

059 932 O-ring seal

10 034 592

FU groove ring

1) 2) 3)

1) 2) 3) 5) 6)

1 1 1 1 1

1 1 1 2

1 1

11 058 506 12 A 075 508 12 B 101 121

13 103 530 14 065 138 15 038 494 16 060 663

1) for motor SIEMENS 1FT5 072

2) for motor SIEMENS 1FT5 076

3) for motor SIEMENS 1FT6 084

4) for motor FANUC alpha 22

5) for motor SIEMENS 1FT5 066

6) for motor FANUC 6S

7) standard version

8) version for medium pressure

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_473520-115702.fm

O-ring seal Cooling lubricant valve, complete Cooling lubricant valve, complete Pinion shaft, complete Radial seal for rotating shaft Deep groove ball bearing O-ring seal

1 1 1 2 2 2

Replacement parts Tool Drive for turret 0.5.473.520 - 125 365

for turret 0.5.473.520 - 125 365

Setscrew is only applied and secured

(LOCTITE 221)

11 12

(16) (14)

(15)

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_473520-125365.fm

Replacement parts Tool Drive

for turret 0.5.473.520 - 125 365

0.5.473.520 - 125 365

No. Ident No. Designation Qty.

1036 588

2067 810 3068 207 4064 594 5000 706

Spaghetti hose O-ring seal Wire race ball bearing O-ring seal Deep groove ball bearing

6 058 075 O-ring seal

068 208 O-ring seal

7076 749 8118 182

Proximity switch Solenoid

9 058 521 O-ring seal

059 308 O-ring seal

10 034 592

11 058 506

FU groove ring O-ring seal

1) 2)

0.636m

1 1 1 1 1

1 2

1 1

1 12 A 075 508 12 B 101 121

13 103 778 14 065 138 15 038 494 16 060 663

1) for motor FANUC 2S

2) for motor FANUC 3S

3) for motor SIEMENS 1FT6 084

4) standard version

5) version for medium pressure

Cooling lubricant valve, complete Cooling lubricant valve, complete Pinion shaft, complete Radial seal for rotating shaft Deep groove ball bearing O-ring seal

F:\Sauter\FRAME-AR\TD\0-5-473-\ger\Ba892\E_473520-125365.fm