OPERATING INSTRUCTIONS Thread unscrewing unit Z 5410, Z5420, Z PDF Free Download

STRACK NORMA GmbH & Co. KG Postfach 16 29 58466 Lüdenscheid Königsberger Str. 11 58511 Lüdenscheid Tel.: 0 23 51 / 87 01-0 Fax: 0 23 51 / 87 01-100 E-Mail: info@strack.de http://www.strack.de D 8138E 02.2009 OPERATING INSTRUCTIONS Thread unscrewing unit Z 5410, Z5420, Z5430

Index of contents page Preamble 3 1. Application according to regulation 4 1.1 Structure and application of the operating instructions 4 2. Purpose of application 4 2.1 Survey over the connections 5 2.2 Technical dates 6 2.3 Application according to regulation 7 2.3.1 Definition Authorised person 7 2.4. Application not according to regulation 8 2.5. Guarantee information 8 3. Essential safety instructions 9 3.1 The used safety symbols 9 3.2 The safety devices 10 3.3. Essential types of risk 10 3.4 Duty to take care of the operator 12 3.5 Demands on the staff 12 4. Transport 13 4.1 Dimensions and weight 13 4.2 Tranist support 13 5. Installation 13 5.1 Requirements of the environment 13 5.2 Assembly 14 6. Initial operation 15 6.1. Supply and removal connections 15 6.2 Preparation for the first start 16 6.3 Execution of the first start 16 6.4 Example of assembly 17 6.5 Controls after the first start 19 7. Operation 20 7.1 Allowed operator stations 20 7.2. The switching-on of the thread unscrewing unit 20 8. Machine maintenance 21 8.1 Things you have to consider 21 8.2 Visual inspections 21 8.3 Cleaning 22 8.4 Maintenance 22 9. Removal from service 23 9.1 Preliminary removal from service 23 9.2 Final removal from service 23 9.3 Removal 24 10. Additional information 24 10.1 Service addresses 24 10.2 Assembly dimensions, dimensions, drawings of the thread core 24 2

Preamble Thank you for the confidence in the product of STRACK NORMA GmbH & Co. KG. We are pleased about your decision to buy a product of STRACK. To facilitate the handling with the product we established these operating instructions. The operating instructions are an important element of the thread unscrewing units Z 5410 - Z 5430 and provide the secure and efficient operating. They are intended for all persons which are operating the thread unscrewing units and which are responsible for the secure operating. For reasons of the operating safety a copy of these operating instructions has to be left at the thread unscrewing unit to guarantee the direct access of the operating personnel. The security advices in the operating instructions have particularly to be respected to recognize and to avoid possible dangers. Please read the operating instructions carefully and completely before mounting and initial operation of the thread unscrewing units. A regular maintenance is necessary to guarantee a secure and economic application. If the instructions and advices of these operating instructions are not observed, any liability on our part for resulting damages and performance losses will be excluded. 3

1. Application according to regulation Survey In this chapter you will find the following subchapters: Structure and application of the operating instructions Indications concerning the manufacturer and contact person 1.1 Structure and application of the operating instructions These operating instructions are valid for the following installation: Denomination: Thread unscrewing unit Type: Z 5410, Z 5420, Z 5430 Date of issue: November 2008 2. Purpose of application The thread unscrewing unit is used for the unscrewing of internal threads out of injection moulded parts. It is attached to an existing injection mould and builds a separate unit. By means of a core pulling control of the injection moulding machine it is electrically operated and is driven hydraulically. The traverse path is actuated by limit switches. The thread unscrewing unit distinguishes itself particularly through the simple mounting and operating. Gear plate Picture 1: Front view of a single-unscrewing unit Z 5410 Base plate 4

2.1 Survey over the connections Hydraulic connections Overflow oil line connections Limit switch Gear wheel Adjusting collar (switch cams) Limit switch Fixing holes at the base plate Picture 2: Top view of a double-unscrewing unit Z 5420 To guarantee the function of the thread unscrewing unit all connections have correctly to be attached by a qualified person which has been trained correspondingly. The overflow oil line connection serves to remove excessive oil from the motor, absolutely attach this connection and guide the included hose back in the oil-holding tank of the injection moulding machine. Thereby the wastage of the hydraulic motor can considerably be reduced. 5

2.2 Technical dates Hydraulic motor: OMM 8 OMM 32 OMP 25 Geometrical displacement 8,2 cm³ 31,6 cm³ 25,0 cm³ Maximal rotation speed 1950 min-1 630 min-1 1600 min-1 Maximal turning moment Int. 1) 15 Nm Int. 1) 57 Nm Int. 1) 47 Nm Peak 2) 21 Nm Peak 2) 64 Nm Peak 2) 67 Nm Maximal performance 2,6 kw 3,2 kw 6,1 kw Maximal drop of pressure 100 bar 100 bar 100 bar Maximal oil flow 20 l/min 25 l/min 45 l/min Maximal starting pressure 4 bar 4 bar 10 bar at unloaded shaft Minimal starting torque 10 Nm 48 Nm 40 Nm at maximal drop of pressure 1) Intermittent operation: the allowed values may all in all appear for the duration of maximal 10 % per minute. 2) Peak load : the allowed values may all in all appear for the duration of maximal 1 % per minute. Installation sizes and standard distances between axless at double-thread-unscrewing units: Type Minimal Maximal Hydraulic motor Type Distanz between axles at thread thread double unscrewing units 1/2 3 mm 12 mm OMM 8 / OMM 32 double 30-50mm 3/4 3 mm 18 mm OMM 8 / OMM 32 double 80 mm 5/6 3 mm 18 mm OMM 8 / OMM 32 double 20 mm 7/8 3 mm 18 mm OMM 8 / OMM 32 double 160 mm Pitch: Minimal thread pitch Maximal thread pitch Installation size 0,3 mm 3,5 mm 25 / 2 0,3 mm 3,5 mm 25 / 2 0,3 mm 3,5 mm 25 / 2 0,3 mm 3,5 mm 25 / 2 0,3 mm 3,5 mm 25 / 2 6

2.3 Application according to regulation 2.3.1 Definition "Authorised person" A person can be considered as an authorised person, if it is charged with certain works at or with the thread unscrewing unit according to instructions. The thread-unscrewing unit and the operating instructions are exclusively be destined for the industrial use. The thread unscrewing unit may not be used or put in operation by private users. In the following each person is considered as operator, which installs, puts in operation, actuates, maintains or disassembles the thread unscrewing unit. Each operator of the thread unscrewing unit has to read the present operating instructions before the installation, the maintenance, the initial operation, the operation or the disassembling carefully and completely. It has to be secured that the operator has understood the present operating instructions completely and that he always acts according to the instructions and recommendations of these operating instructions. Therefore the operator of the thread-unscrewing units should read the present operating instructions in regular intervals repeatedly. The operating company is responsible for training of the operators of the thread unscrewing units. Each operator needs basic knowledge of control engineering, electrical engineering, mechanics and hydraulics. The operating company has to secure that the operator has read the present operating instructions completely and has understood the content, that he can realise the contents of these operating instructions practically and that the contents of these operating instructions are completely be considered. The operating instructions have to be handed to third persons, if the unscrewing unit is handed to third persons (Sale, rental ). A transfer of the thread unscrewing unit without operating instructions is not allowed. Application according to regulation The thread unscrewing unit is only applied according to regulation, if the following points are considered: The thread unscrewing unit is used for the unscrewing of internal threads out of injection moulded parts. The thread unscrewing unit is attached to a present injection mould in an injection moulding machine and builds a separate unit. The thread unscrewing unit is electrically controlled and operated hydraulically. The traverse path is controlled over the limit switches. In the extended condition additionally to the limit switch also the mechanical stop is used. The leakage oil hose is connected correctly and excessive oil is reverted unpressurised in the oil holding tank of the injection moulding machine. The thread unscrewing unit may only be operated with the installed safety installations. The safety- and operating advices of these operating instructions have to be observed. The operating instructions of the operator have to be observed. The legal accident prevention regulations have to be observed. The safety- and operating advices of the injection moulding machine have to be observed. 7

2.4 Application not according to regulation As application not according to regulation in the sense of a predictable faulty operation is considered: Any modifications of the operating procedure or the process, which were not approved by the responsible employee, the operating with modified, removed or bypassed safety installations and the operating of the installation by personnel which is not instructed or unauthorised. 2.5 Guarantee information 12 months from date of invoice we concede for the Thread unscrewing units Types: Z 5410/Z 5420/Z 5430 guarantee for all defects, which are based on material- and fabrication mistakes. Seal parts and wearing parts are excluded from the guarantee. Damages which are caused by improper handling, for example overloading, use of force, modifications, own attempted repairs are excluded from the guarantee. Nonobservance of the operating instructions, utilisation of not mentioned materials, insufficient cleaning and maintenance, as well as improper handling lead to a loss of warranty claim. The opening of the machine may only be effected in the way the operating instructions are giving instruction for that. A further opening or disassembling of the machine is prohibited. If you really have operating problems, please call us or describe your problems by fax. We are pleased to help you. 8

3. Essential safety instructions Survey In this chapter you will find the following subchapters The used safety symbols The safety devices Essential types of risk Duty to take care of the operator Requirements to the personnel First of all The following essential safety advices have to be understood as supplementation to the already valid national accident prevention regulations and laws. That means that besides these essential safety advices at any rate also the existing accident prevention regulations and laws have to be observed. 3.1 The used safety symbols Danger! This symbol points out that there are essential dangers for the health of persons. The word DANGER OF LIFE points separately to possible fatal dangers. Danger! This symbol points out that there are electrical dangers for the health of persons because of electrical voltages. The word DANGER OF LIFE points separately to possible fatal dangers. Attention! This symbol points out that damages for the thread unscrewing unit, the material or the environment can occur. 9

3.2 Safety devices The thread unscrewing unit is equipped with the following safety devices, which by no means may be removed or manipulated: Limit switches (inductive proximity switch) Adjusting collars Please always pay attention to a faultless function of the security devices! The thread unscrewing unit may not be operated with defective security devices! Covering protection: The thread unscrewing unit has to be installed in such a way that it is impossible to enter the unit with body parts or to touch it during the operation. If the thread unscrewing unit is not secured by the cover of the injection moulding machine, a separate protective casing has to be fitted. 3.3 Essential types of risk Content Here you will find information concerning the essential safety advices for the secure handling with the thread unscrewing unit. Risk of injury The thread unscrewing unit is actuated with hydraulic oil, which is transported with high pressure. Extruding oil can cause injuries of the skin, eyes and mucous membranes. Hot hydraulic oil can cause burns. Inform the maintenance staff immediately about damaged cables and components. Maintenance- and repair works may only be effected by trained maintenance staff. Keep all access doors and safety devices locked. Connect the hydraulic motor of the thread unscrewing unit only with the hydraulic couplings and hoses which are provided for that and which are type-approved. Please pay attention that the maximum pressure indicated on the hydraulic hoses and the maximum shelf life is not exceeded. A very high flow velocity of hydraulic oil in hydraulic hoses can cause static electricity and can lead to elec tric shocks. The thread unscrewing unit and all other parts must therefore be connected earthed, this must particularly be considered in explosive areas. 10

Electric shock! The electrical connection may only be effected by electricity specialist or a specially trained operator. Connect the limit switches only to the core puller control of the injection moulding machine which is provided for that purpose. The limit switches may only be operated with 24 V continuous current. Operate in each case only one thread unscrewing unit at one core puller control, no further devices. Consider the connecting diagram of the core puller control. ATTENTION! Modifications at the thread unscrewing unit are not allowed, otherwise the guarantee expires and possibly the thread unscrewing unit does not function. If the thread unscrewing unit should be modified from the delivered execution, or, in case of need, should be repaired, please only use the original replacements, conversion parts and accessories. Or use components which are produced according to drawings which were approved by STRACK NORMA. At utilisation of foreign accessories and replacement parts each liability and guarantee by STRACK NORMA is excluded. In principle it has to be considered that the thread length and the deactivation of the thread un screwing unit is exclusively realised by the delivered limit switches. The thread unscrewing unit may not be operated without the delivered limit switches. For the connection of the limit switches consider the electric connecting diagrams of the respective core puller controls at the injection moulding machine, in which the thread unscrewing unit should be used. 11

3.4 Duty to take care of the operator The thread unscrewing unit was constructed and produced in consideration of a risk analysis and according to a careful selection of the harmonized engineer standards, which have to be kept as well as in consideration of further technical specifications. Therewith it corresponds to the state of technology and guarantees the maximum possible safety. In the operating practice this security can only be reached, if all necessary measures are taken. It is subjected to the duty to take care of the operator to plan these measures and to control their fulfilment. In particular the operator has to secure, that: The thread unscrewing unit is only used according to regulations The system is only operated in faultless, fully functional condition and that in particular the safety devices are controlled regularly concerning their functional efficiency. Necessary personal protective equipments for the operating-, maintenance- and repair staff are available and are used. In each case the operating instructions are available at the site of operation of the system in a readable and complete condition. Only sufficiently qualified and authorised staff operates, maintains and repairs the system. This staff is regularly trained in all appropriate questions concerning operational safety and envi ronment protection, and that the staff knows the operating instructions and particularly the safety instructions, which are included. These operating instructions are preserved at the machine. It must be assured that all persons, who are operating the machine, can review the operating instructions at any time. Additionally to the operating instructions also directives in the sense of the Labour Protection. Law and the Work Equipment Ordinance have to be provided. All securityand operating information signs have to be kept in a very good readable condition. Damaged signs or signs which have become unreadable have to be exchanged immediately. 3.5 Demands on the staff Each operator of the thread unscrewing unit has to read the present operating instructions before the installation, the maintenance, the initial operation, the operating or the disassembly. It has to be secured that the operator has completely understood the present operating instructions and conducts itself always according to the instructions and recommendations of these operating instructions. Therefore the operator of the tread unscrewing unit should repeatedly read the present operating instructions carefully in regular intervals. The operating company is responsible for the training of the operator of the thread unscrewing unit. Each operator needs basic experiences in control engineering, electrical engineering, mechanics and hydraulics. 12

4. Transport Survey In this chapter you will find the following subchapters: Dimensions and weight Transit support 4.1 Dimension and weight Height/width/length in mm Weight: see data sheet in the appendix see data sheet in the appendix 4.2 Transit support The connectors have to be closed against leakage during the carriage 5. Installation Survey In this chapter you will fin the following subchapters: Requirements of the environment Assembly 5.1 Requirements of the environment 2 13

5.2 Assembly The thread unscrewing unit has to be connected firmly with the injection mould; it may not loosen or shift. The thread unscrewing unit may only be attached, where no things can fall down on the thread unscrewing unit. If this is not possible, the thread unscrewing unit has to be protected by a protective covering. Thread core support Fixing screw Thread core Guiding threaded nut Thread core support Both parts are screwed together According to the customer s specifications the pitch of the thread which has to be demoulded, is already in advance manufactured in the threaded nut and the core support at delivery. The toolmaker fabricates only the forming thread core. The pitch of the guiding thread and the thread core must always correspond. 14

6. Initial operation Survey In this chapter you will find the following subchapters: Supply and removal connections Preparations for the first start Execution of the first start Controls after the first start 6.1 Supply and removal connections Hydraulic connection The thread unscrewing unit is operated with hydraulic oil from 10-140 bar. A hydraulic hose, at minimum of the type series 8S from the hydraulic aggregate of the injection moulding machine to the thread unscrewing unit has to be passed. The utilisation of the overflow oil line connection prolongs the service life of the shaft sealing of the Sauer-Danfoss hydraulic motors by a multiple. For this, establish a connection with the delivered oil leakage pipe (plastic hose Ø 6 mm) from the hydraulic motor to the hydraulic holding tank of the injection moulding machine, on which the thread unscrewing unit should be used. Absolutely secure that the leak oil can flow unpressurised in the hydraulic holding tank of the injection moulding machine. Also consider the further operating instructions for the Sauer-Danfoss Hydraulic Motors, particularly the indications concerning the maximal operating pressures. Electrical connection The threat unscrewing unit may not be operated without the included limit switches. Only these limit switches secure an exact positioning of the respective end positions. For the connection of the limit switches please consider the electric connecting diagrams concerning the core puller control of the injection moulding machine, at which the thread unscrewing unit should be used. Secure that the core puller control operates the hydraulic motor of the thread unscrewing unit in the end positions unpressurised. Don t operate further devices with the core puller control which is provided for the thread unscrewing units. If besides the thread unscrewing unit also further devices should be operated, then absolutely use an injection moulding machine with a multicore puller control. 15

6.2 Preparations for the first start The thread unscrewing unit has to be mounted firmly on the injection mould, it may not loosen or shift. All connections have to be joined correctly. 6.3 Execution of the first start Carry out test run to control the adjusted values. Example of a mould with thread unscrewing unit and core puller cylinde 16

6.4 Example of assembly Thread unscrewing unit complete Thread core Insertion of the thread core in the thread core support backwards till the stop Fix the thread core by means of 2 screws Screw the thread core support in the guiding threaded nut Hold both, thread core support and guiding threaded nut, ready 17

Attach the base plate with the two thread core supports and the guiding threaded nuts at the mould by means of fixing screws and tighten them firmly. Plug the gear plate on the thread core supports and fix it with the cylinder head screws. Rotate the gear wheels till the stop is reached. Not before both thread core supports were screwed on the stop, attach and fix the motor. Adjust the desired parameters in the core puller control of the injection moulding machine. Connect the hydraulic tube to the valve of the core puller control. Connect the limit switch with the electronics of the core puller control. 18

Upper limit switch Bottom limit switch Set the adjusting collars at the adjusting collar tube (bottom end position) Adjust the adjusting collars at the adjusting collar tube (upper end position) Execute test run of the correct positioning Start production During the setting it is important to extend with less pressure (to the stop) and to retract with more pressure (unscrewed). This can optionally be adjusted in the core puller control of the injection moulding machine, for example use for the extension 40 bar and for the retraction 80 bar. This guarantees that the thread core supports can loosen again from the stop. If they are once stuck at the stop, in the gear wheel borings exist, which can be used as point of application by means of a face spanner for the loosening without being forced to dismount the thread-unscrewing unit. 6.5 Controls after the first start After the first start control the correct function of the thread-unscrewing unit in connection with the injection moulding machine. Control the made settings. 19

7. Operation Survey In this chapter you will find the following subchapters Allowed operator stations The switching-on of the thread unscrewing unit 7.1 Allowed operator stations The operating of the thread unscrewing unit may only be effected from the same operator stations as the injection moulding machine. IMPORTANT ANNOTATION! All other stations are not necessary for the operation of the thread unscrewing device and are therefore not allowed. 7.2 The switching-on of the thread unscrewing unit The switching-on of the thread unscrewing unit may exclusively be effected by means of the core puller control. 20

8. Maintenance Survey In this chapter you will find the following subchapters Things you have to consider Visual inspection Cleaning Maintenance Repairs 8.1 Things you have to consider The basics: Only effect maintenance- and cleaning works, when the thread unscrewing unit is switched off Inform the maintenance staff immediately about any defect, any leakage or any damage. All maintenance- and repair works may only be effected by specially trained staff. After the first 2 operating hours all screwed fastenings of the whole thread unscrewing unit have to be controlled and if necessary have to be retightened. Thereafter all 100 operating hours. Spray the guiding threaded nut and the thread core support all 100 operating hours with thin fluid oil (WD-40 or equivalent). Please consider the further operating instructions and limits for the Sauer-Danfoss Hydraulic Motors. In particular the indications about the maximal operating pressures. 8.2 Visual inspections Content: Here you learn which visual inspections are necessary to guarantee the functional capability of the thread unscrewing unit. Regular visual inspections: Please effect the following visual inspections: Leak tightness monthly Defect cables and lines monthly Control oil leakage pipe monthly Before each working shift the thread unscrewing unit has to be examined concerning conspicuous defects. If defects are found, these have to be corrected before start of work. 21

8.3 Cleaning Content: Here you learn which regular cleanings are necessary to guarantee the functional capability of the thread unscrewing unit. Strong fouling can cause disruption in operation. Therefore clean on demand, but not later than 100 operating hours the following parts of the system: Guiding thread nut Thread core support Adjusting collar tube Adjusting collar 8.4 Maintenance Content: Here you learn which regular maintenance works are necessary to guarantee the functional capability of the thread unscrewing unit. Dismountings, maintenance works and repairs may only be effected by trained staff. For dismounting, maintenance or repair all connections of the thread unscrewing unit to the energy sources have to be cut. In particular the connections to the hydraulic aggregate and to the current source have to be cut. Protective clothing has to be worn. Always discharge the hydraulic pressure before maintenance- and repair works. Death or serious injuries may occur because of hydraulic oil which escapes with high pressure out of the hydraulic motor of the thread unscrewing unit. Before dismounting clean the thread unscrewing unit efficiently. Dangerous ingredients, which are a peril for health or the environment, have to be completely removed from the hydraulic motor of the thread unscrewing unit. After the first 2 operating hours all screwed fastenings of the whole thread unscrewing unit have to be controlled and if necessary be retightened. Thereafter all 100 operating hours. Spray the guiding threaded nut and the thread core support all 100 operating hours with thin fluid oil (WD-40 or equivalent). Consider the further operating instructions and limits for the Sauer-Danfoss Hydraulic Motors. In particular the indications about the maximal operating pressures. 22

9. Removal from service Survey In this chapter you will find the following subchapters: Preliminary removal from service Final removal from service Removal 9.1 Preliminary removal from service Content: Here you learn which measures are necessary to remove the thread unscrewing unit finally from service. The final removal from service may only be effected by specially trained operators. Bring the thread unscrewing unit in its upper end position (unscrewed) Deactivate the thread unscrewing unit in the core puller control. Cut the thread unscrewing unit from the energy sources and lines. Dismount the thread unscrewing unit from the injection mould. 9.2 Final removal from service Content: Here you learn which measures are necessary to remove the thread unscrewing unit finally from service. The final removal from service may only be effected by specially trained operators. Bring the thread unscrewing unit in its upper end position (unscrewed) Deactivate the thread unscrewing unit in the core puller control. Cut the thread unscrewing unit from the energy sources and lines. Dismount the thread unscrewing unit from the injection mould. 23

9.3 Removal Content: Here you get information concerning the removal of the thread unscrewing unit. Remove all parts of the thread unscrewing unit in such a manner that health problems and environment damages are excluded. You get special advices for the removal: From the documentation and the data sheets of the suppliers From your environmental protection officer 10. Additinal information Survey In this chapter you will find the following subchapters: Service addresses Assembly dimensions, dimensions, drawings of the thread cores 10.1 Service addresses Content: Here you get information concerning the service addresses of the thread unscrewing unit. Service exclusively by: STRACK NORMA GmbH & Co. KG 10.2 Assembly dimensions, dimensions, drawings of the thread In the following appendix you will find assembly dimensions and dimensional drawings of the thread unscrewing units. Additionally you will find dimensional drawings of the thread cores, which are fixed in the thread unscrewing unit. 24