DGD-Intelligent spindles - quality industrial tools
Contents
1. 4 1 Drilling templates in mounting plate 4 1 1 Size 1 Straight attachment 1ZB 4 gt f 31 1 0 1 Offset attachment 1VK B 10 P1916E EN 2012 01 16b Einbau en fm 07 03 2012 Installation 4 1 2 Size 2 Straight attachment 2ZB 035 92 0 1 S 5 29 I mee 35 92 0 1 Offset attachment 2VK B Cd ex Angle head attachment 2WK B amp 16b_Einbau en fm 07 03 2012 P1916E EN 2012 01 11 Installation 4 1 3 Size 3 Straight attachment 3ZB x 268 a 8 E A d EG lt 58 89 0 1 Offset attachment 3VK B 11 0 1 ii Eh 3 07 60 0 3 j Angle head attachment 3WK B J u 7 E 16b Einbau en fm 07 03 2012 P1916E EN 2012 01 Installation 4 1 4 Size 4 Straight attachment 4ZA Straight attachment 4Z1250A 4Z16002. Assembly Instructions P1916E ENrev 2012 01 DGD Intelligent spindles Series BTS For additional product information visit our website at http www apextoolgroup com About the assembly instruction This assembly instruction is the translation of the original assembly instruction and provides important information on safe and correct installation Secondary information P1779E System manual nutsetter control unit m Pro 400S E P1792bE Operator information Nutsetter control unit m Pro 400S E P1909E Spare parts sheet Tightening module P1910E P1911E P1912bE Spare parts sheet Attachment P1913E Spare parts sheet Gearing P1914E Spare parts sheet Motor P1915E Spare parts sheet Transducer P1917E System handbook Modular fastening system m Pro 400S DGD intelligent spindles P1918E Assembly instructions TS TUS tightening module P1919E Assembly instructions Supply module CPS3 P1921E Service manual DGD intelligent spindle Symbols in text gt Identifies instructions to be followed Identifies lists Abbreviations m Pro 400S E Nutsetter control m Pro 400S CPM Nutsetter control unit TS TUS Tightening module 83 Supply module DGD ISD DGD intelligent spindles Symbols in graphics lt Identifies movement in a direction n Identifies function and force Disclaimer Apex Tool Group reserves the right to modify supplement or improve this document or the product without prior notice This document
3. Ltd IndustriestraBe 1 Piccadilly BP 28 A company of 73463 Westhausen Tamworth 25 Avenue Maurice Chevalier Apex Tool Group LLC Germany Staffordshire 77831 Ozoir la Ferri re Cedex A8 No 38 Dongsheng Phone 49 73 63 81 0 B78 2ER France Road Shanghai Fax 49 73 63 81 222 U K Phone 33 1 64432200 China 201201 Phone 444 191 4197700 Fax 33 1 64401717 Phone 86 21 60880320 Fax 44 182 7874128 Fax 86 21 60880298 Mexico Brazil Cooper Tools Cooper Tools Industrial Ltda de M xico S A de C V a company of a company of Apex Tool Group LLC Apex Tool Group LLC Av Liberdade 4055 Vialidad El Pueblito 103 Zona Industrial Iporanga Parque Industrial Quer taro 18087 170 Sorocaba SP Brazil Quer taro QRO 76220 Phone 455 15 3238 3929 Phone 52 442 211 3800 Fax 55 15 3228 3260 Fax 52 442 103 0443 Apex Tool Group GmbH amp Co OHG IndustriestraBe 1 73463 Westhausen Germany Phone 49 7363 81 0 Fax 49 7363 81 222 www apexpowertools eu
4. WARNING A CAUTION A A symbol combined with the word DANGER warns of an impending health risk or risk of fatal injury to personnel If this danger note is not adhered to severest injury that may lead to the death of people is the consequence A symbol combined with the word WARNING warns of a potentially dangerous situation for the health of personnel which could result in death or serious injury if not avoided A symbol combined with the word CAUTION warns of a potentially harmful situation for the health of personnel or damage to property or the environment If this warning is not observed injuries property or environmental damage may occur This symbol indicates a general instruction General instructions include application tips and special useful information but no warnings against dangers Basic requirements for safe working practices Take the fastening system into service only after you have read and completely understood the following safety instructions and this document Failure to observe the instructions below may result in electric shock fire and serious injuries High leakage current Fatal electric shock could occur gt gt gt Always disconnect the power supply before performing maintenance work on the DGD IS and the m Pro 400S CPM Always disconnect the system cable motor or motor cable from the m Pro 400S CPM or DGD IS before making throughput resistance and short circuit measu
5. amp Service Center if necessary A Sharp cooling fins on the m Pro 400S CPM may cause cutting injuries gt Wear gloves when transporting and assembling the machine System components Storage temperature Relative humidity DGD IS 20 to 70 C 0 to 90 no condensation m Pro 400S CPM 20 to 70 C 0 to 90 no condensation TS TUS 20 to 70 C 0 to 90 no condensation Motor 20 to 70 C 0 to 90 no condensation CPS3 25 to 70 C 0 to 90 no condensation 17b_Sicherheit_bedingt en fm 07 03 2012 P1916E EN 2012 01 7 Overview Overview 3 16b Einbau en fm 07 03 2012 P1916E EN 2012 01 Overview Components 3 1 900 880196 900 880196 G00 880196 G00 880 196 G00 880 196 G00 880196 00 8801 96 00 8801 96 00 8801 96 00 8801 96 00 880196 00 880196 00 880196 00 880196 200 880196 OVINM 200 880196 OVINM 200 880196 OVINM c00 880196 OVIAM o qeo MV MVINM 200 680196 MVINM 200 680196 MVINM Jeonpsuel 962986 Jeydepy 996766 v6tve6 geyMr 676766 d MMc S9 v 6 peau 6 gxr c8 V 6 HOMMES CLEVES LIMA 796766 666766 SVMAY 098466 796766 8 MAY 6 8 MAcC 198666 8c2MAL 64676
6. as a hand held tool Always use the DGD IS in combination with the nutsetter control unit m Pro 400S CPM The DGD IS must be fully assembled Insert and lock all connecting cables Secure the DGD IS to an electroconductive mounting plate Always use the DGD IS in combination with the control unit m Pro 400S CPM Only cable types approved by DGD may be used Only accessory parts approved by DGD may be used Unauthorized alterations repairs and modifications are prohibited for reasons of safety and product lia bility Do not operate the DGD IS outdoors Y Always remove the complete DGD IS from a unit Do not open the transducer offset attachment or angle head attachment as this will void the war ranty A repair is only permitted by DGD authorized personnel If repair is required send the com plete component to Sales amp Service Center Do not open the TS TUS or CPS3 as this will void the warranty This does not include the service panel A repair is only permitted by DGD authorized personnel If repair is required send the complete component to Sales amp Service Center Read the following documents when replacing the DGD IS These assembly instructions The system manual m Pro 400S DGD intelligent spindles Service manual DGD IS Spare part sheets y 2 Transport Storage WARNING Transport only in the original packing If the package is damaged check the part for visible damage Inform the carrier or Sales
7. outer diameter of plug connectors with a slide lock should not be visible z m z m Always terminate the ARCNET with an ARCNET terminator at the bus end i e at the last DGD IS order no 961127 This terminator is installed permanently in the nutsetter control unit m Pro 400S CPM bus start 6 Connect the mains cable to the nutsetter control unit DANGER High leakage current Fatal electric shock could occur Establish a grounding connection PE to the nutsetter control unit before taking into operation gt 7 Preset the ARCNET address on each DGD IS under the service panel see System handbookm Pro 400S DGD intelligent spindles Each address can be used only once in the system z m 8 Close the service panel 9 Close the protective devices e g safety grilles 10 Switch on the machine control unit PLC SPS 11 Switch on the nutsetter control unit If there are no faults pending after switching on the unit the Ready LED on the DGD IS lights up green Otherwise see See system manual m Pro 400S DGD intelligent spindles Troubleshooting Ready LED 12 Enter the parameters for the torque angle setting via the m Pro 400S CPM Apex Tool Group specialist staff are responsible for pro gramming the m Pro 400S CPM prior to initial operation The first time the nutsetter control unit is switched on the parameters for controlling fastening sequences must be read in via t
8. 6 2 6766 gHOMAE 6 ALMA 098486 1950 669 65 VOO9IZY 0969 65 VOSCIZY 982126 VZV 883 76 876 200106 gzc ELARA gzL oujueo jueuluoeny 91 980766 916766 6 MENT v8cve6 ay lyr 206766 8MOME 660766 ALAZ 680766 AIAL JeonpsueJ 182966 09987 Gv 26 09091 08 986 V00S8r 674566 00 66 VSe 08l 179626 VO9SESY 064566 VOOEJE 87956 VOLIGC 976 66 VcLOSI Buue o 662986 66 S 6 862986 267466 271196 SAL 271196 SAL 271196 SNL 27 96 SNL 971196 51 971196 51 9vL196 51 971196 SL Burueiui 696666 lnav e 696666 94466 1092 696466 Indl 294466 lav e 294466 lav e 196666 182 095466 181 1O ONN N 1s g OU JOPIO JOPIO 1 p O v 6 2 L 9216 P1916E EN 2012 01 16b Einbau en fm 07 03 2012 Installation 4 Installation The DGD IS can be mounted in any direction Screw the DGD IS to a grounded electroconductive mounting plate Observe the following points during installation the service panel is accessible for one off setting of the ARCNET address warm air must not be produced under the DGD IS also from other components there are no objects obstructing the air flow at the top or bottom the housing is not exposed to direct sunlight V v
9. A gt 24 0 1 55 013 Ale 1 e Offset attachment 4 50 0 1 16b Einbau en fm 07 03 2012 P1916E EN 2012 01 13 Installation 4 2 Attaching the DGD IS to the mounting plate ZB WK Size Tightening torques E Nm 10 mm A B D 1 10 10 6 25 12 15 2 25 50 10 25 3 25 50 25 50 4 50 50 85 85 P1916E EN 2012 01 16b Einbau en fm 07 03 2012 DCD Initial operation 5 Initial operation When operating the machine for the first time read and observe the system manual or the operator informa tion for the m Pro 400S E 1 Position the DGD IS components together via flat toothed interfaces see Service manual Turn size 1 in 15 increments Turn sizes 4 to 2 in 10 increments 2 Connect all components see System handbookm Pro 400S DGD intelligent spindles 3 An additional earth connection to the tool plate to ensure function is not necessary Protective earthing of the DGD IS is guaranteed by conductor in the system cable 4 However protective earthing of moving parts has to be made acc to EN 60204 1 CAUTION Risk of tripping or falling over loose cables on the ground Lay all connected cables safely P 5 Close all plug connectors and lock The red ring around the
10. Sales amp Service Center for the appropriate facility to handle your service requirements Dallas TX Detroit MI Houston TX Lexington SC Apex Tool Group Apex Tool Group Apex Tool Group Apex Tool Group Sales amp Service Center Sales amp Service Center Sales amp Service Center 670 Industrial Drive 1470 Post amp Paddock 2630 Superior Court 6550 West Sam Houston Lexington SC 29072 Grand Prairie TX 75050 Auburn Hills MI 48326 Parkway North Suite 200 USA USA USA Houston TX 77041 Phone 1 800 845 5629 Phone 1 972 641 9563 1 248 391 3700 USA Phone 1 803 359 1200 Fax 1 972 641 9674 Fax 1 248 391 7824 Phone 1 713 849 2364 Fax 1 803 358 7681 Fax 1 713 849 2047 Los Angeles CA Seattle WA York PA Canada Apex Tool Group Apex Tool Group Apex Tool Group Apex Tool Group Sales amp Service Center Sales amp Service Center Sales amp Service Center Sales amp Service Center 15503 Blackburn Avenue 2865 152nd Avenue N E 3990 East Market Street 5925 McLaughlin Road Norwalk CA 90650 Redmond WA 98052 York PA 17402 Mississauga Ont L5R 1B8 USA USA USA Canada Phone 41 562 926 0810 Phone 1 425 497 0476 Phone 1 717 755 2933 Phone 41 905 501 4785 Fax 1 562 802 1718 Fax 1 425 497 0496 Fax 1 717 757 5063 Fax 1 905 501 4786 Germany England France China Apex Tool Group Apex Tool Group LLC Apex Tool Group SAS Apex Power Tools Tra GmbH amp Co OHG Pit Hill Zone Industrielle ding Shanghai Co
11. Torsional length 180 around separate central axis 19 7 in 500 mm min Max acceleration 328 ft s 100 m s G blue i MA G WIB M red blue um T m Ly ln gay n Lm E black lack J Hoy e ed E pink ink E p y bon F HV Versorgung A 9 0 et A 42V Versorgung B white white B MIA K 03 gay K n p zew WD C 3 een green C WO 16h Kabel en fm 07 03 2012 P1916E EN 2012 01 17 Cables DGD 6 2 KMAW type Cable between transducers tightening module TS TUS Order No 961089 002 Length 0 7 ft 0 2 m 961089 003 Length 1 0 ft 0 3 m Thermal properties Ambient temperature 58 158 F 50 70 C in fixed applications 40 158 F 40 70 C in flexible applications Flammability Flame retardant and self extinguishing in accordance with EN 50265 2 1 IEC 60332 1 and UL1581 Chemical properties of the coating Coating material PUR low adhesion resistant to hydrolysis and microbes UV resistant abrasion resistant tear resistant cut resistant notch resistant Oil resistance Oil resistant in acco
12. f the fastening electronics Operator training The fastening system may only be operated by personnel that have been trained and instructed corre spondingly and authorized by the operator The fastening system may only be maintained and serviced by personnel instructed by qualified staff from Apex Tool Group The operator must make sure that all new operating and maintenance personnel are instructed in the operation and maintenance of the fastening system to the same extent and with the same care and attention Personnel who are being trained may work on the fastening system only under the supervision of an experienced operator Personal protective equipment When working Wear the protective goggles to protect against spurting metal splinters Danger of injury by being wrapped up in and caught by machinery Wear close fitting clothing Do not wear jewelry P1916E EN 2012 01 17b Sicherheit bedingt en fm 07 03 2012 Transport Storage 1 5 Intended use The owner is responsible for using the machine according to its designated use When assembling the incomplete DGD IS machine the following conditions must be fulfilled so that the other components can be attached correctly to the machine and assembly can be completed without affect ing the safety and health of personnel NOTE The DGD IS is designed for stationary operation only and is intended exclusively for fastening and loos ening thread connections Do not use
13. he keyboard or a valid parameter file See m Pro 400S operator infor mation for details of nutsetter control unit process programming 17d Inbetriebnahme bedingt en fm 07 03 2012 P1916E EN 2012 01 15 Initial operation Blank page 16 P1916E EN 2012 01 17d Inbetriebnahme bedingt en fm 07 03 2012 Cables 6 Cables 6 1 KMAG type Cable between transducers tightening module TS TUS Order No 961088 002 Length 0 7 ft 0 2 m 961088 003 Length 1 0 ft 0 3 m 961088 004 Length 1 3 ft 0 4 m 961088 005 Length 1 6 ft 0 5 m 961088 006 Length 2 0 ft 0 6 m Thermal properties Ambient temperature 58 158 F 50 70 C in fixed applications 40 158 F 40 70 in flexible applications Flammability Flame retardant and self extinguishing in accordance with EN 50265 2 1 IEC 60332 1 and UL1581 Chemical properties of the coating Coating material PUR low adhesion resistant to hydrolysis and microbes UV resistant abrasion resistant tear resistant cut resistant notch resistant Cil resistance Oil resistant in accordance with DIN VDE 0472 part 803 ASTM oil 1 to 3 Resistance to hydrolysis In accordance with VDE 0283 part 10 Color Gray RAL 7040 Mechanical properties Diameter approx 0 3 in 8 mm Bending radii Single bends 1 2 30 mm Multiple bends 3 1 in 80 mm min flexing action
14. ing connection PE to the nutsetter control unit m Pro 400S CPM before taking into operation WARNING High temperature the motor on the DGD IS may heat up and cause burns during removal max engine temperature 90 C Wear gloves Regular maintenance reduces operating faults repair costs and downtime Implement a safety related maintenance program that takes the local regulations for repair and maintenance for all operating phases of the tool into account 8 Disposal CAUTION Injuries and environmental damage from improper disposal A Components of the DGD IS pose risks to the health and the environment gt DGD IS contains components that can be reused as well as components that require special disposal Separate the components and dispose of them by segregating them clearly gt Catch auxiliary materials oils greases when drained and dispose of them properly gt Separate the components of the packing and dispose of them by segregating them clearly gt Follow the locally applicable regulations Act ElektroG Observe generally valid disposal guidelines such as in Germany the Electrical and Electronic Equipment gt Hand in the DGD IS at your company collection point or return to Sales amp Service Center 17m Wartung Entsorgung bedingt en fm 07 03 2012 P1916E EN 2012 01 19 Sales amp Service Centers Note All locations may not service all products Please contact the nearest
15. may not be reproduced in whole or in part in any way shape or form or copied to another natural or machine readable language or to a data carrier whether electronic mechanical opti cal or otherwise without the express permission of Apex Tool Group DGD is a trademark of the Apex Tool Group Division 2 P1916E ENrev 2012 01 16a Deckbl en fm 07 03 2012 Contents 1 Safety 5 1 1 Warnings and notes een 5 1 2 Basic requirements for safe working practices 5 1 3 Operator training Ew 6 1 4 Personal protective equipment 2 22 6 1 5 Intended Use nun 7 2 Transport Storage 7 Overview 8 3 1 Components ica T 9 4 Installation 10 4 1 Drilling templates in mounting 10 4 2 Attaching the DGD IS to the mounting 14 5 Initial operation 15 6 Cables 17 6 1 KMAG Dee 17 6 2 KMAW ES m KE 18 7 Maintenance Service 19 8 Disposal 19 1916 2012 01 Montage DGD ISIVZ fm 07 03 2012 P1916E ENrev 2012 01 3 P1916E ENrev 2012 01 P1916E EN 2012 01 REV Montage DGD ISIVZ fm 07 03 2012 Safety 1 1 1 DANGER P WARNING gt Safety Warnings and notes CAUTION z eir 1 2 IN
16. rdance with DIN VDE 0472 part 803 ASTM oil 1 to 3 Resistance to hydrolysis In accordance with VDE 0283 part 10 Color Gray RAL 7040 Mechanical properties Multiple bends Diameter approx 0 3 in 8 mm Bending radii Single bends 1 2 in 30 mm min 3 1 80 mm min flexing action Torsional length 180 around separate central axis 19 7 500 mm min Max acceleration 328 ft s 100 m s 6 M L J H E F A B K D C WB TxD RxD RD 0 12V Versorgung 12V Versorgung OV MD MD gt lt 2 gt 18 P1916E EN 2012 01 16h Kabel en fm 07 03 2012 DGD Maintenance Service 7 Maintenance Service Only trained personnel are permitted to perform maintenance See service manual DGD IS DANGER High leakage current Fatal electric shock could occur gt Always disconnect the power supply before performing maintenance work the 060 15 and the m Pro 400S CPM gt Always disconnect the system cable motor or motor cable from the m Pro 400S CPM or DGD IS before making throughput resistance and short circuit measurements gt Do not attempt to repair possible faults on the fastening system by yourself if you do not have the required knowledge Inform the local repair center or your Sales amp Service Center gt Establish a ground
17. rements Do not attempt to repair possible faults on the fastening system by yourself if you do not have the required knowledge Inform the local repair center or your Sales amp Service Center High temperature the motor on the DGD IS may heat up and cause burns during removal max engine temperature 90 C Wear gloves Risk of flying parts Components of the spindle may rotate come loose and cause injury Avoid speed increases of over 3 m s on all axes 17b_Sicherheit_bedingt en fm 07 03 2012 P1916E EN 2012 01 5 Safety CAUTION Work area A 1 3 gt Close all safety devices gt Ensure that there is enough space in the work area gt Keep the work area clean Electrical safety 2 Do not operate the DGD IS outdoors gt Observe the safety notes on the DGD IS Safe working with and around fastening tools gt Inspect screw bits and retaining ring for visible damage and cracks Replace damaged parts immediately gt Always disconnect the power supply to the DGD IS before changing screw bits Only use screw bits for machine controlled fastening tools gt Make sure that the screw bits are retained securely We do not claim that these safety notes are complete Read and observe all applicable general and local safety and accident prevention rules Follow a safety conscious maintenance program which takes into account the local regulations for main tenance and servicing in all phases of operation o
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