Operating Instruction Booklet...Finder and bit are not included in the delivery capacity of the spring sleeve. You will find suitable inserting tools in our catalog D3320 or on the

013742en

Operating Instruction Booklet

- Original instructions -

EC-Screwdriver Spindle for stationary use

MINIMAT-EC

Size 22 320E22-00120 420988 D

320E22-00200 420988 E

NOTICE ALL DOCUMENTATIONS ! Before beginning work this operating instruction booklet and the enclosed safety instructions (no. 016000, pink-colored booklet) have to be read through carefully. Always follow the instructions during operation. Give this operating in-struction booklet and the appropriate safety instructions to the operator.

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Contents

1 SIGNAL WORD AND SYMBOL DEFINITION ...............................................................3 2 SAFETY INSTRUCTIONS .............................................................................................4 3 INTENDED USE ............................................................................................................6 4 DELIVERY CAPACITY..................................................................................................6 5 GENERAL......................................................................................................................7 6 ASSEMBLY INSTRUCTIONS .......................................................................................8 6.1. Installation Instructions...............................................................................................8 6.2. Dimension Sheet ........................................................................................................9 6.3. Installation ................................................................................................................10 6.3.1 Required Equipment...............................................................................................11 6.3.2 Optional Equipment................................................................................................12 6.4. Connect EC-Screwdriver Spindle to AST10/AST11 .................................................13 6.5. Connect EC-Screwdriver Spindle to AST(i)6 Sequence Controller ..........................14 7 OPERATION................................................................................................................15 7.1. Insert and Change Inserting Tool .............................................................................16 8 TESTING THE REPEATABILITY OF THE SCREWDRIVER ......................................17 8.1. Calibration Test Instructions.....................................................................................17 8.2. Overview of the Screwdriver Speed Settings ...........................................................17 8.3. Overview of the Screw Plate and Washer Spring Arrangements .............................18 9 MAINTENANCE AND UPKEEP ..................................................................................19 9.1. Maintenance Plan.....................................................................................................19 10 TROUBLESHOOTING.................................................................................................20 11 SHUT DOWN AND STORAGE....................................................................................20 12 TECHNICAL DATA......................................................................................................21 13 EC-DECLARATION OF INCORPORATION................................................................22 14 SERVICE LOCATIONS AND AUTHORIZED PARTNERS..........................................23

List of illustrations

Illustration 1 - Installation ...................................................................................................10 Illustration 2 - Insert and Change Inserting Tool ................................................................16

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1 Signal Word and Symbol Definition

The signal words and symbols used in the technical documentation (safety instructions, operating instruction booklet, etc.) have the following meaning:

DANGER

Indicates an immediate danger which causes serious injuries or even death if not avoided.

WARNING

Indicates a threatening danger which can cause serious injuries or even death if not avoided.

CAUTION

Indicates a danger or unsafe procedure which can cause injuries to a per-son or material damages if not avoided.

NOTICE

Indicates a potentially dangerous situation which can cause damage to the product or its surroundings if not avoided.

IMPORTANT

Indicates tips and other useful information.

In each case the symbol used does not replace the safety text. The text must always be read fully. In some cases other symbols will be used with the signal words.

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2 Safety Instructions

see also enclosed safety instruction booklet no. 016000

WARNING Potential loss of life due to electric shock! Work on electrical equipment may only be carried out by qualified electrical technicians.

WARNING Serious injuries or even death possible! Disconnect screwdriver from power supply before changing or mounting the screwdriver tool (bit, socket) or accessory.

CAUTION Screwdriver will heat-up in relation to its average load respectively sequence of operation If the selection of the type of screwdriver is incorrectly or its operation is not appropriate for the application, the tool might overheat which could result in injuries (burnings). Use the screwdriver only as described in the operating instruction booklet.

CAUTION Risk of crushing hands between holding bracket and work piece or modification parts in confined spaces. Make sure that any bracket used is correctly installed. Keep hands away from holding fixture (if used). This applies especially when unscrewing.

CAUTION Rotating drive, rotating bit/socket or drive extension. Injuries to fingers or even broken fingers. When wearing gloves (e.g. rubber coated or metal reinforced) make sure that they not become entangled. Do not wear loose fitting gloves or gloves with cut or frayed fingers.

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Never exceed the rated voltage and power.

Never hold the drive, screwdriver tool or drive extension with your hands.

If you cannot support the reaction torque of the machine independently then use a torque support (e.g. linear stand, telescopic arm, holding fixture/holder-on, support grip). It generally applies that: In any case use a torque support to absorb the reac-tion torque above: for straight screwdrivers 4 Nm; for pistol grip screwdrivers 10 Nm and for angle nutrunners 60 Nm.

If it is not possible to use a torque support, use side handles for straight and pistol grip screwdrivers. Side handles are recommended for straight screwdrivers at a torque set-ting over 4 Nm and for pistol grip screwdrivers at torque settings over 10 Nm.

Use a finder/sleeve fitting where practicable.

When using sockets or adapters (e.g. magnet holder) make sure that they are in good condition and suitable for use with this machine.

To prevent sockets breakage use only sockets (e.g. for impact or impulse screwdrivers)which are suitable for use with this machine.

After turning off the tool, the screwdriver tool will continue to rotate (inertia).

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3 Intended Use

This EC-Screwdriver Spindle is part of the EC-Screwdriving System, which is only designed for screw-assembly in an industrial environment. The MINIMAT-EC-Screwdriver Spindle of the series 320E… is designed for the stationary

use in:

Construction Slide Units Multi-Spindle Screwdriving Stations Cartesian Screwdriving Robots Gantry Screwdriving Cells DEPRAG EC-Screwdriver Spindles allow free programming of the screw tightening process. Within the power range of the selected spindle, the torque value the speed the stand-by and the direction of rotation can be adjusted individually to the assembly requirement. The EC-Screwdriver Spindle is insulated to protect against an electrical power surge.

Start-up and continuous operation of the EC-Screwdriver Spindle are only allowed in conjunction with a DEPRAG sequence controller (e.g. AST6, ASTi6, AST10 or AST11).

4 Delivery Capacity

Check that the shipment is complete and that there have been no damages in transit. Quantity Name Order No. 1 Operating Instruction Booklet 013742 1 Safety Instruction Booklet 016000 1 EC-Screwdriver 420988 D / E 1 Calibration Certificate -

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5 General

The EC-Screwdriver Spindle 320E22-00xx0 is part of the EC-Screwdriving System. The essential characteristics of this screwdriver series are:

brush-less EC-Drive with commutator over encoder torque- and angle-controlling The EC-Screwdriving System is designed for the use in an industrial environment for a maximum torque of 1.2 or 2.0 Nm (depending on the type of screwdriver Technical Data). The EC-Screwdriving System mainly consists of two components:

the EC-Screwdriver Spindle of the series 320E22-00xx0. the sequence controller AST10-1 / AST11-1 with integrated amplifier or sequence con-

troller AST(i)6 For more equipment Optional Equipment and Operating Instructions “Sequence Con-troller AST10/AST11” or “Sequence Controller AST(i)6”

IMPORTANT The operation of the screwdriver spindle requires a programmable se-quence controller (AST10-1, AST11-1 or AST(i)6) with integrated amplifier and a motor cable.

The sequence controller offers standard screwdriving programs for tightening screws to a specific torque value respectively loosening at a specific angle value. Their parameters are adjustable directly via the controller’s keyboard. Special screwdriving sequences are easy to create: standard assembly steps, already stored in the controller, can be selected and comfortably built up to form a complete as-sembly process. This happens via the integrated web server’s PC operator board. No special PC software is required – only a normal web browser (such as MS explorer) and an Ethernet port. Additional software modules for documentation and screw join analysis (data logging, graphics, etc.) are available as optional equipment. Also optionally available is an update service for the sequence controller which provides continuous update of the controller’s function and control software. The controller’s integrated display and operating unit indicates the operating mode and assembly status. It also allows a direct change of parameters (such as speed, torque and angle values etc.) within the assembly process and without the need of a PC connection. In automatic mode, the sequence controller communicates with the system’s PLC. Screwdriving programs can be selected and started. After completion of the assembly process, the sequence controller will report the status of the result to the PLC. An Ethernet port allows the network of more screwdriver spindles (i.e. multi spindle sys-tems) with centralized process monitoring (graphics, statistics, individual data sets, etc.).

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6 Assembly Instructions

WARNING Potential loss of life due to electric shock! Before working on the tool (e.g. assembly, installation and maintenance) disconnect the electric equipment from power supply (switch off main switch and pull out main plug).

6.1. Installation Instructions

When installing the EC-Screwdriver Spindle the following points have to be observed:

Install the EC-Screwdriver Spindle according to the Dimension Sheet. The EC-Screwdriver Spindle may be installed in any orientation. Use only mounting brackets having a sufficient size ( Dimension Sheet). Use only the mounting elements delivered to mount the EC-Screwdriver Spindle. Level the EC-Screwdriver Spindle and the screwdriving position so that there are no or

only low radial forces (e.g. by dead load).

Support plates are not included in delivery of the EC-Screwdriver Spindle. Make sure to choose a suitable material (e.g. steel with tensile strength Rm 370 N/m²) for support plates.

Make sure not to exceed the max. driver stroke ( Dimension Sheet) dur-ing screwdriving.

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6.2. Dimension Sheet

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6.3. Installation

see also Dimension Sheet as well as Operating Instructions “EC-Screwdriving System”

Illustration 1 - Installation

Motor Cable KMO-AST10

EC-Screwdriver 320E22-00xx0

Sequence Controller AST10/AST11

measuring cable KN-AST10

or Sequence Controller AST(i)6

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6.3.1 Required Equipment

Name Order No. Sequence controller AST10-1 Sequence controller AST10-1-P (prepared for Profibus) OR Sequence controller AST10-1-P kpl. (with integrated Profibusmodule)

385440 A 385440 B 385440 P

Motor cable KMO-AST1x (length 8.2 / 16.4 / 26.2 / 39.4 ft.) to connect EC-screwdriver spindle with sequence controller

385442 A / B / C / D

alternativ: Motor cable with angle connection 90° KMO-AST1x (length 8.2 / 16.4 / 26.2 / 39.4 ft.) to connect EC-screwdriver spindle with sequence controller

385442 E / F / G / H

Power supply cable KN-AST10/11/40 (length 5.9 ft. EU / 5.9 ft. US, 8.2 ft. CHINA) to connect sequence controller to power supply

385443 A / B / C

Name Order No. Sequence controller AST11-1 OR with module „safety stop“ Sequence controller AST11-1-S

390041 A 390041 B

Motor cable KMO-AST1x (length 8.2 / 16.4 / 26.2 / 39.4 ft.) to connect EC-screwdriver spindle with sequence controller

385442 A / B / C / D

alternativ: Motor cable with angle connection 90° KMO-AST1x (length 8.2 / 16.4 / 26.2 / 39.4 ft.) to connect EC-screwdriver spindle with sequence controller

385442 E / F / G / H

Power supply cable KN-AST10/11/40 (length 5.9 ft. EU / 5.9 ft. US, 8.2 ft. CHINA) to connect sequence controller to power supply

385443 A / B / C

Connector cable AST10-Screwfeeder 385477 A

Name Order No. Sequence controller AST6-1 428001 A Sequence controller ASTi6-1 (without display) 428004 A Power supply cable 230V-1.8 m / 5.9 ft Power supply cable 115V-1.8 m / 5.9 ft

812587 812295

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6.3.2 Optional Equipment

Name Part No. Spring sleeve cpl.

without screw suction with screw suction

364672 A 364672 C

For more equipment – see Operating instruction AST10 and leaflet D3490 E.

Finder and bit are not included in the delivery capacity of the spring sleeve. You will find suitable inserting tools in our catalog D3320 or

on the internet as follows: www.deprag.com Screwdriving Technology Selection program: Inserting tools

Assembly- and Spare Parts Drawing Spring Sleeve cpl. 364672 A

Assembly- and Spare Parts Drawing Spring Sleeve cpl. 364672 C

All catalogs are available for download from our web site: www.deprag.com

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6.4. Connect EC-Screwdriver Spindle to AST10/AST11

see chapter DIMENSION SHEET as well as Instructions „Sequence Controller“

CAUTION Differing power supplies can result in injuries to persons or damage to the equipment Before connecting electrical power, insure that your power supply is compatible with that recommended for the controller ( Technical Data).

Plug-in the motor cable at the sequence controller and fix it.

ATTENTION During operation malfunctions or damages can be caused to the contacts. Fully tighten the plug connection between screwdriver and screwdriver cable!

Plug-in the other end of the motor cable into the upper connection of the EC-screwdriver spindle and then fully tighten the motor cable. Do this by first tightening the plug connection a little and then pushing it in and then tightening it further. This should be repeated as many times as necessary until the thread cannot be turned and tightened any more.

Main switch

Connect the sequence controller to the power supply. Switch on the sequence controller on main switch. Enter the calibration value and the value of the calibration offset in the sequence controller. You will find this values in the calibration certificate ( Operation Instruction “Sequence Controller”).

IMPORTANT For more information about the start-up of the sequence controller, read the quick-start instructions of sequence controller AST10 or AST11 with 320E....Screwdriver which is also included in delivery.

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6.5. Connect EC-Screwdriver Spindle to AST(i)6 Sequence Controller

see chapter DIMENSION SHEET as well as Instructions „Sequence Controller AST(i)6“

CAUTION Differing power supplies can result in injuries to persons or damage to the equipment Before connecting electrical power, insure that your power supply is compatible with that recommended for the controller ( Technical Data).

Plug-in the motor cable at the sequence controller and fix it.

ATTENTION During operation malfunctions or damages can be caused to the contacts. Fully tighten the plug connection!

Connect the sequence controller to the power supply. Switch on the sequence controller on main switch. Enter the calibration value and the value of the calibration offset in the sequence controller. You will find this values in the calibration certificate ( Operation Instruction “Sequence Controller AST(i)6”).

IMPORTANT For more information about the start-up of the sequence controller, read the quick-start instructions of sequence controller AST(i)6 with 320E....Screwdriver which is also included in delivery.

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7 Operation

This design of Screwdriver may be operated in connection with a sequence controller only.

CAUTION

The turning bit may cause an injury to fingers or hands.

Trained personnel may operate the EC-screwdriver spindle only.

IMPORTANT Proceed with the operating according to the “Operating Instructions Se-quence Controller AST10”.

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7.1. Insert and Change Inserting Tool

Disconnect screwdriver spindle from power supply before changing or mounting the screwdriver tool (bit, socket).

IMPORTANT Use only high-quality inserts (e.g. bits) and connecting components with external drive E6.3 as per DIN ISO 1173 respectively external drive E11.2 as per DIN ISO 1173.

You will find suitable inserting tools

in our catalog D3320 or on the internet as follows: www.deprag.com

Screwdriving Technology Selection program: Inserting tools

The screwdriver spindle is equipped with a quick change chuck.

To remove or insert the bit, pull the sleeve into the front. Push the bit into the hex until it locks. Let the sleeve snap back. Drive E 6.3.

Illustration 2 - Insert and Change Inserting Tool

Sleeve

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8 Testing the repeatability of the Screwdriver

To insure the reliability of the reported screwdriving results the user should perform a periodic review or recalibration of the screwdriver and screwdriver electronic controller. The interval or number of assembly cycles in between the calibration check should be defined by the user and the users in house policy.

8.1. Calibration Test Instructions

Testing of the screwdriver is performed using the spring table information from point 8.3. Overview of the Screw plate and Washer Spring Arrangements.

In addition a 1 step program using the command parameter „Drive To Torque“ should be set in the AST Controller.

The Screwdriver speed in the 1 step program should be set according to point 8.2. Overview of the Screwdriver Speed Settings.

8.2. Overview of the Screwdriver Speed Settings

Screwdriver Series 320E – Default Speed Setting

Screwdriver Model Speed (rpm) 320Exx22-00005 240 320Exx22-00012 240 320Exx22-00025 200 320Exx22-00050 160 320Exx22-00080 120 320Exx22-00120 150 320Exx22-00200 100 320Exx27-0004-x 120 320Exx27-0014-x 50 320Exx27-0010/0018-x 200 320Exx27-0022-x 140 320Exx27-0024-x 100 320Exx27-0035-x 100 320Exx27-0040-x 50 320Exx27-0042-x 80 320Exx27-0050-x 30 320Exx27-0060-x 60 320Exx36-0040-x 200 320Exx36-0060-x 150 320Exx36-0090 110 320Exx36-0120-x 80 320Exx36-0180-x 50 320Exx36-0250 35 320Exx36-0280 30

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8.3. Overview of the Screw Plate and Washer Spring Arrangements

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9 Maintenance and Upkeep

WARNING Assembly and maintenance work may only be carried out by service personnel of the company DEPRAG. Incorrect assembly or maintenance work could create hazards for the op-erator and cause damage to the EC-screwdriver.

WARNING Potential loss of life due to electric shock! Disconnect screwdriver spindle from power supply before performing main-tenance and repair work!

The maintenance of the EC-screwdriver may only be carried out by DEPRAG service per-sonnel. The maintenance covers all disassembly and inspection of all mechanical parts as well as the cleaning and re-greasing of all moveable parts (gear, drive). After each maintenance check the shut-off accuracy and if necessary re-calibrate. For this reason it is advisable to carry out maintenance work and re-calibrations of the screwdriver at regular intervals.

9.1. Maintenance Plan

IMPORTANT Adapt the maintenance work depending on the condition of the machine and amount of wear in each individual case.

No. Work to be carried out Cycles Notes 1. Check machine for external

damage Before starting work Replace worn or damaged

cables and parts. 2. Check inserting tool for wear

and tear and if it is undamaged

Before starting work Replace worn or damaged inserting tools immediately.

For further maintenance and repair work, send the machine to DEPRAG.

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10 Troubleshooting

Please consult the operation instruction “Sequence Controller AST10/AST11“ or “Sequence Controller AST(i)6“

Possible faults and their causes are shown below:

Fault Cause Solution No power supply Check correct connection of the motor

cable. Sequence controller not switched on

Switch the sequence controller on at the main switch. AST10/AST11 chapter Connections an Pin Layout AST(i)6 chapter Assembly Instruction

EC-screwdriver does not start

Controller displays error message

see Operating Instruction AST10/AST11 chapter 10 Troubleshooting AST(i)6 chapter Error Display and Troubleshooting

If necessary, please send the tool to DEPRAG for service. For further examples of faults please consult the instruction manual of the sequence controller AST10, AST11 or sequence controller AST(i)6.

11 Shut Down and Storage

For shut-down perform the following steps:

No. Action

1. Disconnect the electric equipment from power supply (switch off main switch and pull out main plug).

2. Disconnect the screwdriver from the power supply. 3. Close all connections (with protection caps).

The screwdriver may now be stored until needed again.

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12 Technical Data

Type 320E22-00120 320E22-00200 Order No. 420988 D 420988 E Torque min. (Nm/in.lbs) 0.24 / 2.12 0.40 / 3.54 Torque max. *) (Nm/in.lbs) 1.20 / 10.62 2.0 / 17.7 Speed min. (rpm) 50 30 Speed max. *) (rpm) 900 550 Weight (kg/lbs) 0.62 / 1.38 0.62 / 1.38 Noise level (dB(A)) 60 60 Line Voltage (DC) (V) 24 24 Internal hex.drive (DIN ISO 1173)

F6.3 (¼ “) F6.3 (¼ “)

Suitable inserting tools and connection parts with DIN ISO 1173 inserting end

E 6.3 (¼ “) E 6.3 (¼ “)

Vibration (m/s²) < 2.5 **) < 2.5 **) *) as per VDI/VDE 2647 **) as per EN 60745

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13 EC-Declaration of Incorporation

EC-Declaration of Incorporation in accordance with the EC Machinery Directive 2006/42/EC, Annex IIB

As manufacturer of the partly completed machine we declare that:

the essential requirements of the Directive 2006/42/EC and where applicable the other Direc-tives and Standards listed below apply to the specified machine.

the relevant technical documentation is compiled in accordance with part B of Annex VII. the relevant technical documentation in accordance with part B of Annex VII will be transmitted

in response to a reasonable request by the national authorities in printed form or in electronic form (pdf).

Manufacturer DEPRAG SCHULZ GMBH u. CO. P.O. Box 1352, Germany-92203 Amberg Carl-Schulz-Platz 1, Germany-92224 Amberg Authorized Person Mr. Josef Bock, address see manufacturer for Documentation Name EC-SCREWDRIVER

Machine Type _________________________________________________________ Serial Number _________________________________________________________ Year of Manufacture _________________________________________________________

Directives Date

2006/42/EG 2006-06 2006/95/EG 2006-12 2004/109/EG 2004-12 Standards Date

DIN EN ISO 12100 2011-03 IEC 801 2007-10 EN 50082-1 1999-09 EN 61000-4-11 2005-02 DIN VDE 0846, 0843, 0871 1994-08; 2008-06 EN 55011 Kl. A 2011-04

This partly completed machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with the provisions of the Directive 2006/42/EC, where appropriate.

02/06/2014

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14 Service Locations and Authorized Partners

Contacts in Germany

as well as

contacts worldwide

can be found on our web site

www.deprag.com

If you need any further information then please either contact your representative or us directly at DEPRAG SCHULZ GMBH u. CO. During business hours our Service-Hotline + 49 (0) 700 00 371-371 is available for German and English speakers. NOTICE: This hotline is subject to charges outside business hours!

DEPRAG SCHULZ GMBH u. CO. P.O. Box 1352, 92203 Amberg, Germany Carl-Schulz-Platz 1, 92224 Amberg, Germany Service Hotline +49 (0) 0700 00 371-371 +49 (0) 9621 371-0 Fax: +49 (0) 9621 371-120 Internet: http://www.deprag.com e-mail: [email protected]

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