Instruction Manual SBZ122 20 30 Date 2007 08 EN PDF

Instruction manual
SBZ 122/20+30
Profile machining centre
Safety regulations
Always disconnect the machine from the pneumatic network and

electrical power supply before carrying out repair work, maintenance work
and servicing work of any nature.
Switch off the electrical master switch and lock it to prevent it being
switched back on again!
Switch off the pneumatic master switch, depressurise the machine and
lock it to prevent it being switched back on again!
Electrical and pneumatic systems must not be changed!
Organisational measures
The user must provide the required personnel safety equipment.
All safety devices fitted must be inspected regularly before starting work.
The user is responsible for correct insertion of the profiles into the machine.
Protective equipment
• All protective equipment must be fitted correctly and must be in operable
condition each time before placing the machine into operation.
• Protective equipment may be removed only
- after the machine has stopped and
- after the machine has been safeguarded against being placed back into
operation.
Informal safety measures

The operator has to prepare operating instructions.
Please always have the Manual ready at hand near to the machine's place of use.
In addition to the Manual, the generally valid and local regulations on accident
prevention and environmental protection must be available for inspection and must
be followed.
All safety and danger information on the machine must be kept in a legible
condition.
Never operate machine under the influence of drink or drugs, as such situations
reduce the operator’s discernment and alertness.
Personnel training
Only trained and instructed personnel may work on the machine.
Machine control
Only instructed personnel are permitted to operate the control.
Safety measures during normal operation

Please operate the machine only when all safety devices are fully operable.
Before switching the machine on, please ensure that no one can be endangered
as the result of the machine starting up.
Inspect the machine at least once per shift for outwardly visible damage and for
operability of the safety devices.
Dangers resulting from electrical power

Have work on the electrical power supply system carried out only by a qualified
electrician.
Clean the machine regularly

SBZ 122/20+30
List of contents
. 1 Safety information .......................................................................................... 1-1
. 2 Safety regulations .......................................................................................... 2-1
2.1 Organisational measures ........................................................................ 2-5
2.2 Protective equipment .............................................................................. 2-5
2.3 Informal safety measures ........................................................................ 2-5
2.4 Personnel training ................................................................................... 2-5
2.5 Machine control ....................................................................................... 2-6
2.6 Safety measures during normal operation .............................................. 2-6
2.7 Dangers resulting from electrical power ................................................. 2-6
2.8 Dangers resulting from the pneumatic system ....................................... 2-6
2.9 Points posing a particular danger ........................................................... 2-7
2.10 Personnel protection ............................................................................... 2-8
2.10.1 Protection against contact with electrically live components ................. 2-8
2.11 Maintenance, servicing and fault-clearance ........................................... 2-9
2.12 Design modifications to the machine ...................................................... 2-9
2.13 Cleaning the machine and waste disposal ............................................. 2-9
2.14 Noise emission of the machine ............................................................. 2-10
2.15 Copyright ............................................................................................... 2-10
. 3 Transportation and storage........................................................................... 3-1
3.1 Packaging ............................................................................................... 3-1
3.2 Scope of delivery..................................................................................... 3-1
3.3 Transportation instructions...................................................................... 3-2
. 4 Technical data................................................................................................. 4-1
4.1 Machine data........................................................................................... 4-1
4.2 Connection data ...................................................................................... 4-1
4.3 Performance and operating data ............................................................ 4-1
Manual I
SBZ 122/20+30
4.4 Dimension and weights ........................................................................... 4-2
4.5 Ambient conditions .................................................................................. 4-2
4.5.1 Noise ...................................................................................................... 4-2
4.5.2 Temperatures ......................................................................................... 4-2
4.5.3 Illumination at the workplace .................................................................. 4-2
. 5 Installation, assembly and commissioning ................................................. 5-1
5.1 Installation location and place of use ...................................................... 5-1
5.1.1 Foundation plan ...................................................................................... 5-2
5.2 Installing and securing the machine ........................................................ 5-3
5.3 Connecting the electrical power and compressed air supply.................. 5-4
5.3.1 Electrical system .................................................................................... 5-4
5.3.2 Pneumatic system .................................................................................. 5-4
5.4 Machine ................................................................................................... 5-5
5.4.1 Operating controls .................................................................................. 5-5
5.4.2 Safety light barrier .................................................................................. 5-8
. 6 Operation ......................................................................................................... 6-1
6.1 Basic machine ......................................................................................... 6-1
6.2 Settings and components ........................................................................ 6-2
6.2.1 Conditioning unit ..................................................................................... 6-2
6.2.2 Proportioning spray device, tool lubrication ........................................... 6-3
6.2.3 Proportioning spray device, rack lubrication (X axis) ............................. 6-6
6.2.4 Clamping system .................................................................................... 6-7
6.2.5 Pneumatic components ........................................................................ 6-10
6.2.6 Central lubrication system .................................................................... 6-11
6.2.7 Limit switches - linear guides ............................................................... 6-14
6.2.8 Electronic time counters ....................................................................... 6-16
6.2.9 Optional accessory: Profile length measuring system ......................... 6-17
6.2.10 Optional accessory: Spindle cooler ...................................................... 6-18
II As per 08/07
SBZ 122/20+30
6.3 Automatic tool changer ......................................................................... 6-19
6.3.1 Version SBZ 122/20 ............................................................................. 6-19
6.3.2 Version SBZ 122/30 ............................................................................. 6-20
6.4 Tools...................................................................................................... 6-21
6.4.1 Clamping the tools ............................................................................... 6-22
6.4.2 Replacing of the tool holders ............................................................... 6-23
6.5 Machining examples ............................................................................. 6-25
6.5.1 Examples for max. profile dimension ................................................... 6-27
6.6 Placing the machine into operation every day ...................................... 6-30
6.7 Placing the machining spindle into operation each day ........................ 6-30
6.8 Faults and malfunctions ........................................................................ 6-31
6.9 Special work instructions for machines with motor spindle .................. 6-32
. 7 Maintenance, servicing and cleaning ........................................................... 7-1
7.1 Maintenance and servicing ..................................................................... 7-2
7.1.1 Replacing the tools................................................................................. 7-2
7.1.2 Conditioning unit .................................................................................... 7-2
7.1.3 Lubrication .............................................................................................. 7-3
7.1.4 Maintenance and servicing schedule ..................................................... 7-3
7.1.5 Machining spindle maintenance............................................................. 7-6
7.2 Cleaning work ......................................................................................... 7-7
7.3 Disposal of the machine .......................................................................... 7-8
7.4 After-sales service................................................................................... 7-8
. 8 Spare parts list and list of parts subject to wear ........................................ 8-1
. 9 Annex ............................................................................................................... 9-1
9.1 Electrical circuit diagram ......................................................................... 9-1
9.2 Pneumatic circuit diagram ....................................................................... 9-1
9.3 Noise emission values ............................................................................ 9-1
9.4 Safety data sheet, oil coolant .................................................................. 9-1
Manual III
SBZ 122/20+30
9.5 Safety data sheet, oil for bed - Central lubrication system...................... 9-1
9.6 "Spindle cooler" (option) User Manual .................................................... 9-1
IV As per 08/07
SBZ 122/20+30
1 Safety information
General
information Please note the information in the Manual
• A knowledge of the fundamental safety regulations is absolutely essential for
safely working with this machine and trouble-free operation of the machine.
• This Manual contains the most important safety information which you will need
to operate the machine safely.
• The Manual, in particular the Safety Information, must be followed by all
persons working on the machine.
• Moreover, please comply with the rules and regulations on accident prevention
applicable to the place of use.
User Obligations of the user
The user is obliged to allow only persons who comply with the conditions below to
work on the machine:
• persons who are familiar with the regulations regarding work safety and
accident prevention and who have been instructed in operating the machine.
• persons who have read, understood and confirmed by their signature the
Chapter on Safety and the warning information in this Manual.
The user must check, at regular intervals, that the personnel are working on the
machine in safety-conscious manner.
Personnel Obligations of the personnel

Persons entrusted with working on the machine are obliged, before starting work,
• to follow the regulations on work safety and accident prevention.
• to read the Chapter on Safety and the warning information in this Manual and
confirm, with their signature, that they have understood this information.
Operator Duties of the operator
Before starting machining programs, the operator must ensure that there is no one
in the machine’s traversing range.
There may be no persons not involved in work itself in the machine’s traversing
range during setting, maintenance and cleaning work.
Safety facilities may not be placed out of operation.
Using the
machine Dangers when using the machine
®
The profile machining centre has been constructed on the basis of the
state of the art and the recognised technical safety rules. The machine may be
used
• only for the intended application and
• only in perfect, safe working order.
Improper use of the machine may pose risks to the life and limb of the user or third
parties or may cause damage to the machine or other valuables.
Faults and malfunctions which could impair safety must remedied immediately.
Manual 1-1
SBZ 122/20+30
Use as
intended Use as intended
®
The only intended use of the profile machining centre is machining

(routing, drilling and tapping) aluminium profiles and thin-walled steel profiles.
Any other use or use over and above this is not considered as use as intended.
®
cannot be held responsible for damage, loss or injury resulting

therefrom.
Use as intended also includes
• compliance with all information in the Manual and
• carrying out scheduled inspection and maintenance work.
Warranty and
liability Warranty and liability
Our "General Terms of Sale and Delivery" always apply. The user will have been
made aware of these Terms at the latest since conclusion of the Contract.
The warranty covers the supplied machine with all parts. We provide warranty
inasmuch as we opt to replace or repair, free of charge, defects on
machines/components demonstrably attributable to manufacturing errors or
defective materials despite correct handling and compliance with the User Manual.
We are unable to accept claims under warranty and liability claims in relation to
personal injury or damage to property if these claims are attributable to one or
more of the following causes:
• use of the machine not as intended
• incorrect assembly, commissioning, operation and maintenance of the machine
• operation of the machine if safety devices and protective equipment items are
defective and/or inoperable
• not following the information in the Manual in relation to transport, storage,
installation, commissioning, operation, maintenance and setting of the machine
• arbitrary design modifications to the machine without authorisation
• arbitrary modifications to the drive conditions without authorisation
(power rating, speed, …)
• inadequate inspection of the machine components subject to wear
• repairs carried out incorrectly
• disasters and catastrophes resulting from the action of foreign bodies or force
majeure.
The information in this publication is reviewed regularly and any required

corrections are incorporated in the subsequent editions.
We would be very grateful to receive any suggestions and improvement proposals
you may have.
This document may not be reprinted, duplicated or translated, even in extract form,
®
without the prior written consent of .

®
constantly endeavour to improve their products and thus reserve the

right to make technical modifications without any prior announcement whatsoever.
1-2 As per 08/07

SBZ 122/20+30
2 Safety regulations
Symbols and
signs Explanation of symbols and signs used
The following words and symbols are used to indicate danger in the Manual:
Danger
This symbol indicates imminent danger to the life and
limb of personnel.
DANGER
If this information is not followed, this will result in
serious detriment to health or even life-threatening
injury.
Warning
This symbol indicates a possible imminent danger to
the life and limb of personnel.
WARNING
If this information is not followed, this may result in
serious detriment to health or even life-threatening
injury.
Caution
This symbol indicates a possibly dangerous situation.
Not following this information may lead to slight injury

CAUTION or damage to property.
Note
This symbol indicates information, tips on use and
useful information.
This information helps you to make best possible use

of the machine's functions.
Manual 2-1
SBZ 122/20+30
Symbols and
signs Explanation of symbols and signs used
The following symbols are attached to the machine:
Caution: High voltage

This symbol indicates an imminent danger to the life
and limb of personnel as the result of electric-shock
hazard.
Control ON
The key identified with this symbol is used to switch
on the control.
Clamp
The key identified with this symbol is used to activate
the work piece clamping device.
Release
The key identified with this symbol is used to release
the work piece clamping device.
Acknowledgement - Light barrier

The key identified with this symbol is used to
acknowledge exit from the work area protected by
light barrier.
On version with 2-section machining (option):

= light barrier 1
= light barrier 2
Slackening/tightening tensioning clamp

(optional “Automatic Tensioner Shift”)
If machine is fitted (as an option) with an automatic
tensioner shift, pressing this button can release the
material tensioner clamp. If clamping cylinders are
closed, they are opened.
2-2 As per 08/07

SBZ 122/20+30
Tool position 1
Tool position 1 in the tool changer is identified with
this symbol.
Tool position 2
this symbol.
Tool position 3
this symbol.
Tool position 4
this symbol.
Tool position 8
this symbol (position for the rotating angle head).
Tool 1
Tool 1 for the rotating angle head is identified with
this symbol.
Tool 2
Tool 2 for the rotating angle head is identified with
this symbol.
Spraying tool machining head

The proportioning spray reservoir for spraying the
tool on the machining head is identified with this
symbol.
Spraying rotating angle head

The proportioning spray reservoir for spraying the
tool on the rotating angle head is identified with this
symbol.
Manual 2-3
SBZ 122/20+30
The following symbols and signs are used in the Manual and on the machine:
Eye-protectors
This symbol indicates that you must wear a pair of
protective goggles to protect your eyes (against
swarf, dust and spray oil).
Ear-protectors
This symbol indicates that you must wear a suitable
pair of ear-protectors to protect your ears (to prevent
hearing impairment).
Hand protectors
This symbol indicates that you must wear a pair of
protective gloves to protect your hands (when
changing the tools).
The protective gloves must be selected allowing for

EN 388.
®
The category recommended by : at least

category II.
2-4 As per 08/07

SBZ 122/20+30
2.1 Organisational measures

The user must provide the required personnel safety equipment.
All safety devices fitted must be inspected regularly before starting work.
The user is responsible for correct insertion of the profiles in the machine.
2.2 Protective equipment

• All protective equipment must be fitted correctly and must be in operable
condition each time before placing the machine into operation:
- the lockable safety master switch which protects the machine against
unintentional or unauthorised operation,
- the safety light barrier,
- the clamping pressure monitoring feature with pressure monitor.
• Protective equipment may be removed only
- after the machine has stopped and only
- after the machine has been safeguarded against being placed back into
operation.
• If optional accessories are supplied, the protective equipment must be attached
correctly by the user.
• The transparent panel serves to protect against flying swarf.
2.3 Informal safety measures

Please always keep the Manual ready at hand near to the machine's place of use.
In addition to the Manual, the generally valid and local regulations on accident
prevention and environmental protection must be available for inspection and must
be followed.
All safety and danger information on the machine must be kept in a legible
condition.
2.4 Personnel training

Only trained and instructed personnel may work on the machine.
The scope of authority of each member of staff must be clearly stipulated in
respect of installation / assembly, commissioning, operation, setting, maintenance
and repair.
Trainees may be allowed to work on the machine only under the supervision of an
experienced member of staff.
Manual 2-5
SBZ 122/20+30
2.5 Machine control

Only instructed personnel are permitted to operate the control.
The warranty shall become null and void if the customer makes modifications to
®
the PC of the machine control without the written consent of .

This shall apply, in particular, if the customer:
• changes the operating system,
• installs a new operating system,
• installs software (e.g. Office products such as Word, Excel or games etc.),
• installs driver software,
• deletes files from the operating system level or
• installs additional hardware.
2.6 Safety measures during normal operation

Please operate the machine only when all safety devices are fully operable.
Before switching the machine on, please ensure that no one can be endangered
as the result of the machine starting up.
Inspect the machine at least once per shift for outwardly visible damage and for
operability of the safety devices.
2.7 Dangers resulting from electrical power

Have work on the electrical power supply system carried out only by a qualified
electrician.
Inspect the machine's electrical equipment regularly. Repair loose connections and
defective cables immediately.
Always keep the switch cabinet locked. Access to the switch cabinet may be
allowed only to authorised personnel with key or an appropriate tool.
When carrying out work on electrically live components, please always have a
second person standing by to switch off the master switch if necessary.
2.8 Dangers resulting from the pneumatic system
• The operating pressure of the machine is 7 bar.
• Have work carried out on the compressed air network only by a qualified
specialist.
CAUTION
Always wear a pair of protective goggles when working on the SBZ since,
otherwise, spray oil and sawing swarf could endanger your eyes.
2-6 As per 08/07

SBZ 122/20+30
2.9 Points posing a particular danger
Tools Mechanical danger as the result of tearing and cutting:

- when changing the tools
When carrying out work on the SBZ, please set the master switch on the switch
cabinet to position "0", i.e. switch it off.
Lock the master switch with the padlock to prevent it being switched back on
DANGER again.
Always wear a pair of protective goggles when working on the SBZ since,
otherwise, swarf could endanger your eyes.
Always wear protective gloves when changing the tools.
Clamping
cylinders Mechanical danger resulting from crushing:
- when clamping the workpiece
The clamping cylinders are clamped pneumatically when start is initiated on the
operating panel.
This means that there is a residual risk posed to unauthorised persons placing
DANGER their hands into the machine.
Material
clamp Danger as the result of parts being ejected at high speed:
Ensure that the material clamp (clamping cylinder) is set so that the profile is
clamped reliably and safely before, during and after the machining operation.
It may be necessary to use shims (check profiles) when working.
First cuts and off-cuts must be clamped so that they cannot be flung out in any
WARNING situation.
Residual sections must always be removed from the work area immediately.
Ensure that it is not possible for parts to be flung out in uncontrolled manner from
the profiles during machining.
These required measures are the responsibility of the machine operator.
Manual 2-7
SBZ 122/20+30
Rotating angle
head Danger owning to hot surfaces:
- when clamping the rotating angle head by hand
Important!
The rotating angle head heats up during machining.
So always wear protective gloves when changing the rotating angle heads by
hand.
2.10 Personnel protection
2.10.1 Protection against contact with electrically live components
Before carrying out maintenance work or servicing work:
Disconnect the machine from the electrical power supply at the master switch and
lock the master switch to prevent it being switched back on again.
• Lock the main control devices and withdraw the key and/or attach a warning
DANGER
sign to the master switch.
• Wait for the capacitor in the DC link to fully discharge! (This takes approx.
1 minute).
• After switching off the master switch, check that the DC link voltage is less than
50 V.
Before placing into operation:
• In order to protect against any contact with electrically live components, attach
and bolt or screw in place all covers and cover flaps etc.
• Check the PE wire connections on all motors and electrical devices!

DANGER
• If it is not possible to close switch cabinets and other accessible electrical

equipment which is electrically live during the start-up phase, have qualified
electricians secure these cabinets and this equipment so that persons
endangered cannot access the cabinets or equipment.
The overcurrent protective device - main fuse for mains connection cable - must be
fitted outside the machine and is not included in the machine's scope of delivery.
2-8 As per 08/07

SBZ 122/20+30
CAUTION!
Do not use residual-current-operated protective devices:
Residual-current-operated protective devices may not be used in conjunction with

DANGER
AC servo-drives on a general basis.
Reason:
On equipment with pulsed power circuitry, a DC fault current which may block
triggering of a residual-current-operated protective device may occur in the event
of short-circuit to exposed conductive parts. Consequently, protection in the case
of indirect contact must be provided in another way, e.g. by over current protective
devices.
2.11 Maintenance, servicing and fault-clearance

• Conditioning unit
(see also Chapter 7)
• The motors require no maintenance.
2.12 Design modifications to the machine

No modifications, attachment work or conversion work may be carried out on the
machine without the manufacturer's approval. This also applies to welding work on
load-bearing components.
No conversion work may be carried out without the prior written consent
®
of .
Machine components which are not in perfect working order must be replaced
immediately.
®
Please use only spare parts and parts subject to wear.

The manufacturer is unable to accept claims under warranty if spare parts and
®
parts subject to wear not manufactured by are used.
2.13 Cleaning the machine and waste disposal

Lubricants and other materials used must be handled correctly and disposed of
correctly, in particular
- when working on the lubrication systems and devices and
- when cleaning with solvents.
Manual 2-9
SBZ 122/20+30
2.14 Noise emission of the machine

The sustained sound pressure level emitted by the machine is dependent on the
profiles to be machined and on the tools used. Please refer to the Annex
(Chapter 9), Noise emission values, for further information.
Since the sustained sound pressure level is > 75 dB(A), the operating personnel
must be provided with appropriate safety equipment in order to prevent hearing
impairment.
2.15 Copyright
®
retains copyright to this Manual.

This Manual is intended only for the user and his personnel.
It contains instructions and information which may not be duplicated or distributed
in any other way, either entirely or in part.
Violations of this clause constitute a criminal offence against which legal action
may be taken.
2-10 As per 08/07

SBZ 122/20+30
3 Transportation and storage

The machine is transported on pallets.
3.1 Packaging
The machine is packed in a plastic film.
Machine type Machine weight

SBZ 122/20 approx. 1660 kg
SBZ 122/30 approx. 1690 kg
Storage of the
machine Please note the following when storing the machine for a long period:
• store the machine only in dry rooms,
• choose a type of packaging suitable for storage (protective film) or leave the
machine in the original packing.
Even though most parts are provided with a corrosion-protection coating, the
machine must be cleaned thoroughly before placing it into operation.
3.2 Scope of delivery

Please check that the machine consignment is complete so that the
®
profile machining centre can be installed correctly on customer

premises:
• SBZ 122
• Accessories
- Automatic tool changer with 4 tool holders (without tools)
and one holder for rotating angle head [SBZ 122/30]
- Automatic tool changer with 4 tool holders (without tools)
and integrated turning device (0°+180°) for rotating angle head [SBZ 122/20]
- 1 rotating angle head for 2 tools (0° / 180°)
- Light barrier (for operator protection)
- 4 horizontal pneumatic material clamps
- Automatic clamp position recognition
- Material stop
- Central chip collection (with chip container)
- Pulsed spray coolant system
- High performance cutting fluid
- Tool measuring gauge
- Set of spanner
- Manual
Manual 3-1
SBZ 122/20+30
3.3 Transportation instructions
3-2 As per 08/07

SBZ 122/20+30
4 Technical data
4.1 Machine data

Designation: Profile machining centre
Type: SBZ 122
Serial number: See rating plate
4.2 Connection data

Electrical: Voltage
Current See electrical circuit
max. back-up fuse diagram for the precise
Connected load connection data.
Compressed air: > 7 bar
4.3 Performance and operating data

Max. processing length
with profile end processing 3650 mm
Max. processing length
without profile end processing 3750 mm
Travelling distance X-axis 3850 mm
v max. 50 m / min.
Travelling distance Y-axis 350 mm
v max. 30 m / min.
Travelling distance Z-axis 280 mm
v max. 30 m / min.
Positioning accuracy:
X-axis +/- 0,1 mm
Y-axis +/- 0,1 mm
Z-axis +/- 0,1 mm
Max. spindle speed 21000 r.p.m.
Max. power output at spindle 6 kW , S 6
Tool chuck HSK F63
Tool holders
for automatic tool change 5
Max. cutter diameter 63 mm
Max. disk cutter 200 mm (man.) , 92 mm (autom.)
Air consumption per work cycle approx. 50 l
Manual 4-1
SBZ 122/20+30
4.4 Dimension and weights

Machine type Length/Depth/Height Weight
[mm] [kg]
SBZ 122/20 4600 / 3230 / 2420 approx. 1660
SBZ 122/30 4600 / 3230 / 2420 approx. 1690
The foundation plan in chapter 5.1.1 shows the maximum space required by the
machine.
4.5 Ambient conditions
4.5.1 Noise
Since the sustained sound pressure level is > 75 dB(A), the operating personnel
must be provided with appropriate safety equipment to prevent hearing
impairment.
The noise emission of the machine is dependent on the profiles to be machined

and on the tools used.
Please refer to the Noise emission values in the Annex.
4.5.2 Temperatures
Permitted ambient influences
The machine must be installed in a dry location protected against frost and
subzero temperatures.
The permitted ambient temperatures are between 10 °C and 30 °C.
Additional cooling of the electrical and electronic components will be required at
temperatures above 30 °C.
Temperatures during operation:
- During operation, the room temperature should not drop below +12 °C and
- should not exceed +26 °C.
These temperatures comply with the EC Workplace Directive.
Ensure that there is adequate intake and extract ventilation!
4.5.3 Illumination at the workplace

The operator is to ensure that the workplace is sufficiently lit.
The minimum intensity of illumination is 300 lux.
®
The intensity of illumination recommended by is 500 lux.
4-2 As per 08/07

SBZ 122/20+30
5 Installation, assembly and commissioning

Supplier's
personnel Safety information
• Ensure that no electrical cables or pneumatic lines are damaged when lifting
the machine with a fork-lift truck.
• Do not use machine components to climb onto the machine!

WARNING
Keep all grips and handles in clean condition!
• Electrical cables must be correctly laid and installed.

The cross-section, length and quality of the cables must comply with local
regulations.
• Before switching the machine on, please ensure that no one will be
endangered by the machine operating.
5.1 Installation location and place of use
User Structural requirements which the user must comply with before
installing the machine:
Please make sure that the base surface / floor has an adequate load bearing
capacity before installing the machine. Please note our information on weight of
the machine.
DANGER The user must install a safety fence around the machine covering the non-
safeguarded zone of the light barriers. This fence must be at least 1,80 m in
height.
The foundation plan on page 5-2 shows the maximum space required by the
machine.
The installation location of the machine must be flat and level.
When installing the machine, please ensure that you comply with the legally
prescribed minimum clearances.
The clearance between machine rear panel and building wall or other machines
DANGER must be at least 0.5 m.
The owner must safeguard the machine against access by unauthorised persons.
Manual 5-1
SBZ 122/20+30
5.1.1 Foundation plan
5-2 As per 08/07

SBZ 122/20+30
5.2 Installing and securing the machine
SBZ 122/20
SBZ 122/30
The profile machining centre may be installed only by fitters.

The profile machining centre must be aligned using a precision levelling unit.
Visual
Inspection Please inspect the machine for any signs of corrosion (screws or bolts) and,
®
should you detect corrosion, please inform the Servicing Department.

Please clean the machine before placing it into operation.
Manual 5-3
SBZ 122/20+30
5.3 Connecting the electrical power and compressed air supply
• Electrical cables must be correctly laid and installed. The cross-section, length
and quality of the cables must comply with local regulations.
• Work on the electrical system may be carried out only by qualified specialists.
DANGER
It is essential to observe IEC 60364 and you may need to contact the
electrical supply company responsible for you.
5.3.1 Electrical system

Before connecting the machine to the mains, please:
• check that the cross-sections of the cables laid comply with the system's
technical data (see electrical circuit diagram).
When connecting the electrical cable, insert it

through a free screwed gland into the left-hand
side panel of the switch cabinet.
The switch cabinet is located on the rear side of
the machine base.
Make the connection to the electrical mains.
5.3.2 Pneumatic system

The connection to the compressed air network must be made at the compressed
air conditioning unit. This is located on the rear side of the machine base.
This compressed air connection must supply dry air at a sustained, constant
pressure of >7 bar.
Work on the machine's pneumatic components may be carried out only by trained
specialists. Please follow the regulations of your employers' liability insurance
associations.
Connection
5-4 As per 08/07

SBZ 122/20+30
5.4 Machine
5.4.1 Operating controls

The most important operating controls of the machine are as follows:
Master switch
The master switch is used
to disconnect and connect
the machine from and to
Master switch the electrical power supply.
The master switch is
located on the switch
cabinet of the machine.
EMERGENCY-STOP button on the control's operating panel

EMERGENCY- The EMERGENCY-STOP
STOP button button is located on the
operating panel. Pressing
the button disconnects the
entire machine from the
electrical power supply.
The button must be turned
in order to release it (this
releases lock).
EMERGENCY-STOP button on the mobile operation terminal (Option)

EMERGENCY- The EMERGENCY-STOP
STOP button button on the mobile
operation terminal (option)
is located on the top of the
operating-control housing.
Manual 5-5
SBZ 122/20+30
Operating panel of the control

Key: Slackening/tightening tensioning
clamp (optional “Automatic Tensioner
Shift”)
Key: Control ON
EMERGENCY-STOP button
Key: Clamp
Key: Release
Key-operated switch: Bridge-over final

positions
Key: Acknowledgement light barrier

This button is used to
acknowledge leaving of the
Key : work area safeguarded by
Acknowledge the light barrier.
light barrier
5-6 As per 08/07

SBZ 122/20+30
Mobile operation terminal (Option)

EMERGENCY-STOP button
Key-operated switch: Terminal ON / OFF
Potentiometer: Rate of feed
Start operating cycle
Stop operating cycle
Acknowledgement operating cycle

(Software)
Foot valve
The preliminary clamping pressure can be
activated and deactivated by operating the
foot valve.
Manual 5-7
SBZ 122/20+30
5.4.2 Safety light barrier

There is a light barrier mounted around the work area for operator safety and in
order to protect against unauthorised and unintentional manual intervention in the
work sequence.
5-8 As per 08/07

SBZ 122/20+30
6 Operation
Only personnel instructed in the appropriate procedures may be allowed to set

the parameters for routing, drilling and tapping.
Operating personnel must have undergone a training course in order to operate

DANGER the profile machining centre (SBZ). Programming and the procedure for
®
machining the work pieces are taught at during a training course.
The safety devices of the profile machining centre must be inspected every day.
6.1 Basic machine

®
The profile machining centre is used to machine aluminium profiles or

thin-walled steel profiles.
All operations like routing, drilling and tapping are carried out with the profile bar
resting to protect the profile surface.
The profile machining centre essentially consists of the machine base with
clamping unit, the traversable machining unit with protective hood, the operating
panel and the switch cabinet.
Three numerically controlled axes position the tools as required by the machining
tasks.
Five deposit positions for four various tools and one rotating angle head are
available for automatic tool change.
SBZ 122/20: A stationary turning device allows the adjustment of the rotating angle
head for 0° and 180°. Therefore a profile can be processed from front and rear with
two different tools.
The profile can be processed on three sides.
SBZ 122/30: A spindle integrated turning device allows an adjustment of the
rotating angle head for 0°/90°/180° and 270°. Therefore a profile can be processed
from front, rear and both ends with two different tools.
The profile can be processed on five sides.
To avoid crash the machining centre is standard equipped with clamping
recognition system.
The PC control of the SBZ performs all closed-loop control, open-loop control and
monitoring tasks.
Operation takes the form of making keyboard entries. The operating panel
incorporates a colour monitor. All functions of the profile machining centre are
displayed in this monitor.
Manual 6-1
SBZ 122/20+30
6.2 Settings and components
6.2.1 Conditioning unit
Shut-off valve The conditioning unit consists of two

components:
Pressure
reducing Pressure reducing valve with
valve pressure gauge
Water separator
Pressure reducing valve
The machine's operating pressure is
set to 7 bar as follows:
Lift the twist grip until it disengages
audibly.
Pressure
Set the pressure using the pressure
gauge
gauge:
- Turning clockwise:
Increases the pressure
- Turning counter-clockwise:
Water Reduces the pressure
separator Re-engage the twist grip after setting.
Water separator
See Chapter 7.1.2, Conditioning unit
6-2 As per 08/07

SBZ 122/20+30
6.2.2 Proportioning spray device, tool lubrication

The machining centre
features one spray device
for tool lubrication.
Tool
lubrication
The spray device serves to

lubricate the tool for
machining from the top and
the tool for machining with
the rotating angle head.
Spray nozzles
on the
machining
head
Spray nozzle
on the
rotating angle
head
Manual 6-3
SBZ 122/20+30
Spray device
Metering The spray lubricant

restrictor reservoir is located on the
rear side of the machining
Sight glass
head.
The metering screw can be
used to vary the intensity of
the mist spray.
The metering restrictor can
be used to vary the air
supply to the spray jet.
Metering of the air and oil
supply depends on the
Spray design of the tools and the
lubricant profile to be machined.
reservoir
Metering The sight glass allows you

screw to monitor the function of
the spray device.
If the spray device is
functioning correctly, the
cutting oil will drip at the set
rate during machining.
Screw,
Bleed valve
Important!
The spray coolant reservoir is pressurised! Relieve the pressure in the spray
coolant reservoir before topping up with spray coolant!
WARNING
6-4 As per 08/07

SBZ 122/20+30
Topping up with spray coolant:
Relieve the pressure in the spray coolant reservoir before topping up with spray
coolant!
Unscrew the blue bleed screw to relieve the pressure in the spray coolant
reservoir.
Do not unscrew the spray coolant reservoir until after relieving the pressure.
Add spray coolant to the reservoir and screw it back on again.
Then screw the blue bleed screw back into the bleed screw opening.
Use only spray oil to top up.
WARNING
Manual 6-5
SBZ 122/20+30
6.2.3 Proportioning spray device, rack lubrication (X axis)
The rack is sprayed with oil

by means of a
proportioning spray device.
Spray device
(Order No:
088 90 71 15 - 1 l)
Spray nozzle
Sight glass The spray lubricant
reservoir is located on the
right-hand side of the
Shut-off cock machining head.
The metering screw can be
used to vary the intensity of
the mist spray.
Metering
The spray function is
restrictor
activated and deactivated
using the shut-off cock.
Spray The metering restrictor for
lubricant air supply to the spray jet is
reservoir located on the shut-off
cock.
Metering of the air and oil
coolant supply depends on
the design of the tools and
the profile to be machined.
Metering The sight glass allows you
screw to monitor the function of
the spray device.
Screw,
If the spray device is
Bleed valve
functioning correctly, the oil
will drip at the set rate
during machining.
Important!
The spray lubricant reservoir is pressurised! Relieve the pressure in the spray
coolant reservoir before topping up with spray coolant!
WARNING
6-6 As per 08/07

SBZ 122/20+30
Topping up with spray coolant:

Turn off spray function at shut-off valve.
Relieve the pressure in the spray coolant reservoir before topping up with spray
coolant!
Unscrew the blue bleed screw to relieve the pressure in the spray coolant
reservoir.
Do not unscrew the spray coolant reservoir until after relieving the pressure.
Add spray coolant to the reservoir and screw it back on again.
Then screw the blue bleed screw back into the bleed screw opening.
Re-open spray feed at shut-off valve.
6.2.4 Clamping system
Dual-circuit safety clamping system
The clamping pressure is set on the pressure reducing valves (with pressure
gauge).
The preliminary clamping pressure is set on pressure reducing valve 1.
The work piece clamping pressure is set on pressure reducing valve 2.
Pressure reducing valve 1 for the low

clamping pressure (preliminary clamping
pressure)
Pressure reducing valve 2 for the high
clamping pressure (work piece clamping
pressure)
The low preliminary clamping pressure permits safe clamping of the work pieces.
This minimises the risk of injury to the operator.
The work piece clamping pressure is applied only after Start key is pressed.
If the network pressure drops below 4 bar, the work piece can no longer be
clamped.
Manual 6-7
SBZ 122/20+30
Setting the clamp
Hexagon The depth of the clamping

socket screw cylinder can be set after
undoing the hexagon
socket screw.
Hexagon The height of the clamping

socket screws cylinder can be set after
undoing the hexagon
socket screws.
The clamp can be set in

X direction after undoing
the clamping lever.
Clamping
lever
The clamps can be set on

the basis of the scale on
the guide.
Reading
Scale
When processing profiles with a profile height less than 30 mm, shims must be
inserted beneath the profiles in order to ensure safe clamping!
WARNING
6-8 As per 08/07

SBZ 122/20+30
After setting, the clamps must be reclamped with the clamping levers and
hexagon socket screws!
WARNING
Clamping recognition system
To avoid crash the

machining centre is
Proximity
equipped with clamping
switch,
recognition system.
clamping
recognition
system
Automatic Tensioner Shift (optional)
Driver pin
(optional)
Manual 6-9
SBZ 122/20+30
6.2.5 Pneumatic components
Pneumatic components on the machining unit

The following pneumatic components are located on the rear side of the machining
head:
Pressure reducing valve
"Spindle locking air"
Pressure reducing valve "Spindle"

Taper cleaning + Clamping / Releasing
The valve bank is located beneath the

hood.
6-10 As per 08/07

SBZ 122/20+30
Pneumatic components on the machine bed

The following pneumatic components are located on the rear side of the machine
bed:
Valve bank
Pressure monitor
Valves for Automatic Tensioner Shift

(optional)
Conditioning unit
6.2.6 Central lubrication system

The central lubrication system supplies all linear guides and drive units for the
axes.
Guide plate
Z-axis
Guides
Y-axis
Guides
X-axis
Manual 6-11
SBZ 122/20+30
Z-axis
The central distributor for
the guides and drive
spindle of the Z axis is
located behind the
machining spindle.
Distributor
Y-axis
the guides of the Y axis is
located on the underside of
the machining head.
Distributor
X-axis
the guides of the X axis is
located on the rear side of
the machining head.
Distributor
6-12 As per 08/07

SBZ 122/20+30
Lube oil pump

The parameters for the
pauses and cycle intervals
are set at the works.
Oil filler
Elumatec basic setting for
neck
lube oil pump:
The operating pressure is set
at the works to 25 bar and
may not be readjusted.
Working Time: 10 seconds
Pause Time: 250 minutes
(The Pause Time can be
prolonged or shortened
depending on the machine's
operating time.)
Febis K68 tool-way lubricant,

order No:
088 90 71 15 ( 1 l ), is used
for lubrication.
®
-settings
Pause Time: DS3 + DS1 (250 minutes)
Working Time: DS2 (10 seconds)
Prelubrication: J1 (YES)
Pressure switch: J2 (Pump with pressure switch)
Setting
DS1
ON
DS2 1 2 3
J2
J1
ON
DS3
1 2 3 4
Manual 6-13
SBZ 122/20+30
6.2.7 Limit switches - linear guides
X-axis
Limit switch and calibration switch, X-axis
Y-axis
Limit switch and calibration switch, Y-axis
6-14 As per 08/07

SBZ 122/20+30
Z-axis
Limit switch and calibration switch, Z-axis
Manual 6-15
SBZ 122/20+30
6.2.8 Electronic time counters
Machine operating time
The counter displays the

machine's completed
operating hours.
The time is recorded in
Machine hours and minutes.
operating
Display:
hours
Hours – Minutes
The time counter is located

on the machine
switchboard.
Spindle running time
The counter shows the

completed running time of the
work/machining spindle.
The time is recorded in hours,
minutes and seconds.
Display:
Hours.Minutes.Seconds
Spindle
running time
The time counter is located on
the machine switchboard.
6-16 As per 08/07

SBZ 122/20+30
6.2.9 Optional accessory: Profile length measuring system
This measuring facility

allows you to measure the
length of profiles.
The profiles must contact
the material stop for this
purpose.
Measuring
stop plate
Manual 6-17
SBZ 122/20+30
6.2.10 Optional accessory: Spindle cooler
Cover, The cooler can be switched

coolant on and off at its master
reservoir switch.
Configuration
parameters:
Supply temperature
setpoint: 20° C
Overtemperature alarm
Master value: 40° C
switch
Undertemperature alarm
value: 10° C
Setting
display
Filling the coolant reservoir

Fill the coolant reservoir as follows:
1. 250 ml Coolant concentrate contains no chlorine, nitrate or zinc
®
- order No.: 088907110 ( 1 l )

2. 1,5 l Antifreezer
®
- order No.: 088907112 ( 1,5 l )

3. and top up the rest with water
The coolant level should reach a point just below the return inlet.
Please refer to the User Manual in the Annex for further information on the
spindle cooler.
6-18 As per 08/07

SBZ 122/20+30
6.3 Automatic tool changer
6.3.1 Version SBZ 122/20
Tool Four tool positions for

positions various tools and one
stationary turning device for
the rotating angle head are
available in the tool
changer.
Turning
device with
rotating angle
head
The stationary turning

device allows the
adjustment of the rotating
angle head.
The rotating angle head
may be turned to positions
Pneumatic
0° or 180°.
cylinder
It is turned by means of a
pneumatic cylinder.
Optional accessory: Tool changer on the right
Tool changer Three tool positions and a

on the right stationary turning device for
one rotating angle head are
available in the tool
changer on the right
(optional accessory).
Manual 6-19
SBZ 122/20+30
6.3.2 Version SBZ 122/30
Tool Four tool positions for

positions various tools and one
holder for the rotating angle
head are available in the
tool changer.
Rotating
angle head
A spindle integrated turning

device allows the
adjustment of the rotating
angle head.
Holder The rotating angle head
rotating angle may be turned to positions
head 0°, 90°, 180° or 270°.
Optional accessory: Tool changer on the right
Tool changer Three tool positions and a

on the right holder for one rotating
angle head are available in
the tool changer on the
right (optional accessory).
6-20 As per 08/07

SBZ 122/20+30
6.4 Tools
Please use only tools which, when fully assembled and balanced together,
achieve a quality level of G2,5 ( G1 is better ) at 21000 r.p.m. to DIN ISO 1940.
DANGER
Please use only original - tools. If other tools are used, always
procure the consent of the machine manufacturer beforehand. The machine may
not be operated with these tools unless they have been approved.
The manufacturer's warranty will be null and void if non-approved, third-party
WARNING
tools are used.
Tools must feature an adequately large chip space.
Tools must have good concentricity and no axial runout.
Manual 6-21
SBZ 122/20+30
6.4.1 Clamping the tools

The tools are clamped in
the tool clamping holder
which can be mounted on a
workbench or at the end of
the work piece table.
Insert the tool taper and
allow the locking pins to
Depth slide engage in the bores.
gauge You can now change the
tools with the
corresponding chuck keys.
Locking pin
Tool clamping
holder
Locking pin
Caution:
Risk of injury!
WARNING
Depth slide gauge

The tool length can be read
off on the depth slide
Depth slide
gauge.
gauge
6-22 As per 08/07

SBZ 122/20+30
6.4.2 Replacing of the tool holders
Important!
The rotating angle head heats up during machining.
So always wear protective gloves when changing the rotating angle heads by
hand.
The balanced tool holders

are either replaced
manually (push button 1
and push button 2) or
automatically.
Push button 1
Push button 2
Manual 6-23
SBZ 122/20+30
Precondition for a long service life of the spindle is a cleaned nose of the spindle
and the tool holder.
By means of the air blast integrated in the spindle, most dirt is removed.
Only if the internal nose is additionally cleaned by hand with a cleaner
(order No. 150 26 10 01), it can be ensured that there is no swarf between the
contact surfaces.
If there are small swarf particles between the contact surfaces the tool insert may
be pulled in asymmetrically. The resulting unbalance will have a negative effect on
the service life of the spindle bearing. An early bearing damage is sure to happen.
Cleaner
(order No. 150 26 10 01)
6-24 As per 08/07

SBZ 122/20+30
6.5 Machining examples
Machining from the top
Machining with the rotating angle head from the front and rear
Manual 6-25
SBZ 122/20+30
Machining from the end of the profile with the rotating angle head
(SBZ122/30)
Machining with disk cutter
6-26 As per 08/07

SBZ 122/20+30
6.5.1 Examples for max. profile dimension
Please bear in mind, that in limit cases tests are absolutely necessary.
Depending on the tools the max. profile dimensions may be different.
Profile bar processing from the top

SBZ 122/20, SBZ 122/30
Profile bar processing from the front and rear with rotating angle head
SBZ 122/20, SBZ 122/30
Manual 6-27
SBZ 122/20+30
Profile bar processing from the top and rear

SBZ 122/20, SBZ 122/30
Profile bar processing with disk cutter

SBZ 122/20, SBZ 122/30
6-28 As per 08/07

SBZ 122/20+30
Profile bar processing from the top

SBZ 122/20, SBZ 122/30
Profile bar processing from the end of the profile with disk cutter
SBZ 122/20, SBZ 122/30
Profile bar processing of the end with rotating angle head

SBZ 122/30
Manual 6-29
SBZ 122/20+30
6.6 Placing the machine into operation every day
• Central lubrication system

- Check the filling level of the supply reservoir
• Spray oil reservoir
- Check the filling level
• Conditioning unit
- Check the system pressure
- The water separator must be drained regularly
• Check all safety devices for proper operation
• Inspect tools for operability
• Check limit switches for correct operation
• Always remove residual profile sections immediately
6.7 Placing the machining spindle into operation each day
The spindle must be operated for a total of ten minutes before starting work in
order to allow it to warm up:
2 min. at 1.000 rpm
2 min. at 3.000 rpm
2 min. at 6.000 rpm
2 min. at 10.000 rpm
• The maximum speed should be reached step by step in five to six minutes if
the electrical spindle has been stopped for at least four hours.
• The run-in process should be prolonged by approximately fifteen minutes if

the electrical spindle has not been operated or has been in storage for a
period of time (longer than six months).
6-30 As per 08/07

SBZ 122/20+30
6.8 Faults and malfunctions
Fault Possible cause Remedy

- Spindle does not turn. - No mains voltage. - Check mains connection.
- Check fuses.
- Mist spray system not - Restrictor is closed. - Open restrictor.
functioning.
- No spray oil in reservoir. - Top up with spray oil.
- Spray oil available. - Check lines and nozzles.
- Material chatters when - Clamping fixture not correctly - Adjust clamping fixture.
machining. set.
Manual 6-31
SBZ 122/20+30
6.9 Special work instructions for machines with motor spindle
Note for
machine
operator Work instructions for operator:
Note before switching on: temperatures
The machine must be installed in a dry location protected against frost and
subzero temperatures.
° The permitted ambient temperatures are between 10 °C and 30 °C. Additional
cooling of the electrical and electronic components will be required at
WARNING temperatures above 30 °C.
Never operate the machine at temperatures below 10°C.
Temperatures during operation:

- during operation, the room temperature should not drop below +12 °C and
- should not exceed +26 °C.
These temperatures comply with the EC Workplace Directive.
Ensure that there is adequate intake and extract ventilation!
The machine manufacturer's warrantee will be rendered null and void if this
technical instruction is not followed.
The spindle must be operated for a total of ten minutes before starting work in
order to allow it to warm up:
° 2 min. at 1.000 rpm
2 min. at 3.000 rpm
WARNING 2 min. at 6.000 rpm
The maximum speed should be reached step by step in five to six minutes if the
electrical spindle has been stopped for at least four hours.
°
The run-in process should be prolonged by approximately fifteen minutes if the
WARNING electrical spindle has not been operated or has been in storage for a period of
time (longer than six months).
6-32 As per 08/07

SBZ 122/20+30
Note for
machine
When switching the machine off: delayed switch-off of sealing air
The machine must remain connected to the pneumatic network for a further 30
minutes in order to protect the spindle bearings. The sealing air prevents
micronic dust particles penetrating the bearing assembly. The machine must
remain connected to the pneumatic network for a further 30 minutes in order to
WARNING prolong the life of the spindle.
Note for
machine
Note before switching on: tools
Please use only tools which, when fully assembled and balanced together,
achieve a quality level of G2,5 ( G1 is better ) at 21000 r.p.m. to DIN ISO 1940.
WARNING instruction is not followed.
®
Please use only original - tools. If other tools are used, always
procure the consent of the machine manufacturer beforehand. The machine may
not be operated with these tools unless they have been approved.
WARNING
The manufacturer's warranty will be null and void if non-approved, third-party
tools are used.
Note for
machine
Note before switching on: cleaning
Cleaning the toolholder
Always keep the inside taper of the toolholder clean and use a lint-free cleaning
cloth or a taper wiper to clean it before each manual tool change in the magazine.
WARNING
Never blow on the toolholder on the motor spindle!

Any swarf penetrating the toolholder system damages the bearings!
Swarf penetrating the toolholder system leads to premature failure of the
clamping assembly or ball bearings.
mandatory instruction of the machine manufacturer is not followed.
Manual 6-33
SBZ 122/20+30
Note for
machine
Note before tool change: clean the inside taper
Clean the inside taper of the toolholder in the motor spindle every eight hours
with the HSK taper wiper!
Replace HSK taper wiper by a new one if soiled.

WARNING Order number: 150261001 Cone cleaner HSKF63 (HSK50)
Note for
machine
Tools with toolholder, referred to only as "tools" below!
Use of tools in motorised spindles as intended
The high speeds of motorised spindles allow excellent surface quality and high
productivity.
WARNING
If used incorrectly, motorised spindles operating at medium to high speeds pose

a high risk potential and may cause excessive wear.
Selection of tools thus requires special care.
Only tools in perfect condition may be used in motorised spindles!
Only use of tools in perfect condition can achieve good machining results and low
wear of the spindle bearings.
WARNING
Only flawless tools may be used in the tool magazine. All tools must comply with
the following conditions:
The permitted tool balancing quality of G 2.5 must always be complied with.
This means that the tool must be designed for high speeds and high centrifugal
forces.
Cutting forces and dead weight of the tool may not overload the bearings.
Speeds
Extreme centrifugal forces occur on the tool at high speed, depending on tool
diameter.
WARNING Consequently and without exception, only tools whose permitted speed lies
above the spindle's switch-off speed may be used.
6-34 As per 08/07

SBZ 122/20+30
Note for
machine
Tools with toolholder, referred to only as "tools" below!
Critical natural frequencies
May occur in the case of:

- long tools,
WARNING - heavy tools and
- tools with a large radius.
In general, short tools provide optimum running smoothness and stress bearings
least.
Loading as the result of cutting forces
Wear of the cutting edge may lead to multiplication of the cutting forces.
This not only impairs the machining process but also shortens the service life of
WARNING the bearings due to overload.
Monitor tool wear very carefully!
Tools should always project out of the toolholder as far as necessary but
as little as possible.
The less the tool projects out of the toolholder the lower the stress on the
WARNING
spindle will be.
Manual 6-35
SBZ 122/20+30
6-36 As per 08/07

SBZ 122/20+30
7 Maintenance, servicing and cleaning
The machine must be regularly serviced and cleaned in order to ensure

operational reliability, operational safety and high performance.
Please always follow the instructions below in order to ensure trouble-free

WARNING operation of the machine:
• Handle the machine correctly in accordance with applicable instructions.
• Clean the machine thoroughly and regularly.
• Regularly service the machine.
Also note and heed all information and specifications in the instructions, Manuals
and documents supplied with the machine.
• Work on the electrical system and pneumatic system may only be carried out
by a qualified specialist.
• Before carrying out maintenance work or cleaning work of any nature, please
DANGER
lock the machine to ensure that it cannot be switched back on again by
unauthorised persons. Always disconnect the machine from the electrical
power supply and pneumatic network.
• Please always follow the mandatory directives and legislation when carrying
out maintenance and cleaning work of any nature.
• Adjustment work must be carried out by authorised personnel.
Before carrying out maintenance work or servicing work:
Disconnect the machine from the electrical power supply at the master switch and
lock the master switch to prevent it being switched back on again.
• Lock the main control devices and withdraw the key and/or attach a warning
DANGER
sign to the master switch.
• Wait for the capacitor in the DC link to fully discharge! (This takes approx.
1 minute).
• After switching off the master switch, check that the DC link voltage is less than
50 V.
Manual 7-1
SBZ 122/20+30
7.1 Maintenance and servicing
7.1.1 Replacing the tools
• Please use only

®
tools.
• Both the cutting characteristics and noise emission are influenced crucially by
the cutting edge geometry and additional measures on the tools.
• Please always use sharp tools.
• Teeth which have broken out will lead to imbalance and the risk of accident.
• Resharpening the tools:
Tools may be sharpened only on modern special-purpose machines
guaranteeing perfect concentricity and no axial run-out (free of imbalance).
7.1.2 Conditioning unit
The water separator must be drained regularly since this could otherwise result in
discharge disturbances.
WARNING
Unscrew the screw union

beneath the sight glass to
empty the water separator.
Screw union
7-2 As per 08/07

SBZ 122/20+30
7.1.3 Lubrication
The lubrication points of the profile machining centre are supplied by a central
lubrication system.
The lube oil pump of the centralised lubrication system is located on the rear side
of the machine base.
The supply reservoir must be topped up with Febis K68 tool-way oil
(order No.: 088 90 71 15).
7.1.4 Maintenance and servicing schedule
Item Designation Activity Maintenance Remarks

interval
1 Entire system Clean Daily Quick cleaning after
each shift
Weekly Thorough cleaning
2 Machine interior Clean Several times Remove swarf from
per day, the entire inside
as required machine area
Preferably use a
vacuum cleaner to
remove swarf or use a
brush or cloth
3 Profile support face Clean Several times Blow off with
per day, compressed air
as required
4 Racks Clean Several times Use a vacuum cleaner
per day, to remove swarf or use
as required a brush or cloth
5 Guide systems Clean Several times Use a vacuum cleaner
per day, to remove swarf or use
as required a brush or cloth
Lubricate Weekly Lubricate with
machine oil
Manual 7-3
SBZ 122/20+30

interval
6 Safety light barrier Clean Weekly, Remove dust from the
as required optical system using a
clean, soft brush and
then use a clean, soft,
damp cloth to clean
the optical system
surfaces.
Do not use cleaning
agents or solvents
which are aggressive
or promote abrasion.
7 Clamping cylinders Inspect Daily Check for leaks;
Inspect clamping
buffers for damage
as required and exchange if
necessary
8 Tools Inspect Daily Check for wear and
damage
as required and exchange if
necessary
Clean Always keep the
toolholders clean and
clean them prior to
each tool change
9 Pneumatic lines and Clean as required Blow off with
screw unions compressed air or
use lint-free cleaning
cloths
Inspect Monthly Visually inspect for
cracks and porous
points;
Check that unions are
firmly tightened and
check for leaks
10 Pneumatic Clean as required Blow off with
conditioning unit compressed air or
- see Chapter 7.1.2
cloths
Inspect Daily Check for leaks;
Water separator:
check the water level
and drain if necessary
7-4 As per 08/07

SBZ 122/20+30

interval
11 Electrical cables and Clean as required Blow off with
screwed glands compressed air or
cloths
Inspect Monthly Visually inspect for
damage;
Check that screwed
glands are firmly
tightened
12 Central lubrication Inspect Daily Check the oil level and
unit as required refill if necessary
recommend oil see
- see Chapter 6.2.6
Chapter 6.2.6
13 Mist spray system, Inspect Daily Check the level and
tool lubrication as required refill if necessary
- see Chapter 6.2.2
14 Mist spray system, Inspect Daily Check the level and
rack lubrication as required refill if necessary
- see Chapter 6.2.3
15 Safety devices Inspect Before each the lockable safety
shift master switch,
the EMERGENCY-
STOP button,
the safety light barrier,
the clamping pressure
monitoring pressure
with pressure monitor
16 Chip container Empty After each Empty the chip
shift, container
as required
17 Operating consoles Inspect Regularly inspect the
and switch cabinets filters in the air inlets
with air cooling Clean and outlets and clean
Exchange as required or exchange them if
clogged
18 Polycarbonate Exchange Every The exchange should
protective hood 5 - 7 years be carried out by
®
service
technicians.
Manual 7-5
SBZ 122/20+30
The time intervals and maintenance intervals specified apply to single-shift

operation.
They must be shortened accordingly in the case of multi-shift operation!
7.1.5 Machining spindle maintenance
• The spindle is covered by a 2000 operating-hours or maximum 1-year warranty.

• The spindle should be inspected after 4000 operating hours:
- Check spindle draw-in force
- Check release unit operation
- It may be necessary to exchange the toolholder and readjust it
- Clean and grease the toolholder
- Visually inspect the spindle
- Manually check for bearing noise and ensure absolutely uniform true running
• After 6000 hours:
- Visually inspect the spindle for signs of wear
• After 8000 hours:
Spindle manufacturer's recommendation: Return the spindle for inspection
before it fails owing to wear.
otherwise:

- Visually inspect the spindle for signs of wear
7-6 As per 08/07

SBZ 122/20+30
7.2 Cleaning work

The entire machine should be given a "once-over clean” once per day (after each
shift) and should be cleaned thoroughly once per week with compressed air or a
lint-free cleaning cloth in order to remove swarf and dust deposits. If using
compressed air for cleaning, never blow swarf against seals or gaskets, toolholder
and spindle nose since they could be damaged.
If soiled, the entire inside machine area should preferably be cleaned with a
vacuum cleaner or cleaned with a brush or cloth in order to remove swarf.
Guide rails, guide shafts, guide carriage and guide bushings, cylinder piston rods,
shock absorbers, ballscrews, spindles and shafts must be brushed off daily using a
hand-brush.
When fitting or replacing tools, please clean the toolholder and the parts to be fitted
with lint-free cleaning cloths in order to remove swarf and dust residue.
Clean the machine surface frequently with a non-corrosive cleaning agent in order
to remove lubricant, spray oil and dust deposits.
Empty the chip trolley regularly.
On control consoles and switch cabinets with air cooling, the filters in the air inlets
and outlets must be inspected regularly and cleaned if clogged. The filter mats
must be exchanged by new filter mats if highly clogged.
Cleaning the toolholder

Always keep the toolholders clean and clean them prior to each tool change with
a lint-free cleaning cloth.
CAUTION Never blow against the toolholder!

Penetrating swarf will cause bearing damage!
Manual 7-7
SBZ 122/20+30
7.3 Disposal of the machine

The machine must be correctly dismantled and disposed of in accordance with
national regulations.
Please note the following when disposing of machine components:
• Metals and plastic components must be recycled.
• Electrical/electronic components must be disposed of as hazardous waste.
7.4 After-sales service

If necessary, our After-Sales Service Department can assist you.
You can contact us as follows:
Address:
®
Maschinenfabrik
elumatec GmbH
Pinacher Str. 61
D 75417 Mühlacker
Telephone:
Switchboard: +49 (0) 70 41 / 14-0
After-Sales Service: +49 (0) 70 41 / 14-250
Fax: +49 (0) 70 41 / 14-280
7-8 As per 08/07

SBZ 122/20+30
8 Spare parts list and list of parts subject to wear
Manual 8-1
SBZ 122/20+30
8-2 As per 08/07

SBZ 122/20+30
9 Annex
All instructions, Manuals and documents supplied with the machine must be noted
and heeded.
9.1 Electrical circuit diagram
9.2 Pneumatic circuit diagram
9.3 Noise emission values
9.4 Safety data sheet, oil coolant
9.5 Safety data sheet, oil for bed - Central lubrication system
9.6 "Spindle cooler" (option) User Manual
Manual 9-1
SBZ 122/20+30
9-2 As per 08/07

8 7 6 5 4 3 2 1
2000 2000
C D
F F
1000
1000
E E
535
535
2000
2000
930
930
D D
6
535
535
5 D
3
805 390 605

C
2 605 390 805
1800 200
C-C ( 1 : 20 ) D-D ( 1 : 20 )
200 1800
C C
4
4
Stückliste
1 Pos. Anz. Zeichnungs. - Nr. Ver. Bezeichnung
1 2 61010790148 Anfangspfosten VKR 45x45
2 1 61010790151 Anfangspfosten Flex II 50x50x2,5 / 60x130 / Zaunhoehe 2000
3 1 61010790152 Durchgangspfosten Flex II 50x50x2,5 / 130x130 / Zaunhoehe 2000
4 2 61010790158 Gitterelement FlexII H=1800 Achsm.=2000 mit Durchbr. 930x390
5 1 61010790159 Tür 1000mm - FlexII -RAL7038
6 1 61010790116 Gitterelement H=1800 Achsm.=1000
B B
7 12 610940800 Dübel Hochleistungsanker FH12/10B
8 3 61010790125 Laschensatz f. Gitterelement Flex II (8 Stück/Satz)
Ursprung: gez. hbr 03.04.2009
Ersetzt durch: gepr.

Freie Maße: Nm.
ges. Änd.-Nr Datum Ind. Feld Art der Änderung Name
Maßstab: Werkstoff: Oberfläche: Rohteil.Nr.
A lackiert RAL7038 A
1:20 Masse: 121.286 kg
R
Benennung: Zeichnungs Nr.
Maschinenfabrik Schutzzaun li+re 3000mm 122101700

75417 Mühlacker-Lomersheim Blatt 1 von 1 A2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
5100
250 2000
F 250 F
200
B A
65
Wand
1000
1000
1000
1000
Tür
1214
1149
E E
600
600
600
600
3600
1210
535
535
1210
2000
2000
930
930
2000
2000
D D
1283,5
1235
ca.890
535
535
Lichtschranke Lichtschranke
805 390 605 3

7 5 B A 605 390 805
1800 200 2050 680
3 1800
2000 4
C C
1 Stückliste
2 Pos. Anz. ZEICHN-NR Bezeichnung
1 1 61010790151 Anfangspfosten Flex II 50x50x2,5 / 60x130 /
Zaunhoehe 2000
6 3 2 2 61010790148 Anfangspfosten VKR 45x45
5 3 3 61010790152 Durchgangspfosten Flex II 50x50x2,5 / 130x130 /
Zaunhoehe 2000
4 2 61010790158 Gitterelement FlexII H=1800 Achsm.=2000 mit
Durchbr. 930x390
B 6 1 61010790124 Tür 1000mm - FlexII B
8 16 610940800 Dübel Hochleistungsanker FH/10B
9 5 61010790125 Laschensatz für Gitterelement FlexII (8Stück/Satz)
Ursprung: gez. hbr 02.04.2009
Ersetzt durch: gepr.

Freie Maße: Nm.
2 Art der Änderung Name
ges. Änd.-Nr Datum Ind. Feld
Maßstab: Werkstoff: Oberfläche: Rohteil.Nr.
A A
1:25 Masse: 1295.051 kg
4 R
Benennung: Zeichnungs Nr.
Maschinenfabrik Montageanleitung Schutzzaun 122040104

75417 Mühlacker-Lomersheim
li+re 3600mm 2-Lagen Blatt 1 von 1 A2
8 7 6 5 4 3 2 1
Artikelnummer Bezeichnung 1 Bezeichnung 2
ETK SBZ 122/20
041160303 Proximity sensor M8‐plug SME‐8M‐ZS‐24V‐K0.06‐M8‐SA
041160634 Connecting cable 3‐pol. M8 5m NEBU‐M8G3‐K‐5‐LE3, GD
041162006 Mounting kit SMBR‐8‐32
041165001 Solenoid coil 24V= MSFG‐24DC/42AC‐OD
041166102 5/2‐Solenoid valve 1/8 24V= JMFH‐5‐1/8 bistable
041166118 5/2‐Solenoid valve 1/8 24V= JMFH‐5‐1/8‐S‐B pilot air ext.
041166123 5/2‐Solenoid valve 1/8 24V= JMFH‐5‐1/8‐S bi/pilot air ext.
041216003 Manometer d=40mm 10bar glass MA‐40‐10‐R1/8‐SA
041216004 Manometer d=40mm 10bar G1/4 MA‐40‐10‐G1/4‐EN
041216007 Manometer d=40mm 16bar G1/8 MA‐40‐16‐1/8
041217011 Cylinder D20 S50 ADN‐20‐50‐I‐P‐A
041217083 Cylinder D32 S50 DSNU‐32‐50‐P‐A‐MA
0412171114 Filter regulator 3/8 no press. gauge, LFR‐3/8‐D‐O‐MINI
041217127 One‐way flow control valve GRLA‐1/8‐QS‐6‐D
041217132 One‐way flow control valve GRLZ‐1/8‐QS‐6‐D
041217152 3/2‐Start valve HE‐D‐MINI
041217157 Filter regulator 1/4 LFR‐1/4‐D‐5M‐MINI‐A
041217173 Pressure regul. G1/4 0,5‐7bar LRB‐D‐7‐O‐MINI
041217184 3/2‐Solenoid valve type C CPV14‐M1H‐2x3‐GLS‐1/8
041217185 5/2
5/2‐Solenoid valve Type M
S l id l T M CPV14
CPV14‐M1H‐5LS‐1/8
M1H 5LS 1/8
041217186 5/2‐Solenoid valve type J CPV14‐M1H‐5JS‐1/8
041218902 Lubricator 110ccm w. connect. plates, LOE‐1/4‐D‐MIDI
041219022 PE converter 3,7bar 2,5m 2x0,75 rising NO
066163807 Abschlussplatte 1,0mm GY 859‐525
066164900 Relay 24Vdc 1 change‐over con. 859‐304 24VDC‐10mA für TS 35
070108206Z Clamping lever M8x20, size 2 (2 pieces)
070108208Z Clamping lever M10, size 3 (2 pieces)
070160304 Foot switch F1‐U1 with UN‐hood in RAL 2004
077351030 Collet diameter 3,0mm
077351040 Collet 4,0mm
088907080 High performance cutting fluid Supra NEOC 1311, 0,5 l
088907115 Oil for bed 1,0l OEST sliding oil CG68
104160609 Solenoid valve plug 180° LED+ protec. circuit, 2,5m 3x0,75
104166107 5/2 Direct. control valve 1/8 24Vdc, S9 581‐1/8, pulsed
104166110 5/3 Direct. control valve 1/8 24Vdc, S9 581RFG‐1/8
104167720 Field bus ‐ computer for axis FBUR
104167721 Field bus ‐ input module IN 16
104167722 Field bus ‐ output module OUT 16
104167726 Field bus ‐ in/output module (8 in‐, 8 outputs 1,5 AMP.)
104167730 Field bus ‐ analog output module, FB‐ANO1‐2 (1 channel)
118108201Z Workpiece support 25x10x160 (4 pieces)
121219004 Valve unit pre‐assembled clamp tool magazine, ARH
122100300Z Key‐operated switch
122100301Z Potentiometer
122100800Z Tool chuck clamp HSK 63
122100801Z Tool chuck clamp HSK 63 (4 pieces)
122101100Z Clamping cylinder D=50 stroke=125 DSNU
122101800Z Spray nozzle (2 pieces)
122102150Z Cylinder proximity switch
122102151Z Cylinder with coupling pin
122105000Z Protective curtain
122108200Z Ill
Illuminated press button red
i t d b tt d
122108201Z Illuminated press button green
122108202Z Illuminated press button white
122108203Z Clamping buffer D50x30 M16 with pressure plates
122108204Z Button with housing
122108205Z Standard counterblock
122164401 1‐phase‐gear pump CME‐BP 230V 22‐28bar
122165000 Power pack 3x340‐460V500W24VDC GNG21‐01; 20A
122210050Z Lubricator G1/4 0,5l supply port left
122219005 Pre‐ass. air conditioning Tool spindle Festo
122219007 Pre ass. air conditioning machine Festo
122219013 Pre‐ass.valve ter.SBZ122/30+31 working head Festo
122351000 Collet 9,0 ‐ 10,0 mm ER 16 double‐slotted
130108200Z Clamping buffer D50x30 M16 (4 pieces)
130160342 Proximity switch M18x1 PNP XS5 18B1PAM12 make 5mmS
130167728 Brake/ZWK‐resistance V5 33R 300W with contact switch
130351000 Collet 7 ‐ 8 mm ER32 double‐slotted
136219014 Cylinder NZKD 6032/0050 pre‐ assemb. 186, ARH 0/180°
140163400 Key‐operated switch 90° locki. 51‐195.025D; 250V/5A; 311
140163402 Emergency switch, Lumotast 25 1.15154.016; 25V/1000mA
142108218Z Pressure plate D50x4 (4 pieces)
142166104 3/2 Direct. control valve 1/8 24Vdc, NW2,5; V9 381RF‐1/8‐NG
150164919 Off‐emergency supervisory relay XPS‐AV11113 24V AC
150166101 3/2 Direct. control valve 1/8 24Vdc, S9 381RF‐1/8‐NG
150166102 3/2 Direct. control valve 1/8 24Vdc, NW1,3;V9 381H‐RF‐1/8‐NG
150167711 Field bus ‐ filter mod. 24V/DC type 1 with FN332‐6/05
150214101 Fastening set Airfit Swing PL16965
150261001 Cleaner f. cone HSKF63 (HSK50) D54x148
244169250Z Emergency stop button complete
244169251Z Press button complete front ring silver
244169252Z Press button complete front ring green
610166110 5/2
5/2 Dir.contr.valve 1/8 24Vdc
Di t l 1/8 24Vd S9 581S‐1/8‐SO valve terminal
S9 581S 1/8 SO l t i l
720213601 Filter regulator G3/8 SK‐3/8‐H
Artikelnummer Bezeichnung 1 Bezeichnung 2
ETK SBZ 122/30
041160634 Connecting cable 3‐pol. M8 5m NEBU‐M8G3‐K‐5‐LE3, GD
041162006 Mounting kit SMBR‐8‐32
041165001 Solenoid coil 24V= MSFG‐24DC/42AC‐OD
041166102 5/2‐Solenoid valve 1/8 24V= JMFH‐5‐1/8 bistable
041166118 5/2‐Solenoid valve 1/8 24V= JMFH‐5‐1/8‐S‐B pilot air ext.
041166123 5/2‐Solenoid valve 1/8 24V= JMFH‐5‐1/8‐S bi/pilot air ext.
041216003 Manometer d=40mm 10bar glass MA‐40‐10‐R1/8‐SA
041216004 Manometer d=40mm 10bar G1/4 MA‐40‐10‐G1/4‐EN
041216007 Manometer d=40mm 16bar G1/8 MA‐40‐16‐1/8
041217011 Cylinder D20 S50 ADN‐20‐50‐I‐P‐A
041217083 Cylinder D32 S50 DSNU‐32‐50‐P‐A‐MA
0412171114 Filter regulator 3/8 no press. gauge, LFR‐3/8‐D‐O‐MINI
041217127 One‐way flow control valve GRLA‐1/8‐QS‐6‐D
041217132 One‐way flow control valve GRLZ‐1/8‐QS‐6‐D
041217152 3/2‐Start valve HE‐D‐MINI
041217157 Filter regulator 1/4 LFR‐1/4‐D‐5M‐MINI‐A
041217173 Pressure regul. G1/4 0,5‐7bar LRB‐D‐7‐O‐MINI
041217184 3/2‐Solenoid valve type C CPV14‐M1H‐2x3‐GLS‐1/8
041217185 5/2‐Solenoid valve Type M CPV14‐M1H‐5LS‐1/8
041217186 5/2
5/2‐Solenoid valve type J
S l id l t J CPV14
CPV14‐M1H‐5JS‐1/8
M1H 5JS 1/8
041218902 Lubricator 110ccm w. connect. plates, LOE‐1/4‐D‐MIDI
066163807 Abschlussplatte 1,0mm GY 859‐525
066164900 Relay 24Vdc 1 change‐over con. 859‐304 24VDC‐10mA für TS 35
070160304 Foot switch F1‐U1 with UN‐hood in RAL 2004
077351040 Collet 4,0mm
088907115 Oil for bed 1,0l OEST sliding oil CG68
104160609 Solenoid valve plug 180° LED+ protec. circuit, 2,5m 3x0,75
104166107 5/2 Direct. control valve 1/8 24Vdc, S9 581‐1/8, pulsed
104166110 5/3 Direct. control valve 1/8 24Vdc, S9 581RFG‐1/8
104167720 Field bus ‐ computer for axis FBUR
104167721 Field bus ‐ input module IN 16
104167722 Field bus ‐ output module OUT 16
104167726 Field bus ‐ in/output module (8 in‐, 8 outputs 1,5 AMP.)
104167730 Field bus ‐ analog output module, FB‐ANO1‐2 (1 channel)
121167506T Frequency converter 380..480V SP2402; 16,5A‐21A; 11Kw
121219004 Valve unit pre‐assembled clamp tool magazine, ARH
122100300Z Key‐operated switch
122100301Z Potentiometer
122100800Z Tool chuck clamp HSK 63
122100801Z Tool chuck clamp HSK 63 (4 pieces)
122101100Z Clamping cylinder D=50 stroke=125 DSNU
122105000Z Protective curtain
122108200Z Illuminated press button red
122108201Z Illuminated press button green
122108202Z Ill
Illuminated press button white
i t d b tt hit
122108203Z Clamping buffer D50x30 M16 with pressure plates
122108204Z Button with housing
122108205Z Standard counterblock
122164401 1‐phase‐gear pump CME‐BP 230V 22‐28bar
122165000 Power pack 3x340‐460V500W24VDC GNG21‐01; 20A
122210050Z Lubricator G1/4 0,5l supply port left
122219005 Pre‐ass. air conditioning Tool spindle Festo
130108200Z Clamping buffer D50x30 M16 (4 pieces)
130160342 Proximity switch M18x1 PNP XS5 18B1PAM12 make 5mmS
130167728 Brake/ZWK‐resistance V5 33R 300W with contact switch
140162205T Mil.spindle HSKF63,Pmax=6kW,S6 Mmax=4,8Nm,max=21000rpm SR32DL
140163400 Key‐operated switch 90° locki. 51‐195.025D; 250V/5A; 311
140163402 Emergency switch, Lumotast 25 1.15154.016; 25V/1000mA
142108218Z Pressure plate D50x4 (4 pieces)
150164919 Off‐emergency supervisory relay XPS‐AV11113 24V AC
150166101 3/2 Direct. control valve 1/8 24Vdc, S9 381RF‐1/8‐NG
150166102 3/2 Direct. control valve 1/8 24Vdc, NW1,3;V9 381H‐RF‐1/8‐NG
150167711 Field bus ‐ filter mod. 24V/DC type 1 with FN332‐6/05
150214101 Fastening set Airfit Swing PL16965
150261001 Cleaner f. cone HSKF63 (HSK50) D54x148
244169250Z Emergency stop button complete
244169251Z Press button complete front ring silver
244169252Z Press button complete front ring green
610166110 5/2 Dir.contr.valve 1/8 24Vdc S9 581S‐1/8‐SO valve terminal
720213601 Filter regulator G3/8 SK‐3/8‐H
SBZ 122
Noise emission values
elumatec Profile machining centre Type: SBZ 122
The workplace–specific emission value LpA, determined in accordance with

DIN EN ISO 11202, supplemented by CEN -TC 142, is as follows:
Idling ..........75,8 dB(A)
Operating noise ..........83,6 dB(A)
The measurement uncertainty constant K is 4 dB (A).
The following supplements, stipulated by CEN - TC142, have been allowed for
in order to obtain an accuracy class better than 3 dB:
− The ambient correction factor K3A is ≤ 4 dB
− The difference between background noise sound pressure level and noise
sound pressure level at each measuring point is ≥ 6 dB
Allowing for ISO 7960, Sections 0 to 4, the machine-specific measurement

conditions were as follows:
Router: d=10 2 cutter edges n=6000 rpm.
Drill: d= 8 2 cutter edges n=1000 rpm.
Workpiece: Aluminium profile
Microphone position: 1m away at central position in front of the machine at a
height of 1,5m.
Note
The values specified above are emission values and thus do not necessarily also represent
safe workstation values. Since there is no correlation between emission values and
workstation values, these figures cannot be used reliably to determine whether or not further
precautions are necessary. Factors which may influence the currant workstation value include
the duration of exposure, the characteristics of the work room or area, other noise source, the
number of machines and other neighbouring influences. The reliable workstation values may
also vary from country to country. However, the above information is intendend to allow the
user to better estimate potential danger and risk.
Noise emission values

1/6
Safety data sheet according to Regulation (EC) No 1907/2006, Annex II
Revision: 29.07.2009 Replaces the version of: 29.07.2009 PDF date: 30.07.2009
SUPRA NEOC 1311
Safety data sheet

according to Regulation (EC) No 1907/2006, Annex II
1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF THE
COMPANY/UNDERTAKING
Identification of the substance or preparation
SUPRA NEOC 1311

Art. no.:
088907080 / 0,5 L
088907081 / 1 L
088907082 / 5,0 L
088907083 / 20 L
088907084 / 200 L
Use of the substance/preparation

Refer to description of material or preparation.
Cutting agent
Metalworking
Company/undertaking identification
Telephone +49 (0) 7041 / 14 - 0, Fax +49 (0) 7041 / 14 - 280
www.elumatec.de
E-mail address of the competent person: [email protected], [email protected]
Emergency telephone
Advisory office in case of poisoning:
Tel.:
Emergency poisoning centre Freiburg Tel.: +49 (0)761 - 19240
Telephone number of the company in case of emergencies:
Tel. --
2. HAZARDS IDENTIFICATION
Preparation is not classified as hazardous in the sense of directive 1999/45/EC.

To people
See point 11 and 15.
Not applicable
Explosive mixtures of vapour and air may form.
Do not heat to temperatures close to flash point.
To the environment
See point 12.
Not applicable
3. COMPOSITION/INFORMATION ON INGREDIENTS
Gen. description:
Mineral oil
Active substance
Chemical name
content % Symbol R-phrases EINECS, ELINCS
Registration number (ECHA)
--
--- ---
2/6
SUPRA NEOC 1311
4. FIRST AID MEASURES
4.1 Inhalation
Remove person from danger area.
4.2 Eye contact
Remove contact lenses.
Wash thoroughly for several minutes using copious water. Seek medical help if necessary.
4.3 Skin contact
Wash thoroughly with soap and copious water - remove contaminated clothing immediately. If skin irritation occurs (redness etc.),
consult doctor.
4.4 Ingestion
Do not induce vomiting.
4.5 Special resources necessary for first aid
n.c.
Indications for the physician:
Symptomatic treatment
5. FIRE-FIGHTING MEASURES
5.1 Suitable extinguishing media

Foam
CO2
Extinction powder
5.2 Extinguishing media which shall not be used for safety reasons
High volume water jet
5.3 Special exposure hazards arising from the substance or preparation itself,
combustion products, resulting gases
In case of fire the following can develop:
Oxides of carbon
Oxides of nitrogen
Oxides of sulphur
Oxides of phosphorus
Organic materials
Inorganic materials
5.4 Special protective equipment for fire-fighters
Protective respirator with independent air supply.
In case of fire and/or explosion do not breathe fumes.
Full protection
5.5 Further information
Dispose of contaminated extinction water according to official regulations.
Prevent from entering drainage system.
6. ACCIDENTAL RELEASE MEASURES
Refer to point 13. and for personal protection refer to point 8.

6.1 Personal precautions
Avoid contact with eyes or skin.
If applicable, caution - risk of slipping
6.2 Environmental precautions
If leakage occurs, dam up.
Prevent surface and ground-water infiltration, as well as ground penetration.
6.3 Methods for cleaning up
Collect using absorbant material (e.g. Universal binding medium), and dispose of according to point 13.
Or:
Collect mechanically and dispose of according to point 13.
3/6
SUPRA NEOC 1311
7. HANDLING AND STORAGE
7.1 Handling
Tips for safe handling:
See point 6.1
Ensure sufficient ventilation.
General hygiene measures for the handling of chemicals are applicable.
Observe directions on label and instructions for use.
Wash hands before breaks and at end of work.
If applicable, suction measures at the workstation or on the processing machine necessary.
Avoid inhalation of the vapours.
7.2. Storage
Requirements for storage rooms and
containers:
Not to be stored in gangways or stair wells.
Store product closed and only in original packing.
Do not store with oxidizing agents.
Special storage conditions:
See point 10
Recommended:
Stability during storage:

12 months.
8. EXPOSURE CONTROLS/PERSONAL PROTECTION
8.1 Exposure limit values
---
8.2 Exposure controls

8.2.1 Occupational exposure controls
Ensure good ventilation. This can be achieved by local suction or general air extraction.
If this is insufficient to maintain the concentration under the WEL or AGW values, suitable breathing protection should be worn.
Applies only if maximum permissible exposure values are listed here.
Keep away from food, drink and animal feedingstuffs.
Respiratory protection: Ensure sufficient ventilation.
Hand protection:
Eye protection: Tight fitting protective goggles (EN 166) with side protection,
with danger of projections.
Skin protection: Protective working garments (e.g. safety shoes EN ISO 20345,
long-sleeved protective working garments)
Additional information on hand protection - No tests have been performed.

Selection made for preparations according to the best available knowledge and information on the ingredients.
Selection of materials derived from glove manufacturer's indications.
Final selection of glove material must be made taking the breakthrough times, permeation rates
and degradation into account.
Selection of a suitable glove depends not only on the material but also on other quality characteristics
and varies from manufacturer to manufacturer.
In the case of preparations the resistance of glove materials cannot be calculated in advance
so it has to be tested before use. The exact breakthrough time of the glove material can be
requested from the protective glove manufacturer and must be observed.
8.2.2 Environmental exposure controls

4/6
SUPRA NEOC 1311
n.av.
9. PHYSICAL AND CHEMICAL PROPERTIES
Physical state: Liquid

Colour: Brown, Yellow
Odour: Characteristic
pH-value undiluted: n.a.
Minimum limit of explosion: 0,6 Vol%

Maximum limit of explosion: 6,5 Vol%
Water solubility: Insoluble
10. STABILITY AND REACTIVITY
Conditions to avoid
See point 7
Stable when handled and stored correctly.
Materials to avoid
See point 7
Avoid contact with strong oxidizing agents.
Hazardous decomposition products
See point 5.3
No decomposition when used as directed.
11. TOXICOLOGICAL INFORMATION
Acute toxicity and immediate effects

Ingestion, LD50 rat oral (mg/kg): > 2000
Inhalation, LC50 rat inhal.(mg/l/4h): n.av.
Skin contact, LD50 rat dermal (mg/kg): Not irritant
Eye contact: Not irritant
Delayed and chronic effects

Sensitization: No
Carcinogenicity: No indications of such an effect.
Mutagenicity: No indications of such an effect.
Reproductive toxicity: No indications of such an effect.
Narcosis: n.c.
Further information
The toxicological information is based on data found on similar products and/or the individual components.
According to our current state of knowledge, the preparation does not put humans at risk under normal conditions of use.
12. ECOLOGICAL INFORMATION
Water hazard class (Germany): 2

Self classification: Yes (VwVwS)
Persistence and degradability: Not totally biodegradable.
Adsorption in ground.
Behaviour in sewage plants: Do not allow to reach waters, wastewater or soil.
Aquatic toxicity:
Product can compose a film on the water surface, which can prevent oxygen exchange.
Ecological toxicity: n.av.
13. DISPOSAL CONSIDERATIONS

5/6
SUPRA NEOC 1311
13.1. for the material / preparation / residue

EC disposal code no.:
Do not carry cleaning cloths soaked in product in trouser pockets.
The waste codes are recommendations based on the scheduled use of this product.
Owing to the user's specific conditions for use and disposal, other waste codes may be
allocated under certain circumstances. (2001/118/EC, 2001/119/EC, 2001/573/EC)
12 - WASTES FROM SHAPING AND PHYSICAL AND MECHANICAL SURFACE TREATMENT OF METALS AND PLASTICS
12 01 wastes from shaping and physical and mechanical surface treatment of metals and plastics
12 01 07 mineral-based machining oils free of halogens (except emulsions and solutions)
Recommendation:
Pay attention to local and national official regulations
E.g. dispose at suitable refuse site.
E.g. suitable incineration plant.
Do not dispose of with household waste.
13.2 for contaminated packing material
See point 13.1
15 01 01 paper and cardboard packaging
15 01 02 plastic packaging
15 01 04 metallic packaging
Empty container completely.
14. TRANSPORT INFORMATION
General statements
UN-Number: n.a.
Road/Rail-transport (ADR/RID)
Class/packing group: n.a.
Classification code: n.a.
LQ: n.a.
Tunnel restriction code:
Transport by sea
IMDG-code: n.a. (class/packing group)
Marine Pollutant: n.a.
Transport by air
IATA: n.a. (class/secondary danger/packing group)
Additional information:
Non-dangerous material according to Transport Regulations.
15. REGULATORY INFORMATION
Classification according to Dangerous Product Regulations incl. EC Directives

(67/548/EEC and 1999/45/EC)
Symbols: Not applicable
Indications of danger: ---
R-phrases:
S-phrases:
Additions: n.a.
Observe restrictions: n.a.
16. OTHER INFORMATION
These details refer to the product as it is delivered.

Storage class VCI (Germany): 12
Revised points: n.a.
Legend:
6/6
SUPRA NEOC 1311
n.a. = not applicable / n.v., k.D.v. = n.av. = not available / n.g. = n.c. = not checked
WEL = Workplace Exposure Limit EH40, TWA = Long-term exposure limit (8-hour TWA (= time weighted average) reference
period), STEL = Short-terme exposure limit (15-minute reference period) / BMGV = Biological monitoring guidance value EH40
AGW = "Arbeitsplatzgrenzwert" (workplace limit value, Germany) / BGW = "Biologischer Grenzwert" (biological limit value, Germany)
VbF = Regulations for flammable liquids (Austria)
WGK = water hazard class (Germany) - WGK 3 = very hazardous, WGK 2 = hazardous, WGK 1 = slightly hazardous to water
VOC = Volatile organic compounds / AOX = Adsorbable organic halogen compounds
VwVwS = Administrative Order relating to substances hazardous to water (Germany)
The statements made here should describe the product with regard to the necessary safety precautions - they are
not meant to guarantee definite characteristics - but they are based on our present up-to-date knowledge.
No responsibility.
These statements were made by:
CHEMICAL / +49 180 52 43 642, Fax: +49 5233 94 17 90, +49 180 50 50 455
. The copying or changing of this document
is forbidden except with consent of the Chemical Check GmbH Gefahrstoffberatung.
1/5
Metalon 11-108
Safety data sheet

COMPANY/UNDERTAKING
Metalon 11-108
Art. no.:
088907095 / 1,0 L
088907096 / 0,5 L
088907097 / 5,0 L
088907998 / 20 L
088907099 / 200 L

Cutting agent
Telephone +49 (0) 7041 / 14 - 0, Fax +49 (0) 7041 / 14 - 280
www.elumatec.de
Emergency telephone
Tel.:
Tel. --

To people
Not applicable
To the environment
See point 12.
Not applicable
Gen. description:
Fatty acid ester
Chemical name
--
--- ---

2/5
Metalon 11-108
4.1 Inhalation
Remove person from danger area.
Supply person with fresh air and consult doctor according to symptoms.
4.2 Eye contact
4.3 Skin contact
consult doctor.
4.4 Ingestion
Rinse the mouth thoroughly with water.
Give water to drink.
In case of symptoms:
Medical attention necessary.
n.c.

Adapt to the nature and extent of fire.
High volume water jet
Oxides of carbon

Danger - risk of slipping.
Collect using absorbant material (e.g. Universal binding medium, sand, kieselguhr) and dispose of according to point 13.
7.1 Handling
See point 6.1
Avoid contact with eyes.
Avoid long lasting or intensive contact with skin.
3/5
Metalon 11-108
7.2. Storage
containers:
Do not store with oxidizing agents.
See point 10
Store cool
Store in a dry place.
---

Respiratory protection: Normally not necessary.
Ensure sufficient ventilation.
Hand protection: Protective gloves (EN 374).
Eye protection: Tight fitting protective goggles with side protection (EN 166).
Skin protection: Usual protective working garments


n.av.

Colour: Colourless
Odour: Mild
Autoflammability: No
Minimum limit of explosion: n.a.
Maximum limit of explosion: n.a.
Product is not explosive.
Density (g/ml): Not detected

4/5
Metalon 11-108
Viscosity: Not detected
Conditions to avoid
See point 7
Materials to avoid
See point 7
Avoid contact with strong oxidizing agents.
See point 5.3
No decomposition when used as directed.

Ingestion, LD50 rat oral (mg/kg): n.av.
Skin contact, LD50 rat dermal (mg/kg): n.av.
Eye contact: n.av.

Sensitization: n.c.
Carcinogenicity: n.c.
Mutagenicity: n.c.
Reproductive toxicity: n.c.
Narcosis: n.c.
Further information
The product was not tested.
No classification according to calculation procedure.
The following may occur:
Irritation of the skin.

Persistence and degradability: n.av.
Aquatic toxicity: n.av.

Recommendation:
See point 13.1
15 01 01 paper and cardboard packaging
15 01 02 plastic packaging
5/5
Metalon 11-108
15 01 04 metallic packaging
General statements
UN-Number: n.a.
LQ: n.a.
Transport by sea
Transport by air

(67/548/EEC and 1999/45/EC)
R-phrases:
S-phrases:
Additions: n.a.

Storage class VCI (Germany): 10 - 13
Legend:
No responsibility.
CHEMICAL / +49 180 52 43 642, Fax: +49 5233 94 17 90, +49 180 50 50 455
1/5
Safety data sheet

COMPANY/UNDERTAKING
Art. no.:
088907115 / 1,0 L

Lubricating oil
Hydraulic oil
Telephone +49 (0) 7041 / 14 - 0, Fax +49 (0) 7041 / 14 - 280
www.elumatec.de
Emergency telephone
Tel.:
Tel. --

To people
Not applicable
To the environment
See point 12.
Not applicable
Gen. description:
Mineral oil raffinate
Additives
Chemical name
--
--- ---

2/5
4.1 Inhalation
Supply person with fresh air and consult doctor according to symptoms.
4.2 Eye contact
4.3 Skin contact
consult doctor.
4.4 Ingestion
In case of symptoms:
Medical attention necessary.
n.c.

Sand
CO2
Extinction powder
Never use water.
Water
Oxides of carbon

If applicable, caution - risk of slipping
Collect using absorbant material (e.g. Universal binding medium), and dispose of according to point 13.
7.1 Handling
See point 6.1
Avoid long lasting or intensive contact with skin.
7.2. Storage
3/5

containers:
See point 10
---

Respiratory protection: Normally not necessary.
Hand protection: Protective gloves, oil resistant (EN 374)
Eye protection: Tight fitting protective goggles (EN 166) with side protection,
with danger of projections.
Skin protection: Protective working garments (e.g. safety shoes EN ISO 20345,
long-sleeved protective working garments)


n.av.

Colour: Light brown
Odour: Characteristic
Setting point
Autoflammability: No
Product is not explosive.

4/5
Conditions to avoid
See point 7
Materials to avoid
See point 7
No dangerous reactions are known.
See point 5.3
Carbon monoxide

Ingestion, LD50 rat oral (mg/kg): n.av.
Skin contact, LD50 rat dermal (mg/kg): Not irritant
Eye contact: Not irritant

Sensitization: No indications of such an effect.
Carcinogenicity: n.c.
Mutagenicity: n.c.
Reproductive toxicity: n.c.
Narcosis: n.c.
Further information
The product was not tested.
The toxicological information is based on data found on similar products and/or the individual components.

Persistence and degradability: n.av.
Aquatic toxicity:
Product can compose a film on the water surface, which can prevent oxygen exchange.

Do not carry cleaning cloths soaked in product in trouser pockets.
13 - OIL WASTES AND WASTES OF LIQUID FUELS (except edible oils, and those in chapters 05, 12 and 19)
13 02 waste engine, gear and lubricating oils
13 02 05 mineral-based non-chlorinated engine, gear and lubricating oils
Recommendation:
See point 13.1
15 01 10 packaging containing residues of or contaminated by dangerous substances
5/5
General statements
UN-Number: n.a.
LQ: n.a.
Transport by sea
Transport by air

(67/548/EEC and 1999/45/EC)
R-phrases:
S-phrases:
Additions: n.a.

Storage class VCI (Germany): 10 - 13
Legend:
No responsibility.
CHEMICAL / +49 180 52 43 642, Fax: +49 5233 94 17 90, +49 180 50 50 455
BETRIEBSANLEITUNG
OPERATING INSTRUCTIONS
INSTRUCTIONS DE SERVICE
VWK 7/1-S
Zertifiziert
nach
DIN EN ISO
9001 : 2000
YOUR PARTNER IN PROCESS COOLING
Operating Instructions
C O N T E N T:
Chapters page
1 SAFETY / PREVENTION OF ACCIDENTS 2
2 TRANSPORT 3
3 INSTALLATION AND INITIAL OPERATION 4
4 CARE AND MAINTENANCE 5
5 OPERATIONAL TROUBLE 6
6 WASTE DISPOSAL 7
7 IMPORTANT INFORMATION ON WATER QUALITY 8
8 PLATE EXCHANGER (OPTION) 9
9 APPENDIX:
- TECHNICAL DATA
- ADJUSTING OUTLET- TEMPERATURE
- ELECTRO-SWITCH-FLAT
IMPORTANT!
These operating instructions have to be read carefully before putting the refrigerating plant into
operation. The manufacturer can`t undertake any liability for damage or operating trouble resulting from
the non-observance of these operating instructions. All rights for technical modification required for
further development are reserved.
PROPER USE OF THE REFRIGERATING PLANT!

This refirigerating plant is designed for the cooling of water. In case you intend to use other agents ( e.g.
deionised water ) please contact the manufacturer. Limits indicated in the technical data mustn`t be
exceeded. Use of the plant to cool flammable or explosive substances is prohibited.
Please keep these operating instructions for further use!

page 2
1 SAFETY / PREVENTION OF ACCIDENTS

General information
These operating instructions contain piepse of information which have to be observed during initial
start, operation and maintenance. Therefore these instructions are to be read by the installer and
operating personnel in charge before putting the plant into operation.
All general safety instructions mentioned in this chapter and special security instructions given in other
sections of this manual have to be observed.
Personnel-qualification and training

Operating, maintenance, inspection and installation personnel must be properly qualified for their
work. Responsibility and supervision must be exactly regular through the operator.
Danger due to non-observance of safety instructions

Non-observance of safety instructions may cause injuries, endanger the environment or damage the
plant. Non-observance of safety instructions will result in the loss of right to claim for damages.
Safety conscious operation

The safety instructions given in these operating instructions, including national regulations on accident
prevention as well as any specific plant safety instructions must be observed.
Safety instructions for user / operator

Protective guards that have been installed to prevent contact with moving parts may not be removed
when the unit is being operated. Danger resulting from the use of electrical power must be excluded.
(For detailed information, refer to the VDE regulations and the regulations of the local power supply
companies.)
Safety instructions on maintenance, inspection, and installation work

Basically non of the cleaning or maintenance tasks may be performed until the unit has come to a
complete stop. The shutdown procedure described in the operating instructions must be observed. As
soon as this work has been completed, all the safety devices and protective equipment must be
mounted or installed according to their proper function.
Arbitrary modification and production of spare parts

The unit may be converted only if an agreement has been reached with the manufacturer. Original
spare parts and accessories accepted by the manufacturer serve as safety guarantee. Use of other
parts may cancel manufacturer`s liability for subsequent damages
Non-permissible operating methods

The operational safety of the delivered unit is guaranteed only if the unit is properly used as intended.
Limits indicated in the technical data must not be exceeded.
Health hazards with the refrigerant

The refrigerant has only a very low acute health hazard. It has narcotic effects only at extremely high
concentrations. After acute exposure to extremely high concentrations the substance is eliminated
over the lungs very quickly. The refrigerant has a certain irritating effect on skin and mucous
membranes. Exposure of the skin to liquid refrigerant can cause frost bite. In the presence of open
flames or hot surfaces refrigerant can decompose and form toxic decomposition products (e.g.
hydrogyn chloride, phosgene). The refrigerant evaporates when exhausted into the air in gaseous
form. Intentional exhausting is not permissible. The refrigeration equipment must be set up so it
cannot be damaged as a result of in-plant traffic or transport operations.
page 3
Safety symboles
Warning
This symbol is to be found next to all the safety instructions involving work that may result in
serious injuries. Observe these instructions and proceed with extreme caution in such
! instances. Inform all other users as well. In addition to the instructions included in this
manual, the applicable general safety and accident prevention regulations must also be taken
into account.
Attention
This symbol is to be found next to the items in this manual that must be strictly observed to
¹ ensure proper application of the guidelines, regulations, instructions and procedure of tasks
and to make sure that the machine or other parts are not damaged or destroyed.
Note
This refrigerating plant is designed according to state-of-the-art technology and is safe to
operate. Dangerous situations may, however, be the result if the unit is used by personnel
without proper training or if it is not used correctly according to its intended purpose.
Accordingly, this may affect efficient operation of the unit.
2 Transport
The refrigerating plant may only be transported in original packaging to the site of initial operation. In
case of damage the manufacturer must be informed immediately. If the unit is moved to another
location in a factory, all connections must be disconnected from the unit. Moving the unit to another
location must be carried out without causing damages. If damage occurs despite these instructions,
the unit must be checked by an expert and repaired as required before it is put into operation again
When transporting the unit , consider the weight indicated in the technical data. Use a fork-lift
truck or a crane with the corresponding minimum load-capacity.
!
The fully-hermetic compressor is mounted on springs. Always transport the refrigerating unit
¹ as mentioned below. Avoid vibrations during transport. Failure to observe can result in the
compressor slipping out of its mount. There is no possibility to repair.
page 4
3 INSTALLATION AND INITIAL OPERATION

Installation
When setting up the refrigerating unit please observe strictly the following points:
• Assure that the required cooling air quantity (see technical data) can be sucked in. (with air-cooled-
plants)
• Distance of air intake: at least 1,0 m (with air cooled plants)
• Distance of air outlet: at least 2,0 m (with air cooled plants)
• Hint: Connection of an air supply and exhaust duct is admitted only for machines with radial.
• The unit must not be set up next to a heater.
• The unit must be set up on level, solid surfaces only, so that stability is ensured.
• If the consumer is placed on a higher level than the cooling unit, a non-return valve has to be
installed in the outlet as well as an solenoidvalve has to be installed in the inlet.
• For plants erected in the open under shelter, the minimum outdoor temperature should be taken
from the technical data.
• For plants with a tank, a water/glycol mixture at the appropriate ratio should be filled in under minus
temperatures Æ refer to technical data.
Electro-connection
The regrigerating unit is ready for connection and it is only necessary to complete the connection to a
threephase network (mains voltage see technical data). The connection has to be completed with a
right handed rotatory field.
¹ If electric connection work is not performed properly factory warranty is cancelled.
Tank filling for basket-type evaporators.

Prior to start up the tank should be filled so that the internal heat exchanger is completely covered by
the medium.
After successful realization of all instructions given in this chapter, the refrigerating plant is switched
on by means of the main switch or of master switch (if installed). Readiness for operation is indicated
by signal lamp „Operation.“
Position: 0 = Off
1 = Operation
Corrosion prevention Evaporator

To avoid corrosion of the stainless steel evaporator and your water, we recommend to use water with
a low salt content (chloride content < 20 mg/l). To avoid thickening of the tank water, we recommend
to replace the system content every 12 to 15 months Æ increasing evaporation of the tank water
means an increasing chloride content. In case of questions please do not hesitate to contact us Æ for
hints refer to chapter 7.
Customer connection
After completing the electric connection it is necessary to connect the system to be cooled type VWK
with the refrigeration unit by hoses or pipes. Use insulated pipes when the distance between
refrigerating unit and equipment to be cooled is greater than usual. Before starting up it is always
necessary to prime pump with the agent to be transported and remove the air.
page 5
Ventilation of the pump
Before starting the process, follow the steps below to release the pump:
- check the waterlevel in the tank and if necessary refill it.

- Open the outlet of the pump, or
- Connect only the outlet of the pump, let the inlet free flow out
If there is still some air in the loop, you have to repeat the steps as described before.
After open the outlet and start the pump for a short time.
Attention
before comisionning the pump, the function of this pump must be absolutly checked
In case of a long standstill of the pump, you have to introduce a screwdriver through the air-grille into
the shaft and turn it clockwise (1-2 turns min. ), until a easiness is produced.
¹ In case of units with hot agents it is necessary to remove the air from the pump with the utmost care
in order to avoid injury to persons by water outflow.
• Remove bleed screw P
• Reinstall bleed screw and tighten as soon as medium exits from filler fitting.
page 6
4 CARE AND MAINTENANCE
Inspektion
General
In case of irregularities occurring during operation of the mechanically-working aggregates or
extraneous noise refrigerating plant has to be switched off by means of the control switch.
Medium to be cooled
Cleanness of the medium to be cooled should be checked everyday. In case of need medium has to
be let off; cooling circuit has to be rinsed and refilled. In addition the pump has to be cleaned. ) To
drain the tank (option) of three-phase plants, turn the filling level pipe to the side.
Cleaning of condenser (with air-cooled-plants)

Make sure that lamellas of the condenser remain clean in order to guarantee required heat exchange.
As demanded by ambience conditions lamellas of condenser should be cleaned in determined time
intervals. Dust and fluffing may be removed by means of compressed air. In case the refrigerating
plant is equipped with an air filter, it has to be exchanged.
Refill of circulating medium
Automatic refill tank (Option)

Automatic water feed guarantees constant level in water tank, so that evaporator always remains
under water. Orderly float valve function of the automatic water feed has to be checked regularly.
Manual feed tank (Option)

Tank is filled by means of fresh water feed. A level indicator which can be seen from the outside is
installed at the housing in oder to check level. Make sure that evaporator lies under water.
Water admixtures
Larger volumes of fresh water admixtures may disturb equilibrium of mixture or reduce concentration
of antifreezing agent. According to the volume of these admixtures effectiveness of water treatment or
content of concentration should be checked in determined intervals of time.
Standstill for prolonged period

In case of longer standstill of refrigerating plant, it is advisable to emty water circuit completely. For
renewed start-up of refrigerating plant the same steps as for the initial start-up have to be taken.
page 7
5 Operational failure
By means of the following instructions a quick failure analysis can be made. Therefore the user can
repair some failures without asking for help. But on the other hand, your descriptive information might
help the consultant (in case of a telephone trouble shooting) to find out about probable causes of
operational failure.
Corrective maintenance of the refrigeration cycle must be performed by competent company

¹ only. In case of any problems concerning the refrigeration cycle should arise, please contact
manufacturer
Operational failures and their causes

Deficiency of refrigerant
Deficiency of refrigerant is detected by immense decrease of cooling capacity. In this case
refrigeration cycle is leaky.
Corrective maintenance of the refrigeration cycle must be performed by competent company

¹ only.
Increased pressure of condenser

If admissible pressure of the condenser is exceeded, high-pressure limiter (Option for capillary pipe
injection) is activated and compensator is switched off.
¹ Manual resetting of the high-pressure limiter (Option for capillary pipe injection) requires an
expert
Probable cause for increased condenser pressure:
- ambient temperature too high (see technical data)

- non-observance of necessary distance (see initial start-up)
- Clogged condenser or filter (option)
- water flow temperature too high (see technical data)
- water volume controller defective (in case of water-cooled plants only)
- contamination of water in- / -outlet (in case of water-cooled plants only)
- cooling water temperature out-of-limits (in case of water-cooled plants only,
see technical data)
- Lack of cooling water supply
Signal lamp indicates failure. (Option)
Evaporator pressure
If necessary evaporator pressure is not reached, low pressure limiter (Option for capillary pipe
injection) is activated and compensator is switched off.
¹ Manual resetting of low pressure limiter (Option for capillary pipe injection) requires an
expert.
Probable causes for decreased compensator pressure:
- ambient temprature too low (see technical data)

- lack of refrigerant
- expansion valve defective
- operational electrovalve defective (if existent, see circuit diagram)
- Medium in the tank is to low → The evaporator have to be complete in the medium.
sein.
page 8
Permanent on / off switching of compressor

Probable reasons for compressor permanently switching on-and-off:
- cooling capacity of plant too high

- switching difference of controller too small
Water flow temperature too high

During operation the refrigerating plant runs at fail-safe condition. Refrigerating plant keeps water flow
temperature on the adjusted set-point. Probable causes for deviation from desired value:
- cooling demand too high (see technical data)

- ambient temperature too high (see technical data)
- non-observance of necessary distances (see initial start-up)
- contaminated evaporator
- contaminated lcondenser
- lack of refrigerant (bubbling in inspection glass)
- level of medium in tank too low
- temperature of medium set too high (see technical data)
Excess current
Any electrical drive of the refrigerating plant is protected by engine protection switches. They are
activated if:
- wrong rotating field

- phase is missing
- plant is overloaded
- Network tension wrong
- frequency is wrong
- engine is defective
- feeder of respective engine is defective
- Temperature in the control cabinet is to high
Anti-freezing protection (option, see circuit diagram)

Anti-freezing controller switches off water-cooled recooler at a temperature of < 8° C, so that
the evaporator does not freeze if temperature is too low.
Flow switch (optional, see circuit diagram)

The refrigerating plant does not start or stands still:
- flow controller switches off plant if water volume is underflown.
→ provides for a bigger flow
6. Disposal
The refrigerant evaporates if being exposed to air. Any intended blowing off is prohibited. Disposal
must be arranged properly according to local regulations.Professional disposal (according to local
regulations) of all components of the refigeratin plant is an absolute necessity. Oil in compressor as
well as probably arising waste water must follow the same rule.
page 9
7. Important information on water quality

In order to achieve a correct and trouble-free operation of cooling systems it is necessary to check the water
quality and, when necessary, carry out a water treatment. Corrosion, furring and biological problems can
occur in cooling systems.
The following system data is especially important for the assessment of a half-open system:
- raw water quality

- all materials having contact with the cooling water
- max. and min. system water temperature
- requirements for water quality
The following general set-up conditions for the water quality must be satisfied:
Industrial CHILLERS
Water quality 1 Water quality 2 Water quality 3
VE-water Tap water Tap water

RO-water conduction < 300 µS / cm conduction < 500 µS/cm
condensate
colour: clear clear clear

free from contarmination free from contarmination free from contarmination
pH-Wert 7-9 7 - 8,5 7 - 8,5
conduction < 50 µS/cm < 300 (without treating) < 500 (without treating)
hardness (°dH) < 0,1 < 10 < 20
alcality (°dH) <1 < 10 (without treating) < 15 (without treating)
chlorid concentration: < 10 mg/L < 50 < 100
Complete < 1000 KBE / ml < 1000 KBE / ml < 1000 KBE / ml
germnumber:
watertreatment Varidos 1+1 Varidos 1+1 Varidos 1+1

3000 mg / L 3000 mg / L 5000 mg / L
Additive Nalco 77350 Nalco 77350 Nalco 77350

(as needed) 250 mg / L 250 mg / L 250 mg / L
Water quality 1 protection against stainless steel corrosion

Water quality 2 stainless steel corrosion is possible
Water quality 3 stainless steel corrosion is definate, watertreating is absolute required
ONDEO Nalco Deutschland GmbH

2002
page 10
Evaporation at the system water surface leads to a concentration in the system water. Raw water values
which are initially below the guide value can increase to exceed the guide value as a result of the
evaporation. An excessive chloride content in the system water, for example, can also cause the stainless
steel to be attacked. We therefore recommend you to regularly monitor the water quality and, if necessary, to
remove the concentrated water from the system by way of a water renewal in order to rematch the water
values to the general set-up conditions.
The following products have proven themselves for the different application areas:
In the case of further questions concerning water treatment. please contact:
Deutschland:
ONDEO Nalco Deutschland GmbH
Herr Marx, Herr Benzmann
Hans-Böckler-Straße 10
40764 Langenfeld
Tel: 02173 – 98 47 0
France
ONDEO Nalco
N°5 rue Rosa Bonheur
59290 WASQUEHAL
Tel: 03 20 11 70 00
Fax: 03 20 11 70 70
Europa:
ONDEO Nalco European Operations
2342 BV Oegstgeest
P.O. Box 627, 2300 Leiden, The Netherlands
Tel: 31-71-524-1100
Fax: 31-71-524-1197
USA:
ONDEO Nalco Company
ONDEO Nalco Center
1601 W.Diehl Road
Naperville, IL 60563-1198 U.S.A.
Tel: 630-305-1000
Fax: 630-305-2900
Südamerika:
ONDEO Nalco Latin America Operations
Av. Das Nacoes Unidas
17.891, 11o, Andar
Santo Amaro 04795-100
Sao Paulo, Brazil
Tel: 55-11-5644-6500
Fax: 55-11-5641-7687
Asien:
ONDEO Nalco Pacific Pte. Ltd
21 Gul Lane, Jurong Town, Singapore 2262
Tel: 65-861-4011
Fax: 65-862-0850
as manufacturer of the treatment products.

page 11
8. Plate exchanger (Option)

Cleaning of plate exchanger
Soldered heat exchanger: For the removal of lime- and rust deposits purifying agent SWEPcip AS,
RS, CS or S ( according to material ) is suitable. leaning may be performed by means of SWEP
cleaning device C.I.P 90 ( circulation method ) or a stationary pump.
Screwed heat-exchanger: In this case the heat exchanger can also be disassembled for cleaning.
Lime Rust Lime + Rust

Steel SWEPcip AS SWEPcip RS SWEPcip S
max. temp: 80 °C max. temp: 80 °C max. temp: 50 °C
max. time: 8 h max. time: 8 h max. time: 8 h
mixture ratio: 1:10 mixture ratio: 1:5 mixture ratio: 1:5
Special SWEPcip AS SWEPcip CS SWEPcip AS
steel max. temp: 80 °C max. temp: 80 °C max. temp: 80 °C
max. time: 8 h max. time: 8 h max. time: 8 h
mixture ratio: 1:10 mixture ratio: 1:5 mixture ratio: 1:10
See attached concept for further technical data.
T E C H N I C A L D A T A S H E E T
=======================================
Recooler
Type: VWK 7/1-S
---------------
1. GENERAL DATA
---------------
Refrigerant gas: R407C
Specifications:
---------------
Nominal ambient air: °C 32
Coolant temperature: °C 20 0 0
Cooling Capacity: W 814
Min ambient air: °C 10

Max ambient air: °C 32
Min coolant temperature: °C 10

Max coolant temperature: °C 25
Evaporator material: Copper
Temperature control: electronic, direct

Temperature display: digital
Control voltage: 230V AC

Main Power supply: 1/N/PE/50/60Hz 230V/+-10%
Total absorbed power: kW max: 0.9
Full load current: A max: 4.6
Safety fuse protection: A 10.00
Paint: floor plate RAL

Cabinet structure: stainless steel, not painted
-----------------
2. AIR CONDENSER: air cooled, axial
-----------------
Nominal Air Flow: m³/h 500.00
Number of fan: Unit 1
Nom Absorbed power: kW 0.01
Starting current: A 0.23
--------------
3. COMPRESSOR: reciprocating
--------------
Number: Unit 1
Technology: direct
Total absorbed power: kW max: 0.53
Full load current: A max: 2.80
--------
4. PUMP:
--------
First PUMP: horizontal centrifugal pump
Type: LNY 2841.0208
Number: Unit 1
Total absorbed power: kW 0.12
Full load current: A 1.25
Nominal flow rate: m³/h 0.24
Nominal pressure rate: bar 2.70
---------------
5. LIQUID TANK: PVC/Plastic insolated
---------------
Volume: l 6.40
Outlet / inlet connections: Inch 3/8
----------------------------
6. WEIGHT AND PHYSICAL SIZE:
----------------------------
Length: mm 557
Width: mm 445
Height: mm 320
Weight : kg 42

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Instruction manual

Always disconnect the machine from the pneumatic network and

Informal safety measures

Safety measures during normal operation

Dangers resulting from electrical power

Clean the machine regularly

. 2 Safety regulations .......................................................................................... 2-1

2.1 Organisational measures ........................................................................ 2-5

2.2 Protective equipment .............................................................................. 2-5

2.3 Informal safety measures ........................................................................ 2-5

2.4 Personnel training ................................................................................... 2-5

2.5 Machine control ....................................................................................... 2-6

2.6 Safety measures during normal operation .............................................. 2-6

2.7 Dangers resulting from electrical power ................................................. 2-6

2.8 Dangers resulting from the pneumatic system ....................................... 2-6

2.9 Points posing a particular danger ........................................................... 2-7

2.10 Personnel protection ............................................................................... 2-8

2.10.1 Protection against contact with electrically live components ................. 2-8

2.11 Maintenance, servicing and fault-clearance ........................................... 2-9

2.12 Design modifications to the machine ...................................................... 2-9

2.13 Cleaning the machine and waste disposal ............................................. 2-9

2.14 Noise emission of the machine ............................................................. 2-10

2.15 Copyright ............................................................................................... 2-10

. 3 Transportation and storage........................................................................... 3-1

3.1 Packaging ............................................................................................... 3-1

3.2 Scope of delivery..................................................................................... 3-1

3.3 Transportation instructions...................................................................... 3-2

. 4 Technical data................................................................................................. 4-1

4.1 Machine data........................................................................................... 4-1

4.2 Connection data ...................................................................................... 4-1

4.3 Performance and operating data ............................................................ 4-1

4.4 Dimension and weights ........................................................................... 4-2

4.5 Ambient conditions .................................................................................. 4-2

4.5.1 Noise ...................................................................................................... 4-2

4.5.2 Temperatures ......................................................................................... 4-2

4.5.3 Illumination at the workplace .................................................................. 4-2

. 5 Installation, assembly and commissioning ................................................. 5-1

5.1 Installation location and place of use ...................................................... 5-1

5.1.1 Foundation plan ...................................................................................... 5-2

5.2 Installing and securing the machine ........................................................ 5-3

5.3.1 Electrical system .................................................................................... 5-4

5.3.2 Pneumatic system .................................................................................. 5-4

5.4 Machine ................................................................................................... 5-5

5.4.1 Operating controls .................................................................................. 5-5

5.4.2 Safety light barrier .................................................................................. 5-8

. 6 Operation ......................................................................................................... 6-1

6.1 Basic machine ......................................................................................... 6-1

6.2 Settings and components ........................................................................ 6-2

6.2.1 Conditioning unit ..................................................................................... 6-2

6.2.2 Proportioning spray device, tool lubrication ........................................... 6-3

6.2.3 Proportioning spray device, rack lubrication (X axis) ............................. 6-6

6.2.4 Clamping system .................................................................................... 6-7

6.2.5 Pneumatic components ........................................................................ 6-10

6.2.6 Central lubrication system .................................................................... 6-11

6.2.7 Limit switches - linear guides ............................................................... 6-14

6.2.8 Electronic time counters ....................................................................... 6-16

6.2.9 Optional accessory: Profile length measuring system ......................... 6-17

6.2.10 Optional accessory: Spindle cooler ...................................................... 6-18

6.3 Automatic tool changer ......................................................................... 6-19