DMU 50 eco serie 4707 EN Planen V1 - EquipNet · in statical calculations) to certify in writing according to DIN 4024 Part 1: flexible structures that support machines with rotating

DMG ECOLINE GMBHOberes Ried 11, A-6833 KlausTel. +43 [0] 55 23 / 90 601-600, Fax +43 [0] 55 23 / 90 601-650

PLANNING DOCUMENTS

Documents for the planning department on preparatory measures for theinstallation, commissioning and operation.

20 30 40

90

100

50 70

DMU 50 ECOLINE

COPYRIGHT This document is intended for the operating, mainte-nance and assembly staff. It is not admissible to pass on or to duplicate this document partly or in whole, to use or to communicate its contents. Exceptions must granted expressly. DMG ECOLINE reserve all rights for a possible patent grant or a possible pattern registration.

Non-compliances oblige to compensation for damage and can have penal consequences.

The publisher retains all rights, also the right to reprint, duplicate parts of the present manual and of the translation.

Without the written permission of the publisher, no part of the manual may be reproduced or may be copied in any form with the aid of electronic duplication systems, not even for instruction and training purposes.

The language acquisition of the manufacturer (German) prevails for the technical content.

Issue: V4711-V1

Ident no.: PU-EN

© 2004 DMG ECOLINE GmbH

1
1 Planning documentation . . . . . . . . . . . . 1-1
1.1 What is the purpose of this documentation? . . 1-1

1.2 Effective use of the machine: . . . . . . . . . . . . . 1-1

1.3 Notes for your planning . . . . . . . . . . . . . . . . . . 1-1

1.4 Used symbols . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Necessary preparatory measures . . . . . . . . . . 1-4

1.6 Installation site. . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.7 Ambient conditions for the machine . . . . . . . 1-11

1.8 Note for machines with series transformers . 1-11

1.9 Empty conduits for external data transfer . . . 1-11

1.10 Installation plans . . . . . . . . . . . . . . . . . . . . . . 1-12

1.10.1 Symbol explanation . . . . . . . . . . . . . . . . . 1-24

1.10.2 Foundation plan . . . . . . . . . . . . . . . . . . . . 1-25

1.10.3 Arrangement of the electrical and pneumatic connections . . . . . . . . . . . . . . . 1-26

1.11 Machine supports . . . . . . . . . . . . . . . . . . . . . 1-27

1.12 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

1.12.1 Machine weight. . . . . . . . . . . . . . . . . . . . . 1-29

1.12.2 Installation weight . . . . . . . . . . . . . . . . . . . 1-29

1.12.3 Floor load 16 tools . . . . . . . . . . . . . . . . . . 1-30

1.12.4 Floor load 30 tools . . . . . . . . . . . . . . . . . . 1-31

1.13 Electrical power supply . . . . . . . . . . . . . . . . . 1-32

1.13.1 Installation. . . . . . . . . . . . . . . . . . . . . . . . . 1-32

1.13.2 Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

1.13.3 Machine connection:. . . . . . . . . . . . . . . . . 1-33

1.13.4 Connection values . . . . . . . . . . . . . . . . . . 1-34

DMU50ECOLINE-pu-en Page 1-1

1.14 Pneumatic supply . . . . . . . . . . . . . . . . . . . . . . 1-35

1.15 Initial filling 8 000 rpm. . . . . . . . . . . . . . . . . . . 1-38

1.16 Initial filling 10 000 rpm. . . . . . . . . . . . . . . . . . 1-39

1.17 Lubricant selection table. . . . . . . . . . . . . . . . . 1-40

1.18 Application and maintenance of coolant lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

1.19 Water-soluble coolant lubricants . . . . . . . . . . 1-46

1.20 Requirement for the technical specification of the mixing water: . . . . . . . . . . . . . . . . . . . . 1-51

1.21 Coolant lubricants not soluble in water. . . . . . 1-53

DMU50ECOLINE-pu-enPage 1-2

Planning documentation

1 Planning documentation

1.1 What is the purpose of this documentation?

Basics

This documentation is aimed at the people responsible for installing the machine and their staff. This documentation contains all the information necessary for the preparation of the machine's installation site and its surroundings such that the machine can be installed immediately after delivery. Information on the transport of the machine to the installation site is also included.

Please also note the information on the tools and lubricants necessary, as well as on the tool mountings and retention bolts necessary for operation.

Commissioning

The machine is only allowed to be commissioned by a person authorised by the machine manufacturer. Otherwise, DMG ECOLINE will accept no liability whatsoever for any damage or malfunctions that may occur.

1.2 Effective use of the machine:

Training courses

DMG ECOLINE offers the training and the further training of experts as a service of our training academy. Whether the machine's features are actually used depends on the user's qualifications. For this reason, clarify in good time whether your staff has the necessary knowledge. Plan your training course dates so that all training measures are completed before the delivery of the machine.

1.3 Notes for your planning

Planning

The floor area figures stated in this documentation only apply to machines with the peripherals shown.

For information of the floor area and space requirements for the options you have ordered, please refer to the related installation plans.

The machine documentation applies irrespective of the specifications made in this documentation .



1.4 Used symbols

Note

Special information on operating processes, machine reactions and economic use of the machine.

Figure 1-1

• Please pay attention to the related information.

• Also pass on all notes to other operators.

Attention

Special notes, requirements and prohibitions on the prevention of damages.

Figure 1-2


• Also pass on all warnings and safety instructions to other operators.

Danger

Information, actions that must be performed and actions that are not allowed to prevent injury and extensive damage.

Figure 1-3


• Take particular care in these cases to prevent accidents.

• Also pass on all safety instructions to other operators.

ATTENTION!

DANGER!



Hazard due to electrical voltage

Warning of dangerous electrical voltage, there is a mortal danger!

Figure 1-4


• Take particular care in these cases to avoid placing people at risk due to electrical power.

• Also pass on all safety instructions to other operators.

Hazard due to powerful magnetic fields

Special prohibitions for avoiding injuries and damages:

Figure 1-5

Along with the instructions in the machine manual, general regulations on safety and accident prevention must be taken into account and followed.



1.5 Necessary preparatory measures

Actions to be undertaken by the customer

The customer is responsible for the following preparatory measures:

Installation site

• Prepare the installation site of the machine

- see "Installation site"

• Ensuring the availability of:

- Supply of electricity, light, water, telephone

Transport

• Arrangement of unloading of the machine

• In-house transport to the installation site and installation of the machine

- The machine is to be transported to the installation site

- The machine is to be placed onto the levelling elements

E/P connection

• Connection of the machine

- Machine must be connected electrically ("CW rotating field").

- The machine must not be connected to a power supply with a residual-current circuit breaker. (Permanent connection necessary)

- Upon delivery to countries with large voltage fluctuations in the supply line of the system, a power supply stabilizer must be used in order to protect the electronic components.

- The machine must be connected to the compressed air supply

Commissioning

• Preparation for commissioning

- Preparation of the necessary lubricating oils / coolant lubricants

- Clean machine (degreasing)

- The temperature at the installation site must be controlled to a constant value.

- Align machine: +/- 0.1 mm/m

- Provide suitable assistants during commissioning

Tools

• A tool holder with appropriate retention bolts must be available



Service / Maintenance

"In accordance with, respectively in amendment to the General installation conditions VDW 502 A and LMW 188 A, the customer is obliged to provide technical support during the installation and repair works, in particular by providing suitable and necessary platform ladders, installation platforms, scaffolds, transport equipment, heavy tools, lifting devices, etc."

The main switch of the machine may only be switched on in the presence of the authorized service staff member!

DANGER!



1.6 Installation site

Customer information

It is imperative that this information is checked, safeguarded and implemented by the customer prior to the delivery of the machine.

The customer remains responsible for the correct location of the machine. The customer is fully responsible for an appropriate installation site.

If problems should occur later on that have been caused by a non-observance of the notes, DMG ECOLINE cannot be held responsible.

Ambient temperature

A fully air conditioned room fulfils all of these conditions.

• Constant room temperature of +/- 1°C. (Not a certain value, like e.g. 20 °C)

• It is very important that the temperature is the same in all machine points.

Wear reduction

In order to reduce the wear, there must be no machines in the same room which produce dusty machining residues:

Figure 1-6

• Also prevent grinding or erosion dust from entering the machine via workpieces and coolant lubricant.

ATTENTION!



Corrosion prevention

In order to prevent corrosion at workpiece and machine, the installation site must be dry and free of aggressive vapours:

Figure 1-7

• No soldering, welding, varnishing, pickling or electroplating systems in the same room.

Foundation

An appropriate bottom plate that has been approved by the structural analyst (engineer engaged in statical calculation) is necessary.

Figure 1-8

• The bottom plate must not have any expansion joints in the area covered by the machine.

• Cracks, cable ducts or other interruptions are not allowed in the area covered by the machine.

• Place the machine onto a firm ground that makes sure that the machine is stable

• The machine must constantly be levelled in order to guarantee the accuracy of the machine.

• The floor must not be elastic so that the machine stays aligned precisely.

• The installation area must be free of oil and grease so that the coefficient of friction of the installation elements is not reduced.

• The ground must be firm and resistant against all liquids used at the machine in accordance with the locally valid environmental regulations.



Load bearing capacity

Ensure a sufficient load bearing capacity of the floor:

Figure 1-9

• Have the load bearing capacity checked by a structural analyst (engineer engaged in statical calculations).

Have the structural engineer determine in a binding manner

• that the floor, basement floor, intermediate floor or substructure has the required load bearing capacity (especially in old buildings),

• that the installation site is in conformity with applicable building regulations.

Centre of gravity

Please note that the centre of gravity is shifted due to the workpiece weight and to the traversing paths.

Maximum weight

For the floor load bearing capacity, take into account

Figure 1-10

• the maximum installation weight of the machine and additionally the maximum weight of tool and accessory cabinets including contents,

- workpieces and devices,

- people,

- transport means,

- other devices in the immediate vicinity of the machine.

kg

ATTENTION!

kg k k k



Basement floors, intermediate floors

When installing the machine on basement floors, intermediate floors or on other load-bearing structures:

Figure 1-11

Ask a structural analyst experienced in structural dynamics (engineer engaged in statical calculations) to certify in writing according to DIN 4024 Part 1: flexible structures that support machines with rotating elements,

• that the supporting structure is capable of bearing the effects of the forces of gravity of the machine,

• or, if this certification cannot be provided, that the measures for vibration damping that are then to be arranged are adequate.

Floor vibrations

Figure 1-12

Floor vibrations or shocks caused by adjacent machines or other producers must not affect the function and accuracy of the machine.

For absorbing vibrations, it generally suffices to place the machine onto vibration insulating plates. If necessary, an isolated foundation must be provided.

Figure 1-13



Access

Figure 1-14

Adequately large access openings must be available for moving the machine to its installation site.

Room height

Figure 1-15

Please note that the room is high enough to enable installation and maintenance work to be executed without impediments.

Machine area

Figure 1-16

Make sure that there are no columns or other obstructing objects in the machine area which could cause impediments when executing installation and maintenance work.



1.7 Ambient conditions for the machineA fully air conditioned room fulfils all of these conditions.

• Constant room temperature of +/- 1°C.

(not a specific value, like e.g. 20 °C)

It is very important that the temperature is the same in all machine points.

• Permissible ambient temperature: +15° to + 35° C

• Maximum relative air humidity: 80 %

• Maximum installation altitude: 1000 m above sea level

If one of these values is exceeded at the installation site of the machine or in case of special operational conditions, e.g.

• action of powerful electric or magnetic fields

• installation in potentially explosive atmospheres or areas containing potentially explosive substances

contact your DMG ECOLINE (DMG) representative.

1.8 Note for machines with series transformersThe cable connection between the overcurrent protection device (main fuse) and the separate series transformer depends on the operating voltage at the customer. Appropriate protection against short circuits is to be provided by the customer.

The cable for the connection between the series transformer and the machine is part of our scope of delivery (in accordance with the installation site in the installation plan).

1.9 Empty conduits for external data transferIf external data transfer is planned, appropriate empty conduits made of metal must be installed for the data cable.

Data cables must not be laid alongside cables carrying high currents or cross such cables.



1.10 Installation plans

Figure 1-17

Height

Machine max. . . . . . . . . . . . . . . . . . . . . . . . . . .mm . . . . . . . . . . . . . . . 2 465

Transport height . . . . . . . . . . . . . . . . . . . . . . . .mm . . . . . . . . . . . . . . . 2 051

Width 16 WZM

without controls . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . . . . . . . . . . 1 810

with controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . . . . . . . . . . 2 790

open machining compartment door . . . . . . . . . . . . mm . . . . . . . . . . . 1 872

open machining compartment door with controls. . mm . . . . . . . . . . . 2 862

with chip conveyor and controls . . . . . . . . . . . . . . . mm . . . . . . . . . . . 4 275

Width 30 WZM

without controls . . . . . . . . . . . . . . . . . . . . . . . .mm . . . . . . . . . . . . . . . . 2082

with controls . . . . . . . . . . . . . . . . . . . . . . . . . . .mm . . . . . . . . . . . . . . . . 3070

H

B

L



with chip conveyor and controls . . . . . . . . . . . mm . . . . . . . . . . . . . . . 4 275

Length 16 / 30 WZM

without grip . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . . . . . . . . . . . . . . 2 125

with grip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . . . . . . . . . . . . . . 2 200

with controls . . . . . . . . . . . . . . . . . . . . . . . . . . mm . . . . . . . . . . . . . . . 2 720

Installation area L x W

with 16 WZM KSB . . . . . . . . . . . . . . . . . . . . . mm . . . . . . . . .4 630 x 3 990

with 16 WZM, SPF . . . . . . . . . . . . . . . . . . . . . mm . . . . . . . . .4 630 x 5 470

with 30 WZM, KSB . . . . . . . . . . . . . . . . . . . . . mm . . . . . . . . .4 630 x 4 270

with 30 WZM, SPF . . . . . . . . . . . . . . . . . . . . . mm . . . . . . . . .4 630 x 5 470

WZM = tool magazine

Moreover, the escape routes and the safety areas must be observed in accordance with local regulations, laws and instructions.

ATTENTION!



with 16 WZM, KSB and 8 000 rpm

Figure 1-18

1810

1642

785190 49

89

910

1740 19

36

2465

1

2

3

1 Coolant lubricant container

2 Tool magazine

3 Table centre



Figure 1-19

60024402790

600

2910

3430

600

R1018

R295

R 495R714R 7

14

1450

600

3990

1120

2200

4630

520

1119.5

757

1872

11

1 Opening dimensions



with 16 WZM, KSB and 10 000 rpm

Figure 1-20

1810

89

49

910

1740 19

36

2465

785190

1642

1

2

3


2 Tool magazine

3 Table centre



Figure 1-21

60024402790

R 714

R 714

145060

029

1034

30

600

R1018R 295

R 495

600

3990

1120

2200

4630

520

527.5

757

1872

11




with 16 WZM, SPF and 8 000 rpm / 10 000 rpm

Figure 1-22

49 89

910

1740 19

36

2465

485980

1570

785

1810

3290

3561

2

3

1 Chip conveyor

2 Tool magazine

3 Table centre



Figure 1-23

R714

R714

R 495

R295

R10181450

2440 600

1872

600

2910

4275

527.5

757

600

3430

5470

4630

520

600

2200

74

1200

620

1945

258

1

12

1 Chip conveyor 2 Opening dimensions



with 30 WZM, KSB and 8 000 rpm/ 10 000 rpm

Figure 1-24

2082

1290

125

89

49

910

1740

1936 2465

2066

1957

2

1

3


2 Tool magazine

3 Table centre



Figure 1-25

60024403070

1452

R 714

R 714

600

2910

3430

600

R1018

600

1120

42702200 4630

R295

R 495

520

527.5

757

1872

11




with 30 WZM, SPF and 8 000 rpm / 10 000 rpm

Figure 1-26

4989

910

1738 1936 24

65

2080

485

980

1570

2066

785630

3290

1

2

3

1 Chip conveyor

2 Tool magazine

3 Table centre



Figure 1-27

R 714 R 714

R 495

R295

R1018

2440

1450

600

520

600

4275

2200

74

4630

3430

757

1872

258

620

527

600

2910

1945

5470

600

1

12

1 Chip conveyor 2 Opening dimensions



1.10.1 Symbol explanation

Information symbols

Space requirement

Operating side

Electrical switch cabinet

Switch cabinet connection

Pneumatic connection

Additionally, escape routes and safety areas in accordance with the local regulations, laws and instructions must be observed.

- - -

E

P

ATTENTION!



1.10.2 Foundation plan

Figure 1-28

An appropriate bottom plate that has been approved by the structural analyst (engineer engaged in statical calculation) is necessary.

1344

878

2

1

1 Machine support (4) 2 Foundation dimensions



1.10.3 Arrangement of the electrical and pneumatic connections

Figure 1-29

E

P

C D

BA

626.5 600

770

1212 134

100

70

30

1

3

2

1 Machine rear

2 Machine side wall on the right

3 Setscrew position



1.11 Machine supports

Standard

Figure 1-30

Installation elements

Number 4

Type GS41 + TK8

Manufacturer Messrs. Nivell AG

4995

90

142

145

54

3

67

41

100

136

16

6



Arrangement of the machine supports

Figure 1-31

E

P

C D

BA

626.5 600

770

1212 134

100

70

30

1

3

2

1 Machine rear


3 Setscrew position



1.12 Weight

1.12.1 Machine weightMachine with 16 WZM. . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . . 3 960

Machine with 30 WZM. . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . . 4 660

1.12.2 Installation weightMachine with max. weight for workpiece, tool and consumables, coolant lubricant system

Load upon the machine foot . . . . . . . . . . . . . . . . . . . . see machine support

WZM = tool magazine



1.12.3 Floor load 16 toolsDynamic

A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . 1 820

B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . 1 360

C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . 1 610

D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . 1 700

Static

A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . 1 240

B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . . . 790

C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . . . 980

D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . 1 070

Figure 1-32

E

P

C D

BA

626.5 600

770

1212 134

100

70

30

1

3

2

1 Machine rear


3 Setscrew position



1.12.4 Floor load 30 toolsDynamic

A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . . 2 230

B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . . 1 410

C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . . 2 030

D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . . 1 480

Static

A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . . 1 580

B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . . . 900

C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . . 1 850

D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. kg . . . . . . . . . . 1 480

Figure 1-33

E

P

C D

BA

626.5 600

770

1212 134

100

70

30

1

3

2

1 Machine rear


3 Setscrew position



1.13 Electrical power supply

1.13.1 InstallationDuring the electrical installation, attention is to be paid to ensuring EN 60 204, part 1, point 6.3.3 "Protection by automatic interruption of the power supply" is met.

On this topic, also see IEC 364-4-41 (DIN 57 100, VDE 0100, part 410).

The machine must not be connected to a power supply with a residual-current circuit breaker. See EN 50 178, section 5.3.2.3.

As our machine has a leakage current higher than 3.5 mA AC due to EMC measures, it must have a fixed connection.

Furthermore, one of the measures specified below must be executed according to EN 50178, section 5.3.2.1.

• Cross section of the protective earth conductor at least 10 mm2 Cu (see "Electrical data").

• This also applies to special systems that may have been connected directly to the customer's power supply and that have not been routed across the machine.

or

• Monitoring of the protective earth conductor by a device that will automatically shut down the electronic equipment in the event of a fault.

or

• Laying of a second conductor, electrically in parallel with the protective earth conductor, using separate terminals. This conductor must fulfil the requirements for protective conductors on its own according to section 543 of the harmonization document (HD) 384.5.54 S1 (old DIN VDE 0100 part 540) for protective earth conductors.

If the supply voltage is a TN-S power supply and if the 400 VAC operating voltage is within the tolerances ± 10%, i.e. 360 VAC to 440 VAC, the machine may be connected directly.

If the supply voltage is a TN-S power supply and if the operating voltage is not within the limits of 360 VAC to 440 VAC, the machine requires a pre-disconnecting transformer.

1.13.2 Main fuseThe overcurrent protection (main fuse) for the mains connection cable must have been installed outside of the machine and is not part of the scope of delivery of DMG ECOLINE.



1.13.3 Machine connection:The power supply for connecting the machine or parts of the machine must be a TN-S power supply with 3 conductors (L1, L2, L3) and a neutral conductor (N) as well as a protective earth conductor (PE).

Power supply. . . . . . . . 3 phases (L1, L2, L3), neutral conductor and protective conductor, 50/60 Hz, 400/230 VAC with tolerance ± 10%

The actual mains voltage is not allowed to vary from the rated voltage by more than the permitted tolerance, even under load.

Cross section of the connection cable according to DIN 57100 / VDE 0100 or other locally valid standards!

Risk of accident due to electrical voltage!

• The electrical connection is only allowed to be made by an electrician.

• Observe primarily the locally valid regulations and directives.

When working on electrical equipment, damages may occur at electronic components due to incorrect or faulty connections. Always observe the specifications in the wiring diagrams.

Supply cable, fuse protection

Power supply and fuse protection are to be designed as per the information on the type plate for the switch cabinet.

ATTENTION!

ATTENTION!



1.13.4 Connection valuesMain drive:

Machine connection . . . . . . . . . . . . . . . . . . . . . 3N/PE~50/60 Hz .400/230 V

Pre-disconnecting transformer:

Output voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/400 V 50/60 Hz

Pre-disconnecting transformer DIN at . . . . . . .V. . . 200, 220, 420, 440, 500

Pre-disconnecting transformer CSA/UL at . . .V. . . . . . . 208, 230, 460, 575

Nominal performance. . . . . . . . . . . . . . . . . . . . kVA . . . . . . . . . . . . . . . . . 20

In max. induced (400 V) . . . . . . . . . . . . . . . . . .A. . . . . . . . . . . . . . . . . . . 394

Fuse protection. . . . . . . . . . . . . . . . . . . . . . . . .A. . . . . . . . .3 x 35 slow-blow

Primary dimensions

200 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A. . . . . . . . . . . . . . . . . . 57.8

220 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A. . . . . . . . . . . . . . . . . . 52.5

420 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A. . . . . . . . . . . . . . . . . . 27.5

440 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A. . . . . . . . . . . . . . . . . . 26.2

500 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A. . . . . . . . . . . . . . . . . . 23.1

Open cable length above floor . . . . . . . . . . . . .m . . . . . . . . . . . . . . . . . . 0.8

Cross section of connection cable . . . . . . according to DIN 5710/VDE 0100

VersionIn max. at 100 % ED

A

Power consumption at

100 % ED, kVA

Max. back-up fuse

A

8 000 rpm 28 17 35

10 000 rpm 28 17 35



1.14 Pneumatic supply

Figure 1-34

Figure 1-35

1 Pneumatic connection

Requirements

At the connection point, the compressed air must be:

• free from condensate, air cooling to 2-5 °C is recommended (e.g. by air dryer)

• Free of dust, recommendation: air filter immediately in front of the machine (customer side) filter mesh= 40 μm filter size matched to air consumption of the machine

1



To be observed

To be provided by the customer:

Pneumatic connection . . . . . . . . . . . . . . . . . . .Bosch . . . . . . 1 823 376 010

Compressed air connection . . . . . . . . . . . . . . . . .∅ mm . . . . . . . . . . . . . . 10.1

Minimum nominal size . . . . . . . . . . . . . . . . . . .mm . . . . . . . . . . . . . . . . . 7.2

Prepared with the machine:

Pneumatic connection . . . . . . . . . . . . . . . . . . .Bosch . . . . . . 1 823 351 017

Air flow rate:

Machine without blast air tool cooling. . . . . . . .m3/h . . . . . . . . . . . . . . . . . 10

Blast air tool cooling

additional (continuous operation) . . . . . . . . . . .m3/h . . . . . . . . . . . . . . . . . 20

min. air pressure. . . . . . . . . . . . . . . . . . . . . . . . bar . . . . . . . . . . . . . . . . . 6.0

max. air pressure . . . . . . . . . . . . . . . . . . . . . . .bar . . . . . . . . . . . . . . . . . 8.0

Setting value at the pressure gauge. . . . . . . . . bar . . . . . . . . . . . . . . . . . 6.0

Pressure connection . . . . . . . . . . . . . . . . . . . . . . .∅ mm . . . . . . . . . . . . 9 (3/8g)

Minimum nominal size . . . . . . . . . . . . . . . . . . .mm . . . . . . . . . . . . . . . . . 7.2

Keep compressed air incoming line (customer side) as short as possible!

If compressed air is necessary when using peripheral units, it is ensured that an operating pressure of 4-8 bar, air quality according to ISO 8573-1 is available.



Solid matters / particle size

Quality class 5. . . . . . . . . . . . . . . . . . . . . . . . . µg . . . . . . . . . . . . . . . . . < 40

Water / Pressure dew point

Quality class 4. . . . . . . . . . . . . . . . . . . . . . . . . °C . . . . . . . . . . . . . . . . . < +3

Oil / Residual oil content

Quality class 2. . . . . . . . . . . . . . . . . . . . . . . . . mg/m3 . . . . . . . . . . . . . < 0.1

Volume (V) . . . . . . . . . . . . . . . . . . . . . . . . . . . m3/min. . . . . . . . . . . . . . . . 3



1.15 Initial filling 8 000 rpmUpon delivery, the machine is filled with the exception of the coolant lubricant.

Minimum requirements for lubricating and hydraulic oils in accordance with DIN 51 517 part 3.

Deterging hydraulic oils which simultaneously fulfil the requirements according to DIN 51 524 part 2 are recommended.

It is imperative to continue to use the lubricants which have been used for initial filling.

If this is not possible due to company reasons, only products in accordance with the lubricant selection table may be used.

Medium Manufacturer Viscosity range

Location Symbol

Hydraulic oilHLP/

HLP-D 46

BP 41,4 - 50,5 Hydraulic unit

Low viscosity grease Zeller &Gmelin

90 Central lubrication unit

Coolant lubricant To be defined by

user.

Observe the chapter concerning

coolant lubricant!

Coolant lubricant container

HLP/HLP-D 46

GP000-K-20

S



1.16 Initial filling 10 000 rpmUpon delivery, the machine is filled with the exception of the coolant lubricant.

*depending on the machine equipment

Medium Manufacturer Viscosity range

Location Symbol

Hydraulic oil HLP/HLP-D 46

BP 41,4 - 50,5 Hydraulic unit

Lubricant oil CLP 150

Shell Tool magazine(only in case of 30 tools)

Low viscosity grease

ZellerGmelin

90 Central lubrication unit

Rotary swivelling circular table

Anti-freeze BASF Mixture 70 : 30 water: 70 % antifreeze (Glysantin G48 Protect Plus) 30 %

Cooling unit

Coolant lubricant To be defined by user.

Observe the chapter concerning coolant lubricant!

Coolant lubricant container

HLP/HLP-D 46

CLP150

GP 000 K-20

R

S



1.17 Lubricant selection table

Edition: 04/2006

Reliable operation of the machine will only be ensured if the correct lubricants are used.

Lubricant approval

Minimum requirements for following lubricating and hydraulic oils:

DIN standard

Lubricant oil CL 46 in accordance with DIN 51 517, part 2

Lubricant oil CL 150 in accordance with DIN 51 517, part 2

Lubricant oil CLP 46 in accordance with DIN 51 517, part 3

Lubricant oil CLP 68 in accordance with DIN 51 517, part 3

Hydraulic oil HLP 10 in accordance with DIN 51 524, part 2




Hydraulic oil HLP-D 68 in accordance with DIN 51 524, part 2

If water in the hydraulic oil cannot be excluded, so-called "HLP-D oils" may be advantageous. Such oils must be in compliance with the minimum requirements according to DIN 51 524, part 2 for hydraulic oil HLP 46 except the demulsifying capacity, and in addition to this must have detergent properties.

Low viscosity grease GP 000 K-20 according to DIN 51826

Grease KP 2 K-20 in accordance with DIN 51 825

ISO standard

Gear oil L-CKC 46 in accordance with ISO 12925-1

Hydraulic oil L-HM 10 in accordance with ISO 11158




Hydraulic oil HLP-D

Grease KP 2 K-20 does not currently meet any ISO requirements standard.

The following products fulfil the above conditions in accordance with the mineral oil manufacturers and are available on the European and international market.

This list will be continuously updated. Request the current list.

Any liability in connection with other lubricants is excluded!



Lubricant oil, hydraulic oil

Lubricant oil Hydraulic oil

DIN 51 502

ISO 6743 viscosity

at 40° C

CKD 4646

HM 1010

HM 2222

HM 4646

HM 6868

Agip OSO 46 Precis

System Fluid 46

OSO 10 OSO-D-22 OSO 46

ARAL DegolCL 46 T

Aral-Vitam GF 46

DegolBG 68

Vitam DE 10

Vitam DE 22

Aral Vitam DE 46

Aral Vitam GF 46

Aral Vitam DE 68

Aral Vitam HF 68

AVIA AVIA FluidRSL 46 AVILUB

Hydraulic DD 46

AVIA Fluid RSL 10

AVIA FluidHLPD 10AVULUB Hydraulic

DD 10

AVIA FLUID

HLP-D 22AVIA

FLUID RSL 22AVILUB

Hydraulic DD 22

AVIA FLUID

HLP-D 46AVIA

FLUID RSL 46AVILUB

Hydraulic DD46

BP EnergolRC-R 46

BP Energol HLP 46

EnergolGR-XP 68

Energol HLP-HM

10

BP Energol HLP-D 22

BP Energol HLP 22

BP Energol HLP-D 46

BP Energol HLP 46

BP-Energol

HLP-D 68

Castrol HyspinVG 46

HyspinAWS 150

Hyspin AWS 46HyspinSP 46

Vario HDX 46

ALPASP 68

Hyspin AWS 10Hyspin SP 10

Hyspin AWS 22

Hyspin SP 22

Hydraulic oil HLP-D

22 SF

Vario HDX 46

Hyspin AWS 46

Hyspin SP 46

Hydraulic oil

HLP-D 46 SF

CASTROL HYSPIN AWS 68

ESSO NUTO H 46 NUTO H 10

HLPD oil 22

NUTO H 22

HLPD oil 46

NUTO H 46

NUTO H 68

FUCHS RENOLIN MR 15 VG 46

RENOLIN B 15 VG 46

RENOLIN B 3

RENOLIN MR 5 VG

22 B RENOLIN B 5/ VG 22

RENOLIN MR 15 VG

46 RENOLIN B 15/ VG

46

RENOLIN MR 20

RENOLIN B 20

GULF GULF HARMONY 68 AW

CL46

CL150

CLP46

CLP68

HLP10

HLP/HLP-D

22

HLP/HLP-D

46

HLP/HLP-D

68



Lubricant oil Hydraulic oil

DIN 51 502

ISO 6743 viscosity at

40° C

CKD 4646

HM 1010

HM 2222

HM 4646

HM 6868

Klüber COREX HLP-D 68

MOTOREX Klüber oil GEM 1-46

LAMORA HLP 46

RHENUS Hydranor HLP 10

Hydranor HLP 22

Hydranor HLP-D 22

Hydranor HLP 46

Hydranor HLP-D 46

Shell Morlina150

Tellus oil 46 Tellus oil 10 Hydrol DO 22

Tellus oil 22

Hydrol DO 46

Tellus oil 46

SHELLUS TELLUS OIL 68

Zeller & Gmelin

Divinol ICL ISO 46Divinol

DHG ISO 46

Divinol HLP ISO

10

Divinol HLP ISO

22Divinol

DHG ISO 22

Divinol HLP ISO

46Divinol

DHG ISO 46

CL46

CL150

CLP46

CLP68

HLP10

HLP/HLP-D

22

HLP/HLP-D

46

HLP/HLP-D

68



Grease, low viscosity grease

DIN 51 502 Grease Low viscosity grease

ISO 6743Viscosity at 40 °C

AVIA AVIA LITHOPLEX 2 EPAVIALITH 2 EP

BP

Castrol Spheerol AP 2Spheerol EPL 2

ESSO Nebula EP 2Beacon EP 2

FUCHS RENOLIT S2

Klüber CENTOPLEX 2

RHENUS Norlith MZP 2Norplex LKR 2

Shell Alvania EP grease 2

Zeller & Gmelin Divinol grease EP 2 Divinol grease L 800

KP2 K-20

GP000 K-20



1.18 Application and maintenance of coolant lubricants

Increased danger of accidents when using oils and coolant lubricants! Protective goggles must be worn when working with oil or coolant lubricants.

General

Only the correct selection of suitable coolant lubricants as well as proper care and maintenance of the coolant lubricant will ensure that no problems arise.

In the following, some important aspects for the quality of manufacture and the ecology are listed:

• Mineral oil content

• Water polluting classes

• Additives

• Universal suitability for a wide range of machining tasks and materials

• Skin tolerance

These aspects are to be specified by the machine operator himself and lie within his scope of responsibility.

The selection of the coolant lubricants as well as their care is the task of the machine user. However, here the requirements placed by DMG ECOLINE GmbH must be met.

DANGER!



For this reason, DMG ECOLINE GmbH cannot be held responsible for machine damage caused by the organisation operating the machine by

• the use of unsuitable coolant lubricants

• the lack of, or incorrect care and servicing of the coolant lubricant

• the use of unsuitable mixing water.

In case problems arise, please consult the supplier of your coolant lubricant (CL supplier). We would be pleased to provide assistance if you have any further questions.

Deliberately, specific products are not recommended; only information on chemical-physical and microbiological guidelines and properties is stated.

The coolant lubricant must be matched to the mixing water for the coolant lubricant emulsion and the machining tasks without fail.

In case of a written confirmation by your coolant lubricant supplier, that the coolant lubricant delivered by him fulfils the parameters (see "Requirements and specifications for the coolant lubricant used in the machine"), nothing speaks against its use in machines made by DMG ECOLINE.

In order to ensure a safe functioning of the machine/system, the water-soluble coolant lubricant must be inspected at least once per week (also in case of a machine standstill) as far as the concentration, the pH value, the bacteria and the attack by fungi are concerned (see "Requirements for the inspection and documentation of the coolant lubricant").

The proof for the adherence to the given limit values is given by tests listed in the guideline which are normally executed by your coolant lubricant supplier or by independent laboratories, if you do not have the necessary equipment yourself.

ATTENTION!



1.19 Water-soluble coolant lubricants

Requirements and specifications for the coolant lubricant used in the machine

General

The coolant lubricants used must comply with the current regulations from the related authorities.

It must also be ensured that only those coolant lubricants are used which comply with the requirements listed in the table.



Coolant lubricant table

a. A detailed description of the test methods can be requested free of charge from Profluid GmbH, Häuslesäkker 3, 89198 Westerstetten, [email protected].

No. Parameter/test process

Limits Unit

1 Corrosion protection in accordance with DIN

51360 part 2Grey cast iron chip filter test, additional

expansion a following DIN 51360 part 2

No corrosion after 2 hours



Note 0

Note 0

Note 0

2 Paint compatibilityCross-hatch test

Round bar bending test

No attack to the machine lacquers in accordance with

VDI 3035

DetachmentSoftening

3 Elastomeric compatibilityFor exposure

conditions, see paint test

No change of the shore hardnesses A and D as well

as of the expansibility

4 Microbiological stability at the

recommended service concentration

measurement via inoculation cycle test a

Corrosion 2Germs 10 2Fungi 10 2

NoteCFUCFU

CFU = Colony

forming unit

5 Non-ferrous metal compatibility a

No attack to copper, brass and aluminium parts

6 Bonding agent residue behavioura after a slow

condensation at 50 °C

Non-bonding!No "Sell tape effect" small re-solubility or re-emulsive

quality

7 Foam behaviour aUltraturrax 11 000 rpm

with air frit

No overflow of the 500 ml beaker / 1 minute



Explanations

About 1.) The inspection for corrosion protective measures is executed with the grey cast iron chip test in accordance with DIN 51360 part 2. The DIN method foresees a reading after one hour. However, at variance with this requirement, the filter papers are assessed after 1 hour and after 12 and 24 hours. The assessment scale is in accordance with DIN 51360 part 2.

About 2.) The coolant lubricant should not degrade the properties of the coating in the cross-hatch test in accordance with DIN EN ISO 2409 after soaking for 14 days at 50 °C. Also, the paint hardness in accordance with (EN ISO 2815) should not be degraded. In the round bar bending test (12 mm) on a coated 0.7 mm metal plate there should not be any cracking up to 45°.

About 3.) In accordance with DIN 53505, the values for Shore hardness A and D must remain unchanged, also the linear dimensions in accordance with DIN 53534.

About 4.) On machine tools with a dedicated coolant lubricant system, analyses, care and the addition of service chemicals are often uneconomical, for this reason the coolant lubricants must have suitable basic properties and stability for this type of machine from the start. A suitable coolant lubricant should demonstrate the necessary bio stability reserves in the inoculation cycle test.



Abbreviated test description for inoculation cycle test:

Solutions or emulsions are prepared from the coolant lubricants to be tested using sterile standard water (20°dH). The mixtures are inoculated with reference germs once a week. By means of subsequent, weekly determination of the pH value, the corrosion protection properties (filter paper chip test) as well as the determination of the number of colonies, the limit for the micro bacterial load is determined. The following germs are used for this purpose:

Mixtures of bacteria:

• Pseudomonas aeroginosa (NCIB 6749)

• Shewanella putrifaciens (NCIB 12202)

• Citrobacter freundii (NCIB 12203)

• Alcaligenes faecali (NCIB 13104)

Mixtures of fungi:

• Fusarium solani

• Geotrichum candidum

About 5.) Qualitative evaluation of the non-ferrous metal corrosion with copper strips made of electrolytic copper.



About 6.) During this test, 25 ml of the 5 % (percentage by weight) CL mixture is evaporated in a glass Petri dish with the water from the user. The bonding behaviour is stated as "honey-like" (draws thin threads), "thick" (paint-like film), "transparent adhesive tape" (bonds like transparent adhesive tape, contact surface similar to familiar adhesive tape). The bonding action should be as weak as possible. Please note that an excessively strong bonding action can have negative effects on the machine functions, particularly if the machine is not used for an extended period of time.

About 7.) The test is suitable for comparing the tendency to form foam and foam stability of coolant lubricants. In an extension, it is also possible to determine the "soda effect" (tendency to discharge due to bursting foam bubbles). Coolant lubricants and CL working solutions with inadequate foam properties can be detected more easily.

For this reason, the following general requirements apply to the coolant lubricant:

• They must be non-polluting and suitable for the workplace. Consequently they must be free of nitrites, PCB, chlorines and nitrosable diethanolamine (DEA) (as per TRGS 611).

• It should be possible to provide skin tolerance assessments.

• Mineral oil content in accordance with DIN 51417 at least. 40 % in the concentrate.

• As far as possible, they must be suitable for universal application for all machining tasks and materials.

• High cutting performance due to appropriate additives.

The coolant lubricant is not allowed to contain more than 15 % by volume of inflammable liquid (e.g. oil). Deflagration / danger of explosions!

When using coolant lubricants with an increased portion of combustible fluid, an additional "explosion protective package" machine is under all circumstances necessary (inquiry at DMG ECOLINE).

DMG ECOLINE does not assume any guarantee for follow-up damages, if inappropriate coolant lubricants are used!

DANGER!

ATTENTION!



1.20 Requirement for the technical specification of the mixing water:(Please also follow any applicable regulations and limits from your regional water authority)

Explanation

About 1.) The optimum total hardness for mixing coolant lubricants is generally 8 - 12 °dH (1.4 - 2.1 mMol) and it is recommended to keep to this range. Please clarify the optimum water conditions with your CL supplier and take actions as necessary. Have the limits confirmed in writing by the CL supplier.

About 2.) In case of deviations, it is imperative you discuss possible methods of water treatment with your CL supplier and implement the necessary measures.

About 3.) If the conductivity of the mixing water is higher, there is an increased risk of corrosion. It is imperative to treat the water appropriately.

About 4.) In case of a high chloride content, there is an acute risk of corrosion, for this reason it is imperative to treat the water appropriately.

About 5.) It is imperative the mixing water is germ-free (drinking water quality), as otherwise there is an increased risk of micro bacterial infestation and corrosion. Problems are often caused by poorly maintained water treatment systems. Please contact your coolant lubricant supplier under all circumstances.

No. Parameters: Limit values: Unit:

1 Total hardness 5 - 20 recommended 8 - 12 (0.9 - 3.6)

°dH (degree of German

hardness), (mMol)

2 pH value 7 +/- 0.5 pH

3 Conductivity max. 700 µS (micro Siemens)

4 Chloride max. 50 mg/l

5 Germ load without infestation (germ-free / drinking water quality)

CFU



Mixing

Please note the anticorrosion data in the VKIS data sheet (manufacturer's specifications) in order to reach the recommended concentration for the necessary anticorrosion effect.

A mixer must be used to prepare the emulsion.

Only add fully mixed emulsion to the coolant lubricant system!

• Do not use clear water, since this will cause corrosion immediately

• Ideal water hardness: 8 - 12 ° dH

In case of deviations from this standard value, malfunctions of the coolant lubricant system (saponification of the coolant lubricant at the edge-type filter due to a too hard mixing water) or to a bubbling over of the coolant lubricant in case of a too soft mixing water!

Do not store emulsion in zinc-plated containers.

Mixing temperature: When mixing the emulsion, please note the following mixing temperatures, as excessively large temperature differences between the concentrate and mixing water can cause complications.

Minimum Maximum

Concentrate 20° C 30° C

Mixing water 20° C 30° C

ATTENTION!



1.21 Coolant lubricants not soluble in water

Coolant lubricants (cutting oils etc.) with an oil content of >15 % may only be used in connection with a machine which has been equipped with an "explosion protection package"!

It is not admissible to use non-water-soluble coolant lubricants (cutting oils) due to safety reasons (danger of explosion).

High machining performance and the related higher tool speeds will result in heavy atomisation of the coolant lubricant that cannot be mixed with water.

There is the possibility of a deflagration or of an explosion.

Hazard due to deflagration

Deflagrations at the machine or in the machining environment may occur if the following conditions occur at the same time:

• In case of cutting operation including the grinding of metals at the machine.

• On the use of a coolant lubricant with more than 15 % by volume oils or concentrates (with flash point) or less than 85 % by volume water content.

• When splashing or atomizing coolant lubricants to a large extent with a concentration exceeding 10 g/m3

• The machine has a limited or enclosed chamber (machine housing, machine encapsulation) where an explosive mixture can build up.

Measures

When using non-water-soluble coolant lubricants, an additional "explosive protection package" is under all circumstances necessary. (Inquiry at DMG ECOLINE).

DDANGER!

DANGER!

ATTENTION!


