Foerster 6.453 Operating Instructions Manual Download Page 1

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CIRCOGRAPH

Sensor system Ro 130

6.453

Operating Instructions

Summary of Contents for 6.453

Page 1: ...CIRCOGRAPH DS Sensor system Ro 130 6 453 Operating Instructions...

Page 2: ......

Page 3: ...ine faults can only be avoided and fault free operation of the ma chine can only be guaranteed through knowledge of the operating instruc tions It is therefore particularly important that all responsi...

Page 4: ...the User Manual Any use over and above this is expressively prohibited Violations of this clause shall entail liability to pay compensation for damages and may also result in prosecution under crimin...

Page 5: ...s 1 3 1 9 Personal safety equipment 1 4 1 10 Safety measures at the installation location 1 4 1 11 Protective safety devices 1 4 1 12 Behaviour in the event of an emergency 1 4 1 13 Declaration of con...

Page 6: ...the protective nozzles 4 2 4 2 2 Required tools 4 3 4 3 Changing nominal diameter 4 4 4 3 1 Preparation 4 4 4 3 2 Remove Entry Nozzle 4 5 4 3 3 Adjusting nominal diameter 4 7 4 3 4 Remove exit nozzles...

Page 7: ...3 Removing and fitting the test heads 5 2 5 4 Replacing parts subject to wear 5 5 5 5 Maintenance of the roller guides 5 6 5 5 1 Lubrication 5 6 5 5 2 Replacing the track rollers 5 7 5 5 3 Removing t...

Page 8: ...SENSORSYSTEM Ro 130 CONTENTS 4 6 453 01 2006 Notes...

Page 9: ...ng and maintenance of the machine must be appropriately qualified and must strictly follow the information provided in these operating instruc tions Your safety is at stake 1 2 Safety information and...

Page 10: ...nly in conjunction with a suitable conveying mechanism and a lifting table On no account may you convert or modify the sensor system arbitrarily for reasons relating to safety DANGER Masses rotating a...

Page 11: ...otective safety devices or render them inoperable by making modifications to the system 1 7 Workstations The workstation is located on the electronic equipment cabinet or on the operating panel of the...

Page 12: ...on is always clean and unobstructed by issuing appropriate in company instructions and con ducting inspections 1 11 Protective safety devices The CIRCOGRAPH sensor system is shut down when opening the...

Page 13: ...orresponding standards European Directive 89 392 EEC Safety of machines European Standards EN 12100 EN 60204 European Directive 73 23 EEC Safety of electrical apparatus European Standard EN 61010 Euro...

Page 14: ...SENSORSYSTEM Ro 130 1 6 6 453 01 2006 Notes...

Page 15: ...f testing material 10 to 130 mm Preferably piece testing Surface free of scale wherever possible bright Testing without physical contact at rotational speeds up to 3 000 rpm End condition free of proj...

Page 16: ...obe crosses a crack it generates a signal Thus the rotat ing system generates a high number of consecutive signals that reliably indicate a flaw of a certain length The testing speed is a result of th...

Page 17: ...ed for a complete test system besides the sensor system which scans the test material and generates the eddy current signal A separate leaflet CIRCOGRAPH DS System 6 430 Order No 163 852 1 will inform...

Page 18: ...3 01 2006 Roller guide Clamping ring Nozzle Adapter Flange Nozzle Nozzle holder Inner and Outer sleeve Roller guide Fig 2 2 CIRCOGRAPH Sensor system Ro 130 main view legend see Chap 2 7 Flaw direction...

Page 19: ...ves the purpose of contact and burst protection as well as dust collection This chamber is provided to connect an external extraction system to be provided by customer The Ro 130 sensor system consist...

Page 20: ...e is a mathematical relationship between the number and track width of the test heads the rotational speed and the testing speed The following table shows these relationships and gives typical example...

Page 21: ...he motor by means of a high power profile flat belt It is supported in the housing by two high speed bearings The high precision rotating disc for holding the test heads is fitted on the front side A...

Page 22: ...eld current for the rotat ing probes from the stator to the rotor and in the opposite direction transmits the test signal to the test electronics for evaluation Rotating head electronics The rotating...

Page 23: ...nal speed switchable 1 500 or 3 000 rpm with electrical breaking minimized bearing wear through adaptation of rotational speed to test ing speed for applications with changing testing speeds The motor...

Page 24: ...and exit of the test material provided that the straightness conditions and the end properties are observed Protective nozzles are available in nominal sizes of 10 0 to 135 mm They limit the maximum...

Page 25: ...customer on the basis of drawings WARNING Operation without protective nozzles is not permitted for damage and safety reasons Fig 2 7 Top Protective nozzles main picture 31 68 exchangeable nozzle wit...

Page 26: ...st electronics can be adjusted sim ply since the rotating probes periodically scan the test flaw and display the signal quasi statically For setting of clearance compensation there is no need to hold...

Page 27: ...r gapless testing 2x5 mm track width vmax _ for 2 TH rpm 1 500 0 5 m s rpm 3 000 1 0 m s Dimensions see dimension drawing Mass approximately 370 kg Drive Three phase motor no 1 420 rpm P 2 kW no 2 830...

Page 28: ...SENSORSYSTEM Ro 130 2 5 Dimension sheet DESCRIPTION 2 14 6 453 01 2006 2 5 Dimension sheet Fig 2 9 Dimension sheet 1 Entry side View in y direction M1 2 5...

Page 29: ...SENSORSYSTEM Ro 130 DESCRIPTION 2 5 Dimension sheet 6 453 01 2006 2 15 Fig 2 10 Dimension sheet 2...

Page 30: ...ssible 85 condensation not permissible Degree of protection test head rotating system EN 60 529 IP 65 IP 43 Storage and transport Storage transport and handling may be carried out in original packagin...

Page 31: ...ner sleeve 6 451 01 1001 5002 1243560 16 2 Outer sleeve 6 453 01 1001 5001 1277642 8 Nozzle entry 31 68 Nozzle adapter 65 entry 6 453 01 1001 57 1276026 7 Adapter ring 6 453 01 1001 5701 1276859 11 1...

Page 32: ...SENSORSYSTEM Ro 130 2 7 Standard Components DESCRIPTION 2 18 6 453 01 2006 Notes...

Page 33: ...level Cable skid for protecting the cables against damage when traversing the lifting table The two horizontal end positions of the lifting table maintenance posi tion test position should each be mon...

Page 34: ...r terminal of the electronic cabinet and the other system components e g control cabinets motor control ro tating heads with the next main protective conductor terminal 16 mm2 A green yellow lead with...

Page 35: ...ot intervene manually in the sensor system when the rotating unit is running Danger of injury Switch off drive before carrying out any work Wait for machine standstill Deceleration times from max rota...

Page 36: ...t material diameter The protective nozzles can be selected more precisely depending on the test diameter if the quality of guidance is sufficiently precise This can im prove the test results Test head...

Page 37: ...0 Nozzle exchange and diameter setting Hexagon screwdriver warped a f 6 mm extend 012 562 8 Hexagon screwdriver warped a f 8 mm extend 012 563 6 Hexagon screwdriver warped a f 4 mm with pin 016 549 2...

Page 38: ...stem Move sensor system out of the test line Opening the roller guides Turn the locking bolt in ccw direction up to the stop Swivel out the roller guide WARNING For safety reasons a safety switch inte...

Page 39: ...and remove the clamping ring 11 2 Remove the nozzle 12 from the adapter 13 clamping ring 10 remains locked Change diameter range 10 30 31 68 mm Undo three allen screws M 8x20 DIN 912 B Open and remove...

Page 40: ...apter 7 clamping ring 10 remains locked Change diameter range 31 68 69 135 mm Untighten three allen screws M 8x25 DIN 912 B Open and remove insert the clamping ring 10 Change adapter 7 watch index pin...

Page 41: ...ng nominal diameter 6 453 01 2006 4 7 4 3 3 Adjusting nominal diameter Housing flange Unscrew three allen screws M 6x10 DIN 912 C Turn ccw and remove housing flange Note Mass housing flange approx 17...

Page 42: ...nt probe protection APK A of minimum 0 2 mm is given With worse testing conditions e g drawing line with bent ends or re duced guidance quality a higher probe protection is given with that scale setti...

Page 43: ...will be clamped when reverse winding Relax two clamping screws D approx turn Adjust probe lever to the new nominal diameter with hexagon screw driver a f 5 according to the scale Tighten two clamping...

Page 44: ...see Chap 2 7 4 3 4 Remove exit nozzles Nozzle 10 30 mm Note Outer sleeve 16 2 remains fitted Untighten three allen screws M 6x25 DIN 912 E Remove inner sleeve 16 1 with exit nozzle fitted 17 from out...

Page 45: ...tighten clamping ring 2 Nozzle 31 68 mm Note The nozzle adapter 14 1 remains fitted Untighten three allen screws M 6x22 DIN 912 G Remove adapter 14 2 Pull out exit nozzle 15 of the nozzle adapter 14...

Page 46: ...ing them carefully Check for wear each time before using them Do not use worn nozzles WARNING Adjust the test heads to the nominal diameter of the protective nozzles before inserting the nozzle refer...

Page 47: ...amping ring entry 11 1 onto adapter ring 7 Tighten three allen screws M 6x10 DIN 912 A with 6 Nm Entry nozzle 69 135 mm Fit the entry nozzle 9 into the housing flange 6 by turning it Fit clamping ring...

Page 48: ...453 01 2006 Fig 4 9 Fitting nozzles exit side legend see Chap 2 7 Exit nozzle 69 135 mm Note The adapter 14 1 is not in place Fit the exit nozzle 3 into the faceplate by turning it and fit the clampin...

Page 49: ...ion up to the stop If required set track roller approx 0 4 to 1 0 mm closer in diameter rotating by 40 max 100 at the hand wheel NOTE A lower pretension of the track rollers protect both the test mate...

Page 50: ...500 or 3 000 rpm The motor control supplies the required voltages and currents and contain the necessary switching and safety devices contactors motor protection switches protective circuits Achievab...

Page 51: ...1 500 rpm approx 10 sec 3 000 rpm Deceleration times without braking approx 210 sec 1 500 rpm approx 360 sec 3 000 rpm Deceleration times with braking approx 15 sec 1 500 rpm approx 40 sec 3 000 rpm...

Page 52: ...SENSORSYSTEM Ro 130 4 5 Switching on motor OPERATION 4 18 6 453 01 2006 Notes...

Page 53: ...s are valid for maximum rotational speed 3 000 rpm Important Parts which are worn or damaged must be replaced immediately when changing dimensions each shift each week each month Roller guide clean ch...

Page 54: ...leansing agent Make sure the areas around the rotating parts are clean Remove abrasion and dirt with an industrial vacuum cleaner Clean rotating disc and test heads with alcohol Clean test piece senso...

Page 55: ...e allen screws M 8x16 DIN 912 C Turn and remove housing flange Loose the test head Untighten three allen screws 6 M3 x 8 DIN 912 Remove cover 7 Untighten allen screws 8 M5 x 10 DIN 912 Remove washer 9...

Page 56: ...ig 5 5 bearing ring seal 3 and test head bearing bushing Reassembling vice versa Note the correct installation position the stop on the test head must contact the control edge of the rotating disk Do...

Page 57: ...n slide on or protective strips can be repaired prop erly only by the manufacturer Fig 5 4 Parts subject to wear in the test heads Fig 5 5 Wear parts back side test head front side bearing ring seal 1...

Page 58: ...6 453 01 2006 5 5 Maintenance of the roller guides 5 5 1 Lubrication The lubrication points marked with CLP 68 must be lubricated 1 x weekly with lubricant oil of ISO viscosity class 68 DIN 51519 or...

Page 59: ...ange all three rollers at the same time When roller lever 4 fitted open the roller guides to the maximum diameter Unscrew the allen screw 1 M 6x40 DIN 912 Draw off track roller 3 with roller pin 2 ins...

Page 60: ...bolts 5 of lever 4 Remove fishplates 11 Unscrew groove nut 8 Remove washer 9 shim washer 10 if present O ring 2 and thrust washer 3 Pull lever 4 thrust washer 3 and O ring 2 off bearing pin 1 Reassem...

Page 61: ...01 2006 5 9 5 6 Checking and changing the cone belt Set the belt s bowing under load so that it does not whistle or lisp during acceleration NOTE For exact tensioning check with a spring balance Fig...

Page 62: ...the clamping screws M 8x25 DIN 912 accessible through the 4 holes in the belt pulley In order to tension the belt adjust the hexagon screw M 8x25 DIN 933 and lock with nut M 8 DIN 934 Fig 5 11 Settin...

Page 63: ...crews M 8x25 DIN 912 ref to Fig 5 12 Loosening the hexagon screw M 8x25 DIN 933 and lock M 8 DIN 934 ref to Fig 5 13 lower the motor Unscrew eight allen screws M 8x25 DIN 912 WARNING Mass of the face...

Page 64: ...screwed on the special washers fitted on the screws must be checked for damage earth fault They must be replaced by new ones if necessary Put on faceplate tighten eight allen screws M 8x25 DIN 912 wi...

Page 65: ...6 453 01 2311 180 739 0 6 453 03 2311 2 4 Test head track width 2 x 5 148 169 0 6 453 01 2321 166 454 9 6 453 03 2321 2 4 Test head track width 2 x 10 148 078 2 6 453 01 2331 180 764 1 6 453 03 2331 2...

Page 66: ...SENSORSYSTEM Ro 130 5 7 List of parts subject to wear MAINTENANCE 5 14 6 453 01 2006 Notes...

Page 67: ...on TS Semi finished Product Testing In Laisen 70 72766 REUTLINGEN GERMANY Telephone Fax E mail Internet 49 7121 140 270 49 7121 140 459 ts foerstergroup de www foerstergroup de 6 453 Order no UA06 EN...

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