Instructions SBZ122 23 24 33 34 35 64 Version 1 1 0 Date 2010 02 EN PDF

Instructions
SBZ 122/23 /24 /33 /34 /35 /64
Version 1.1.0 en
Translation of the original instructions
Retain for future use.
SBZ 122/23 /24 /33 /34 /35 /64
elumatec GmbH
Pinacher Straße 61
D 75417 Mühlacker-Lomersheim
Postfach 1253
D 75402 Mühlacker
Phone +49(0)7041 14-0

Fax +49(0)7041 14-280
mail@elumatec.de
www.elumatec.com
©
10.02.2010
This document was produced by the Technical Documentation department at elumatec GmbH.
All rights over this documentation, especially the right of reproduction and dissemination as well as translation are held by
elumatec GmbH, including with regard to patent applications. No part of this documentation may be reproduced without the
prior written consent of elumatec GmbH. The same applies to processing, reproduction or dissemination of this document with
the use of electronic systems. Errata and technical modifications reserved.
elumatec GmbH cannot be held liable for any errors in this documentation. No liability will be accepted, subject to this being
legally permissible, for direct and indirect damages associated with the delivery or use of this documentation.
1.1.0
SBZ 122/23 /24 /33 /34 /35 /64
Safety instructions
Before starting any repair, service and maintenance work on the machine, always first isolate it
completely from its pneumatic and electrical power sources.
Shut down electricity by turning off the mains isolator switch, and secure switch with a padlock to
prevent it from being turned back on accidentally!
Turn off the pneumatic main isolator switch, depressurize the machine and secure switch with a
padlock to prevent it from being turned back on accidentally!
No modifications are permitted to electrical and pneumatic systems.
Organizational precautions
The operator must provide the required personal protective equipment (PPE).
All existing safety equipment must be checked on a regular basis before starting work.
The operator is responsible for placing profile sections in the machine correctly.
Safety guards
• All safety guards must be fitted properly and be fully operational before the machine is started up.
Safety guards must never be removed except in the following cases:
• -- after the machine has come to a complete stop and
after the machine has been secured to prevent it from being restarted accidentally.
Informal safety precautions

The operating company must produce a set of operating instructions.
The operating manual must always be stored beside the machine.
In addition to the operating manual, the generally applicable and local directives on accident
prevention and environmental protection must be provided and complied with.
All safety and danger notices on the machine must be retained in a legible condition.
Never operate the machine while under the influence of alcohol or drugs. Situations of this kind impair
personal judgement and response times to emergencies.
Staff training
The machine must only ever be operated by suitably skilled and trained personnel.
Machine control
Only authorized personnel are permitted to operate the control system.
Safety precautions during normal operation

Only operate machine once all protective equipment and guards are fully operational.
Before switching on the machine, always ensure that no-one is risk from the machine starting to
operate.
At least once a shift, check the machine for visible signs of damage and check that safety equipment
if fully functional.
Hazards posed by electrical power

All work on electrical power supply to be carried out by a trained electrician.
Clean the machine regularly

Table of contents (TOC)
1 Safety warnings
.......................................................................................................................... 1
1.1 Follow
..........................................................................................................................
instructions in the operating manual 1
1.2 Obligations
..........................................................................................................................
of the operator 1
1.3 Personnel
..........................................................................................................................
obligations 1
1.4 Operator's
..........................................................................................................................
responsibilities 1
1.5 Hazards
..........................................................................................................................
when working with the machine 1
1.6 Intended
..........................................................................................................................
use 2
1.7 Warranty
..........................................................................................................................
and liability 2
2 Safety regulations
.......................................................................................................................... 3
2.1 Explanation
..........................................................................................................................
of symbols and warnings 3
2.2 Organisational
..........................................................................................................................
measures 6
2.3 Protective
..........................................................................................................................
equipment 6
2.4 Informal
..........................................................................................................................
safety precautions 6
2.5 Staff
..........................................................................................................................
training 6
2.6 Machine
..........................................................................................................................
control 7
2.7 Safety
..........................................................................................................................
precautions during normal operation 7
2.8 Electrical
..........................................................................................................................
hazards 7
2.9 Pneumatic
..........................................................................................................................
hazards 7
2.10 Points
..........................................................................................................................
posing a particular hazard 8
2.11 Personal
..........................................................................................................................
protection measures 9
2.11.1 ..........................................................................................................................
Protection against contact with energized parts 9
2.12 Servicing
..........................................................................................................................
and maintenance, troubleshooting 10
2.13 Machine
..........................................................................................................................
modifications 10
2.14 Machine
..........................................................................................................................
cleaning and waste disposal 10
2.15 Machine
..........................................................................................................................
noise 11
2.16 Copyright
.......................................................................................................................... 11
3 Transport and storage
.......................................................................................................................... 11
3.1 Packaging
.......................................................................................................................... 11
3.2 Machine
..........................................................................................................................
storage 12
3.3 Scope
..........................................................................................................................
of supply 12
3.4 Transport
..........................................................................................................................
instructions 13
4 Specifications
.......................................................................................................................... 15
4.1 Machine
..........................................................................................................................
data 15
4.2 Connection
..........................................................................................................................
data 15
4.3 Performance
..........................................................................................................................
and operating data 15
4.4 Dimensions
..........................................................................................................................
and weights 16
4.5 Environmental
..........................................................................................................................
conditions 17
4.5.1 ..........................................................................................................................
Noise 17
4.5.2 ..........................................................................................................................
Temperatures 17
4.5.3 ..........................................................................................................................
Illumination in the workplace 17
5 Setup, assembly and commissioning
.......................................................................................................................... 18
5.1 Setup
..........................................................................................................................
location, place of use 18
5.1.1 ..........................................................................................................................
Foundation diagram 19
5.2 Setting
..........................................................................................................................
up the machine 25
5.3 Connecting
..........................................................................................................................
the power supply 26
5.3.1 ..........................................................................................................................
Electrics 26
5.3.2 ..........................................................................................................................
Pneumatics 26
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SBZ 122/23 /24 /33 /34 /35 /64
5.4 Controls
.......................................................................................................................... 27
5.4.1 ..........................................................................................................................
Main switch 27
5.4.2 ..........................................................................................................................
EMERGENCY STOP button on the control panel 27
5.4.3 ..........................................................................................................................
EMERGENCY-STOP button on the mobile user terminal (optional) 27
5.4.4 ..........................................................................................................................
Control panel 28
5.4.5 ..........................................................................................................................
Acknowledgement of light barrier 28
5.4.6 Foot..........................................................................................................................
valve 28
5.4.7 ..........................................................................................................................
Mobile user terminal (optional) 29
5.5 Safety
..........................................................................................................................
light barrier (PE cell) 29
6 Operation
.......................................................................................................................... 30
6.1 Base
..........................................................................................................................
machine 30
6.2 Settings
..........................................................................................................................
and components 31
6.2.1 ..........................................................................................................................
Maintenance unit 31
6.2.2 ..........................................................................................................................
Spray unit 32
6.2.3 ..........................................................................................................................
Metering spray unit for rack lubrication (X-axis) 36
6.2.4 ..........................................................................................................................
Clamping system 37
6.2.5 ..........................................................................................................................
Clamping unit 38
6.2.6 ..........................................................................................................................
Automatic clamp recognition 40
6.2.7 ..........................................................................................................................
Automatic clamp displacement (optional) 40
6.2.8 ..........................................................................................................................
Pneumatic components 41
6.2.9 ..........................................................................................................................
Central lubrication unit 42
6.2.10 ..........................................................................................................................
Limit switch - linear guides 46
6.2.11 ..........................................................................................................................
Electronic timer 48
6.2.12 ..........................................................................................................................
Spindle cooling (optional) 49
6.3 Automatic
..........................................................................................................................
tool changer 50
6.3.1 Tool..........................................................................................................................
changer SBZ 122/23 + 24 50
6.3.2 Tool..........................................................................................................................
changer SBZ 122/33 + 34 + 35 + 64 50
6.4 Tools
.......................................................................................................................... 51
6.4.1 ..........................................................................................................................
Clamping the tools 52
6.4.2 ..........................................................................................................................
Overview - Clamp tool HSK F63 53
6.4.3 ..........................................................................................................................
Changing the tool holders 54
6.5 Machining
..........................................................................................................................
examples 55
6.5.1 ..........................................................................................................................
Maximum profile dimension examples 55
6.6 Daily
..........................................................................................................................
start-up procedure 58
6.6.1 ..........................................................................................................................
Daily start-up of system 58
6.6.2 ..........................................................................................................................
Daily start-up of machining spindle 58
6.7 Faults
.......................................................................................................................... 59
6.8 Particular
..........................................................................................................................
work instructions for the machine operator
on machines with powered spindle(s) 60
6.8.1 ..........................................................................................................................
Temperatures 60
6.8.2 ..........................................................................................................................
Delayed switch-off of sealing air 61
6.8.3 ..........................................................................................................................
Tools 61
6.8.4 ..........................................................................................................................
Cleaning 62
6.8.5 ..........................................................................................................................
Cleaning the internal taper 62
6.8.6 ..........................................................................................................................
Tools with tool support 63
7 Servicing, maintenance and cleaning
.......................................................................................................................... 65
7.1 Servicing
..........................................................................................................................
and maintenance 66
7.1.1 ..........................................................................................................................
Maintenance unit 66
7.1.2 ..........................................................................................................................
Lubrication 67
7.1.3 ..........................................................................................................................
Servicing and maintenance schedule 67
7.1.4 ..........................................................................................................................
Maintenance of machining spindles 70
7.2 Cleaning
..........................................................................................................................
work 71
7.3 Machine
..........................................................................................................................
disposal 71
7.4 After-sales
..........................................................................................................................
service 72
8 Spare and wear parts
.......................................................................................................................... 73
9 Annex
.......................................................................................................................... 82
9.1 Noise
..........................................................................................................................
emission data 82
9.2 Safety
..........................................................................................................................
data sheets 82
9.2.1 ..........................................................................................................................
SUPRA NEOC 1311 82
9.2.2 ..........................................................................................................................
Metalon 11-108 82
9.2.3 ..........................................................................................................................
OEST anti-friction oil CG 68 82
9.2.4 ..........................................................................................................................
Coolant concentrate, MOTOREX FRIGOSOL 82
9.3 Electrical
..........................................................................................................................
circuit diagram 82
9.4 Pneumatic
..........................................................................................................................
circuit diagram 82
9.5 Plans
..........................................................................................................................
and drawings 82
9.6 Operating
..........................................................................................................................
manual "Cooling unit - spindle cooling"
(option) 82
Index
.......................................................................................................................... 83
1.1.0
SBZ 122/23 /24 /33 /34 /35 /64
1 Safety warnings
1.1 Follow instructions in the operating manual
A knowledge of the basic safety regulations is an essential requirement for operator safety and
for downtime-free operation of this machine.
This operating manual contains important instructions on how to operate the machine safely.
The operating manual, and in particular the safety warnings, must be observed by everyone
working on the machine.
In addition, all work safety directives and regulations applicable at the operating site must be
observed.
1.2 Obligations of the operator

The operating company undertakes only to allow people to operate this machine who:
are aware of the health and safety regulations and have been instructed in using the machine.
have read and understood the safety chapter of this operating manual and confirmed this by their
signature.
The operating company shall carry out checks at regular intervals to ensure that all personnel are
fully aware of safe working procedures and practices.
1.3 Personnel obligations

People employed to work on the machine are obliged, before starting work:
to observe the health and safety regulations.
to read the chapter on safety and the warning in this operating manual and to confirm by
signature that they have understood them.
1.4 Operator's responsibilities

The operator must ensure that no other persons are within the machine's travelling zone before
commencing with machining programmes.
No third parties may be within the machine's travelling zone while setting-up, servicing or cleaning
work is being carried out.
Safety devices may not be deactivated.
1.5 Hazards when working with the machine

The bar machining centre is built in accordance with state of the art technology and
recognised safety regulations.
The machine is only

intended for designated use
and use in perfect condition in terms of safety.
If used improperly, risks to life and limb of the user or third parties may arise, or the machine or
other assets may get damaged.
Malfunctions which may adversely affect safety must be remedied immediately.
1
1.6 Intended use
The sole intended purpose of the bar machining centre is the machining (routing,
drilling and thread cutting)
of aluminium and thin-walled steel profiles.
No other or additional form of use can be deemed as intended use. cannot be held
liable for any resultant damage.
Intended use also includes:
observing all notices in the operating manual and
adhering to the inspection and servicing schedules.
1.7 Warranty and liability

In all cases, our "General Sales & Delivery Terms and Conditions" apply. The operator will receive
a copy of these no later than at the time of contract signing.
Warranty cover extends to the supplied machine with all components. This cover ensures that
defects on machines/components which can verifiably be demonstrated to have arisen as a
consequence of manufacturing faults and/or material defects, despite operation at all times in strict
accordance with the operating manual, are remedied by ourselves, and we are free to choose
whether to replace or repair affected parts.
Warranty and liability claims relating to personal injury and damage to equipment will not be
countenance if these problems arose as a result of one or more of the following causal factors:
Use of the machine different from its intended application
Incorrect machine installation, commissioning, operation and/or maintenance
Operating the machine with defects and/or non-functioning safety and protective devices
Non-compliance with the operating manual instructions regarding machine transport, storage,
installation, commissioning, operation, maintenance and setup
Unauthorised modifications to the machine
Unauthorised changes to drive conditions (power, speed, etc.)
Poor monitoring of machine components subject to wear
Repairs performed improperly
Catastrophic incidents caused by extraneous causes and force majeure.
The information in this publication is checked regularly and any necessary corrections included in
the subsequent editions.
Reprinting, reproduction and translation, whether wholly or in part, requires the prior written
consent of .
continually strives to improve its products and therefore reserves the right to make
technical changes without any notification.
1.1.0 2
SBZ 122/23 /24 /33 /34 /35 /64
2 Safety regulations
2.1 Explanation of symbols and warnings
The following designations and symbols for hazards are used in the operating manual:
Indicates a hazard with a high degree of risk.
If the hazard is not properly avoided, death or severe injuries

will result.
Indicates a hazard with medium degree of risk.
If the hazard cannot be properly avoided, death or severe injuries will

result.
Indicates a hazard with low degree of risk.
If the hazard cannot be properly avoided, minor to moderate injuries will

result.
This section gives you important warnings regarding how to prevent

damage to the machine. Tips for use and useful information that help
you use the functions of the machine in an ideal manner.
3
The following symbols are applied to the machine:
Caution, voltage
This symbol indicates the presence of an immediate danger from
electrical current threatening human life and health.
Controller ON
The button marked with this symbol switches on the machine's
controller.
Controller OFF
The button marked with this symbol switches off the machine's
controller.
Clamp position 1
The button marked with this symbol activates workpiece clamping for
position 1 (closes the clamping cylinders).
Pressing the button again deactivates workpiece clamping for
position 1 (the clamping cylinders are opened).
Clamp position 2 (only in 2-position machines)

The button marked with this symbol activates workpiece clamping for
position 2 (closes the clamping cylinders).
Pressing the button again deactivates workpiece clamping for
position 2 (the clamping cylinders are opened).
Clamp clamping position 1 (only when running with automatic

clamp displacement - optional)
The button marked with this symbol clamps the clamps belonging to
position 1 onto the guide rods or releases them, as the case may be.
Clamp clamping position 2 (only when running with automatic

clamp displacement - optional - only in 2-position machines)
The button marked with this symbol clamps the clamps belonging to
position 2 onto the guide rods or releases them, as the case may be.
Run back
The key switch designated with this symbol can be accessed freely
from its limit stop position.
1.1.0 4
SBZ 122/23 /24 /33 /34 /35 /64
Position 1 light barrier acknowledgment

The button marked with this symbol is used to acknowledge the signal
issued when people leave the working area protected by the light
barrier around position 1.
Position 2 light barrier acknowledgment (only in 2-position

machines)
The button marked with this symbol is used to acknowledge the signal
issued when people leave the working area protected by the light
barrier around position 2.
The following symbols are used as warning notices in the operating manual and on the machine:
Eye protection
Wear protective goggles to protect your eyes.
(against swarf, dust, spray oil etc.)
Ear protection
To protect the ears (safeguarding the sense of hearing), wear suitable
ear defenders.
Hand protection
Wear gloves to protect your hands.
(e.g. when changing tools)
Protective gloves must be selected in accordance with EN 388.

Category recommended by : at least Category II.
5
2.2 Organisational measures
The operator must provide the required personal protective equipment.
All available safety equipment must be inspected regularly before the start of work.
The operator is responsible for placing sections in the machine correctly.
2.3 Protective equipment

Before every machine start-up, all protective equipment and guards must be fitted properly and
be fully operational:
- the locking mains isolator switch which ensures that the machine cannot be started up
accidentally or by unauthorized persons
- emergency stop button
- safety light barrier
- clamping pressure monitoring by means of pressure sensor.
Protective equipment and guards must only ever be removed
- once machine is stationary and
- after securing the machine to prevent it from restarting.
When supplying sub-components, the operator must always reinstall the protective equipment
and guards properly afterwards.
The viewing screen (protective hood) provides protection against projectile swarf.
2.4 Informal safety precautions

The operating manual must always be kept beside the machine.
In addition to the operating manual, generally applicable as well as local directives governing
accident prevention
and environmental protection must be displayed clearly and followed.
All safety and danger notices on the machine must be maintained in a legible condition.
2.5 Staff training

The machine must only ever be operated by suitably skilled and trained personnel.
The personnel responsible for assembly, start-up, operation, retooling, maintenance and service
work must be defined clearly.
While staff are learning the job, they must always be supervised by an experienced person while
working on the machine.
1.1.0 6
SBZ 122/23 /24 /33 /34 /35 /64
2.6 Machine control

Only authorised personnel are permitted to operate the controls.
Warranty is rendered null and voice if the customer makes changes to the PC on the machine's
control system without prior written consent from .
This applies in particular if the customer:
changes the operating system.
installs a new operating system.
installs software (e.g. Office products like Word, Excel, games etc.)
installs driver software.
deletes files from the operating system level.
installs additional hardware.
2.7 Safety precautions during normal operation

Only operate machine once all protective equipment and guards are fully operational.
Before switching on the machine, always ensure that no-one is risk from the machine starting to
operate.
At least once a shift, check the machine for visible signs of damage and check safety equipment
for full functionality.
2.8 Electrical hazards

All work on the electrical power supply must always be carried out by specialist electricians.
Arrange for regular inspection of all electrical equipment on the machine. Take immediate
corrective action with
any loose connections and defective cables.
Keep the switch cabinet closed and locked at all times. Access is restricted to authorised
personnel with a key or appropriate tool.
When working on electrically live components, always have a second person in attendance who
can, if necessary, shut down the main switch.
2.9 Pneumatic hazards
The machine has an operating pressure of 7 bar.

All work on the pneumatic circuit must be carried out by a skilled
specialist.
During any work on the bar machining centre, it is essential to wear

protective goggles, otherwise oil spray and swarf may get into your
eyes.
7
2.10 Points posing a particular hazard
Mechanical tearing and cutting hazard:
whenever tools are being replaced
Before starting work on the machining centre, always set the main
switch to its '0' position, i.e. switch it off.
Always fit and secure a padlock to prevent the main switch from being
switched back on accidentally.
It is essential to wear protective goggles when working on the bar

machining centre in order to prevent swarf from getting into your eyes.
Always wear protective gloves when changing tools.
Mechanical crushing hazard:

when clamping the tool
The clamping cylinder is operated pneumatically whenever the foot switch

is actuated and the work sequence is initiated on the control panel.
There is a residual level of risk for any unauthorized person reaching into
the machine.
Danger of flying parts

Material clamping
Make sure that the material clamping mechanism (clamping cylinder) is

adjusted in such a way that the section is securely clamped before, during
and after machining.
If necessary, use shims (counter sections).
Ensure that no parts can fly off the sections uncontrolled during
machining.
These necessary measures are the responsibility of the machine operator.
1.1.0 8
SBZ 122/23 /24 /33 /34 /35 /64
Hazard posed by heating

when changing the angle milling cutter head
Caution!
The angle milling cutter head becomes hot during machining.
Because of this, make sure to always wear protective gloves when
changing angle milling cutter heads manually.
2.11 Personal protection measures

2.11.1 Protection against contact with energized parts
Prior to all maintenance and repair work:
De-energize machine through main switch and padlock the main switch to
prevent it from being switched back on accidentally.
Lock down all main control panels and remove keys and/or fit a warning
notice to the main switch.
Wait for the capacitors in the intermediate circuit to discharge fully
(approx. 1 min.) !
After switching off the main switch, check that the intermediate circuit
voltage is below 50V.
Before commissioning:
Install and screw all covers, protective covers, etc. in order to protect
people and objects from accidental contact with live parts.
Check all protective earth conductor connections to motors and
electrical devices!
If electric cabinets and other accessible electrical equipment that is
energized cannot be closed during commissioning, they must be
secured by electricians in such a way that people at risk are unable to
access them.
The overcurrent protection device's main fuse for the power cord must be
installed outside of the machine, and is not part of the machine's scope of
supply
9
CAUTION!
Do not use any residual current devices:
Generally, ground fault circuit interrupters must not be used together with
AC servo drives.
Reason:
In equipment with pulsed power electronics, a residual DC current that
can block a ground fault circuit interrupter from being tripped can be
generated in the event of a frame fault. Because of this, protection in the
event of indirect contact must be established another way, e.g., with
overcurrent protection devices.
2.12 Servicing and maintenance, troubleshooting

Maintenance unit
see chapter Maintenance unit 66 in Servicing and Maintenance
Ensure that the central lubrication and the spray reservoir levels are always sufficient.
The motors are zero-maintenance units.
2.13 Machine modifications

No modifications, attachments or conversions are permitted on the machine without the prior
approval of the manufacturer.
This also applies to the welding of load-bearing components.
All conversion work require prior written confirmation from .
Any machine components in less than perfect condition must be replaced immediately.
Only use genuine spare parts and wearing parts.
If other makes of spare and wearing parts are sourced for this purpose, the manufacturer's
warranty liability is rendered null and void.
2.14 Machine cleaning and waste disposal

Handle and dispose of used substances and materials properly, especially
when working on lubrication systems and lubricating units and
when cleaning using solvents.
1.1.0 10
SBZ 122/23 /24 /33 /34 /35 /64
2.15 Machine noise

The noise emissions levels from the machine are dependent on the profiles being machined and
on the tools being employed.
For more precise details, please refer to the Annex, Noise emission data 82 .
Due to the fact that the continuous noise level is > 75 dB(A), operating
personnel must be equipped with appropriate safety equipment to
protect them against permanent hearing impairment.
2.16 Copyright
Copyright for this operating manual remains the property of .
This operating manual is intended solely for the operating company and its employees.
The manual contains specifications and instructions which must not be reproduced,
disseminated or otherwise put into circulation, either wholly or in part.
All violations can result in legal action being instigated against the infringing party.
3 Transport and storage

The machine is transported on pallets.
3.1 Packaging
The machine is packaged in a plastic film.
Gross weight
Machine type
depending on configuration
SBZ 122/23 approx. 2200 kg
11
3.2 Machine storage
If the machine is stored for extended periods, always note the following points:
only store in dry rooms,
use suitable packaging for storage (protective film) or leave in original packaging.
Although most parts are coated with a protective coating, the system must
be thoroughly cleaned before commissioning.
3.3 Scope of supply

To install the bar machining centre properly at the customer's site, always check the
delivered machine for completeness first:
Configuration / accessories:
Automatic tool changer with 5 tool compartments (without tools) and a compartment with an
integrated rotating mechanism (0°/180°) for a rotating angle milling cutter head
[SBZ 122/23 + 24]
Automatic tool changer with 5 tool compartments (without tools) and a compartment for a
rotating angle milling cutter head [SBZ 122/33 + 34 + 35 + 64]
A rotating mechanism integrated into the machining spindle, for adjusting the rotating angle
milling cutter head (0°/90°/180°/270°) [SBZ 122/33 + 34 + 35 + 64]
1 rotating angle milling cutter head for 2 tools
Safety light barrier (to protect the operator)
4 horizontal pneumatic material clamping units
Automatic clamp recognition
Material stop
Central swarf disposal unit (with swarf box)
Spray metering unit
Oil mist
Maintenance unit
Depth gauge
Set of spanners
Operating manual
1.1.0 12
SBZ 122/23 /24 /33 /34 /35 /64
3.4 Transport instructions
13
1.1.0 14
SBZ 122/23 /24 /33 /34 /35 /64
4 Specifications
4.1 Machine data
Designation: Bar machining centre
Type: SBZ 122
Serial number: see type plate
The type plate is located at the back of the machine base
4.2 Connection data

Electrical: Voltage
current precise data:
max. pre-fusing see circuit diagram
connected rating
Compressed air: > 7 bar
4.3 Performance and operating data

SBZ122/23 * SBZ122/24 * SBZ122/64
SBZ122/33 SBZ122/34
SBZ122/35
Max. machining length 3,800 mm Position 1= 1,800 Position 1= 3,630

without frontal machining mm mm
(3-sided machining) Position 2= 1,700 Position 2= 3,250
X axis mm mm
Total length: Total length:
3,800 mm 7,250 mm
Max. machining length 3,700 mm Position 1= 1,700 Position 1= 3,360

with frontal machining mm mm
(5-sided machining) Position 2= 1,600 Position 2= 3,050
X axis mm mm
Total length: Total length:
3,700 mm 7,000 mm
Travel distance of X axis v 60 m/min.

max.
Travel distance of Y axis 350 mm
v max. 30 m/min.
Travel distance of 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
* SBZ122/23 and SBZ122/24: Frontal machining with rotating angle milling cutter head not
possible
15
Max. spindle speed 24,000 rpm
Max. spindle power 7 kW S1
Tool support HSK F63
Tool compartments for 5 x tools for machining from above

automatic tool changes 1 x angle head
Max. milling cutter diameter 63 mm
Max. disk milling cutter 200 mm (manual tool changing)

diameter 92 mm (automatic tool changing)
Air consumption per minute 75 l with spraying
4.4 Dimensions and weights

Length/depth/height Gross weight [kg]
Machine type
[mm] depending on configuration
SBZ 122/23 approx. 4850/3240/2540 approx. 2200
Maximum space required. See section Foundation diagram 19
1.1.0 16
SBZ 122/23 /24 /33 /34 /35 /64
4.5 Environmental conditions

4.5.1 Noise
Due to the fact that the continuous noise level is > 75 dB(A), operating
personnel must be equipped with appropriate safety equipment to
protect them against permanent hearing impairment.
The noise emission levels from the machine are dependent on the sections being machined and
on the tools being employed.
Noise emission data 82 refer to the Annex in the operating manual.
4.5.2 Temperatures
Permitted environmental factors
The machine must be erected in a dry condition, and never in sub-zero temperatures.
The permitted ambient temperatures are between 10°C and 30°C.
At temperatures above 30°C, additional cooling of the electrical and electronic components is
required.
During this work:

the ambient temperature should not fall below +12°C and
not exceed +26°C.
These temperatures correspond to the workplace directive.

Ensure adequate levels of ventilation and waste air extraction!
4.5.3 Illumination in the workplace

The owner must provide sufficient illumination in the workplace.
The minimum illumination intensity is 300 Lux.
The illumination intensity recommended by is 500 lux.
17
5 Setup, assembly and commissioning
Safety Warnings
When the machine is raised with a forklift truck, always ensure that
none of its electrical or pneumatic lines get damaged.
Do not use machine components as climbing aids!
Keep all grab handles free of dirt!
Electrical wiring must be routed and fitted professionally.
Cross section, length and quality of wiring must comply with local
requirements.
Before switching on the machine, always ensure that no-one is risk from
the machine starting to operate.
5.1 Setup location, place of use

Constructional requirements which the operator must assure prior to
setting up the machine:
Before the machine is set up in location, first always assure that the
ground has sufficient load-bearing capacity. To establish this, pay careful
attention to the information about machine weight which we provide.
The operator must set up a protective area around the machine which
extends right across the area not protected by light barriers. This fencing
must be at least 1.80 meters high.
The foundation diagram shows the maximum space occupied by the

machine.
The ground on which the machine is to be set up must be level and flat.
When setting up the machine, ensure that legally specified minimum

distances are complied with.
The distance between back wall of machine and building wall or other
machines must be at least 0.5 meters.
The machine must be protected to prevent access by unauthorized
persons.
1.1.0 18
SBZ 122/23 /24 /33 /34 /35 /64
5.1.1 Foundation diagram
122051712-Foundation plan-Page1-SBZ122/23 + 33
19
1.1.0 20
SBZ 122/23 /24 /33 /34 /35 /64
21
1.1.0 22
SBZ 122/23 /24 /33 /34 /35 /64
Foundation plan-SBZ122/64
23
122051711-Foundation plan-SBZ122/35
1.1.0 24
SBZ 122/23 /24 /33 /34 /35 /64
5.2 Setting up the machine
[SBZ122/23]
[SBZ122/35]
The bar machining centre may only be set up by fitters.

The bar machining centre is aligned with a precision level.
The positions of the light barriers and the safety fences can be gathered from the Foundation
diagram 19 .
Visual inspection
Check the machine for any signs of corrosion (screws) and notify Service if you spot
any signs of corrosion.
Clean the machine prior to commissioning.
25
5.3 Connecting the power supply
Electrical wiring must be routed and fitted properly.

Cross section, length and quality of wiring must comply with local
legislative requirements.
All work on the electrical system must be carried out by specialist staff.
IEC 60364 must be taken into account in all cases. If necessary, contact
us to obtain details of the electricity utility responsible for your supply.
5.3.1 Electrics
Before connecting the machine, always satisfy yourself of the following points:
That the routed cable cross sections correspond to the technical data for the equipment (see
circuit diagram).
The electrical wiring for connecting power is
routed through a free screw connection in the
left side panel of the main electric cabinet.
The main electric cabinet is located on the
back of the machine sub-frame.
A = electrical connection
5.3.2 Pneumatics
Connection to the pneumatic circuit is made via the maintenance unit. This is located on the back
of the machine sub-frame.
This compressed air connection must be able to deliver clean and dry air at a continuous pressure
of > 7 bar.
All work on the pneumatic system must be carried out by specialist staff. Observe all directives
from trade associations.
Maintenance unit for 1-position machines Maintenance unit for 2-position machines
1.1.0 26
SBZ 122/23 /24 /33 /34 /35 /64
5.4 Controls
5.4.1 Main switch
With the main switch, the machine is

connected and disconnected from its mains
power source.
The main switch is located in the machine's
control cabinet.
A = main switch
5.4.2 EMERGENCY STOP button on the control panel
The EMERGENCY STOP button is located on

the control panel. The entire machine is de-
energised when the button is pressed. To
release the button, it needs to be turned
(detent then releases).
A = EMERGENCY OFF button
5.4.3 EMERGENCY-STOP button on the mobile user terminal (optional)
The EMERGENCY-STOP button on the

mobile terminal (optional) is located on top of
the panel housing.
27
5.4.4 Control panel
B = control ON
C = control OFF
D = Clamp position 1
E = Clamp clamping position 1 (only

when running with automatic clamp
displacement - optional)
F = Clamp position 2 (only in 2-position

machines)
G = Clamp clamping position 2 (only

when running with automatic clamp
displacement - optional - only in 2-position
machines)
H = Run back
5.4.5 Acknowledgement of light barrier

With these buttons personnel can
acknowledge when they leave the working
area protected by a light barrier.
A = acknowledging light barrier Pos1
B = acknowledging light barrier Pos2

(only with 2-position-machines)
5.4.6 Foot valve

Preload is enabled and disabled by means of
this foot valve.
1.1.0 28
SBZ 122/23 /24 /33 /34 /35 /64
5.4.7 Mobile user terminal (optional)

B = key switch: control panel ON/OFF
C = feed rate potentiometer
D = start work sequence
E = stop work sequence
F = acknowledge work sequence (software)
5.5 Safety light barrier (PE cell)

For operator safety and to protect against any unauthorized and/or accidental intervention in
ongoing operations, a permanent safety light barrier is fitted around the machining area.
The positions of the safety light barriers and the safety fences are described in the Foundation
diagram 19 .
29
6 Operation
Only properly trained personnel are permitted to set parameters for

routing, drilling and thread cutting work.
Training is required before operating the bar machining centre. Details on
programming, as well as the procedure followed when machining
workpieces, are taught at during a training course.
The protection facilities on the bar machining centre must be inspected on
a daily basis.
6.1 Base machine

The bar machining centre makes it possible to machine aluminium profiles and thin-
walled steel profiles.
All operations, such as milling, drilling and thread cutting, are performed on stationary profile stock.
The bar machining centre consists primarily of a machine base with a clamping unit, a mobile
machining assembly with a protective cover, a control panel and a switch cabinet.
Three numerically controlled axes position the tools according to the machining tasks to be
performed.
There are 6 compartments for 5 different tools and 1 rotating angle milling cutter head available for
automatic tool changing.
SBZ 122/23 + 24: A stationary rotating mechanism in the tool changer makes it possible to adjust
the rotating angle milling cutter head at 0° and 180°. This allows for the profile to be machined from
the front and back with 2 different tools.
There is the option of using 3-sided profile machining.
SBZ 122/33 + 34 + 35 + 64: A rotating mechanism that is integrated into the machining spindle
makes it possible to adjust the rotating angle milling cutter head at 0°/90°/180° and 270°. This
allows for the profile to be machined from the front, back and frontally with 2 different tools.
There is the option of using 5-sided profile machining.
The bar machining centre PC controller handles all feedback control, open-loop control and
inspection/monitoring tasks.
The system is operated via keyboard input. A colour monitor is an integral part of the control panel.
This screen displays all the bar machining centre's functions.
1.1.0 30
SBZ 122/23 /24 /33 /34 /35 /64
6.2 Settings and components

6.2.1 Maintenance unit
The maintenance unit consists of a filter control valve - consisting of a pressure control valve, a
pressure gauge and a water separator - and a switch-on valve.
A = pressure control valve, turning handle

B = pressure gauge
C = water separator
D = switch-on valve
Maintenance unit for 1-position-machines
Pressure control valve

The operating pressure of the machine is set to 7 bar, as follows:
Raise rotary handle until it locates audibly.
Set pressure with the help of the pressure gauge:
- turn clockwise: Pressure rises
- turn anti-clockwise: Pressure reduces
After this setting operation, lock down the rotary handle again.
Water separator
See the section on the maintenance unit in Servicing and maintenance 66
31
6.2.2 Spray unit
The machining centre has a spray unit for tool
lubrication.
The spray unit is used for tool lubrication
when using machining from above or
machining with the rotating angle milling
cutter head.
The spray unit consists of three separate
spraying circuits. The circuits are selected
according to the corresponding machining
tasks.
A = spray container
The spraying agent is conveyed from the

reservoir to the metering pumps and fed into
the spray air, in minute amounts, in a cyclic
manner.
The spraying agent volume can be adjusted
by modifying the cycle time.
The metering pump is located on the back of
the machining head.
A = metering pump
The stroke of the small red piston must be

monitored through the sight glass in order to
make sure that the metering pumps are
working correctly.
A = metering pump
B = sight glass
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During machining, the spray container is pressurised in order to convey

the cutting fluid to the metering pump. This pressure is set permanently to
1 bar on the pressure reducer on the back of the machining head and
cannot be modified.
A = metering pump
B = pressure reducer
The individual spray nozzles' flow rate is

adjusted on the corresponding adjusting
throttles on the machining head.
Two spraying nozzles are intended for
machining from above.
One spraying nozzle is intended for the
rotating angle milling cutter head.
A = adjusting throttles
33
Spray container
The spray container for the high-performance

cutting medium is located on the back of the
machining unit.
The fill level can be seen on the sight glass
tube located on the side of the spray
container.
A = spray container
B = sight glass, fill level
C = shut-off valve (gate valve)
D = sealing plug, filler opening
Caution!
Spray reservoir is pressurised! Before topping up spraying agent, the
spray container must first be vented!
Top up spraying agent

Before refilling the spraying agent, the spray container must be bled first!
The spraying agent supply must be cut off with the shut-off valve (gate valve) in order to bleed the
spray container.
The sealing plug may only be screwed out after the container has been bled.
Fill up the container with spraying agent.
After this, the sealing plug must be screwed back into the filler opening.
Resume the spraying agent supply with the shut-off valve (gate valve).
1.1.0 34
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Only use high-pressure cutting medium when topping up the

reservoir.
order no.: 088 90 70 80 (0.5 l)
088 90 70 81 (1.0 l)
088 90 70 82 (5.0 l)
088 90 70 83 (20.0 l)
088 90 70 84 (200.0 l)
35
6.2.3 Metering spray unit for rack lubrication (X-axis)
The rack is sprayed with oil by a spray
metering unit.
Spraying agent:
-order no. 088 90 71 15 - 1l
A = spray unit
B = spray nozzle
The spray container is located to the right of

the machining head.
The metering screw can be used to adjust the
intensity of the atomized spray.
The metering nozzle for directing air to the
spray jet is located on the right side of the
spray container.
Via the sight glass you can keep an eye on
how the spray unit is functioning.
If the spray unit is intact, oil is released during
the machining process at the desired
metering rate.
A = spray container
B = metering screw
C = metering restrictor
D = sight glass
E = bleed valve
Caution!
Spray container is pressurised! Before topping up spraying agent, the
spray container must first be vented!
Top up spraying agent

Before topping up spraying agent, the spray container must first be vented!
To vent the spray container, unscrew and remove the blue screw connection above the bleed
valve.
The spray container cannot be unbolted until it has been depressurised.
Top spray medium into the reservoir and then screw the reservoir back down in position.
After that, the blue screw connection must be tightened back into the breather aperture.
1.1.0 36
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6.2.4 Clamping system
Dual-circuit safety clamping system
Clamping pressure is set by the pressure relief valves (with pressure gauge).
The preload pressure for the tensioning devices is set to 1 on the pressure relief unit.
Workpiece clamping pressure is set to 2 on the pressure relief unit.
In machines with 2-position machining, each position is equipped with its own clamping system.
A = Pressure relief unit 1 for lower

clamping pressure (preload pressure)
B = Pressure relief unit 2 for higher
clamping pressure (workpiece clamping
pressure)
A = Pressure relief unit 1 for lower

clamping pressure of position 1
(preload pressure)
B = Pressure relief unit 2 for higher
(workpiece clamping pressure)
C = Pressure relief unit 3 for lower
(preload pressure)
Maintenance unit for 2-position-machines D = Pressure relief unit 4 for higher
(workpiece clamping pressure)
The lower preload pressure enables workpieces to be clamped safely, i.e. without causing a
hazard.
This action reduces the risk of injury to the operator to a minimum.
The workpiece clamping pressure is not exerted until the work sequence has started.
If the circuit pressure drops below 5 bar, all movements on the machine are stopped.
37
6.2.5 Clamping unit
SBZ122/23 /24 /33 /34 /64

Process with automatic clamp displacement (optional)
The clamping cylinders are height-adjustable
and depth-adjustable.
Height adjustment
After releasing the clamping screws, the
height of the clamping cylinder can be
adjusted.
The clamping screws must be tightened again

after the adjustment!
A = clamping screws
When machining profiles with a height of less than 30 mm, the profiles
must have washers fitted under them to ensure secure clamping.
Depth adjustment
After unfastening the clamping screw, the
depth of the clamping cylinder can be
adjusted.
The clamping screws must be tightened again

after the adjustment!
A = clamping screw
1.1.0 38
SBZ 122/23 /24 /33 /34 /35 /64
SBZ122/23 /24 /33 /34 /64

Process with manual clamp displacement
The height and depth adjustments are carried

out as described above.
After releasing the clamping lever, the

clamping cylinder can be adjusted in the
X-axis direction.
After the adjustment, the clamps must be
clamped onto the guides again by using the
clamping lever.
A = clamping lever
SBZ122/35
The clamping cylinders are height-adjustable

and depth-adjustable.
After releasing the clamping lever, the height

of the clamping cylinder can be adjusted.
After releasing the clamping screws, the

height of the clamping cylinder can be
adjusted.
The clamping lever and the clamping screws

must be tightened again after the adjustment!
A = clamping lever
B = clamping screw
39
6.2.6 Automatic clamp recognition
The bar machining centre is equipped with an
automatic clamp recognition mechanism
designed to prevent collisions.
A = Automatic clamp recognition

proximity switch
B = Automatic clamp displacement
carrier (optional)
6.2.7 Automatic clamp displacement (optional)

The bar machining centre can also be
equipped with an automatic clamp
displacement mechanism in addition to the
automatic clamp recognition mechanism
(optional).
A = Automatic clamp recognition

proximity switch
B = Automatic clamp displacement
carrier (optional)
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6.2.8 Pneumatic components
Pneumatic components on the machining unit
The following pneumatic components are

located at the back of the machining head:
A = pressure relief unit

spindle sealing air
B = pressure relieve unit
Tool clamping / unclamping
C = Valve battery
D = cycle-operated spraying valves for tool
spraying
E = metering pump for tool spraying
EF = pressure reducer for tool spraying
G = pressure reducer for:
1x profile length measurement (optional)
1x angle head locking device detent
on the machining spindle
(SBZ 122/33 + 34 + 35 +64)
41
Pneumatic components on the machine base
The following pneumatic components are

located at the back of the machine base:
A = maintenance unit
B = valves for automatic clamp displacement
(optional)
C = Valve battery
D = pressure monitor for workpiece clamping
pressure
6.2.9 Central lubrication unit

The central lubrication unit supplies all axis linear guides and drive units.
A = guide carriage on X axis,

machining unit
B = guide carriage on Y axis,
machining unit
A = guide carriage on Z axis,

machining spindle
B = guide carriage,
profile length measurement (optional)
1.1.0 42
SBZ 122/23 /24 /33 /34 /35 /64
A = guide carriage on Z axis,

machining spindle
Central lubricant distributor, Z axis
The central lubricant distributor for the Z axis

guides and drive screws is located behind the
machining spindle.
A = central lubricant distributor
43
Central lubricant distributor, Y axis
The central lubricant distributor for the Y axis

guides is located on the bottom side of the
machining unit.
Central lubricant distributor, X axis
The central lubricant distributor for the X axis

guides is located on the back of the
machining unit.
1.1.0 44
SBZ 122/23 /24 /33 /34 /35 /64
Lubricating pump
The parameters for pauses and cycle
intervals are set as factory settings.
Default Elumatec setting for lubricant
pump:
The operating pressure is set to 25 bar at the
factory and must not be modified.
Operating time: 10 sec.
Cycle time: 250 min.
(The cycle time can be increased or
decreased according to the machine's period
of use.)
A = oil filler opening

B = cover
CG68 path bed oil (sliding oil) is used for lubrication.

order No.: 088 90 71 15 (1l)
- Settings
Cycle time: DS3 + DS1 (250 min.)
Operating time: DS2 (10 sec.)
Pre-lubrication: J1 (with pre-lubrication)
Pressure switch: J2 (pump with pressure switch)
The cover must be removed before calibration.

Setting:
A = DS1
B = DS2
C = DS3
D = J1
E = J2
When the machine is switched on with the main switch, the central
lubrication unit is activated automatically, i.e. the pump time and the
following pump cycle run automatically.
Because of this, the machine must be switched off with the main switch
when the machine will not be run for extended periods of time.
45
6.2.10 Limit switch - linear guides
X axis
X = X axis limit switch
Y axis
Y = Y axis limit switch
1.1.0 46
SBZ 122/23 /24 /33 /34 /35 /64
Z axis
Z = Z axis limit switch
47
6.2.11 Electronic timer
Machine operating time
A = Counter for machine operating hours

B = Counter for spindle operating time
This counter records the completed hours of machine operation.

Time is recorded in hours and minutes.
Display: Hours - minutes
The time counter is located in the machine's switch cabinet.
Spindle operating time
A = Counter for machine operating hours

B = Counter for spindle operating time
This counter records the completed spindle operating time.

Time is recorded in hours, minutes and seconds.
Display: Hours - minutes - seconds
The time counter is located in the machine's switch cabinet.
1.1.0 48
SBZ 122/23 /24 /33 /34 /35 /64
6.2.12 Spindle cooling (optional)
The cooling unit is switched on and off with

the main switch.
Configuration parameters:
Nominal supply temperature value: 20°C
Excess temperature alarm value: 40°C
Insufficient temperature alarm value: 10°C
A = Main switch - cooling unit ON/OFF

B = Indicator - setting
C = Shut-off cock - supply line, return line
The coolant reservoir must be filled up as

follows:
1. 250 ml coolant concentrate
chlorine-free, nitrate-free, and zinc-free
order No.: 088907110 ( 1 l )
2. 1.5 l antifreeze
order No.: 088907112 ( 1.5 l )
3. Fill up the rest with destilled water.
The coolant level should be a little below the

return line inlet when the system is full.
D = Cap, coolant reservoir
For more information on the spindle cooling unit, please consult the
operating instructions included in the appendix.
49
6.3 Automatic tool changer
6.3.1 Tool changer SBZ 122/23 + 24
The tool changer features five tool

compartments for different tools for
machining from above and one stationary
rotating mechanism for a rotating angle
milling cutter head.
The stationary rotating mechanism makes it

possible to adjust the rotating angle milling
A = compartment for rotating angle milling cutter head.
cutter head The rotating angle milling cutter head can be
B = compartments for tools for machining turned to angular positions of 0° and 180°.
from above It is turned with a pneumatic cylinder.
C = pneumatic cylinder
6.3.2 Tool changer SBZ 122/33 + 34 + 35 + 64

The tool changer features five tool
compartments for different tools for
machining from above and one compartment
for a rotating angle milling cutter head.
The rotating angle milling cutter head is

adjusted with a rotating mechanism that is
integrated into the spindle.
A = compartment for The rotating angle milling cutter head can be
rotating angle milling cutter head turned to angular positions of 0°, 90°, 180°
B = compartments for tools for and 270°.
machining from above
1.1.0 50
SBZ 122/23 /24 /33 /34 /35 /64
6.4 Tools
Only use tool supports which are balanced together in fully assembled
condition and comply with at least quality grade G2.5 ( G1 would be
better ) at 21000 rpm, as defined in DIN ISO 1940.
Always use genuine tool supports. Prior approval must be

obtained from the machine manufacturing plant before any other tools can
be used. Without this approval, the machine cannot be operated with
these tools.
All warranty cover is rendered null and void if non-authorized tools sourced
from a third party are used.
Tools must have a large enough swarf chamber.

Tools must possess high roundness and face runout properties.
51
6.4.1 Clamping the tools
The tools are clamped in the tool clamp
holder, which can be installed on a workbench
or at the end of the tool desk.
Insert the tool taper and let the stop bolts click
into place in the boreholes.
The tool can now be changed with the
appropriate chuck keys.
A = depth gauge
B = tool clamp holder
C = stop bolt
Caution!
Risk of injury !
The depth gauge can be used to read the tool

length.
1.1.0 52
SBZ 122/23 /24 /33 /34 /35 /64
6.4.2 Overview - Clamp tool HSK F63
53
6.4.3 Changing the tool holders
Caution!
The rotating angle milling cutter head becomes hot during machining.
Because of this, make sure to always wear protective gloves when
changing rotating angle milling cutter heads manually.
The balanced tool holders are changed

manually or automatically.
To manually clamp and release them, these
buttons beside the machining spindle must be
pressed down.
A = "Clamping / Releasing" button
To achieve long spindle service life, the taper on the spindle and the tool holder need to be kept
clean.
Manual cleaning of the internal taper with a taper cleaner
( order no.: 150 26 10 01) can ensure that no swarf builds up between the contact
surfaces.
However, if small amounts of swarf do build up between the contact surfaces, this can cause the
tool insert to become misaligned as it may be pulled into position asymmetrically. The resultant
imbalance has a negative impact on the service life of the spindle bearing.
Premature bearing damage is then virtually inevitable.
Taper cleaner
-order no.: 150 26 10 01
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6.5 Machining examples

6.5.1 Maximum profile dimension examples
Please note that tests have to be carried out for machining projects that
use the maximum profile dimension limits.
The available maximum profile dimensions can vary depending on the
tool.
Bar machining from above
[X axis]
[Y and Z axes]
55
Frontal bar machining with disk milling cutter
[X axis]
[Y and Z axes]
Frontal bar machining with rotating angle head - SBZ122/33 /34 /35
[X axis]
1.1.0 56
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Bar machining from above and below
[Y and Z axes]
Bar machining from front and back with rotating angle head
[Y and Z axes]
57
6.6 Daily start-up procedure
6.6.1 Daily start-up of system
Central lubricating unit
- check reservoir fill level
Spray container
- check fill level
Maintenance unit
- check system pressure
- drain water separator
Check that all safety equipment and guards are functioning properly
Check that tools are in operational condition
Check that limit switches work properly
Always remove remaining profile sections immediately
6.6.2 Daily start-up of machining spindle

Before starting work, always warm up the spindle for 10 minutes first:
2 mins. at 1000 rpm
2 mins. at 3,000 rpm
If the electric spindle was stationary for at least 4 hours, maximum

speed should be reached in stages over a 5 to 6 minute period.
If the electric spindle is stationary or in storage for a certain period of
time (more than 6 months), the warm-up procedure should be extended
by approx. 15 minutes before recommencing operational service.
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6.7 Faults
Fault Possible cause Remedial action
Spindle does not rotate. No mains power. Check mains power connection.
Check fuses.
Spray unit does not function. Throttle is closed. Open throttle.
Spray medium reservoir empty. Top up spray medium:
Spray medium present. Check lines and nozzles.
Material flaps during machining. Tensioning device not set Adjust tensioning device.
correctly.
59
6.8 Particular work instructions for the machine operator on
machines with powered spindle(s)
6.8.1 Temperatures
Note before switching on: Temperatures
The machine must be erected in a dry condition, and never in sub-zero

temperatures.
The permitted ambient temperatures lie between 10°C and 30°C. At
temperatures in excess of 30°C, additional cooling of electrical and
electronic components is essential.
Operation of the machine below 10°C is prohibited.
During this work:

- room temperatures should not drop below +12°C and
- room temperatures should not rise above +26°C.
These temperatures correspond to the workplace directive.
Ensure adequate levels of ventilation and waste air extraction!
Failure to comply with these directives required by the spindle

manufacturer nullify the machine manufacturer's warranty cover.
Before starting work, always warm up the spindle for 10 minutes first:

If the electric spindle was stationary for at least 4 hours, maximum speed
should be reached in stages over a 5 to 6 minute period.
If the electric spindle is stationary or in storage for a certain period of time

(more than 6 months), the warm-up procedure should be extended by
approx. 15 minutes before recommencing operational service.

1.1.0 60
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6.8.2 Delayed switch-off of sealing air
Whenever the machine is shut down: Delayed switch-off of sealing air
To protect the spindle bearing, the machine must remain connected to the
pneumatic circuit for a further 30 minutes. This sealing air prevents the
ingress of minute particles of dust in the bearing. To extend spindle
service life, air must remain connected for a further 30 minute period.

6.8.3 Tools
Note before switching on: Tools
Only use tool supports which are balanced together in fully assembled
condition and comply with at least quality grade G2.5 ( G1 would be better
) at 21000 rpm, as defined in DIN ISO 1940.
The machine manufacturer's warranty cover is rendered null and void by

any failure to comply with these stipulations.
Always use genuine tool supports. Prior approval from the

machine manufacturing plant must be obtained before any other tools can
be used. Without this approval, the machine cannot be operated with
these tools.
All warranty cover is rendered null and void if non-authorized tools

sourced from a third party are used.
61
6.8.4 Cleaning
Note before switching on: Cleaning
Cleaning the tool support
Always keep inner taper of tool holder clean and wipe with a lint-free cloth
or taper wiper before every manual tool change in the magazine.
Never use compressed air to blast clean the tool support on the
powered spindle.
The ingress of swarf can cause bearing damage!
The ingress of swarf can cause premature failure of the clamping gear or
ball bearing.

6.8.5 Cleaning the internal taper
Note when changing tools: Cleaning the internal taper
Clean internal taper on tool support in powered spindle every 8 hours with
the HSK wiper!
Replace HSK wiper when it gets dirty.

Order number: 150261001 Taper cleaner HSKF63 (HSK50)
1.1.0 62
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6.8.6 Tools with tool support
Tools with tool support, hereinafter simply called tools!
Intended usage for tools in powered spindles
Superlative surface quality and high productivity levels can be achieved

using powered spindles operating at high rotational speeds.
If used improperly, there is great potential for hazards as well as

mechanical wear when operating the system at medium and high
rotational speeds.
For this reason, great care must be exercised when choosing tools.
Only use tools in perfect condition for operation in powered

spindles.
The only way to achieve good machining results and low wear on spindle
bearings is through proper intended usage.
Only use defect-free tools in the tool magazine. All tools must comply with
the following requirements:
Permitted tool balancing quality of G 2.5 must be achieved at all times.
This means that the tool must be officially approved for use at high
speeds and centrifugal forces.
Cutting forces and inertia weight of the tool must not overload the
bearings.
Speeds
Extreme levels of centrifugal force can occur on the tool at high rotational
speeds, depending on tool diameter.
For this reason, tools can only be used without restriction if their permitted
rotational speed is higher than the disengagement speed of the spindle.
63
Critical natural frequencies
can occur with:

- long tools,
- heavy tools and
- tools with a large radius.
In all cases, short tools operate most smoothly and apply the lowest
loading levels on bearings.
Loading applied by cutting forces
Wear on blade can lead to cutting forces being multiplied, i.e. increased
exponentially.
This adversely affects the machining process as well as bearing service
life, especially when permitted bearing loads are exceeded in this way.
Monitor tool wear very closely!
The tools should always protrude from their tool support as far as
necessary and as little as possible.
The shorter the clamping length of the tools, the lower are the loads
applied to the spindles.
1.1.0 64
SBZ 122/23 /24 /33 /34 /35 /64
7 Servicing, maintenance and cleaning
Operational reliability and performance of this machine depend upon

regular servicing and cleaning.
To ensure fault-free operation of the machine, always pay attention to and

comply with the following specifications:
proper and intended use of the machine.

thorough, regular cleaning of the machine.
timely machine servicing.
All notes and specifications included in the instructions and documents

provided with the machine must also be observed.
All work on the electrical system and pneumatics must be carried out by
specialist staff.
Secure the machine safely before all maintenance and cleaning work,
so that no-one can restart it accidentally. Always disconnect machine
from its pneumatic and electrical power sources in such instances.
When carrying out maintenance and cleaning work, always comply in
full with precautionary measures specified by trade associations and in
prevailing legislation.
All adjustments must be carried out by authorised personnel.
65
Prior to all maintenance and repair work:
De-energize machine through main switch and padlock the main switch to
prevent it from being switched back on accidentally.
Lock down all main control panels and remove keys and/or fit a warning
notice to the main switch.
Wait for condensers in the intermediate circuit to discharge fully
(approx. 1 min.) !
After switching off the mains isolator switch, check that intermediate
circuit voltage is below 50V.
7.1 Servicing and maintenance

7.1.1 Maintenance unit
The water separator must be drained regularly, otherwise malfunctions

may occur during normal operations.
To drain the water separator, you need to

unscrew and remove the screw connection
below the sight glass.
A = union
1.1.0 66
SBZ 122/23 /24 /33 /34 /35 /64
7.1.2 Lubrication
The bar machining centre's lubricating points are supplied by a central lubrication system.
The central lubrication unit's lubricating pump is located on the back of the machine base:
The reservoir must be refilled with path bed oil - order No.: 088 90 71 15 (CG 68 sliding
oil)
7.1.3 Servicing and maintenance schedule
Servicing
Item Designation Activity Comment
interval
1 Entire system to be cleaned daily Rough clean after every shift
Thorough clean
weekly
2 Internal machine area to be cleaned Several times Clean swarf out of entire
a day, as internal area of machine
required
Preferably use suction, or
remove swarf by sweeping or
wiping with a cloth
3 Profile locating face to be cleaned Several times Blow clean with compressed
a day, as air
required
4 Gear racks to be cleaned Several times Suction cleaning, sweeping or

a day, as wiping off swarf
required
5 Guide systems to be cleaned Several times Suction cleaning, sweeping or

a day, as wiping off swarf
required
lubricate weekly Lubricate with machine oil
6 Safety light barrier to be cleaned weekly, as Remove dust from optical

required system with clean, soft brush,
then wipe with clean, soft and
damp cloth. Do not use any
aggressive and/or abrasive
cleaning agents or solvents.
7 Clamping cylinder to be daily Check seal integrity; check

checked tensioning buffer for signs of
damage,
as required replace if necessary
67
Servicing
interval
8 Tools to be daily Check for signs of wear and/

checked or damage,
as required replace if necessary
Always keep tool supports

to be cleaned clean: this also involves
cleaning them before every
tool change
9 Pneumatic lines and to be cleaned as required Blow clean with compressed

connections air or use lint-free cleaning
cloths.
to be monthly Visual inspection for cracks

checked and porous areas;
check that threaded
connections are securely
seated and free of leaks
10 Pneumatic maintenance to be cleaned as required Blow clean with compressed

unit air or use lint-free cleaning
cloths.
- See the following
chapter: Maintenance to be daily Check seal integrity /
unit 66 checked leakage;
water separator: Check fill
level and drain if necessary
11 Electrical wiring and to be cleaned as required Blow clean with compressed

connections air or use lint-free cleaning
cloths.
to be monthly Visual inspection for cracks

checked and porous areas;
check that threaded
connections are securely
seated
12 Central lubrication unit to be daily Check oil level;

checked as required refill if necessary
- See the following For recommended oil, see the
chapter: Central following chapter: Central
lubrication unit 42 lubrication unit 42
13 Spray unit, tool lubrication to be daily Check fill level;

checked as required refill if necessary
- See the following
chapter: Spray unit 32
14 Spray unit, rack to be daily Check fill level;

lubrication checked as required refill if necessary
- See the following

chapter: Spray
metering unit for rack
lubrication (X axis) 36
1.1.0 68
SBZ 122/23 /24 /33 /34 /35 /64
Servicing
interval
15 Safety equipment to be before every lockable mains isolator switch

checked shift (safety feature)
EMERGENCY STOP button
Safety light barrier (PE cell)
Clamping/tensioning pressure
monitoring by pressure
monitor
16 Swarf box to be drained after every Emptying swarf box

shift,
as required
17 Control console and air- check Regularly inspect the air

cooled main electric clean intake and outlet filters and
cabinets replace clean if soiled;
replace if necessary
18 Polycarbonate protective replace every The replacement should be

hood 5 - 7 years performed by -
service technicians.
The time and servicing intervals quoted refer to single-shift operation.

These figures should be shortened in multi-shift operations.
69
7.1.4 Maintenance of machining spindles
Warranty cover on the spindle covers 2000 operating hours or a maximum of 1 year.
After 4000 hours, the spindle needs to be inspected:
- Spindle pull-in force
- Release unit operation
- Replacement of tool clamp and recalibration if necessary
- Tool clamp cleaning and lubrication
- Visual spindle inspection
- Manual testing of bearings for noise and absolutely uniform
concentricity
After 6000 hours:
- Spindle pull-in force
- Release unit operation
- Replacement of tool clamp and recalibration if necessary
- Tool clamp cleaning and lubrication
concentricity
- Visual inspection of spindle for signs of wear
After 8000 hours:
Spindle manufacturer recommendation: Send spindle in for service overhaul before wear causes
the spindle to fail
otherwise:
- Retraction force of spindle

- Function of release unit
- Possible replacement of tool clamp and recalibration
- Cleaning and greasing of tool clamp
concentricity
- Visual inspection of spindle for signs of wear
1.1.0 70
SBZ 122/23 /24 /33 /34 /35 /64
7.2 Cleaning work

The entire machine should be given a rough clean every day (after every shift) and a thorough
clean once a week with compressed air or a lint-free cloth to remove swarf and dust deposits.
Never blast swarf against gaskets, the tool holder or the spindle tip because these would get
damaged in the process.
The entire interior of the machine must be cleaned whenever it gets dirty, preferably using suction,
sweeping or wiping actions to remove swarf.
Guide rails, shafts, carriages and bushes, cylinder piston rods, shock absorbers, ball roller
spindles, axes and shafts must be dusted daily with a handheld customer or with a cloth.
Clean the machine surface frequently with a non-corrosive cleaning agent to remove deposits of
lubricant, spray oil and dust.
When installing or changing tools, clean swarf and dust residue off the tool support and
components to be installed with a lint-free cloth.
Empty the swarf containers regularly.
On control consoles and switch cabinets with air cooling the filters on the air inlets and outlets must
be inspected regularly and cleaned if soiled.
The filters pads should be replaced by new ones if heavily soiled.
Cleaning the tool support
Always keep the tool support clean and wipe with a lint-free cloth before
every tool change.
Never direct an air blast at the tool support for cleaning purposes!
The ingress of swarf can cause bearing damage!!
7.3 Machine disposal

The machine needs to be dismantled professionally and must then be disposed of in accordance
with national regulations.
When disposing of machine components, always observe the following points:
Recycle metals and plastic components
Send electrical/electronic components to hazardous waste recycling
71
7.4 After-sales service
If necessary, our After-Sales Service team is there to assist you.
Here are our contact details:
Address:
elumatec GmbH
Pinacher Straße 61
75417 Mühlacker-Lomersheim, Germany
Tel.:
Switchboard: +49 (0) 70 41 / 14-0

After-Sales Service: +49 (0) 70 41 / 14-250
Fax: +49 (0) 70 41 / 14-280
mail@elumatec.de
www.elumatec.com
1.1.0 72
SBZ 122/23 /24 /33 /34 /35 /64
8 Spare and wear parts
Spare and wear parts, mechanics
122109800 SBZ 122/23+24
Product Designation 1 Designation 2

number
006830002 Ball bearing 6203 DDU DIN 625 grease: AV2S, d17 D40 L12
011233200 Clamping lever M10, size 3 plastic black
024821201 Retaining ring 47x1,75 DIN 472
0412170155 Cylinder D32 S50 ADN-32-50-I-P-I-S2
0412170168 Cylinder D16 S300 DSNU-16-300-P-A
0412170227 Cylinder D50 S125 DSNU-50-125-P-A-MA-
SA234492AM
041217076 Cylinder D25 S250 DSNU-25-250-PPV-A
041217083 Cylinder D32 S50 DSNU-32-50-P-A-MA
055934013 Compr. spring 1,8x16,1x28
078233201 Clamping lever M8x20, size 2 plastic black
088907080 High performance cutting fluid Supra NEOC 1311, 0,5 l
088907114 Oil for bed FEBIS K68
088907115 Oil for bed 1,0l OEST sliding oil CG68
104980816 Bush 1015 DU
104980836 Bush 0810 DU
120980133 Sinter bearing D12 d 8 L 6
121111304 Workpiece support 34x30x120
121112212 Nozzle adapter D12x15
121112300 Planetary gear, I=1:10 low-backlash
121112301 Toothed wheel m=2,0 t=32 d1=40 19°31'42 left-h. helical gear
121112302 Clamp. set D40x26, hub D22x21 PSV 2061-22x40
121112315 Front protective curtain L=342
121112402 Shaft coupling 10H7-11H7 DKN 45/41
121980543 Bearing unit WBK 12-01A
121980544 Movable bearing WBK 12S-01
122111100 Linear guide cpl. L=4500 for X-axis with tooth
122111101 Linear guide cpl. L=4500 for X-axis
122111171 Guide bar D20x4500
122111172 Support rail L=4500mm
122111350 Standard counterblock 60x20x80
73
number
122112158 Top guide plate right 65x20x276

122112159 Top guide plate left 65x20x276
122112160 Guide plate right 25x20x336
122112161 Guide plate left 25x20x336
122112172 Code guiding 20x17x120 for angle head
122112208 Spring band spiral L=600 for Z-axis
122112209 Linear guide L=830 for Z-axle
122112239 Link protective L=856 17 links, aluminium
122112305 Protective shield L=457
122112308 Guide rail cpl. NK-02-40-2-620
122112311 Protective curtain right/left L=442
122112402 Linear guide L=860 for Y-axle
122112403 Swarf curtain 226x80x3
122112481 Ball screw cpl. stroke=490mm for Z-axis; L=704,5
122112482 Ball screw cpl. stroke=430mm for Y-axis
122114000 Spray nozzle L=18
122219005 Pre-ass. air conditioning Tool spindle Festo
122219007 Pre ass. air conditioning machine Festo
122219010 Pre-ass.valve ter.SBZ122/20+21 machine Festo
122219017 Pre-ass.valve ter. CAN-connec. working head Festo
122262101 Locating wascher D190x36,5
122830000 Lin. ball bearing KNO 20 B PP
122970441 O-ring seal 10x6,5
125262106 Stop washer D30 d6,6 L5
125262112 Rack round D15x120 rework on 125262180
125262117 Connecting flange 120x83x124 for angle router head HSK
125980801 Guide bush d15 D21 L16 sintered bronze
130117201 Clamping buffer dia50x30 M16
136262103 Bearing shoe 55x54x73
136262105 Toothed wheel m=1,0 t=30 d=30 PA=20°, rework on 125262110
136262106 Distance washer D30 d21 L2
140219052 Pre-assembled oil container f. high perf.cutting fluid Festo
140350801 Tool chuck clamp HSK 63 rework on 125350800
150112171 Stop bolt D5 L49 M10x1 without locknut
150112608 Spray nozzle M4 D=10 L=8 d1=5
150261001 Cleaner f. cone HSKF63 (HSK50) D54x148
150970739 Square ring seal 7,59x2,62 NBR 70, black
177830001 Ball bearing 6005 DDU DIN 625 grease: AV2S, d25 D47 L12
610216301 Lubricator element, 3-fold L33 KY2034
1.1.0 74
SBZ 122/23 /24 /33 /34 /35 /64
122109801 SBZ 122/33+34

number
011233200 Clamping lever M10, size 3 plastic black

0412170156 Cylinder D25 S10 DZF-25-10-P-A
SA234492AM
055934013 Compr. spring 1,8x16,1x28
104980816 Bush 1015 DU
104980836 Bush 0810 DU
122111171 Guide bar D20x4500
75
number

122112308 Guide rail cpl. NK-02-40-2-620
122112602 Spray pipe L=160
122219007 Pre ass. air conditioning machine Festo
122262103 Retention pin for angle router rework on 103810101
122970441 O-ring seal 10x6,5
136112605 Index bush D18x12 for turnig device for rotating WiKo
136112606 Index bolt D15x18 for tunring device for rotating WiKo
136112610 Spritznozzleassignment D6x8 for turning gear WIKO
1.1.0 76
SBZ 122/23 /24 /33 /34 /35 /64
122109802 SBZ 122/35

number
041217011 Cylinder D20 S50 ADN-20-50-I-P-A

0412170323 Cylinder D80 S900 DNCB-80-900-PPV-A
0412170324 Cylinder D50 S60 ADN-50-60-A-P-A
055934013 Compr. spring 1,8x16,1x28
088907110 Coolant concentrate 1,0l without chlorine, nitrate, zinc
088907112 Antifreezer 1,5l Protect Plus G48
104980815 Bush 1010 DU
122111171 Guide bar D20x4500
122111180 Strip brush L=2000 BH=20 d=0,1 TH=35
122111181 Strip brush L=1000 BH=20 d=0,1 TH=35
122111211 Flange element 112x44 rubber-metal
122111217 Linear guide cpl. L=1850 for protective hood
122111256 Protective shield L=4856 R=1712
122111267 Web plate 4900x818x10
122111331 Clamping element MKR 2000 A
122111361 Clamping buffer D50x30 M12x1,25
77
number
122111389 Driving pin D9,8x18

122112602 Spray pipe L=160
122219018 Pre-as.valve ter.SBZ122/eluCam clamp loosen Festo
122970441 O-ring seal 10x6,5
136350800 Quick-action chuck HSK-F63 for chucking capacity 1-10mm
136350817 Collet holder ER 32 HSK-F63 for collets 2 - 20 mm AG
170980808 Bush 1020 DU
1.1.0 78
SBZ 122/23 /24 /33 /34 /35 /64
122109803 SBZ 122/64

number
041217011 Cylinder D20 S50 ADN-20-50-I-P-A

SA234492AM
055934013 Compr. spring 1,8x16,1x28
104980815 Bush 1010 DU
104980816 Bush 1015 DU
104980836 Bush 0810 DU
1221111146 Linear guide compl. L=7830 for X-axle
1221111147 Linear guide compl. L=7828 for X-axle with toothing
1221111148 Guide bar D20x7830
1221111149 Support rail L=3300
1221111153 Support rail L=4515
122111331 Clamping element MKR 2000 A
79
number

122112308 Guide rail cpl. NK-02-40-2-620
122112602 Spray pipe L=160
122219019 Pre-ass. air conditioning SBZ122/64
122970441 O-ring seal 10x6,5
170980808 Bush 1020 DU
When ordering the machining spindle as a spare part, please include

exact information regarding the spindle. This information can be gathered
from the type plate on the milling spindle.
1.1.0 80
SBZ 122/23 /24 /33 /34 /35 /64
Spare and wear parts list, electrics/electronics

see circuit diagram
Spare and wear parts list, pneumatics

see circuit diagram
When ordering spare parts, please always indicate the machine type,
serial number and year of manufacture.
This information can be gathered from the type plate on the machine.
Address:
elumatec GmbH
Pinacher Straße 61
D 75417 Mühlacker, Germany
Tel.:
Switchboard: +49 (0) 70 41 / 14-0

After-Sales Service: +49 (0) 70 41 / 14-250
Fax: +49 (0) 70 41 / 14-280
mail@elumatec.de
www.elumatec.com
81
9 Annex
All instructions and documents provided with the machine must be observed.
9.1 Noise emission data

- see following document
9.2 Safety data sheets

9.2.1 SUPRA NEOC 1311
9.2.2 Metalon 11-108

9.2.3 OEST anti-friction oil CG 68

9.2.4 Coolant concentrate, MOTOREX FRIGOSOL

9.3 Electrical circuit diagram

See separate document
9.4 Pneumatic circuit diagram

See separate document
9.5 Plans and drawings

The following section contains all plans and drawings of the operating manual.
- see following documents
9.6 Operating manual "Cooling unit - spindle cooling" (option)

1.1.0 82
SBZ 122/23 /24 /33 /34 /35 /64
..........................................................
Follow Instructions in the 1
Index Operating Manual
A Foot..........................................................
valve 28
..........................................................
Acknowledgement of light 28
barrier ..........................................................
Foundation diagram 19
..........................................................
After-Sales Service 72 H
..........................................................
Hazards when working with the 1
..........................................................
Annex 82
machine
..........................................................
Automatic clamp displacement 40
(optional) I
..........................................................
Illumination in the Workplace 17
..........................................................
Automatic clamp recognition 40
..........................................................
Informal safety precautions 6
B ..........................................................
Intended Use 2
Base..........................................................
machine 30
L
C Limit..........................................................
switch - linear guides 46
..........................................................
Central lubrication unit 42
..........................................................
Lubrication 67
..........................................................
Changing the tool holders 54
..........................................................
Clamping system 37 M
..........................................................
Machine cleaning and waste 10
..........................................................
Clamping the tools 52 disposal
..........................................................
Clamping unit 38 ..........................................................
Machine control 7
..........................................................
Cleaning the internal taper 62 ..........................................................
Machine data 15
..........................................................
Cleaning the tool support 62 ..........................................................
Machine disposal 71
..........................................................
Cleaning work 71 ..........................................................
Machine modifications 10
..........................................................
Connecting the power supply 26 ..........................................................
Machine noise 11
..........................................................
Connection data 15 ..........................................................
Machine storage 12
..........................................................
Control panel 28 Main..........................................................
switch 27
..........................................................
Coolant concentrate, 82 ..........................................................
Maintenance of machining 70
MOTOREX FRIGOSOL spindles
..........................................................
Copyright 11 ..........................................................
Maintenance unit 31, 66
D ..........................................................
Maximum profile dimension 55
Daily..........................................................
start-up of machining 58 examples
spindle
..........................................................
Metalon 11-108 82
Daily..........................................................
start-up of system 58
..........................................................
Mobile user terminal (optional) 29
..........................................................
Delayed switch-off of sealing 61
..........................................................
MOTOREX FRIGOSOL 82
air
..........................................................
Dimensions and weights 16 N
..........................................................
Noise 17
E ..........................................................
Noise emission data 82
..........................................................
Electrical circuit diagram 82
..........................................................
Electrical hazards 7 O
..........................................................
Obligations of the operator 1
..........................................................
Electrics 26
..........................................................
OEST anti-friction oil CG 68 82
..........................................................
Electronic timer 48
..........................................................
Operating manual "Cooling unit 82
..........................................................
EMERGENCY STOP button on 27 - spindle cooling" (option)
the control panel
..........................................................
Operation 30
..........................................................
EMERGENCY-STOP button on 27
the mobile user terminal
..........................................................
Operator's Responsibilities 1
(optional) ..........................................................
Organisational measures 6
..........................................................
Explanation of Symbols and 3 ..........................................................
Overview - Clamp tool HSK 53
Warnings F63
F P
..........................................................
Faults 59 ..........................................................
Packaging 11
83
..........................................................
Performance and operating 15 ..........................................................
Tools 51, 61
data
..........................................................
Tools with tool support 63
..........................................................
Personnel obligations 1
..........................................................
Transport and storage 11
..........................................................
Plans and drawings 82
..........................................................
Transport instructions 13
..........................................................
Pneumatic circuit diagram 82
W
..........................................................
Pneumatic components 41 ..........................................................
Warranty and liability 2
..........................................................
Pneumatic hazards 7
..........................................................
Pneumatics 26
..........................................................
Points posing a particular 8
hazard
..........................................................
Protection against contact with 9
energized parts
..........................................................
Protective equipment 6
S
..........................................................
Safety data sheet, Metalon 82
11-108
..........................................................
Safety data sheet, MOTOREX 82
FRIGOSOL
..........................................................
Safety data sheet, OEST 82
anti-friction oil CG 68
..........................................................
Safety data sheet, SUPRA 82
NEOC 1311
..........................................................
Safety light barrier (PE cell) 29
..........................................................
Safety precautions during 7
normal operation
..........................................................
Scope of supply 12
..........................................................
Servicing and maintenance 67
schedule
..........................................................
Servicing and maintenance, 10
troubleshooting
..........................................................
Servicing, maintenance and 65
cleaning
..........................................................
Setting up the machine 25
..........................................................
Setup location, place of use 18
..........................................................
Setup, assembly and 18
commissioning
..........................................................
Spare and wear parts 73
..........................................................
Spindle cooling (optional) 49
Spray..........................................................
metering for rack 36
lubrication (X axis)
..........................................................
Spray unit 32
Staff..........................................................
training 6
..........................................................
SUPRA NEOC 1311 82
T
..........................................................
Temperatures 17, 60
Tool..........................................................
changer SBZ 122/23 + 24 50
Tool..........................................................
changer SBZ122/33 + 34 50
+ 35 + 64
1.1.0 84
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: 08.12.2009 Replaces the version of: 29.07.2009 PDF date: 08.12.2009
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: info@chemical-check.de, k.schnurbusch@chemical-check.de
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: 1.
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
088907098 / 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
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
5/5
Metalon 11-108
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
Revised points: 1.
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
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)


n.av.

Colour: Light brown
Odour: Characteristic
Setting point
Autoflammability: No

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.
Mutagenicity: 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.

Revised points: 1.
Legend:
No responsibility.
CHEMICAL / +49 180 52 43 642, Fax: +49 5233 94 17 90, +49 180 50 50 455
1/5
MOTOREX FRIGOSOL
Safety data sheet

COMPANY/UNDERTAKING
MOTOREX FRIGOSOL
Art. no.:
088907110 / 1,0 L

Cooling lubricant
Telephone +49 (0) 7041 / 14 - 0, Fax +49 (0) 7041 / 14 - 280
www.elumatec.de
Emergency telephone
Swiss Toxicological Information Centre (STIC)
Tel. --

To people
Not applicable
To the environment
See point 12.
Not applicable
Gen. description:
Corrosion inhibitor
Chemical name
--
--- ---
4.1 Inhalation
4.2 Eye contact
2/5
MOTOREX FRIGOSOL

4.3 Skin contact
consult doctor.
4.4 Ingestion
Do not induce vomiting. Consult doctor immediately.
Keep Data Sheet available.
n.c.

Product is not combustible.
None known
Oxides of carbon
Oxides of nitrogen
Oxides of sulphur
Full protection, if necessary

Attempt to stop the escape of the product.
Collect using absorbant material (e.g. Universal binding medium, sand, kieselguhr) and dispose of according to point 13.
Or:
Collect mechanically and dispose of according to point 13.
7.1 Handling
See point 6.1
7.2. Storage
containers:
3/5
MOTOREX FRIGOSOL

See point 10
Protect from direct sunlight and warming.
---

Respiratory protection: --
Hand protection: Skin protection preparation for unlimited application to the skin.


n.av.

Colour: Fluorescent, Yellow
Odour: Slightly
pH-value undiluted: 8,4 - 8,6
Ignition temperature: n.a.
Minimum limit of explosion: n.a.

Maximum limit of explosion: n.a.
Vapour pressure: Not detected
Water solubility: Mixable

4/5
MOTOREX FRIGOSOL
Conditions to avoid
See point 7
Decomposition:
Materials to avoid
See point 7
No dangerous reactions are known.
See point 5.3

Ingestion, LD50 rat oral (mg/kg): > 2000
Skin contact, LD50 rat dermal (mg/kg): n.av.
Eye contact: n.av.

Sensitization: n.c.
Mutagenicity: n.c.
Narcosis: n.c.
Further information
No classification according to calculation procedure.

Persistence and degradability: > 75% OECD 302 B
Aquatic toxicity: n.av.

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 09 machining emulsions and solutions free of halogens
Recommendation:
Empty container completely.
See point 13.1

5/5
MOTOREX FRIGOSOL
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.

Revised points: 1.
Legend:
No responsibility.
CHEMICAL / +49 180 52 43 642, Fax: +49 5233 94 17 90, +49 180 50 50 455
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
L L
Seitenansicht
side view
Vue latérale
Vorderansicht
K K
front view
vue de face
Tür
door
Porte
J J
2231
2170
2170
I I
1278
H
Option Werkzeugwechsler: H
1x Winkelkopf / 5x Werkzeuge Technische Daten:

8x Werkzeuge
Anschlußleistung / Connected load / Puissance raccordée: 11KW
Option Tool changer: max. Vorsicherung / max.fuse / Fusibles préal max.: 16A
Druckluft / Compressed air / Air comprié: 7 bar
G
1x Angle head / 5x Tools G
8x Tools Unverbindliche Zeichnung zur Vorabinformation.

Non-binding drawing as advance information.
Option Changeur d`outils: Dessin sans engagement pour information préalable.
Draufsicht
top view 1x Tetè a renvoi d`angle / 5x Outils
F
Vue de dessus 8x Outils F
optional: Schutzzaun hinten
Tür Wand / Wall / Mur

door
Porte
E Standard E
300
optional: Schutzzaun hinten

1826
D D
max. Bearbeitung max. Bearbeitung

von oben Lage 1 3630 3250 von oben Lage 2
C C
Lichtschranke Lichtschranke
Light barrier Light barrier Zugangstür
ermittelte Werte für max. Bearbeitungen Barrièr photo-électrique Barrièr photo-électrique

898 600 898
- Lage 1 -> 3-Seiten 3630 mm
- Lage 1 -> 5-Seiten 3360 mm 2772 2396 2767
B B

Ursprung: gez. Grau 26.01.2009
gesamte Länge -> 3-Seiten 7250 mm Ersetzt durch: gepr.

Freie Maße: Nm.
gesamte Länge -> 5-Seiten 7000 mm ISO 2768 m ges. Änd.-Nr Datum Ind. Feld Art der Änderung Name
Maßstab: Werkstoff: Oberfläche: Rohteil.Nr.
1:20 Masse: 75625.04 kg
Zeichnungs Nr.
A R
Benennung: A
Maschinenfabrik Maschinenbett - SBZ 122 Bearbeitung - 6780mm
75417 Mühlacker-Lomersheim Blatt 1 von 4 A0
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
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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Instructions

SBZ 122/23 /24 /33 /34 /35 /64

Phone +49(0)7041 14-0

No modifications are permitted to electrical and pneumatic systems.

Informal safety precautions

Safety precautions during normal operation

Hazards posed by electrical power

Clean the machine regularly

1.2 Obligations of the operator

1.3 Personnel obligations

1.4 Operator's responsibilities

1.5 Hazards when working with the machine

The machine is only

1.7 Warranty and liability

Indicates a hazard with a high degree of risk.

If the hazard is not properly avoided, death or severe injuries

Indicates a hazard with medium degree of risk.

If the hazard cannot be properly avoided, death or severe injuries will

Indicates a hazard with low degree of risk.

If the hazard cannot be properly avoided, minor to moderate injuries will

This section gives you important warnings regarding how to prevent

Clamp position 2 (only in 2-position machines)

Clamp clamping position 1 (only when running with automatic

Clamp clamping position 2 (only when running with automatic

Position 1 light barrier acknowledgment

Position 2 light barrier acknowledgment (only in 2-position

Protective gloves must be selected in accordance with EN 388.

2.3 Protective equipment

2.4 Informal safety precautions

2.5 Staff training

2.6 Machine control

2.7 Safety precautions during normal operation

2.8 Electrical hazards

2.9 Pneumatic hazards

The machine has an operating pressure of 7 bar.

During any work on the bar machining centre, it is essential to wear

It is essential to wear protective goggles when working on the bar

Always wear protective gloves when changing tools.

Mechanical crushing hazard:

The clamping cylinder is operated pneumatically whenever the foot switch

Danger of flying parts

Make sure that the material clamping mechanism (clamping cylinder) is

Hazard posed by heating

2.11 Personal protection measures

Prior to all maintenance and repair work:

2.12 Servicing and maintenance, troubleshooting

2.13 Machine modifications

2.14 Machine cleaning and waste disposal

2.15 Machine noise

3 Transport and storage

SBZ 122/23 approx. 2200 kg

SBZ 122/24 approx. 2200 kg

SBZ 122/33 approx. 2200 kg

SBZ 122/34 approx. 2200 kg

SBZ 122/35 approx. 2450 kg

SBZ 122/64 approx. 2750 kg

3.3 Scope of supply

3.4 Transport instructions

Type: SBZ 122

Serial number: see type plate

The type plate is located at the back of the machine base

4.2 Connection data

Compressed air: > 7 bar