BETRIEBS-

ANLEITUNG
Operating Instructions · Manuel d’opération

Option for the Machine

Counterpressure attachment

INDEX G200
INDEX G300
INDEX ABC

Control INDEX C 200 - 4

LL13 02.1 046 1 - 02.99

0299/KR
Note on applicability
Some illustrations in this publication may deviate slightly from the product supplied, but this will not detract
from their instructional value.
The right of alteration by reason of technical progress is reserved by INDEX.

A word on copyright
This publication is protected by the law of copyright. The rights thereby established, particularly those of
translation, reprinting, extraction of illustrations, reproduction by photo-mechanical or similar means, and
storage in data processing installations, are strictly reserved, even for use as extracts.
Photo-copies for personal and other use of one’s own may only be made of individual sections or parts thereof
as single copies.

© Copyright by INDEX-Werke GmbH & Co. KG Esslingen 1999

Contents

General ............................................................................................................................................................... 4
General description ............................................................................................................................................ 4
Workpiece chucking with counterpressure ................................................................................................. 4
Workpiece chucking without counterpressure ............................................................................................ 5
Important machine functions (MAFU) ............................................................................................................... 5
M-Functions used ............................................................................................................................................... 6
Important description of errors ......................................................................................................................... 6

Setting the Chucking Pressure ...................................................................................................................... 7

Operating elements for pressure setting ......................................................................................................... 7
INDEX G200, G300 ....................................................................................................................................... 7
INDEX ABC .................................................................................................................................................... 8
Setting the chucking pressure and the chucking counterpressure ................................................................ 9

Counterpressure attachment - INDEX G200, G300 und ABC; Control C200-4

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General

General description

Workpiece chucking with counterpressure

(M1=228 or MAFU 01/02 respectively)

Normal chucking cylinders do not function with a chucking pressure under 10 bar.
Therefore the chucking force, mainly for thin-walled workpieces, is still too high in
many cases.

With the counterpressure attachment, at two separate pressure regulating valves

,two different pressures are set which are effective on both sides of the piston
simultaneously.

The difference between both pressures results in the chucking force for the material
chucking system.

Example: Chucking pressure (high pressure)...............35 bar

Counterpressure (low pressure) ..................28 bar
Pressure difference.........................................7 bar

The following restrictions apply:

• The high pressure may be set between 20 and 40 bar only.
• The pressure difference must be at least 5 bar.
• The attachment is allowed only for chucking with a collet or an
expanding mandel, and a chucking stroke of 0,2 mm.

The counterpressure attachment can,

- be fitted to the main- and/or the counterspindle
- be applied for external- and internal chucking (expanding mandrel), while the above
mentioned restrictions apply.
- be operated as a single pressure-chucking attachment (refer to: ”Workpiece chucking
without counterpressure”).

Attention!
For safety reasons, the non-return valves fitted to the chucking
cylinder are without function when the counterpressure attachment
is used, i.e. at drop of the chucking pressure the workpiece may be
thrown out of the chucking means. For this reason chucking means
with a chucking stroke over 0,2 mm must not be used.
The use of power chucks in conjunction with the counterpressure
attachment is forbidden for this reason.

The hydraulic system must not switch off automatically when the
counterpressure attachment is used.
For this reason must be the MAFU 13/05 =1 (refer to description of
errors 81051 too).

Counterpressure attachment - INDEX G200, G300 und ABC; Control C200-4

– 4 –
General

Workpiece chucking without counterpressure

(M1=128)

This function correspons to the single-pressure chucking system, i.e. in this case all
types of chucking means, collets and power chucks as well, may be used.

The max. chucking pressure of 80 bar may be set.

The same pressure setting at both pressure regulating valves is

recommended.

Important machine functions (MAFU)

The following machine functions are required for the operation of the counterpressure
attachment. For the selection and operation of MAFUs refer to the brochure: ”Setting
up and operation INDEX C200-4).

• MAFU 01/01 Chucking cylinder 1 –> main spindle

• MAFU 03/01 Chucking cylinder 3 –> counterspindle1)
0 = clamped at rear (draw type chucking)
1 = clamped at front (thrust type chucking)

• MAFU 01/02 Multiple chucking pressure –> main spindle

• MAFU 03/02 Multiple chucking pressure –> counterspindle1)
0 = function chucking counterpressure contollable by Mx=y28
1 = function chucking counter pressure is continuously selected

• MAFU 01/03 Chucking travel monitoring –> main spindle

• MAFU 03/03 Chucking travel monitoring –> counterspindle1)
0 = disabled
1 = enabled

• MAFU 01/04 Start at open chucking system –> main spindle

• MAFU 03/04 Start at open chucking system –> counterspindle1)
0 = disabled
1 = enabled

• MAFU 13/05 Automatic auxiliary drive OFF

0 = enabled
1 = disabled

1) not applicable for INDEX ABC

Counterpressure attachment - INDEX G200, G300 und ABC; Control C200-4

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General

M-Functions used
The following functions are required for the operation of the counterpressure chucking
attachment.

Mx = 68 chucking cylinder on
Mx = 69 chucking cylinder off
Mx = 25 checking the clamping means (refer to error No. 81311/81301)
Mx = 128 without counterpressure
Mx = 228 with counterpressure

1 = main spindle
3 = counterspindle1)

Important description of errors

The following description of errors contains additional information for the operation of
the counterpressure chucking attachment.

Error No. 81345

81346
81347
81348
81311
81301
81051

1) not applicable for INDEX ABC

Counterpressure attachment - INDEX G200, G300 und ABC; Control C200-4

– 6 –
Setting the Chucking Pressure

Operating elements for pressure setting

INDEX G200, G300

Main spindle

L1301.10461_2

1 pressure gauge (for S20.0)

2 pressure regulating valve S20.0
3 pressure gauge (for S8.4)
4 pressure regulating valve S8.4

Counterspindle

L1301.10461_3

1 pressure gauge (for S20.1)

1 pressure gauge (for S12.4)
2 pressure regulating valve S20.1
4 pressure regulating valve S12.4

Counterpressure attachment - INDEX G200, G300 und ABC; Control C200-4

– 7 –
Setting the Chucking Pressure

INDEX ABC

Main spindle

L1301.10461_5

1 pressure gauge (for S20.0)

2 pressure regulating valve S20.0
3 pressure gauge (for S8.4)
4 pressure regulating valve S8.4

L1301.10461_4

Counterpressure attachment - INDEX G200, G300 und ABC; Control C200-4

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Setting the Chucking Pressure

Setting the chucking pressure and the chucking

counterpressure
By reversing the chucking direction from ”clamped in back position” to ”clamped
when piston at the front” the function of the pressure regulating valves is reversed
as well.

In the following sketches is shown at which pressure regulating valve the respective
pressure is set.

,yy,y,y,y,y,y,y,
Main spindle
1. Case: Clamped when piston is at the back - e.g. Draw type chucking system

Chucking cylinder y,y,y,y, Chucking tube

Counterpressure Chucking pressure

pressure regulating valve (4) S8.4 pressure regulating valve (2) S20.0
pressure gauge (3) pressure gauge (1)

yy
, ,y,y,
2. Case: Clamped when piston is at the front - e.g. Thrust type chucking system

Chucking cylinder
,
y
,y
y ,
y
,y,
y
,y,
y
, Chucking tube

Chucking pressure Counterpressure

pressure regulating valve (4) S8.4 pressure regulating valve (2) S20.0
pressure gauge (3) pressure gauge (3)
L1301.10461_1

Counterpressure attachment - INDEX G200, G300 und ABC; Control C200-4

– 9 –
Setting the Chucking Pressure

Counterspindle1)

yyyy
,,,,
1. Case: Clamped when piston is at the back - e.g. Draw type chucking system

,,,,
yyyy
Chucking tube
,,,,
yyyy Chucking cylinder

Chucking pressure Counterpressure

pressure regulating valve (7) S20.1 pressure regulating valve (8) S12.4
pressure gauge (5) pressure gauge (6)

yyyy
,,,,
2. Case: Clamped when piston is at the front - e.g. Thrust type chucking system

,,,,
yyyy
,,,,
yyyy
Chucking tube Chucking cylinder

Counterpressure Chucking pressure

pressure regulating valve (7) S20.1 pressure regulating valve (8) S12.4
pressure gauge (5) pressure gauge (6)

L1301.10461_1
Chucking pressure -> 20 - 40 bar
Pressure difference -> minimum 5 bar

1) not applicable for INDEX ABC

Counterpressure attachment - INDEX G200, G300 und ABC; Control C200-4

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INDEX-Werke GmbH & Co. KG
Hahn & Tessky
Postfach 10 03 54
D-73726 Esslingen
Telefax (0711) 3191 - 587
 Verteiler für technische Dokumentation • Abt. TED

Titel: Gegenspanndruckeinrichtung Lit. Nr.: LL1302.1046 1 Ausgabe: 02.99

Maschine: G200 ,G300, ABC Steuerung: C200-4 Sprache: ENGLISCH

Datum: 22.02.99 Name: Krause ACROBAT PDF vorhanden? ja

Anmerkung: Der fertig ausgefüllte Verteiler ist die letzte Seite der elektronischen Datei und liegt auch den Druckvorlagen bei.

Anzahl Anzahl
KB 1/H.Großmann D-VTE/H. Ragab
KB 2/H.Faas D-VTM1/H.Beck MS…
KB 3/H.Trautmann D-TKD3/ H.Haidorfer/H.Huber MS…
KB 4/H.Hafla D-MON1/H.Schmid/H.Scheer MS…
TKD/H. Aigner D-MON/Mstr.Stürzl (Einrichterei) L3, L4
TKD4/H. Maier D-MON/Mstr.Traub (mech.) L3
VTK/H.Bader D-MON/Mstr.Schein/H. Frick (elektr.) L3
D-MON/Mstr.Reimer (elektr.) L4

D-MON/Mstr. Rachel (mech.) L4

MON/Mstr.Veit (Einrichterei) T6, T7, L6

MON/Mstr.Breymayer (mech.) T6, T7
Ausland
MON/Mstr.Henzler T6, T7, L6
VKA1/H.Stähle
6 (2x I.C., 2x Synergon, 2x Kingsbury) D-AVM/H.Specht (L3, L4)
AVM/H.Lehnig (L6, T6, T7)
VKA2/H.Jung
VFZ/H. Reutter
VID1/H.Spanbalch
(1x Springmann, 1x Liges) AVT/H.Kröner (L3, L4)

VID1/H.Götzenberger
(2x INDEX-France)

VID1/H.Götzenberger
(1x Prodeco, 1x H.Marks)

Summe der zusätzlich

6
zu druckenden Exemplare

Bemerkungen bzw. Änderungen zum Vorgänger

Änderung Seite 9 und 10 - Druckregelventile !!

Counterpressure attachment - INDEX G200, G300 und ABC; Control C200-4

Technische Dokumentation / Allg. Ablage / Formulare / Verteiler f. techn.Dok. / Ausgabe 25.11.98

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