Sicherheitsvorschriften 01-2007-EN

Safety regulations
Safety regulations....................................................................................................................................................1
Observe the safety regulations. ...........................................................................................................................2
Your personal safety is important............................................................................................................................2
Use only according to manufacturer’s instructions..............................................................................................3
Ambient conditions for the operation of CHIRON precision machines................................................................3
Machine safety equipment...................................................................................................................................4
EMERGENCY STOP BUTTON ...........................................................................................................................4
Transport and installation. ...................................................................................................................................6
At the workplace ..................................................................................................................................................7
Tools ....................................................................................................................................................................7
Control of clamping devices ....................................................................................................................................8
Cleaning and maintenance ..................................................................................................................................9
Risk of explosion .....................................................................................................................................................9
Entering the machine ...........................................................................................................................................9
Cooling lubricants ..............................................................................................................................................10
Risk of explosion ...................................................................................................................................................10
Cutting oil ...........................................................................................................................................................10
Machines with oil machining without automatic fire extinguishing system ........................................................11
Electric system...................................................................................................................................................12
Danger to life from electrocution! ..........................................................................................................................12
Pneumatic system..............................................................................................................................................12
Hydraulic system................................................................................................................................................12
In an emergency ................................................................................................................................................13
Noise emission...................................................................................................................................................13
Mobile telephone................................................................................................................................................13
Accessories........................................................................................................................................................13
Welding ..............................................................................................................................................................13
Environmental protection ...................................................................................................................................13
Linear drives ......................................................................................................................................................14
Free the stuck body parts:..............................................................................................................................18
Disposal - linear drives ......................................................................................................................................19
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Sicherheitsvorschriften 01-2007_EN.doc
DOKU/Rl/HOL/PUC
This CHIRON - machine is designed according to the latest technology
and, when used according to safety regulations, is safe to operate.
The relevant rules for accident prevention, as well as other established
safety regulations, must be observed.
Observe the safety regulations.

Your personal safety is important.
Every person responsible for installing, operating, maintaining, repairing

and inspecting the machine must have read and understood the following
safety regulations.
The machine may only be operated by trained and authorized personnel.
The responsibilities for operating, servicing and maintaining the machine

must be clearly defined and adhered to.
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DOKU/Rl/HOL/PUC
Use only according to manufacturer’s instructions.
The machine can be used for
milling, drilling, tapping, centring, reaming and boring of metallic materials.
Details with regard to the allowed tools can be found in the “Work area”
drawing.
The machine is not designed for machining combustible material.
If the machine is not used according to its intended purpose or not used
properly, this may lead to
a life-threatening situation,
damage to the machine,
further material damage
Ambient conditions for the operation of CHIRON precision

machines
CHIRON machines are designed for machining at ambient temperatures

between 10°C and 40°C and for altitudes under 1000 m above sea level.
Ambient temperatures under 10°C and over 40°C can lead to malfunctions
in individual components.
At altitudes higher than 1000 m above sea level, the performance of elec-
trically driven components falls considerably.
CHIRON provides solutions for problems under such conditions.
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DOKU/Rl/HOL/PUC
Machine safety equipment
EMERGENCY STOP BUTTON

On every control panel there is a red emergency stop button with which
the machine can be instantly stopped.
The emergency stop buttons must be freely accessible at all times.
Note: the main switch of the machine has no emergency stop function .
Protective doors
The protective doors are those which allow access to the machine's work
area and to the tool magazine.
Attention: beware of automatic closing of the protective doors!
Make sure that no other person is within the operating area of the doors
or inside the machine.
Protective door monitoring
The protective doors are monitored. If one of the doors is opened, the
machine cannot be started.
Protective door - Interlock
During machining, the protective doors can not be opened.
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DOKU/Rl/HOL/PUC
Door bypass button
When the machine is being set-up, the door bypass button allows limited
operation with the protective doors open.
The operator must make sure that no one can enter the danger zone or
be hit by parts hurled from the machine (set up block or protective wall).
Two-handed start
Available as option.
In order to close the doors and the clamping device, the buttons must be
pressed with both hands.
Serious injuries or death
are possible if you remove or deactivate the safety equipment.
The machine may only be operated with the safety equipment intact.
The operator is obliged to report anything which could impair safety.
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DOKU/Rl/HOL/PUC
Transport and installation.
Wear protective clothing (helmet, gloves, protective footwear).
The machine can crush you!
Use only means of transportation (fork lift, crane, ropes) of sufficient po-
wer and size.
Do not step under the machine when it is being moved.
Maintain a safe distance from the machine.
Do not lift the machine higher than necessary.
Never reach under the machine with your hand.
Observe the floor loading capacity.
The floor must be capable of sustaining the machine load. A stress ana-
lyst should be appointed to do the calculations.
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DOKU/Rl/HOL/PUC
At the workplace
There is a danger of slipping if oil or coolant spills on the floor. You can
be seriously injured if you slip while holding heavy parts or sharp tools.
Keep the workplace clean and well lit.
Tools
Be careful when using sharp tools! Risk of injury
Always wear protective gloves.
Never touch a moving tool.
baggy clothing,
long hair,
necklaces,
rings,
wristwatches
ties
can all get caught in the spindle or tool.
Beware of protruding tools, risk of injury!
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DOKU/Rl/HOL/PUC
Control of clamping devices
1. Clamping devices with clamping movements dangerous to
persons.
a) With these devices, the clamping/unclamping movements may only
be executed with the protective doors closed.
Clamping/unclamping function triggered with the manual control
button CLAMP / UNCLAMP or by the M10/M11 function of the con-
trol.
b) The following movement sequence is defined for devices with dan-

gerous movement sequences, but which require the clamping process to
be monitored:
The clamping function can be triggered with the two-hand switch

with the operating door open.
The clamping/unclamping function can be triggered with the manual
control button, but only with the protective doors closed.
2. Clamping devices which do NOT have dangerous clamping

movements.
The clamping device is operated via foot switches in this case, which are
electrically connected with the machine via movable cable connections
and a plug connection.
(With W and S machines, one, with L machines, two foot switches)
Initiating the clamp/unclamp function with the foot switch.
The clamping/unclamping function can be triggered with the manual
control button, but only with the protective doors closed.
CAUTION
The clamping/unclamping movement may not be greater than
5 mm.
Important note:
If it is necessary to exchange the clamping devices, it must be made
absolutely sure that the corresponding clamping trigger is selected
for this.
In other words:
If the foot switch is used, since the clamping device is not
dangerous, but afterward a clamping device is set up which is dan-
gerous, it must be made sure that the foot switch is unplugged and
is put away for safekeeping by the person responsible.
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DOKU/Rl/HOL/PUC
Cleaning and maintenance
Regular cleaning and maintenance maintain the operating safety of the
machine.
Switch off the main switch of the machine before starting cleaning or
maintenance work.
Secure main switch against unauthorized switching on (padlock).
Parts of the electric system remain live even when the main switch has
been switched off.
Risk of explosion
An explosive mixture can be formed when oil mist and air combine! The-
refore, do not blow off the machine with compressed air or oxygen.
Avoid naked flames (smoking).
Cleaning agents, which attack plastics, rubber or paint, must not be used.
They may damage hoses (hydraulic, pneumatic), cables and seals.
Cleaning agents may contain substances hazardous to your health.

Observe the manufacturer's instructions.
Entering the machine

Do not walk on the telescopic covering!
Within the machine there is a danger of slipping from coolant and oil.
Surfaces which can be stepped on should be made safe (e.g. with rub-
ber mats)
Beware of protruding tools, risk of injury!
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DOKU/Rl/HOL/PUC
Cooling lubricants
Cooling lubricants, which attack plastics, rubber or paint, must not be
used. These may damage hoses (hydraulic, pneumatic), cables and
seals.
Cooling lubricants may contain harmful substances.
Cooling lubricants pose an environmental hazard; make sure they are

disposed of properly.
Observe the manufacturer's instructions.
Cooling lubricants containing more than 15% oil may only be used
when the machine is completely encapsulated and is equipped with
an effective exhaust fan.
Risk of explosion
exists where cooling lubricants with more than 15 % oil content are used.
An explosive mixture can be formed when oil mist and air combine! For
this reason, do not blow off the machine and device with compressed air
or oxygen.
Avoid naked flames (smoking).
Take preventive measures so that fires can be fought quickly.
Cutting oil
Please observe the section ‘Cutting oil’ in the maintenance instructions.
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DOKU/Rl/HOL/PUC
Machines with oil machining without automatic fire
extinguishing system
1. Machines which are operated with a coolant mixture containing more
than 15% oil are flammable/explosive.
If these machines are operated WITHOUT an automatic fire extinguishing
system, the customer is responsible for providing the following:
1.1 Suitable extinguishing agent and suitable extinguishing equipment.
1.2 Presence of trained personnel in the event of a fire.
1.3 Set-up of fire alarm system.
2. Procedure for the event that a fire or explosion should occur in the
machine.
2.1 Trigger alarm
2.2 Press the EMERGENCY STOP button.

(The protective doors are automatically unlocked when the axes and
spindle are stopped.)
2.3 Only open the protective doors so far so that the fire can be extin-
guished with the hand-held fire extinguisher.
2.4 Switch off main switch.
2.5 Initiate extinguishing process.

3. Note:
If the main switch is switched off first when a fire or explosion occurs, and
not the EMERGENCY STOP button pushed, then the protective doors
won't be automatically unlocked.
The doors can then be unlocked via the door bypass button.
Attention! - Danger of injury

The decelerating main spindle poses a potential danger of injury here!
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DOKU/Rl/HOL/PUC
Electric system
Danger to life from electrocution!
All work on the electric system, such as connection to the mains, mainte-
nance and repair, may only be carried out by qualified electricians.
Parts of the electric system remain live even when the main switch
has been switched off.
Pneumatic system
All work on the pneumatic system, such as set-up, maintenance and
repair work, may only be carried out by qualified experts.
Before work is carried out on the pneumatic system and on pneumatically

actuated components, switch the system off and depressurise it.
Hydraulic system
All work on the hydraulic system, such as set-up, maintenance and repair
work, may only be carried out by qualified experts.
Lines, devices and cylinders have to be checked for tightness regularly,

especially after commissioning and after the machine hasn't been in op-
eration for a long period of time.
Oil spills on the floor can cause accidents (danger of slipping).
Before work is carried out on the hydraulic system and on hydraulically

actuated components, switch the system off and depressurise it.
No manipulations may be made on the hydraulic accumulator and safety

valves
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DOKU/Rl/HOL/PUC
In an emergency
Press emergency stop button.
Render first aid, call for help or doctor if necessary.
In case of fire
Switch off current supply (fuse).

Alarm fire brigade.
Use only CO2 (carbon dioxide) to extinguish flame.
Noise emission
The equivalent continuous A-weighted sound level of this machine is < 80
dB(A).
Mobile telephone
Caution: Mobile telephones should not be used near the machine. It can't
be ruled out that they have an interfering effect on the CNC control.
Accessories
Accessories for the machine and other modifications must be approved
by CHIRON. Modifications which influence the machine's operational
safety must not be made.
Welding
Electrical components can be damaged if electric welding is carried out
on the machine or to parts connected to it, even where the machine is
switched off. Chiron accepts no liability for damage so caused.
Environmental protection
For the sake of the environment: make sure that used operating materials
are disposed of properly.
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DOKU/Rl/HOL/PUC
Linear drives
Safety instructions
The extremely strong static magnetic fields, which are generated by the
permanent magnets in the 1FN1 secondary parts, as well as the associ-
ated high ferromagnetic attractive forces, may pose a direct health risk
(e.g. for persons having cardiac pacemakers) or even an indirect health
risk (e.g. due to fast motor movements and high thrusts).
According to current medical knowledge, magnetic fields weaker than 5

mT have no influence on the human body. At a distance of only approxi-
mately 100 mm, the flux density of the 1FN1 secondary part is less than
5 mT (at 150 mm, approx. 0.5 mT). Since the field strength for synchro-
nous motors results exclusively from the magnetic fields of the secon-
dary parts, this value is independent of the operating condition of the
motor.
Special care, then, should only be taken in the direct close-up area of the
secondary part (within 100 mm of it).
Warning!
The warnings and safety instructions given in this chapter must be
followed. By doing so, you prevent accidents from happening and
damage from being done to material due to improper handling.
Attention!
The linear drives of this machine are equipped with strong magnets -
STRONG MAGNETIC FIELDS + HIGH MAGNETIC ATTRACTIVE
FORCES!
• Keep clocks/watches and magnetised data carriers (e.g. credit
cards, diskettes, etc.) away from the linear drives.
• Wear working gloves during installation and maintenance work.
• Work should not be done by persons who have cardiac pa-
cemakers.
• Do not put heavy metal objects near the secondary part.
• Installation, commissioning, operation and maintenance work
should only be carried out by trained personnel.
For emergencies, keep at least two wedges made of solid, non-
magnetic material - e.g. V2A - (wedge angle approx. 10° - 15°)
readily available, as well as a hammer (approx. 3 kg), for sepa-
rating magnetic parts which are "stuck" on the synchronous sec-
ondary parts.
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DOKU/Rl/HOL/PUC
Storage and transportation regulations
• Label the storage places ("Caution: Strong magnets").
• Never store them unpacked, but use non-magnetic packaging
material with a thickness of at least 2 cm.
• Observe the warnings on the packaging.
• Keep storage place dry.
• Protect from heat.
• When transporting machines or machine parts with the primary
and secondary parts already installed, secure these from trav-
ersing unintentionally (due to there being no auto-inhibition).
Installation regulations
• Only remove the wooden packaging of the secondary part right
before installation.
• Only carry out installation work with a partner, never alone.
• Never place metal onto magnetic surfaces.
• Never place the primary part directly onto the secondary part.
• Hold on tight to steel tools and approach the secondary part
slowly from the side.
• When doing installation work on machines with the secondary
parts already installed, cover the secondary parts with at least 2
cm of non-magnetic material (e.g. wood).
• Prevent the not-yet-fixed primary or secondary part from moving
in the traversing direction unintentionally (as a result of magnetic
forces).
• Prevent the primary or secondary part already mounted on the
linear guides, from moving in the traversing direction uninten-
tionally (as a result of magnetic forces).
• If necessary, use specially made auxiliary installation equipment.
Commissioning regulations
• Never fiddle around in the traversing range when the machine is
turned on.
• Make sure that the axis travel is free.
• Check the commutation before switching on.
• Limit motor currents.
• Set the speed limit to a small value.
• Monitor end positions.
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Operation regulations
• Keep the motor area free of chips.
• Pay attention to noise development.
• If there are precision problems on the workpiece, check the tra-
vel to make sure there is sufficient clearance and the current
consumption of the machine.
• Make sure the linear motor cooling system is functioning prop-
erly.
Maintenance and repair regulations

• Before working in the traversing range, always switch off the
machine (switch so that there is definitely no voltage).
• Check the axis travel regularly to make sure axis travel has suffi-
cient clearance.
• Check the current consumption in the defined test cycle.
• Clean the motor area regularly of chips.
• When carrying out dismantling work, observe the items under
"Installation regulations".
• Regularly check the condition of the primary and secondary part
surfaces on the side with the air gap.
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Emergency set, linear drives
The linear drive emergency set is located in the control cabinet area.
What to do in case of an emergency
• If the machine is connected to the power mains, immediately
• Press the EMERGENCY STOP button.
CAUTION
The danger which is posed by the secondary parts (permanent
magnets) results from the tremendous magnetic attractive forces of
the permanent magnets.
Hereby, it is to be observed that an EMERGENCY STOP does not
lead to the termination of the magnetic forces.
• Immediately call for first aid.
If, during installation/dismantling work, body parts (hand, fingers,
foot, toes) should get stuck between two synchronous secondary
parts or a synchronous secondary part and a ferromagnetic part
(e.g. steel plate, steel support, machine bed, etc.) as a result of
high magnetic attractive forces!
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Free the stuck body parts:
• Drive the wedges (made of solid, non-magnetic material, wedge
angle approx. 10 – 15°) into the separation gap with the help of a
hammer (approx. 3 kg) in order to separate the parts which are
sticking together.
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Disposal - linear drives
• Disposal information
Danger of death, serious bodily injury and/or material damage exists if a
direct drive or its components (especially components with permanent
magnets) are not properly disposed of.
Direct drives and their components are to be disposed of properly!
Integral parts of proper disposal
Especially to be done for the proper disposal of direct drives or their components:
• The complete demagnetisation of the components with permanent

magnets
• Recycling of components (if possible)
• Proper disposal of electric scrap
Demagnetisation of the secondary parts

Disposal companies which specialize in demagnetisation use special
disposal ovens. The inner parts of the disposal oven are made of non-
magnetic material.
The secondary parts are put in a solid, heat-resistant container (e.g.
cage) made of non-magnetic material in the oven, and are left in there
during the entire demagnetisation process. The temperature in the oven
must be at least 300°C over a period of at least 30 min.
Escaping gas emissions must be absorbed and neutralized without
harming the environment.
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Disposal of electronic components
Electronic components (primary parts, drive systems, wires, etc.) are to be dis-
posed of properly as electronic scrap.
Disposal of the packaging
The packaging and packing material used by us do not contain any problematic
substances. They are all recyclable with the exception of wood materials, and
should be fundamentally disposed of in the recycling bin. Wood materials
should be disposed of for waste incineration for thermal dissipation.
Only recyclable plastics are used in the packing materials:
• Code 02 PE-HD (polyethylene)
• Code 04 PE-LD (polyethylene)
• Code 05 PP (polypropylene)
• Code 04 PS (polystyrene)
Returns
Direct drives and their components in the original packaging will be accepted by
the manufacturer for return for the purpose of proper disposal. The shipping and
disposal costs will be charged to the sender. Original packaging can be re-
quested from your responsible Siemens establishment.
The cost for the original packaging can be clarified before every return case
(type and quantity).
Disposal address:
Siemens Linear-Motor Systems GmbH & Co. KG
Georg Reismüller Str. 32
D-80999 München
The package should be clearly marked with the note:
"Zur kostenlosen Verschrottung“ (for free scrapping)
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DOKU/Rl/HOL/PUC

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Safety regulations

Observe the safety regulations.

Every person responsible for installing, operating, maintaining, repairing

The machine may only be operated by trained and authorized personnel.

The responsibilities for operating, servicing and maintaining the machine

The machine is not designed for machining combustible material.

Ambient conditions for the operation of CHIRON precision

CHIRON machines are designed for machining at ambient temperatures

CHIRON provides solutions for problems under such conditions.

EMERGENCY STOP BUTTON

Protective door monitoring

Protective door - Interlock

During machining, the protective doors can not be opened.

Serious injuries or death

are possible if you remove or deactivate the safety equipment.

The operator is obliged to report anything which could impair safety.

Wear protective clothing (helmet, gloves, protective footwear).

The machine can crush you!

Do not step under the machine when it is being moved.

Maintain a safe distance from the machine.

Do not lift the machine higher than necessary.

Never reach under the machine with your hand.

Observe the floor loading capacity.

Keep the workplace clean and well lit.

Always wear protective gloves.

Never touch a moving tool.

Beware of protruding tools, risk of injury!

b) The following movement sequence is defined for devices with dan-

The clamping function can be triggered with the two-hand switch

2. Clamping devices which do NOT have dangerous clamping

Cleaning agents may contain substances hazardous to your health.

Entering the machine

Beware of protruding tools, risk of injury!

Cooling lubricants may contain harmful substances.

Cooling lubricants pose an environmental hazard; make sure they are

Observe the manufacturer's instructions.

Take preventive measures so that fires can be fought quickly.

1.1 Suitable extinguishing agent and suitable extinguishing equipment.

1.2 Presence of trained personnel in the event of a fire.

1.3 Set-up of fire alarm system.

2.1 Trigger alarm

2.2 Press the EMERGENCY STOP button.

2.4 Switch off main switch.

2.5 Initiate extinguishing process.

Attention! - Danger of injury

Before work is carried out on the pneumatic system and on pneumatically

Lines, devices and cylinders have to be checked for tightness regularly,

Oil spills on the floor can cause accidents (danger of slipping).

Before work is carried out on the hydraulic system and on hydraulically

No manipulations may be made on the hydraulic accumulator and safety

Switch off current supply (fuse).

According to current medical knowledge, magnetic fields weaker than 5

Maintenance and repair regulations

• The complete demagnetisation of the components with permanent

• Recycling of components (if possible)

• Proper disposal of electric scrap

Demagnetisation of the secondary parts

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