GISS 2000

GISS 2000
Operating Manual
GISS 2000 Operating Manual
Inhaltsverzeichnis
Contents
Introduction..........................................................................................................................................3
Symbols and pictographs...................................................................................................................3
1.) Safety...............................................................................................................................................4
1.1 Danger potential of the equipment . .....................................................................................4
1.2 Safety notes.............................................................................................................................4
1.3 Correct application..................................................................................................................5
1.4 Work area requirements.........................................................................................................5
1.5 Authorised operators..............................................................................................................6
2.) Shipping and packaging.................................................................................................................6
2.1 Delivery....................................................................................................................................6
2.2 Unpacking................................................................................................................................6
3.) Decription of equipment................................................................................................................7
3.1 Functional description............................................................................................................7
3.2 Types........................................................................................................................................7
3.3 Dynamic output regulator .....................................................................................................8
3.4 Key pad and display................................................................................................................8
3.5 System summary....................................................................................................................9
4.) Commissioning and operation....................................................................................................10
4.1 Electrical connection............................................................................................................10
4.1.1 GISS 2000........................................................................................................................10
4.1.2 SPEED-COOLER.............................................................................................................. 11
4.2 Installation and assembly.................................................................................................... 12
4.2.1 GISS 2000........................................................................................................................ 12
4.2.2 SPEED-COOLER (optional)............................................................................................ 14
4.2.3 Inserting the adaptors.................................................................................................... 15
4.2.4 Speed Cooler Manager.................................................................................................. 16
4.3 Switching-on the equipment............................................................................................... 17
4.4 Menu guide........................................................................................................................... 17
. 4.4.1 Shrink fit menu.............................................................................................................19
. 4.4.2 Setting the heating time..............................................................................................20
4.4.3 Setting the language . .................................................................................................21
. 4.4.4 Setting the dimensional system ................................................................................22
4.4.5 Selecting the operating type . ....................................................................................22
4.4.6 Retrieving company settings......................................................................................23
4.5 Operating process ...............................................................................................................25
4.5.1 Suitable shrink fit chucks .............................................................................................25
. 4.5.2 Preparing the shrink fit chucks and tools....................................................................25
. 4.5.3 Heating the shrink fit chuck..........................................................................................26
. 4.5.4 Cooling the shrink fit chuck..........................................................................................29
4.6 Switching-off the equipment ..............................................................................................30
4.7 GISS 2000 Trouble-shooting................................................................................................31
. 4.7.1 Error messages..............................................................................................................31
. 4.7.2 Other malfunctions........................................................................................................31
4.8 SPEED-COOLER Troubleshooting.......................................................................................33
. 4.8.1 Venting the cooling system..........................................................................................34
. 4.8.2 Water pump not running..............................................................................................34
. 4.8.3 Condensation on dissipator.........................................................................................35
4.9 Important notes regarding the shrink fitting process.......................................................35
5.) Cleaning.........................................................................................................................................36
5.1 Speed Cooler.........................................................................................................................36
5.2 GISS 2000 shrink fit system.................................................................................................36
6.) Maintenance and repairs.............................................................................................................37
6.1 Maintenance..........................................................................................................................37
6.2 Replacing the GISS 2000 fine-wire fuse.............................................................................37
7.) Technical data................................................................................................................................38
8.) Replacement parts........................................................................................................................39
2
GISS 2000 Operating Manual
Vorbemerkung
Introduction
With the purchase of GISS 2000 you have acquired an innovative and easy to operate
system for changing tools in shrink fit chucks.
Please read this operating manual carefully and observe the safety notices prior to
commissioning the system in order to ensure longevity and above all safe operation
of GISS 2000.
All personnel entrusted with operating the GISS 2000 shrink fit system must also be
familiar with and observe this operating manual prior to the initial operation.
Keep this operating manual readily available in order to ensure access to the information at all times.
It is not permitted to photocopy, save on a computer system or forward extracts of this
operating manual without prior consent of Gühring oHG.
Gühring oHG reserves the right to undertake technical and visual changes at any time
without specific notification in the interest of further development. All dimensions, notes
and specifications in this operating manual are not covered by the warranty. Legal claims
based on the operating manual can subsequently not be exercised.
Gühring oHG Conditions of Sale and Terms of Payment apply.
Symbols and pictographs
Warning signs
General warnings of risk of danger to human life
or property are demonstrated with the following
symbols:
Warning of risk of danger through electric current
or electric shock respectively:
Warning of a specific danger. Pictograph with a
rectangular border, standing on a corner:
Mandatory signs
Mandatory signs are round, light pictograph on
dark background:
3
GISS 2000 Operating Manual
Sicherheit
1.) Safety
1.1 Danger
The GISS 2000 shrink fit system has been manufactured in accordance with the latest
technologies and safety regulations. Function and safety tests have been carried out.
However, the system can be a source of danger if not operated by trained or at least
instructed personnel. The same applies to inappropriate or incorrect use of the GISS
2000 system.
If this operating manual is not observed there is the risk of the following •
electric shock,
•
health hazards,
•
damage to the equipment.
1.2 Safety notes
• The GISS 2000 shrink fit system and the SPEED COOLER (cooling unit) must only
be operated with the correct mains supply voltage.
It is paramount to check the specification plate.
• The mains plug must only be plugged into a socket with an earthing contact! The
protective capacity must not be eliminated by the use of an un-earthed extension
lead.
Disconnection of the earthing wire inside or outside of the equipment is dangerous
and prohibited.
• The equipment must only be operated if in perfect condition. If one of the units is
damaged, the system must no longer be used.
• Due to the process, the shrink fit chuck becomes very hot in localised areas. There
is an acute danger of burning if these areas are touched. The equipment has been
designed so the hot shrink fit chuck does not need to be removed, thus, it should
always be left in the holder until it has cooled down.
• Always wear protective gloves when handling the shrink fit chucks and the tools.
The gloves protect against cuts from the sharp edges of the tools. In addition, they
provide protection against burns from the hot areas of the shrink fit chucks.
• The shrink fit system operates using a high frequency. Subsequently, a person with
a heart pace maker must not operate the equipment. During the operation of the
shrink fit system such persons must also observe a minimum safety distance of 1
metre to the equipment.
• Under no circumstances must metal objects come into the sphere of the induction
spindle. They would heat up intensively when the shrink fit system is operated. This
applies especially to jewellery, i.e. a ring on a finger or a chain, as there is an acute
danger of burning
• The shrink fit system must not be operated without an inductor limit stop collar. A
missing or incorrect inductor limit stop collar can result in scatter fields exiting the
spindle area. If the aforementioned is not observed, it may cause a risk to the operator and damage to the equipment or tools respectively.
4
GISS 2000 Operating Manual
Sicherheit
• The equipment must be disconnected from the mains supply prior to any cleaning,
maintenance or repair work being carried out. The same applies if the equipment is
not used for prolonged periods.
• During cleaning, liquid must not be allowed to enter inside the housing. Protect the
system against moisture. Risk of electric shock.
• Position the power supply cables in such a way as to prevent anybody tripping over
or getting caught up in them.
• Repairs to the GISS 2000 shrink fit system must only be carried out by qualified
personnel. Electrical work on the equipment must only be carried out by a qualified
electrician. The opening of the housing by unauthorised personnel is prohibited.
Attention! Dangerous residual voltage may be present in the housing up to 5 minutes after turning off the equipment.
• No dissassembly of safety devices. The dissassembly, by-passing or closing down
of safety devices is prohibited.
1.3 Correct application
The GISS 2000 shrink fit system has been designed and developed especially for the
tool change in shrink fit chucks. The system is suitable for shrink fitting HSS tools with a
shank-Ø from 6 to 32 mm and carbide tools with a shank- Ø from 3 to 32 mm.
With the aid of a chuck adapter system all standard taper size shrink fit chucks can be
applied. In addition, the coolant body adapter system enables the cooling of chucks with
any outer contour.
The system is only intended for industrial applications.
Gühring oHG cannot accept liability for applications not described in this operating
manual. Equally, such actions forfeit any claims made under warranty.
1.4 Work place requirements
Keep the workplace tidy and clean. Untidiness at the workplace increases the danger
of an accident.
The equipment must be positioned on a sufficiently rigid and level substructure. During
operation it must not be exposed to impact or be tilted.
The system must be protected against moisture and contamination.
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GISS 2000 Operating Manual
1.5 Authorised operators
The GISS 2000 shrink fit system must only be operated by authorised and trained personnel.
The operator is responsible for third parties in the work place.
The owner must
• instruct the operator regarding his tasks,
• make the operating manual available to the operator
• ensure that the operator has read and understood the manual.
2.) Shipping and packaging
2.1 Delivery
The GISS 2000 shrink fit system is despatched suitably packaged to ensure that, under
regular shipping conditions, it reaches its point of destination undamaged.
Note:
The carrier is liable for any damage that occurs during transportation. If damage to the
packaging is visible and there is reason to believe that the contents are damaged, immediately contact the carrier regarding the claim for damages.
Transportation and storage should be performed under normal conditions, i. e. at temperatures between +5°C and +70°C and a relative humidity of maximum 80%.
Attention!
The system may be permanently damaged if stored or transported under prohibited conditions. It is possible that the damage is not visible externally.
In this case, the manufacturer does not accept the warranty and the liability for consequential damages.
2.2 Unpacking
Remove all packaging and take out the system including the accessories.
Ensure that all the components of the GISS 2000 shrink fit system are included in accordance with the delivery note and the accompanying documents and are undamaged.
Compare the data on the type plates to that on the delivery note and your order documents.
If you do not require the packaging for further use, i. e. for the return of the system for
repairs, please dispose of it in an environmentally friendly way.
6
GISS 2000 Operating Manual
Beschreibung des Gerätes
3.) Description of equipment
3.1 Function principle
The GISS 2000 shrink fit system’s function principle is an induction spindle, also called an
inductor. The inductor is a current-carrying spindle that produces a magnetic alternating
field. When a ferrous metal object is inside the spindle it is heated up.
The frequency of the alternating field is set so the metal object, in this case a shrink fit
chuck, only heats up near the surface. The generation of heat in the shrink fit chuck is
continued by GISS 2000 until it is possible to manually remove or insert the tool, the
time required is approximately 5 seconds.
This is achieved before the tool itself becomes hot. At this point, heat has only generated
on the surface of the shrink fit chuck, as there has been insufficient time for the heat to
penetrate. This way, only a relatively small amount of energy is supplied or consumed
respectively. It is, therefore, possible to keep the subsequent cooling phase very short.
Cooling is achieved via water-cooling. The cooling power is provided by the SPEEDCOOLER. The cooling water permanently circulates through the cooling body. The hot
shrink fit chuck remains in its holder and is rotated into the cooling position via the
turntable. The water-cooled cooling body is then positioned over it. The cooling power
is transferred by direct contact with the shrink fit chuck. After a short time the shrink fit
chuck can be touched again.
The GISS 2000 shrink fit system is designed to carry out a continuous tool change (thanks
to the simple adapter system all standard shrink fit chucks can be used).
The GISS 2000 shrink fit system‘s design and operation allow a very quick tool change
to be carried out. Subsequently, the shrink fit chucks have a long tool life as they only
become hot in localised areas and, in addition, further contact is only necessary after
they have cooled down again.
Therefore, a simple and safe operation is ensured.
3.2 Versions
GISS 2000 Eco
GISS 2000 Eco is the cost-efficient entry level version into shrink fitting. This version
already incorporates the powerful electronics and the easy software for carbide and
high speed steel tools up to Ø 32 mm. It includes a shrink fitting station but not a cooling unit.
GISS 2000 Eco Plus
The GISS 2000 Eco Plus shrink fit system also includes a cooling unit and cooling body to enable a fast cooling down of the shrink fit chucks.
The GISS 2000 Eco version can be up-graded to the GISS 2000 Eco Plus version using
a special upgrade kit.
GISS 2000 Comfort
The GISS 2000 Comfort is the fully equipped version for an efficient operation. In addition to a cooling facility, this version also includes a turn table with three shrink fitting
stations.
7
GISS 2000 Operating Manual
Beschreibung des Gerätes
This makes a continuous operation possible without interruption.
The GISS 2000 Eco Plus system can be up-graded to the comfort version using an upgrade kit.
GISS 2000 Comfort Plus (special)
The GISS 2000 Comfort Plus is the universal solution for the shrink fitting of tools. Its
special electronics offers twice the performance in comparison to the other models. With
an additional inductor, it is possible to shrink fit for insertion and withdrawal carbide and
high speed steel tools up to Ø 50 mm. A cooling unit and a turntable with three shrink fit
stations are part of the standard equipment. It is not possible to up-grade the standard
versions to the Comfort Plus model.
3.3 Dynamic output control
Depending on the local power supply, the voltage in the network may be subjected to
heavy fluctuations.This also has an effect on the heating capacity of the GISS 2000 shrink
fit system. With a reduced voltage supply, the heating capacity may not be sufficient to
heat-up the holders quickly. If the voltage increases, there is the danger of the holders
over-heating.
The GISS 2000 shrink fit system solves this problems with dynamic output control. The
heating capacity is determined and controlled during the entire shrink fit process.
The intermediate circuit voltage is displayed during the shrink fit process, it should not
fall by more than 35 Volts prior to the shrink fit process.
This ensures that optimal results are achieved under all operating conditions.
3.4 Keypanel and display
a Enter / confirm key
b Plus key
for increasing the tool-Ø
c Minus key
for reducing the tool-Ø
d Inductor start key
ESC
e LCD display
f ESC-key
8
GISS 2000 Operating Manual
Beschreibung des Gerätes
3.5 System summary
1 Mains switch SPEED-COOLER
2 Coolant hose return
3 Coolant hose
4 Inductor plug-in connection
Ø 3 - 32 mm
5 Mains switch GISS 2000
6 Inductor linear unit
7 Handle with brake
8 Inductor start key
9 Inductor energy supply hose
10 Drawspring
11 Equipment-on indicator
lamp
12 Cooling bodies
12aCooling bodies with interchange lock
13 Inductor
14 Shrink fit chuck adapter
15 Turntable
16 Tool depository
17 Keypanel and display
18 Trolley (option)
19 Fine-wire fuse for
electronic control
20 Plug-type connector for
inductor Ø 40 - 50 mm
optional
21 Cooling body Ø 40 - 50 mm
optional
22 Plug-type connector for
SPEED-COOLER control line
optional
ESC
9
GISS 2000 Operating Manual
Inbetriebnahme und Bedienung
4.) Commissioning and operation
In the following, the required procedures are
described in the correct sequence for commissioning
the GISS 2000 shrink fit system. Operating the
system is relatively simple. However, you should
familiarise yourself with the equipment prior to
working with it.
Incorrect operation can be dangerous for the operator and damage the equipment, in particular there
is the danger of the shrink fit chuck overheating.
4.1 Electrical connection
If the GISS 2000 shrink fit system or the SPEEDCOOLER have not been supplied with the correct
plug, a suitable plug must be fitted.
Important:The above must be carried out by a qualified electrician.
4.1.1 GISS 2000
The electrical connection is 4-pole. Connect the 3phases and earth. The connection to earth is compulsory to comply with electrical safety regulations.
Neutral is not connected. The rotary field of the 3
phases does not need to be observed.
Please ensure:
• The electrical connection (socket-outlet) with
the customer must have a connected earthing
contact.
• If the plug is replaced, the earth is connected to
the green/yellow wire.
• The power supply must correspond with the data
on the type plate.
• Depending on the distance to the main distribution, the conductor cross-section of the customer‘s electrical connection should be chosen generously. Furthermore, no additional equipment
should be connected to this supply line. If the
above is not observed, the voltage level may drop
too much during the shrink fit process resulting
in the necessary shrink fitting output not being
achieved.
Customer fuse protection:
GISS 2000 Eco, Eco Plus, Comfort: 3 x 16 Ampere
GISS 2000 Comfort Plus (special): 3 x 32 Ampere
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GISS 2000 Operating Manual
Inbetriebnahme und Bedienung
• If connected via a transformer, it must be checked
that there is a continuous earth connection from
the equipment plug to the voltage connection
on-site with the customer..
Attention! Under no circumstances must the system be operated with a higher rating fuse protection.
4.1.2 SPEED-COOLER
The voltage connection must be 3-pole. Live, neutral and earth must be connected. The connection
to earth is compulsory to comply with electrical
safety regulations.
Please ensure:
• The power supply must correspond with the data
on the specification plate.
Earth
yellow/green
• The electrical connection (socket-outlet) with
the customer must have a connected earthing
contact.
• When using adapterplugs extreme care should
be taken to ensure that the earthing contact is
continuous to the socket. Often with adapters
the earthing is not continuous.
• If the plug is replaced, the earth is connected to
the green/yellow wire.
• Customer fuse protection: 10 Ampere
• If connected via a transformer, it must be ensured there is a continuous earth connection from the
equipment plug to the voltage connection on-site
with the customer.
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GISS 2000 Operating Manual
Inbetriebnahme und Bedienung
4.2 Location and assembly
The GISS 2000 system and the SPEED-COOLER must
be positioned on sufficiently rigid level ground.
During operation the equipment must not be positioned at an angle, be tilted or exposed to impact
and vibration..
4.2.1 GISS 2000
Space required:
Distance to the wall:
GISS 2000 Eco
L = 0
GISS 2000 Eco Plus
GISS 2000 Comfort L = 150
Optimal table height for all versions: H = approx.
800 mm
GISS 2000 is to a large extent pre-assembled. It is
only necessary to fit and align the linear unit (6) onto
the housing with the screws provided.
Important: For safety reasons an electrically conductive contact must exist between the linear unit
and the housing. Therefore, the linear unit must be
fitted very carefully.
• Unscrew the four screws (22).
GISS 2000 Economic and Economic Plus (without
turntable):
The supplied contact springs (24) must be
inserted between the base plate and the housing.
The springs are situated under the retaining plate
(25), that is screwed to the housing.The retaining
plate (25) serves only for protection of the contact
springs (24) during transportation and can be
removed.
GISS 2000 Comfort and Comfort Plus (with
turntable):
The four tooth lock washers (23) must be inserted
between the screwhead and the base plate.
• Position the linear unit (6) together with the base
plate.
• Screw-in the screws (22) and tighten lightly
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GISS 2000 Operating Manual
Inbetriebnahme und Bedienung
• Mount the inductor (13) into the holder of the
linear guide. Ensure the locking bolt (19) is engaged.
• Position a shrink fit adapter (14) onto the turntable (15).
• Insert a suitable shrink fit chuck (21) into the
adapter (14.
• Insert the limit stop washer (20) corresponding
with the diameter of the selected shrink fit chuck
into the inductor (13).
• Align the linear unit (6) so the inductor (13) is centred over the chuck (21). Tighten the four screws
(22).
• Connect the inductor plug (4) to the housing
Only applies to GISS 2000 Komfort Plus:
The two inductors have different plugs, eliminating
a mix-up of the plugs. The plug-type connectors on
the GISS 2000 Profi Plus are arranged so only one
of the connectors can be opened.This prevents both
inductors being connected at the same time
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GISS 2000 Operating Manual
Inbetriebnahme und Bedienung
4.2.2 SPEED-COOLER (option)
Front view
Space required:
Important!
The SPEED-COOLER uses ambient air to cool the
water in the cooling circuit. It must be ensured that
there is sufficient free space for the air to circulate
(see top view). Otherwise the cooling output will
be insufficient.
• Position the SPEED-COOLER on a sufficiently
rigid and level substructure alongside or below
the GISS 2000 system.
• Fill the SPEED-COOLER with a mixture of
tap water and anti-freeze (e.g. commercial
automotive anti-freeze).
Mixture ratio water : anti-freeze = 2 : 1
Generally, new systems are already filled with
anti-freeze. All that is then required is to add tap
water to the cooler. The system is filled via the
screw-type cap situated on the upper side. The
cooling spiral in the water reservoir must be
completely covered.
• Bleeding the SPEED-COOLER:
Connect the nipple with the hose piece (1) (supplied) to the flow pipe (3) of the SPEED-COOLER.
Do not turn the SPEED COOLER on. The pump
could be damaged if run dry. After a short time
water will run out of the pipe. Remove the nipple
with the hose.
• Bleeding the cooling circuit:
Connect one of the GISS 2000 system‘s two
circulation hoses of to the flow pipe (3) of
the SPEED-COOLER. Connection is via quick
release couplings. The circulation hoses are
interchangeable (the direction of circulation in the
cooling bodies (12) is not important).
Connect the mains cable of the SPEED-COOLER.
Ensure the supply voltage corresponds with that
on the type plate of the SPEED-COOLER.
GISS 2000 Comfort Plus only: Connect the control line of the SPEED-COOLER
to the connector (22) of the GISS 2000 system.
Turn-on the GISS 2000 system at the mains
switch (5).
Turn-on the SPEED-COOLER. Water is now
pumped into the cooling system forcing the air
to vent from the hoses and the cooling bodies.
Top view
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GISS 2000 Operating Manual
Wait unil water exits the open hose, then connect the hose to the return (2) of the SPEEDCOOLER.
Switch-off the SPEED-COOLER.
GISS 2000 Comfort Plus: Turn-off the GISS 2000
system at the mains switch (5). The mains switch
of the SPEED-COOLER remains on. The SPEEDCOOLER is automatically turned on and off by
the GISS 2000 system.
Top up the SPEED-COOLER with tap water
(drinking water). The cooling spiral in the water
reservoir must be completely covered.
Note: To ensure perfect functioning of the re-cooling
plant, the fins of the air-cooled condensator must
be kept clean. Particularly if the ambient air is of a
high oil and dust content, the fins of the condenser
can become excessively soiled. Regular cleaning
is necessary, as described in chapter 5. A trolley is
available as an option which is optimally suited for
positioning and setting-up the two systems (see
system summary)..
4.2.3 Inserting the adapters
The adapter system consists of shrink fit chuck
adapter (14) and the inductor limit stop washer (20).
The purpose of the inductor limit stop washer (20)
is the correct positioning of the inductor above the
shrink fit chuck (21). Furthermore, the limit stop
washer controls the magnetic alternating field (20),
preventing the tool from heating up and providing
an upwards shield for the alternating field.
The correct adapter system must be used for each
shrink fit chuck size.
Not observing the above can lead to dangerous
situations for the operator and to equipment or tool
damage.The application of an incorrect inductor limit
stop washer (20) can result in stray fields exiting
the spindle area. The shrink fit system must not be
operated without an inductor limit stop washer
(20).
Sectional limit stop washers (optional) can be applied
for tools possessing a larger cutting edge diameter
than the shank diameter (i.e. T-slot drills).
Shrink fit chuck adapters (14)
The shrink fit chuck adapters (14) are marked with
the holder taper size.
• Insert the correct shrink fit chuck adapter (14) into
the turntable (15) from above.
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GISS 2000 Operating Manual
Inbetriebnahme und Bedienung
Inductor limit stop washer (20)
The inductor limit stop washer (20) is inserted
manually (without tool key). The inductor limit stop
washer (20) is designed with a bajonet fitting.
• Select the correct inductor limit stop washer (20)
for the respective tool.
• Insert the inductor limit stop washer (20) into the
inductor from above.The red dot on the inductor
limit stop washer (20) must be aligned with the
red dot on the inductor housing.
• Insert index finger and middle finger into the
recesses of the inductor limit stop washer (20)
and rotate clockwise until it engages. A spring
element snaps into a notch of the inductor limit
stop washer (20).
The shrink fit system is now prepared and ready for
the tool change of a specific shrink fit chuck.
4.2.4 Speed-Cooler Manager
The cooling manager (Guhring no.: 4759 code 1,000)
automatically switches the SPEED-COOLER on and
off.This prevents forgetting to switch-on the cooler or
the cooler running constantly, protecting the cooler
and minimising maintenance costs. See separate
assembly instructions.
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GISS 2000 Operating Manual
Inbetriebnahme und Bedienung
4.3 Turning-on the equipment
Connect to the mains supply. Ensure that the mains
voltage corresponds with that on the specification
plate. If yes, plug-in the mains plug.
• Connect the mains cable of the SPEED-COOLER.
Mains supply fuse protection: 10 Ampere.
• Connect the mains cable of the GISS 2000 system. Mains supply fuse protection: GISS 2000 Eco,
Eco Plus, Comfort:
3 x 16 A
GISS 2000 Comfort Plus (special):
3 x 32 A
Attention! Under no circumstances must the
systems be operated with a fuse protection of a
higher rating.
• Turn-on the SPEED-COOLER at the mains switch (1). The circulation pump will start operating.
The SPEED-COOLER does not require a warming-up
period. Immediately after switching-on the SPEEDCOOLER you can begin with the first tool change.
• Turn-on the GISS 2000 system at the mains switch (5).
• When applying the Speed Cooler Manager, the Speed Cooler is switched-on when the induction
spindle is activated.
Attention! The electronics of the GISS 2000 Comfort
Plus system must be cooled by the SPEED-COOLER
to prevent over-heating. A temperature controller will
otherwise turn-off the system after a short time and
only release the system again after a cooling down
period. Therefore, GISS 2000 Profi Plus must only be
operated when the SPEED-COOLER is turned-on.
4.4 Menu guide
After switching-on, you enter the shrink fit menu.
Here, you can select the type and the size of the
shrink fit chuck and start the shrink fit process.
Different setting possibilities are available in
sub-menus.
• +
• • +
• • • I
ESC
-
keys - simultaneously branch into sub-menu
key
to previous menu point
key
to next menu point
key
select menu point
key
return to overriding menu,
without saving
key
confirm and save
ESC
17
GISS 2000 Operating Manual
Overall menu
Shrink Fit Menu
Schrumpfmenü
Display
Anzeige
Shrink
Fit Cucks
Schrumpffutter
Taste
- key -
Select
Auswahl
voriges Futter
previous
chuck
aus
fromListe
list
Taste
+ key+
Auswahl
Select
nächstes
Futter
next chuck
aus
fromListe
list
+ - keys
Tasten
-+
simultaneously
gleichzeitig
Select
Auswahl
next group
nächstes
Gruppe
aus
fromListe
list
Taste
key
Anzeige der
Display
Schrumpfshrink
fit
parameters
parameter
start key
Starttaste
or ITaste
key I
oder
Schrumpfvorgang
Shrink fit process
mit Anzeige
withder
data
display
Daten
+ - keys
Tasten
-+
simultaneously
gleichzeitig
Taste
ESC
ESC key
Heizzeit
Heating
time
Taste
+/+ / - key
Tastekey
Heizzeit
Modify
verändern
heating
time
Sprachen
Language
+ / - key
Taste
+/-
Taste
+/+ / - key
Taste
ESC ESC
key
Tastekey
Sprache
Select
auswählen
language
System of
Maßsystem
measurement
Taste
+/+ / - key
ESC key
Taste
ESC
Tastekey
Maßsystem
Select
system
auswählen
of measurement
Taste
ESC
ESC key
Betriebsarten
Operating
type
Tastekey
Taste
+/+ / - key
Betriebsarten
Select
wählentype
operating
Manufacturer‘s
settings
ESC key
Taste
ESC
Werkseinstellung
Tastekey
Rücksetzen
Return to
auf Werksmanufacturer‘s
einstellungen
settings
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GISS 2000 Operating Manual
4.4.1 Shrink fit menu
The display always shows the currently set shrink fit chuck.
Typedes
of shrink
Typ
fit chuck
Schrumpffutters
Standard
Größe
des fit
Size of shrink
chuck
Schrumpffutters
Ø 10 - 12
Spindle
Spule Pos. #4
Einstellung
der Spule
Spindle setting
• – key • + key
• + – keys simultaneously
• press and hold key
*
to previous chuck
to next chuck
to next chuck type
displays shrink fit parameters
Max.
Heizzeittime
Max. heating
Frequenz
Frequency
Parameter
Parameters
7,0 kHz
545 E
525 V
4.5 s
450 r
23 °C
Spannung
in
Intermediate
Zwischenkreis
circuit voltage
• START key
or I
Temperatur
Electronics
temElektronik
perature
starting the shrink fit process
* only for special spindle with adjustment possibility
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GISS 2000 Operating Manual
4.4.2 Setting the heating time
Taste
ESC ESC
key
Heating
time
Heizzeit
Zurück
Return ins
to
shrink fit menu
Schrumpfmenü
Taste
key
Standard
Ø 10 - 12
Heating
time
Heizzeit
0 - 60: 4.5 s
Display of
heating
time
Anzeige
der
Heizzeit
für dasfor
eingestellte
set chuck Futter
key
Taste
* markerblinkt
flashing
Markierung
be modified
Zeittime
kanncan
verändert
werden
im angegebenen
Bereich
for range specified
Taste
ESC
ESC key
+ / - key
Tasten
-/+
Select
Auswahl
previous
/ next
voriges
/ nächstes
Futter
chuck aus
fromListe
list
Tasten
-/+
+ / - keys
gleichzeitig
simultaneously
Auswahl
Select
nächste
Gruppe
next group
aus
fromListe
list
Standard
Ø 10 - 12
Heating
time
Heizzeit
0 - 60: 4.5 s
Taste
ESC
ESC key
Zurück
ohne
Back w/o
speichern
saving
Taste
ESC ESC
key
Zurück
ohne
Back w/o
speichern
saving
Taste
+/+ /- key
Modifying
Zahlenwert
ändern
numerical value
Taste
key
Speichern
Save
and back
und zurück
Displaying max. heating time of current chuck
Typ
des
Type
of shrink
Schrumpffutters
fit chuck
Standard
Ø 10 - 12
Heizzeittime
Heating
0 - 60:
4.5 s
Einstellbereich
Setting range
Größe
des fit
Size of shrink
Schrumpffutters
chuck
Eingestellter
Set valueWert
• – / + key
to previous / next chuck
• + – key to next chuck type
simultaneously
•
key
set value is marked by a flashing *. Value may now be changed.
20
GISS 2000 Operating Manual
Standard
Ø 10 - 12
Markierung,
blinkt
Marker flashing
Heating
time
Heizzeit
0 - 60:
• – or + key
•
key
• ESC key
• I key
4.5 s
changing the value
save and return
return without saving
return to shrink fit menu
4.4.3 Setting the language
Sprachen
Language
Taste
ESC
ESC key
Zurück
Return ins
to
shrink fit menu
Schrumpfmenü
Taste
key
Speichern
Save
und
and zurück
return
Sprachen
German
deutsch
Taste
key
ESC ESC
key
Taste
Zurück
Returnohne
w/o
speichern
saving
Taste + / Speichern
Save
und
and zurück
return
Taste
key
Sprachen
English
english
Taste
ESC ESC
key
ESC
key
Zurück
Returnohne
w/o
speichern
saving
Speichern
Save
und
and zurück
return
Taste
key
Sprachen
French
français
Taste
ESC ESC
key
Zurück
Returnohne
w/o
speichern
saving
Speichern
Save
und
and zurück
return
Taste
key
Sprachen
Italian
italiano
Taste
ESC ESC
key
Zurück
Returnohne
w/o
speichern
saving
Speichern
Save
und
and zurück
return
Taste
key
Sprachen
Spanish
español
Taste
ESC ESC
key
Zurück
Returnohne
w/o
speichern
saving
Display of set language
Sprachen
deutsch
English
• – / + key
• key • ESC key
• I key
set language
Eingestellte
Sprache
to next/previous language
saves the language displayed and return
return without saving
return to shrink fit menu
21
GISS 2000 Operating Manual
4.4.4 Setting the system of measurement
System of
measurement
Maßsystem
Taste
ESC
ESC key
Zurück
Return ins
to
shrink fit menu
Schrumpfmenü
Tastekey
Speichern
Save
und
and zurück
return
Taste
key
Maßsystem
Metric
system
mm
Taste
ESC
ESC key
Zurück
Returnohne
w/o
speichern
saving
Taste
ESC ESC
key
Zurück
Returnohne
w/o
speichern
saving
Taste
+/+ / - key
Speichern
Save
und
and zurück
return
Taste
key
Maßsystem
Imperial
system
Inch
inch
Displaying the set system of measurement
Maßsystem
Metric
system
mmmm
Eingestelltes
Set metric
system
Maßsystem
• – / + key
•
key
• ESC key
• I key
change system of measurement: mm / Inch
saving the system of measurement displayed and return
return without saving
return to shrink fit menu
4.4.5 Selecting the operating type
Betriebsarten
Operating
type
ESC key
Taste
ESC
Zurück
Return ins
to
shrink fit menu
Schrumpfmenü
Taste
key
Historie
Read-outauslesen
history
über
via
USB-Schnittstelle
USB interface
Taste
key
Betriebsarten
Operating
Historietype
readout
history
auslesen
Taste
ESC ESC
key
Zurück
Return
Taste
ESC ESC
key
Zurück
Return
Taste
+/+ / - key
Load
programProgramm
via über
einlesen
USB-Schnittstelle
USB interface
Taste
key
Betriebsarten
Operating
type
Programm
load program
einlesen
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GISS 2000 Operating Manual
Displaying the set operating type
Betriebsarten
Operating
type
history readout
Historie
auslesen
Eingestellte
Set
operating
type
Betriebsart
In the operating type “History read-out“ data from previous shrink fit processes can be read on PC via the USB
interface. The data can be evaluated by the manufacturer
to diagnose malfunctions.
Betriebsarten
Operating type
load program
Programm
einlesen
In the operating type “load program“ it is possible to load
new software via the USB interface.
• – / + key
•
key
• ESC key
• I key
change operating type
execute the displayed operating type
return without executing
return to shrink fit menu
4.4.6 Restoring the manufacturer‘s
settings
Manufacturer‘s
settings
Werkseinstellung
Taste
ESC
ESC key
Zurück
Return ins
to
Schrumpfmenü
shrink fit menu
Taste
key
Zurück
Return
Taste
key
Werkseinstellung
Manufacturer‘s
settings
Ja/Nein:
Nein
yes / no: No
Taste
ESC ESC
key
Zurück
Return
Taste
ESC ESC
key
Zurück
Return
+ / - key
Taste
+/Return to auf
Rücksetzen
manufacturer‘s
Werkseinstellung
settings
Taste
key
Werkseinstellung
Manufacturer‘s
settings
Ja/Nein:
yes / no: YesJa
This function enables returning the shrink fit parameters to the original manufacturer‘s
settings. Previously set parameters are lost.
23
GISS 2000 Operating Manual
Werkseinstellung
Manufacturer‘s
settings
/ no: No
Ja /yes
Nein:
Nein
•
key • ESC key
• I key
return without restoring parameters
return without restoring parameters
return to shrink fit menu
• – / + key
change between yes / no
Werkseinstellung
Manufacturer‘s
settings
/ no: Nein
No
Ja /yes
Nein:
•
key
restoring parameters and return
24
GISS 2000 Operating Manual
4.5
Operating sequence
Inbetriebnahme
und Bedienung
Always wear gloves when handling shrink fit chucks
and tools. The cutting edges of the tools are very
sharp and can cause cuts to the skin. Furthermore,
gloves also protect against burning should you
accidentally make contact with a hot shrink fit
chuck.
We recommend gloves made of Kevlar, Guhring no.
4750 1,000. They are breathable and wear-resistant
against the sharp tools. Kevlar does not melt and
offers a good protection against burning.
4.5.1 Suitable shrink fit chucks
The GISS 2000 system is primarily designed for
shrink fit chucks with an outer contour to DIN
69882 – 8. In addition, there is a large selection of shrink fit chucks and extensions that can
also be applied with the GISS 2000 system. For chucks with different dimensions please contact
Guhring.
Under no circumstances must the chuck (21) make
contact with the internal wall of the inductor (13).
Subsequently, there is a maximum permissible chuck
size (see fig.).
Inductor for Ø 3-32: max. Ø 44
Smin= 3 mm
Inductor for Ø 40-50 (only Comfort Plus): max. Ø 80
Smin= 7 mm
4.5.2 Preparing shrink fit chuck and tool
Please ensure that
• the shrink fit chucks and tools are dry, free of
grease and dry. Special brass brushes and
cleaning mandrels (Guhring no. 4918 for Ø 6 to 40)
are available for cleaning the shrink fit chucks.
• the milling cutter possesses a shank tolerance h6
or closer.
• the shank is not rough and uneven.
Scratches, burrs or even improper laser markings
can make the shrink fitting for withdrawal process
more difficult.
Do not use easily flammable cleaning agents, there
is a fire risk during the shrink fitting process.
• Remove any residual swarf and soluble oil if
necessary and dry the shrink fit chuck. Any coolant residue could burn into the holder during the
shrink fitting process!
Note: In order to prevent corrosion, shrink fit chucks
should be lightly oiled when stored.
25
GISS 2000 Operating Manual
Inbetriebnahme und Bedienung
4.5.3 Heating up the shrink fit chuck
• Only GISS 2000 Comfort Plus:
Select and fit the inductor
For shrink fit chucks from Ø 32 S­ (re-inforced)
to Ø 50 S the large inductor is required.
The inductor (13) is inserted in the holder
of the linear guide (see also chapter “Location and assembly”) and connected to the
housing using the plug-in connector (20).
The large inductor is operated at higher output
figures than the smaller inductor.Therefore, there
are two different plug-in type connectors (4, 20)
located in the housing of the GISS 2000 Profi
Plus system. They are arranged so one inductor
only can be connected at any one time in order
to prevent a mix-up or the application of two
inductors.
• Select the size of the shrink fit chuck.
Different shrink fit chucks possess different
internal and external diameters. According to the
size of the chuck, the GISS 2000 system operates
with adapted performance values. In order to
simplify finding the most suitable setting, the
different types of shrink fit chuck are subdivided
into groups.
Press the + and – keys simultaneously to move
from one group to the next.
Standard
Extension
Chuck
.....
It is possible to change between the individual
sizes using the + or – key. The size selected is
visible in the display.
Verlängerung
Extension
ØA 25 ØI 14 - 16
Spindle
Spule pos.
Pos. #4
Größe
desshrink
Schrumpffutters
Size of
fit chuck
Typ
des
Type
of shrink
fit chuck
Schrumpffutters
Einstellung
der Spule
Spindle setting
*
Example 1:
Shrink fitting a shrink fit extension for insertion
(external-Ø 25, internal-Ø 10) in a standard
shrink fit chuck
Group: Standard
Size:
Ø 25 - 32
Spindle positon*:
#8
26
GISS 2000 Operating Manual
Example 2:
Shrink fitting a milling cutter with shank-Ø 10 for
insertion in a shrink fit extension with external-Ø
25, internal-Ø 10):
Group: Extension
Size:
ØA 25, ØI 8-12
Spindle positon*: #3
*Ony for special spindle with adjustment possibility
Important: S-chucks with an increased external diameter for heavy machining operations in combination
with HSS milling cutters can only be shrink fitted
with type “2002” spindles. The spindles are marked
accordingly on the top surface.
Ensure that the turntable (15) is engaged.The inductor
(13) must be in raised position.
• Insert the shrink fit chuck (21) into the shrink fit
chuck adapter (14) below the inductor (13).
• Release the brake of the inductor slide by pulling
the handle (7) and pull the inductor (13) over the
shrink fit chuck.
The inductor limit stop washer (20) makes contact
with the top surface of the shrink fit chuck (21).
The chuck (21) length must be sufficient for the limit
stop washer (20) with the correct diameter to rest
on the chuck. The inductor (13) must not touch the
chuck.
Clamping the tool:
• Hold the tool (22) in the right hand up to the bore
of the chuck.
• Press the start key (8) or key (d) respectively until
the tool can be inserted.The process takes approximately 5 seconds.
Unclamping the tool:
• Hold the tool (22) firmly in the right hand and pull
lightly upwards.
• Press the start key (8) or key (d) respectively until
the tool can be withdrawn. The process takes approximately 5 seconds.
For as long as the the start key (8) or (d) respectively
are pressed, the equipment-on indicator lamp (11) remains on. However, the maximum period of inductor
activity is limited due to safety reasons.The following
is displayed during the shrink fit process:
27
GISS 2000 Operating Manual
Auslastung
der
Output regulator
capacity
Leistungsregelung
Spannungcircuit
in
Intermediate
Zwischenkreis
voltage
Restliche
Heizzeit
Remaining heating
time
80 %
410 Int.
510 V
565 r
2.8 s
109 A
48 °C
558 M
Spindle current
Spulenstrom
Temperatur
Electronics
Elektronik
temperature
In the event of a malfunction, an error message is
diplayed.
• Release the brake of the inductor slide by pulling
the handle (7) and immediately lift the inductor
(13) off the shrink fit chuck.
Important: Do not press the start key (8) or (d)
respectively for longer than necessary. The system
allows the running of only one maximum shrink
fitting cycle. A further shrink fitting process is then
possible after approximately 5 seconds.
Pause:
1.2 s
Wait:
Time
remaining: 2.4 s
Restzeit:
Wartezeit
bisuntil
zum
Waiting time
the next
nächsten
Schrumpfvorgang
shrink
fit process
Remaining
time
Restlicheheating
Heizzeit
The process is simple and quick. If it is not possible
to clamp or unclamp the tool there is a malfunction.
Immediately after the shrink fit process is finished,
the inductor must be lifted off the hot shrink fit
chuck. Otherwise the inductor can overheat inside
and sustain damage
Please check the following:
– Is the diameter setting correct?
– Is the correct limit stop washer inserted?
– Is the bore of the holder contaminated?
– Is the shank-Ø of the tool to tolerance h6?
– Is the shank of the tool undamaged?
– Is the output of the power supply sufficient?
28
GISS 2000 Operating Manual
Small cable cross-sections or the use of extension leads
can lead to a drop in voltage during the heating-up process. This can be checked the following way:
Press the key
The following is displayed:
Frequenz
Frequency
Spannungcircuit
in
Intermediate
Zwischenkreis
voltage
Parameters
Parameter
7,0 kHz
4.5 s
545 E
450 r
525 V
23 °C
Max.
Heizzeit
Max. heating
time
Temperatur
Electronics
temperature
Elektronik
Vergleichen Sie die Spannung im Leerlauf mit der
Spannung, die während des Heizens angezeigt
Compare the voltage under no-load operation with
the voltage displayed during the heating process.
If the voltage should drop by more than 35 V, the
power supply must be improved.
Before a new attempt, the chuck must have cooled
down completely..
If an operator error is not evident, have the system
checked.
The shrink fit chuck becomes very hot in localised
areas.There is a danger of burning if these areas are
touched. The hot shrink fit chuck does not need to
be removed. Always leave it in the holder until it
has cooled down.
• Rotate the turntable (15) clockwise by one
notch.
4.5.4 Cooling the shrink fit chuck
With the aid of the cooling bodies the hot shrink fit
chucks are cooled down very quickly. Pre-requisite
is a good contact between the cooling body and the
chuck (surface contact). Modern shrink fit chucks
have a standardised external contour, subsequently
all current shrink fit chucks can be cooled with the 5
different cooling bodies available.The cooling bodies
are marked with the bore diameters of the standard
shrink fit chucks.
However, there are shrink fit chucks that are not
manufactured in accordance with the standard.This
applies to, for example, older production chucks and
also shrink fit extensions. In order to be able to also
cool these chucks quickly and economically, there is
an adapter system available. The cooling bodies in
the sizes 14–16 and 25–32 are equipped with an interlocking system. Adapters with any internal contour
can be inserted into these cooling bodies..
Adapter blanks are available from your supplier.
29
GISS 2000 Operating Manual
The blanks are finished externally and only require
adapting to the internal form of the respective shrink
fit chuck.
Note: During the cooling period the adapters can
become jammed in the shrink fit chuck. Therefore,
the adapters must have a complete slit on at least
one side
• Position the correct cooling body (12) on
the just applied shrink fit chuck (if necessary, first insert the adapter into the cooling body). The diameter of the bore of the
holder is marked on the cooling body.
W h e n a p p l y i n g ch u ck s f o r h e a v y m a chining operations, always use
a cooling body the next size up.
An adapter (23) is required for shrink fit extensions
Attention! The cooling body (12) must only be inserted when the SPEED-COOLER is switched-on.
Otherwise the cooling body (12) can overheat and
leak.
The cooling process requires between 20 to 150
seconds. During this time the next clamping procedure can be carried out. This enables a continuous
operation.
• Withdraw the cooling body (12).
• Remove the cool shrink fit chuck
4.6 Switching off the equipment
If the equipment is used on a daily basis:
• Turn off both systems at the mains switch after
finishing work.
• If required, clean the shrink fit chuck (see chapter
5).
If the equipment is to be shut down for a prolonged
period:
• Turn off both systems at the mains switch.
• Pull out both mains plugs.
• Clean the shrink fit system (see chapter 5).
• Top up the water reservoir of the SPEED-COOLER.
The cooling spiral in the reservoir must be covered completely.
30
GISS 2000 Operating Manual
4.7 GISS 2000 Troubleshooting
4.7.1 Error messages
Error messages
Incorrect
diameter
Cause
Remedy
Incorrect selection of shrink
fit chuck on display panel
•Select correct setting
Spindle too hot
Temperature in spindle too
hot
No spindle connected
Plug of spindle defect
•Allow spindle to cool down for approx. 10 minutes
•Connect spindle
•Return spindle and base unit to manufacturer for
repair
•Replace spindle
•Allow equipment to cool down
Spindle missing
Temperature inside
housing too high
Mains voltage too
low
Mains voltage too
high
Mains problem
Spindle defective
Temperature inside housing
too high
Equipmrnt defective
Mains voltage too low
500 V
Mains voltage too high
•Mains voltage must be between 380 V and
Mains voltage drops too
much during the shrink fit
process
•If extension lead is used, connect equipment
directly to socket or use cable with larger crosssection
•Connect equipment to socket with higher voltage
•Lay cable from the main distribution directly to the
shrink fit system
•Check system fuses
•Electrician to check if all 3 phases are there and
are connected correctly (socket and plug of machine)
•Return base unit to manufacturer for repair
•Return base unit to manufacturer for repair
1 phase missing in mains
supply
Power element defect
•Return base unit to manufacturer for repair
•Mains voltage must be between 380 V and
Equipment defective
Equipment defective
500 V
4.7.2 Other malfunctions
Problem
No display or only
black bars after
turning-on the
equipment
Cause
Mains voltage below 350 V
1 phase missing in mains
supply
Display defective
Remedy
•Connect equipment to a socket with a higher
voltage
•Use a voltage transformer
•Check system fuses
•Electrician to check if all 3 phases are there and
are connected correctly (socket and plug of
machine)
•Return base unit to manufacturer for repair
31
GISS 2000 Operating Manual
Problem
Shrink fitting process
stops after a short
time (approx. 0,5
seconds)
Cause
Very big voltage drop in the
current supply
Remedy
•If using an extension cable: Connect the system
directly to socket or use cable with a larger cross
section.
•Connect system to a socket with higher voltage
•Lay cable from the main distribution directly to
the shrink fit system
•Check system fuses
•Electrician to check if all 3 phases are there and
are connected correctly (socket and plug of
machine)
•Return base unit to manufacturer for repair
Equipment defective
•Do not attempt to drive the tool from the chuck
General notes
by force. This can cause damage to the bore
and the shank
•Do not anneal the holders
Shank-Ø is too large
•Only apply tools with shank tolerance h6
Tool shank is contaminated
•Clean tool shank prior to shrink fitting for insertion
or damaged (burr, scratches, •Only use undamaged tools
indentations)
•Remove any rough areas (hone)
Incorrect system parameter
•Select correct setting in display
settings
Holder not cooled down
•Always allow the holder to cool down completecompletely
ly prior to re-heating
Holder overheated
•Shrink fitting for withdrawal not possible. Return
(annealed)
chuck with tool to the manufacturer for repair if
possible
Mains voltage too low
•Connect system to a socket with higher voltage
•Use a voltage transformer
Current supply unstable.
•If using an extension lead:
Displayed voltage drops beConnect the system directly to socket or use
low 495 V during the shrink
cable with a larger cross section.
fitting process
•Connect equipment to a socket with a higher
voltage
•Lay cable from the main distribution directly to
the shrink fit system
1 phase missing in mains
•Check system fuses
supply
•Electrician to check if all 3 phases are there and
are connected correctly (socket and plug of
machine)
Bore of shrink fit chuck is
•Clean bore with brush
contaminated
Shank-Ø is too small
•Only apply tools with shank tolerance h6
Bore of chuck too large
•Apply other shrink fit chuck
Wall of the chuck too thin
•Use re-inforced version (S-chuck) .
1 phase missing in mains
supply
It is not possible to
shrink fit the tool or
extension for withdrawal
Clamping force of
chuckk is insufficient
32
GISS 2000 Operating Manual
Inbetriebnahme und Bedienung
4.8 SPEED-COOLER Troubleshooting
Problem
No cooling or
cooling performance
insufficient
Leaking cooling
body
Water reservoir
leaking
Condesation on
coolant bodies
Cause
System and cooler not bled
Remedy
•Bleed (see below)
•Top-up water and anti-freeze mixture, unil cooling spirals are well covered
Mixture ratio: water : anti-freeze = 2 : 1
Water pump and driving
•Turn the impeller with a screwdriver to release
motor stuck
the motor (see below)
•
Return equipment to the manufacturer for repair
Water pump defective (e. g.
run dry for too long)
•De-frost and top-up with water and anti-freeze
Water reservoir or cooling
mixture
spirals frozen
Mixture ratio: water : anti-freeze = 2 : 1
Insufficient rate of flow in the •Check rate of flow:
Disconnect the water return line
water circuit
Switch-on cooler
Min. rate of flow 2 l/min
•If necessary, remove any kinks in hoses.
•If no improvement:
Return cooling system to the manufacturer for
inspection
•Check voltage
Incorrect mains supply
see specification plate
Heat exchanger contaminated •Clean the cooling fins with compressed air
Air circulation of the SPEED- •Observe unrestricted (see notes regarding location)
COOLER restricted.
Compressor has become too • Switch-off cooler, wait15 minutes and then
reactivate temperature protection switch. If the
hot , triggered temperature
temperature protection switch is triggered again,
protection
Ambient temperature too the compressor is defective. Return cooler for
repair.
high, compressor defective
Coolant body placed on hot •Replace coolant body (exchange)
chuck with cooling system
turned off → melting seal
No or insufficient water in
the reservoir
Compression connection has
become loose
Soldering joint broken
Water temperature set too
low
Thermostat defective (does
not switch off)
No or insufficient water in
reservoir
•Tighten
•Return equipment to the manufacturer for repair
•Adjust cooling performance (see below)
•Return equipment to the manufacturer for repair
•Top-up water and ant-freeze mixture, until cooling spirals are well covered.
Mixture ratio: water: anti-freeze = 2 : 1
33
GISS 2000 Operating Manual
4.8.1 Bleeding the cooling system
• Bleeding the SPEED-COOLER:
Connect the bleed nipple with the length of hose
(1) (supplied) to the flow connection (3) of the
SPEED-COOLER. Do not turn the SPEED COOLER
on. The pump could be damaged if run dry.
After a short time water will run from the hose.
Remove the nipple with the length of hose.
• Bleeding the cooling circuit: Connect one of the two circulation hoses of the
GISS 2000 system to the flow connection (3)
of the SPEED-COOLER. Connection is via quick
release couplings. The circulation hoses are interchangeable (the direction of circulation in the
cooling bodies is not important).
Turn on the SPEED-COOLER.
Water is now pumped into the cooling system,
bleeding the hoses and the cooling bodies.
Wait until water exits the open hose.
Connect the hose to the return (2) of the SPEEDCOOLER.
Turn off the SPEED-COOLER.
Top-up the SPEED-COOLER with tap water. The
cooling spiral must be completely covered.
4.8.2 Water pump doesn‘t start
• Turn off the SPEED-COOLER
• Move (turn) the ventilation wheel (3) with a screw
driver through the housing (1) and the protective
cover of the motor (2).
• Remove the screw driver
• Start the cooling system
• Check if the pump is running
If the pump is not running: Electrical defect
34
GISS 2000 Operating Manual
Inbetriebnahme und Bedienung
4.8.3 Condensation on cooling bodies
The cooling output is set too high.
• Unplug the mains plug
• Remove the cover (1)
• Take the cover off the switch box (2)
• Turn the temperature control anticlockwise
in 15° increments until there is no more
condensation on the cooling bodies.
• Close the switch box (2)
• Refit the cover (1)
4.9 Important notes regarding the shrink fit process
1.It must be ensured the shrink fit chuck is correctly centered in relation to the spindle
and does not make contact with the spindle housing following the heating process.
If it comes into contact it will damage the plastic spindle housing. Therefore, it is also
important the holder carrier (spider) corresponds with the tool holder interface and
the turntable is engaged.
2. Following the shrink fitting process for insertion/withdrawal the spindle must be
removed immediately from the shrink fit chuck to prevent the radiant heat from
heating up the spindle.
3. If a tool can not be shrink fitted for withdrawal within the set time, under no circumstances should it be attempted to heat it up for a second time immediately afterwards.
This would allow the shrink fit chuck to heat up to an unacceptable 500° or more and
lead to permanent damage. In this case, the shrink fit chuck must be allowed to cool
down completely before retrying the shrink fit process for withdrawal again.
4. If it is not possible to shrink fit a tool for withdrawal, the following may be the cause:
-
-
-
-
-
-
-
Shrink fit system parameter settings not optimal
Tool shank is too large (not h6 tolerance)
Tool shank is damaged (burr, pressure marks on the Weldon flat)
Shrink fit chuck form not suitable (wall thickness too large)
Shrink fit chuck is heavily contaminated (oil)
Incorrect selection of limit stop washer
Incorrect fit of the limit stop washer face
5. Any residual coolant (especially inside) should be removed prior to shrink fitting for
withdrawal. Otherwise the coolant vaporizes and can cause an explosive ejection of
the tool.
6. The system operates with a high electric voltage. Therefore, for reasons of safety, the system should be kept clean at all times. Regularly remove any coolant, swarf and
tools shrink fitted for removal.
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GISS 2000 Operating Manual
Wartung und Instandhaltung
5.) Cleaning
5.1 Speed Cooler
To ensure the perfect functioning of the recooling plant it is paramount to keep the fins
of the aircooled condenser clean.
If the ambient air is of a high oil content:
Ambient air of a high oil content combined with dust will result in an increased
contamination of the condensor fins.
The following should be observed:
A thorough cleaning can not be achieved by simply brushing the outside whilst the fan
is running. It is paramount to apply an oil-soluble agent such as petroleum ether or
similar for a thorough cleaning. For this purpose we recommend the use of a spray gun
to penetrate deep inside the condensor. The functional items installed in the lower part
must be well covered for the cleaning agent with the impurities to be able to drain off
or be removed respectively without damaging the surrounding components. Cleaning
should be carried out at regular intervals, depending on the degree of contamination
due to the location of the Speed Cooler
.
5.2 GISS 2000 shrink fit system
The GISS 2000 shrink fit system should be cleaned on a regular basis.
• Turn-off the system at the mains switch.
• Unplug the mains plug.
• Clean the surface of the equipment with a damp, fluffless cloth.
During cleaning, liquid must not be allowed to enter inside the housing.
Protect the equipment against moisture, risk of electric shock.
Do not use strong cleaning agents.
Inductor
The inside of the inductor should be cleaned as required. Evaporating soluble oil or
similar can lead to contamination.
To a large extent this type of contamination can be prevented. As specified, only insert
clean and dry shrink fit chucks in the GISS 2000 system.
Linear unit
If contaminated, the linear unit must be cleaned to maintain its functionality and smooth
running. The guide rods should be lubricated with a drop of resin-free oil and the felt on
the sledge should be impregnated respectively.
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GISS 2000 Operating Manual
Wartung und Instandhaltung
6.) Maintenance and repairs
Repairs to the GISS 2000 shrink fit system and the SPEED-COOLER must only be carried out by qualified personnel. Electrical repairs to the system must only be carried
out by a qualified electrician. The opening of the housing by unauthorised personnel is
prohibited.
Attention! Dangerous residual voltage may be present in the housing up to 5 minutes
after turning off the equipment.
We recommend the equipment be returned to the manufacturer in the event of repairs
becoming necessary.This ensures the repair work is carried out professionally, of benefit
for a safe operation and longevity of the systems.
6.1 Maintenance
The GISS 2000 shrink fit system and the SPEED-COOLER are to a large extent maintenance-free.
SPEED-COOLER water level
Check the water level of the SPEED-COOLER at regular intervals. If necessary, top-up
with clean tap water. The cooling spiral in the reservoir must be completely covered..
6.2 Replacing the fine-wire fuse of the GISS 2000 system
The fine-wire fuse of the electronic control is situated next to the mains connection on
the left side.
• Switch-off the system at the mains switch and pull out the mains plug.
• Unscrew and remove the fuse.
• Replace with a new fuse with the description T50 mA — 500 V 6.3 x 32. Attention! Only use a fuse suitable for 500 Volt.
• Screw in the fuse and reconnect the mains supply.
Should the fuse fail again it indicates a system defect. The equipment should then be
checked by a qualified electrician.
Important! The fuse is a safety device for the equipment and the operator and under no
circumstances must be by-passed..
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GISS 2000 Operating Manual
Technische Daten
7.) Technical data
GISS 2000 shrink fit system:
Mains supply (in accordance with the data on the type plate):
Nominal voltage............................................................3 x 400 - 480 V ˜
min. actual operating voltage......................................3 x 360 V ˜
max. actual operating voltage.....................................3 x 500 V ˜
Frequency......................................................................50 - 60 Hz
Power consumption Standard.....................................11 kVA
Comfort Plus (special)........................20 kVA
Mains supply fuse protection Standard......................3 x 16 A
Comfort Plus (special).......................3 x 32 A
Fine-wire fuse for control electronics..........................T50 mA — 500 V 6,3 x 32 slo-blo
Clamping, un-clamping time.......................................approx. 5 seconds
Dimensions...................................................................approx. 500 x 670 x 700 mm
Weight............................................................................approx. 45 kg
Alternating magnetic fields in the working area........< 100 µT
High performance SPEED-COOLER:
Mains supply (in accordance with the data on the type plate):
Nominal voltage............................................................230 V ˜
Frequency......................................................................50 - 60 Hz
Power consumption......................................................1 kVA
Mains supply fuse protection......................................10 A
Water circulation:
Tap water/anti-freeze mixture
Mixture ratio..................................................................2 : 1
Quantity.........................................................................approx. 5 l
Cooling down time.......................................................20 to 150 seconds
Dimensions...................................................................approx. 565 x 440 x 335 mm
Weight............................................................................ca. 45 kg
Overall dimensions incl. trolley...................................600 x 1000 x 1530 mm
Overall weight incl. trolley...........................................ca. 100 kg
Permitted ambient temperature:
Storage and shipping...................................................+5° to +70° C
Operating.......................................................................+10° to +40° C
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GISS 2000 Operating Manual
8.) Replacement parts
39
GISS 2000 Operating Manual
40
GISS 2000 Operating Manual
No. Description
1
2
3
5
6
7
8
9
10 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 Guhring no. + code no.
Induction spindle from Ø 3-32 Induction spindle from Ø 40-50 (only Comfort Plus) Scale lamp E10 Limit stop washer Ø 3-5 Limit stop washer Ø 6-12 Limit stop washer Ø 14-16 Limit stop washer Ø 18-20 Limit stop washer Ø 25-32 Guide unit Cheese head screw Handle Grip Pressure spring Rubber Straight pin Straight pin Set screw Cap screw Tenon block Base plate for turn table version Base plate for single holder Turn table Holder Fastening set for turn table Milling cutter rest Back panel with cover Back panel without cooling Roller set short (complete) Roller set long (complete) Hook Wall mounting for water distributor (standard) Strip terminal for water distributor (standard) Elbow joint Sleeve 1 holder carrier SK 30 1 holder carrier SK 40 1 holder carrier SK 45 1 holder carrier SK 50 1 holder carrier HSK 25 1 holder carrier HSK 32 1 holder carrier HSK 40 1 holder carrier HSK 50 1 holder carrier HSK 63 1 holder carrier HSK 80 1 holder carrier HSK 100 Plate for SK + HSK (25-80) Plate for 1xHSK 100 2xSK Plate for 2xHSK 100 1xSK Plate for 3. HSK 100 2 fine-wire fuses Eye Screw connection Holder for cooling body Ø 40-50 (only Comfort Plus) 4743 32,000
on request
on request
4769 5,000
4769 12,000
4769 16,000
4769 20,000
4769 32,000
on request
DIN 912 M 6x14
on request
on request
on request
on request
DIN 7979 D D6x26
DIN 6325 3m6x24
DIN 913 M6x10
Guhring std. 7380 M5x8
5 St M5
on request
on request
on request
on request
on request
4746 1,000
on request
on request
on request
on request
on request
on request
on request
GCK-1/4-PK6-KU no. 6270
QM-1/4-1/4 no. 2255
on request
4744 40,000
on request
4744 50,000
on request
4745 32,000
4745 40,000
4745 50,000
4745 63,000
4745 80,000
4745 100,000
on request
on request
on request
on request
T 50mA 500 V 6.3 x 32
on request
11.0414 / 1 / 1/8‘‘
on request
41
GISS 2000 Operating Manual
No. Description
56 57 58 59 70 71 72 73 74 75
76 77 78 79 80 81 82 83 84 85 86 Guhring no. + code no.
Wall mounting for water distributor (only Comfort Plus) on request
Strip terminal for water distributor (only Comfort Plus) on request
Set of water hoses, 2 x 2.45 m, on request
spiral bound
Limit stop washer Ø 40 - 50 (only Comfort Plus) on request
Locking set on request
Cooling body complete Ø 6–8 on request
Cooling body complete Ø 10–12 on request
Cooling body complete Ø 14–16 interlocking on request
Cooling body complete Ø 18–20 on request
Cooling body complete Ø 25–32 interlocking on request
Cooling adapter for extension no. 1 on request
Cooling adapter for extension no. 2 on request
Cooling adapter blank for cooling body Ø14–16 on request
Cooling adapter blank for cooling body Ø25–32 on request
Cooling body complete Ø 40 - 50 on request
Limit stop washer Ø 3 - 5, geteilt on request
Limit stop washer Ø 6 - 12, split on request
Limit stop washer Ø 14 - 16, split on request
Limit stop washer Ø 18 - 20, split on request
Limit stop washer Ø 25 - 32, split on request
Cooling adapter for extension no. 0 on request
42
GISS 2000 Operating Manual
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43
Gühring oHG
PO BOX 10 02 47 . D-72423 Albstadt
Herderstr. 50 - 54 . D-72458 Albstadt
www.guehring.de . info@guehring.de
Tel:
(07431) 17-0
Fax:
(07431) 17-279
44
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