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Operating Instructions

Weber Screwdriving Spindle ( Robotic ) LCS-R 5/20/50


V 1.00

WEBER
Screwdriving unit
LCSR 05/20/50
LCS-R
5/20/50
V 1.00

WEBER Schraubautomaten GmbH

SER03/SER10/SER30_EN
www.weberusa.com

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30LCS-R 5/20/50
V 1.00

Table of contents
1. Preface................................................................................................................................................................................................... 4
1.1

How to use this manual ......................................................................................................................................................... 4

1.2

Your individual configuration ............................................................................................................................................... 4

1.3

Modifications / Copyright ...................................................................................................................................................... 4

1.4

How to contact WEBER ......................................................................................................................................................... 4

2. Safety instructions ............................................................................................................................................................................... 5


2.1

Warning signs and symbols : The following signs and designations are used in the manual to
designate instructions of particular importance:................................................................................................................ 5

2.2

Basic operation and designated use.................................................................................................................................... 5

2.3

Organisational measures relating to safety......................................................................................................................... 5

2.4

Selection and qualifications of personnel; basic responsibilities .................................................................................... 6

2.5

Maintenance safety instructions........................................................................................................................................... 6

2.6
2.6.1
2.6.2
2.6.3

Warning of specific dangers ................................................................................................................................................. 6


Electrical energy....................................................................................................................................................................... 6
Hydraulic and pneumatic equipment ........................................................................................................................................ 6
Oil, grease and other chemical substances ............................................................................................................................. 6

3. Machine description ............................................................................................................................................................................. 7


Elements of the Drive spindle ............................................................................................................................................................. 8
3.1
3.1.1

Screwdriver head assembly ................................................................................................................................................ 10


Function of the Nosepieces.................................................................................................................................................... 11

3.2

FK Guide Head ( where applicable ) ................................................................................................................................... 12

3.3

Bit stroke ( LCS-R 5/20/50) .................................................................................................................................................. 13

4. Commissioning................................................................................................................................................................................... 14
4.1

Unpacking ............................................................................................................................................................................. 14

4.2

Installation at users facility location .................................................................................................................................. 14

4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5

Connecting pipelines and cables ....................................................................................................................................... 15


Spindles with EC-motor drive: ................................................................................................................................................ 16
Spindles with air motor drive .................................................................................................................................................. 16
Connection of proximity switch............................................................................................................................................... 17
Connection of the feed hose .................................................................................................................................................. 17
Connection of the vacuum pump (at spindles with vacuum module) ..................................................................................... 17

4.4
4.4.1

Electrical commissioning .................................................................................................................................................... 17


Version: with ZSU control system (stationary) ....................................................................................................................... 17

5. Maintenance, adjustments................................................................................................................................................................. 18

5.1
5.1.1
5.1.2
5.1.3

Screwdriving head assembly .............................................................................................................................................. 18


Cleaning of the screwdriving head assembly ......................................................................................................................... 18
Cleaning of the swivel arm ..................................................................................................................................................... 19
Adjustment of the swivel arm ................................................................................................................................................. 21

5.2

Centering head (cleaning) ................................................................................................................................................... 22


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Operating Instructions
Weber Screwdriving Spindle ( Robotic ) LCS-R 5/20/50
V 1.00

5.3
5.3.1
5.3.2
5.3.3

Bit stroke module ................................................................................................................................................................. 23


Adjusting the forward stroke speed ........................................................................................................................................ 23
Adjusting the return stroke speed........................................................................................................................................... 23
Adjusting the bit stroke sensor for returned position .............................................................................................................. 24

6. Depth sensor....................................................................................................................................................................................... 25
6.1
6.1.1

Proximity sensor .................................................................................................................................................................. 25


Adjustment of the depth sensor.............................................................................................................................................. 26

7. Screwdriver Pneumatic or DC Electric ( Where Fitted )................................................................................................................ 27


7.1

Mounting instructions.......................................................................................................................................................... 27

8. Bit / Tool change................................................................................................................................................................................. 28


9. Replacing the feed hose .................................................................................................................................................................... 29
9.1

Mounting of hard feed hose (with collet chuck)................................................................................................................ 30

9.2

Mounting of soft feed hose (with hose adaptor) ............................................................................................................... 30

10. Faults ................................................................................................................................................................................................... 32

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Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
1. 0BPreface

1. Preface
1.1 How to use this manual
These operating instructions are designed to familiarize the user with the machine / system and its designated use.
The operating instructions contain important information concerning use of the machine/system in a

safe
correct and efficient manner.

Observance of these instructions helps to:

avoid risks,
reduce repair costs and shutdown periods,
increase the reliability and lifespan of the machine/system.

The operating instructions must be available at all times wherever the machine is in use. These operating instructions must be read and
applied by any person charged with carrying out work with and on the machine, such as

operation, including setting up,


troubleshooting in the course of work,
care,
disposal of oils and consumables,
maintenance (servicing, inspection, repair) and/or transport.

In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in
the country and place of use of the machine, the generally recognised technical rules for safe and proper working must also be
observed. The operating instructions should be supplemented with national regulations for the prevention of accidents and the
protection of the environment.
1.2 Your individual configuration
This Operating manual describes several models and versions that WEBER offers within the same series.
We hope you will understand that versions and features are included which you might not have.
For your individual configuration please refer to the spare parts list.
If features of your configuration are not described in this manual, supplementary manuals are enclosed.
1.3 Modifications / Copyright
The right to carry out alterations in technical design and changes to documentation without prior notice is reserved. WEBER reserves
copyright to these operating instructions. Any duplication, EDP recording or filming of any kind is forbidden without written authorisation.
1.4 How to contact WEBER
Please contact your local representative if you have difficulties using this manual or require amendments to be made.
Our service department can help should you have inquiries concerning commissioning, maintenance and adjustment of the
machine/system (tel. 914-962-5775).
We would like to take this opportunity to draw attention to our training program for machine operators and set-up personnel.
Please ask for your customer service department (tel. 914-962-5775 EXT 3021 ).
(Area representatives are organised according to postal code districts)
Please have the machine number of your machine/system ready when making enquiries.
IMPORTANT !
Read the machine operation and use instructions and have the serial number of the machine available before you call.

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Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30LCS-R 5/20/50
V 1.00
2. 1BSafety instructions

2. Safety instructions
2.1 Warning signs and symbols: The following signs and designations are used in the manual to designate instructions of
particular importance:
Attention.
Refers to special information and/or orders and prohibitions for the prevention of
damage.
ATTENTION

Danger.
Refers to orders and prohibitions designed to prevent injury or extensive damage.

DANGER

The warranty is invalidated if these warning instructions are disregarded.


2.2 Basic operation and designated use
The machine/system has been built to state-of-the-art standards and in accordance with recognised safety rules. Nevertheless, its use
may constitute a risk to the life and limb of the user or of third parties, or cause damage to the machine and to other material property.
The machine/system must only be used in technically perfect condition in accordance with its designated use and the instructions set
out in the operating manual, and only by safety-conscious persons who are fully aware of the risks involved. Any functional disorders,
especially those affecting the safety of the machine, must be rectified immediately.
The machine/system is designed exclusively for assembling connecting and fastening elements (screws, nuts, pins or clips). Using the
machine/plant for purposes other than those mentioned above is considered contrary to its designated use. The machine/system is
designed for special performance data (e.g. torque, speed, feed), along with special connecting and fastening elements and bit
geometries. Any use of the machine/plant beyond the bounds of this performance data can lead to damage and is considered contrary
to its designated use. The manufacturer/supplier cannot be held liable for any damage resulting from such misuse. The risk is borne
solely by the user.
Correct use of the machine/system also includes observation of the operating instructions and inspection and maintenance directives.
2.3 Organisational measures relating to safety
The operating instructions must always be at hand at the place of use of the machine/system (e.g. by storing them in the tool
compartment or compartment intended for this purpose).
The operating instructions must be supplemented by instructions covering duties involving supervision and notification of special
organisational features, such as work organisation, work procedures or the personnel entrusted with the work).
Personnel entrusted with work on the machine must have read the operating instructions (and in particular the chapter concerning
safety) before beginning work. Reading the instructions after work has begun is too late. This applies especially to persons working only
occasionally on the machine (e.g. during setting up or maintenance).
Personnel must wear suitable working clothes. For reasons of safety, long hair must be tied back or otherwise secured, garments must
be close-fitting and no jewellery (e.g. chains or rings) or unsuitable gloves should be worn because of the danger of them catching on
moving parts.
Protective glasses or a respiration mask must be worn due the risk (among others) of metal chip formations being generated (e.g. selftapping screws). This applies in particular to overhead assembly work.
The part should be adequately secured against any movement. Suitable clamping devices, among other measures, are necessary for
this purpose. Avoid any unusual posture and radius of action as well as any unstable standing position.
Observe all safety instructions and warnings on the machine/system. Ensure that all safety instructions and warnings on the machine
are complete at all times and perfectly legible.
In the event of safety-relevant modifications or changes in the behaviour of the machine/system occurring during operation, stop the
machine/system immediately and report the malfunction to the competent authority/person.
Never carry out modifications, additions or conversions which might affect safety without the suppliers approval. This also applies to the
installation and adjustment of all safety devices and valves, as well as any welding work on load bearing elements.
Spare parts must comply with the technical requirements specified by the manufacturer. Spare parts from original equipment
manufacturers always comply with these specifications.
Never modify the software of programmable control systems.

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Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
2. 1BSafety instructions

2.4 Selection and qualifications of personnel; basic responsibilities


Employ only trained or instructed staff to operate the machine and set out clearly the individual responsibilities of personnel in relation to
operation, set-up, maintenance and repair.
Set-up, test running and work on the machine/system should only be carried out by a skilled person or by properly instructed persons
under the supervision and guidance of a skilled person and in accordance with general technical rules and regulations.
WEBER carries out courses in operating and maintaining WEBER machines at the WEBER premises - and by request at the customers
premises. Information can be obtained from the WEBER service department (Telephone 914-962-5775 EXT; 3021).
2.5 Maintenance safety instructions
In the event of malfunctions, stop the machine/system immediately and secure it. Have any defects rectified immediately.
Observe the adjusting, maintenance and inspection activities and intervals set out in the operating instructions, including information on
the replacement of parts and equipment. These activities must be executed by skilled personnel only. Maintenance activities can be
carried out by the manufacturer as well. Information can be obtained from the WEBER service department (Telephone 914-962-5775
EXT; 3021).
Always observe the start-up and shut-down procedures set out in the operating instructions and the information on maintenance work
during work relating to the operation, adaptation to production, conversion or adjustment of the machine/system and its safety-oriented
devices or any work relating to maintenance, inspection and repair.

Always isolate the mains supply and air supply when carrying out any maintenance
or repair work on compressed air operated machines/systems.

DANGER

If the machine / system is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by:

locking the principal control elements and removing the start key and / or
securely attaching a warning sign to the main switch.

Always tighten any threaded connections that have been loosened during maintenance and repair.
2.6 Warning of specific dangers
2.6.1

Electrical energy

If provided for in the regulations, the power supply to parts of machines and systems on which inspection, maintenance and repair work
is to be carried out must be disconnected. Before starting any work, check the de-energized parts for presence of power and ground or
short-circuit them, in addition to insulating adjacent live parts and elements.
2.6.2

Hydraulic and pneumatic equipment

De-pressurize all system sections and pressure pipes (hydraulic system, compressed-air system) to be removed in accordance with the
specific instructions for the unit concerned before carrying out any repair work.
Hydraulic and compressed air lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths
and quality of the hoses must comply with the technical requirements.
2.6.3

Oil, grease and other chemical substances

Observe the product-related safety regulations when handling oil, grease and other chemical substances.

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Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
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3. 2BMachine description

3. Machine description
Each assembly job is different. There is a broad variety of fasteners including metric screws, self-forming screws of all sizes and
geometric variations, nuts, studs and set screws of various types. For this reason, your screwdriver system is individually adapted to
your particular screw driving application. All of these fastening elements should be automatically fed and mounted trouble-free and
safely.
Screwdriving spindles with automatic feeding of this type have an axial movement:

The bit stroke allows the screwdriving bit to be moved forward to the workpiece automatically.

Depending on the tool model and complexity purchased, will determine if the pneumatic or DC electric tool and transducer will also
move in unison with the bit stroke device.
The quick-change system reduces the time for maintenance and cleaning to only a few seconds (e.g. changing the screw driving head
assembly and screwdriver bit).
The power transfer is achieved via a hex female from the screwdriver thought the bit extension and into the screwdriver bit or socket.
Due to the modular design you have the choice of different drives, gearboxes, and control options for greater control over the fastening
process.
The spindle strokes and screw driving depths are checked and monitored by proximity switches, which helps to recognize and avoid
assembly faults. These depth sensors have different functions, such as: depth achieved start feeding cycle, set counter blast air, speed
change, etc.

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Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
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3. 2BMachine description

Elements of the Drive spindle


A WEBER stationary assembly system consists of a screwdriver spindle and (depending on the configuration), a feeding unit.
The screwdriver spindle and feeding unit are assembled in modules, so that they can be adapted to the specific application.

Illustration 1: Spindle LCS-R 5/20/50


The above diagram highlights the components and features of the LCS Spindle Range (Note: some features are optional and you
should consult your sales engineer for more details).

Description

Variants

Spindle Head

Fastener Feeding Head

Connecting Sleeve

Quick change lining

Shock Absorber

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Guide Head (not shown)

WEBER Schraubautomaten GmbH

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
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3. 2BMachine description

Motor saddle mount

Bit stroke pneumatic cylinder

Power drive assembly

Electric DC motor ( without illustration )

Air Motor ( as shown )

Side plate cover

Plexiglas

Steel full safety shield ( optional )

Rear exhaust port - RE PORT indicates when the tools stops or clutch fires ( manufacturer supplied - one shot clutch tools only )

High accuracy proximity switch

10

Air Electric Switch used in conjunction with the RE Port on the tool

( this item is optional )

11

Bit Stroke Advance

With flow control adjustment ( advance speed )

12

Bit Stroke Retract

With flow control adjustment ( retract speed )

13

Proximity switch bit stroke in home position

14

Bit adaptor

15

Tool mount adapter

16

Rod aligner

17

Pillow block

18

Linear bearing

The screwdriver spindles can differ through:

Screwdriving head assembly,


The stroke lengths of the screwdriver and head stroke,
Type and size of the power drive assembly / measurement device (transducer).

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Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
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3. 2BMachine description

3.1 Screwdriver head assembly

Illustration 2: Screwdriving head assembly shown with 3-finger aligning guide


1 Nosepiece (various styles available)
a) 3-finger aligning guide
b) 2-finger aligning guide
c) Collet sleeve with collet chuck
d) Ball Guide
2 Screwdriving head
3 Swivel arm
4 Guide bushing (without illustration)
5 Swivel arm bracket
6 Set collar with clamp screw
7 Lever
8 Feed tube
9 Connecting sleeve (Quick change lining)
10 Connection for inverted air blast (only in case of screwing from bottom up)
11 Connection for air blast for positive pressure to displace contamination (used for inverted screwdriving)
According to the screw geometry and dimensions, the following standard nosepiece categories are used:

10

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Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
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3. 2BMachine description

Illustration 3 Standard nosepieces


The nosepiece is screwed in the screwdriver head assembly. (Caution: left-hand thread)
3.1.1

Function of the Nosepieces

The screwdriver head assembly contents all spindle components that comes into contact with the fastener (screw, stud). For this
reason, it is individually adapted and adjusted to your assembly application and due to this fact - is suitable only for a particular size of
a fastener.
The screwdriving head assembly is fastened by a quick change lining at the connecting sleeve positioned above bit stroke module.
The driving tool is fastened by a quick change lining with bit stroke module and is guided by a guide bushing inside screwdriving head.
The screw which has been blown through the feed tube, swivel arm and screwdriving head arrives in the nosepiece. The screw is fixed
in the nosepiece (by the aligning jaws) until the bit is in place and is ready to fasten the screw.
The screwdriving head assembly extends and places the nosepiece over the assembly position, the screwdriver bit follows (rotating)
and extends, the bit is inserted into the engagement of the screw; the screw is tightened.

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Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
3. 2BMachine description

3.2 FK Guide Head (where applicable)


The FK head guides the screwdriving tool.

Illustration 4: Guide head with quick change lining (left) and with union nut (right)

1
2
3
4
5
6

12

Version with quick change lining (left)


Centering head
Guide bushing (not illustrated)
O-ring (2x) (not illustrated)
Locking Collar
Cheese head screw for clamping the guide bushing
Connecting sleeve with quick change lining for mounting the guide head

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Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
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3. 2BMachine description

3.3 Bit stroke ( LCS-R 5/20/50)


The screwdriver bit stroke moves the screwdriver bit during the loading and fastening process.
The stroke speed can be adjusted with throttle valves. The throttle valves are release throttles. They control the stroke speed of the
cylinder using the outlet air from the cylinder chamber that is currently not under pressure. The more the valve is opened, the faster the
air flows out of the chamber; and the opposing pressure in the non pressurised cylinder chamber is reduced.
A proximity switch signals the upper end (home) position of the screwdriver piston.

Illustration 5: Bit stroke module


1
2
3
4

Bit stroke module


Return stroke pressure connector with advance stroke throttle (quick-action connection 6)
Advance stroke pressure connector with return stroke throttle (quick-action connection 4)
Proximity switch bit stroke in home position

Pressure connectors can be attached to the opposite side of the spindle ( if the
cylinder is rotated 180 deg )

NOTE

Screwdriving sequence
Screwdriver and feed unit are ready for operation.
The screw driving process can be started.

Please refer to the electrical appendix (program manual) or functional diagram


(depending on the scope of delivery) for the screwdriving cycle sequence.

NOTE

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Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
4. 3BCommissioning

4. Commissioning
The screwdriving systems supplied by WEBER (screwdriving spindle, control, feeding system and, if available, fixtures) are very often
already pre-assembled and configured according to the application (e.g. screwdriving programs, friction clutch adjustments, mechanical
adjustment of the feeding system). Please refer to the inspection sheets for the adjustment values. Avoid adjustment work or aimless
tinkering around with the screwdriver if you cannot be certain that the measures taken will lead to the desired success.
4.1 Unpacking
Unpack the delivered spindle.
- Do not use sharp or pointed objects to unpack the spindle and feeding system.
- Avoid shocks and blows, in particular in the area of the screw head assembly and the dynamic transducer.
Degrease any greased components with an appropriate degreasing agent and a soft, lint-free cloth.
- While greasing components with polished metal surfaces prevents corrosion during transport and storage. Ensure that fasteners
do not come into contact with residual grease when they pass through the feeding system, because this can lead to sticking and
influence the operational capability of the screwdriving spindle.
- Do not bend compressed air pipes or cables.
- Do not pull violently on electrical cables.
- Do not squeeze or crush any electrical cables or connectors.
Check the delivery for completeness, or damaged as a result of shipping.
Inform WEBER and the logistics/shipping company immediately of any detected damage.

4.2 Installation at users facility location


Check the installing location.
- The standard screwdriving spindle is suitable for all positions from 0 to 90 (vertical and horizontal work direction). The
screwdriving unit must be specially aligned for vertical and horizontal work directions involving screw threading operations from
90 to 180.
Ensure that the fastening/support/holder is sufficiently stable, and does not bend or oscillate.
Clean installing location (spindle location fixture).
- The guide rails provided (WEBER scope of delivery) should be included in preparation of the installing location if possible, in
order to ensure an exact mounting.
- A workpiece carrier with an inserted workpiece must be placed in the final working position before the spindle is secured in the
installing location.
Fasten the spindle in the spindle receptacle fixture with the aid of suitable screws and washers, so that the spindle can be adjusted
later.

IMPORTANT.
The spindle must be installed above the workpiece in such a way, that the nose piece doesnt come into contact with the surface of
the workpiece. The distance differs from spindle to spindle and should have a value that allows the fastener (screw, stud) this is
guided in the jaws, before entering in driving location.
Make sure that driving spindle is positioned correctly. Refer to the dimension sheet or the drawing supplied.
The spindle must be positioned directly above the screw location to ensure a perfect result. Ensure here that axial and angular offset
to the fasteners axis which may occur during production is as low as possible.

Incorrect adjustment will result in incorrect driving, damage to fasteners or


workpiece and/or increased wear on spindle components (e.g. bearings, bits).

ATTENTION

Tighten securing screws completely.


- The spindle is now in the working position.
Check by manually positioning all relevant connection parts, along with all screw positions, workpiece holders and connection
variations, if the spindle is positioned exactly above the driving position.

The spindle is in the working position with the head stroke fully extended. Do not
position/traverse the spindle automatically when adjusting (e.g. with the aid of an
x/y system or manipulator).
ATTENTION

14

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Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
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4. 3BCommissioning

Turn the screwdriving head assembly on the quick-change chuck to the ideal position, ensuring that the feed hose is not bent or subject
to pulling stress.
Ensure that the aligning guide does not come into contact with interfering component edges.
Check the swivel arm for smoothness of movement inside head assy.
Check if the connector cables, feed lines and hoses can be laid with a large enough bend radius. Note at the same time all possible
movements and limit positions of the spindle.
Compressed air and electrical pipes and cables should not be bent. Make sure that no pipes or cables rub or are caught on other
components / holders / fixtures / etc...
Check all hose connections and electrical cables for secure contacts which could become loose during transport.
If the spindle has to operate in several screwdriving positions, these procedures should be carried out at each screwdriving position.
4.3 Connecting pipelines and cables
Locate maintenance unit as near as possible to the machine and connect it to compressed air.
a) For lubricated operation with maintenance unit consisting of filter, pressure reducer, oiler, and separation module and pressure
reducer refer to pneumatics scheme.
b) For oil free operation with a maintenance unit consisting of filter, pressure reducer, separation module and pressure reducer refer
to pneumatics scheme.
Make sure before connecting, that compressed air supply meets safety standards.

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Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
4. 3BCommissioning

We recommend use of clean and quality compressed air in accordance with the ISO 8573-1:
Class

Residue of Oil Content


mg / m

Dirt Residue

Water Residue

particle size m

max.
Concentration mg /
m

pressure
dewpoint C

max. Concentration
g / m

Oiled air
4

15

+3

-20

0,88

Oil free air

Nominal operation pressure (flow pressure) is 6,3 bar. At air motors, resp. spindle systems also flow through quantity must meet the
requirements.
Hoses have to be as short as possible and allow a large enough bend radius; do not bend them.
Connect valve bank to maintenance unit refer to pneumatics scheme.
Connect pipelines to valves and spindle refer to pneumatics scheme.
The hoses (pneumatic lines) must be cut off straight and smoothly and then pushed into the fittings up to the end stop.
LCS- 5 driving spindles are suitable both for oiled and non lubricated air. The required oil quantity is adjusted at the oiler on the
maintenance unit and depends on drive type.

For a spindle with electric motor drive, oil quantity has to be adjusted at maintenance unit to 1 oil drop for aprox. 30 working
strokes.
For a spindle with air motor drive, oil quantity has to be adjusted at maintenance unit to 1 oil drop for aprox. 15 working cycles.

4.3.1

Connect supplied cables for motor, resolver, and dynamic transducer. The cables with polar sockets and plugs prevent any
confusion. (only where used) refer to circuit diagram

4.3.2

16

Spindles with EC-motor drive:

Spindles with air motor drive

Insert air hose with coupler connection to socket on air motor and connect it to motor valve.
On air motors with functional feedback, an additional hose line has to be connected to RE-Switch refer to pneumatics scheme in
attachment.

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Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
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4. 3BCommissioning

4.3.3

One end of these cables is connected to the junction box.


The other end of the cable is provided with a coupling that has to be connected to its assigned proximity switch. Each cable is
provided with a tag, indicating junction resp. the corresponding plc address (plc address is assigned to proximity switch
description printed on tag). refer to circuit diagram of control system/junction box

4.3.4

Connection of the feed hose

Insert one end of the feed hose to the screwdriving head assembly of the spindle and tighten it with male fitting (sleeve).
Connect the other end of the feed hose to escapement of feeding unit and tighten it with male fitting (sleeve). (At tough hose
variant tighten knurled nut) refer to chapter Replacing the feed hose.

4.3.5

Connection of proximity switch

Connection of the vacuum pump (at spindles with vacuum module)

Determine the location site of the vacuum pump. The vacuum pump should be mounted as close as possible to the screwdriving
location. The pump operates free of oil, and the suctioning in of oil mist should be avoided. The location should be well ventilated, as
the vacuum pump generates heat.
Please refer to the separate operators manual in the appendix for vacuum pump connection.
Attach the vacuum hose to the respective connection on the vacuum pump, connecting the other end to the vacuum module.

4.4 Electrical commissioning


4.4.1

Version: with ZSU control system (stationary)

No workpiece for threading operations has yet been positioned under the spindle. No screw has yet been inserted in the
mouthpiece.
Set control system toggle switch to ON (illuminates green).
Insert a workpiece with an already driven in screw under the screwdriver.
Insert the bit/blade at engagement of the screw using the Jog key.

The bit is in engagement:

If the machine only has one depth sensor the LED must light at this position.
If the machine has two depth sensors, the functions of these depth sensors (control depth, to deep, set counter blast air...) refer
to specific data sheet) have to be adjusted accordingly.
The sensors must be readjusted if the LEDs do not light (see chapter Depth Sensor of the operators manual).
Move the screwdriver to home (returned) position using the Jog key.
Feed in a screw by pressing the Single escapement key (key symbol with screw). The Single escapement lamp must light
continuously.
Move a workpiece to be threaded into the driving position under the spindle.
Ensure that the screwdrivers mechanical clutch is correctly adjusted.
Start a test screwdriving cycle by pressing the Single cycle key.

Commissioning is complete when the fastening output is O.K. .

WEBER Schraubautomaten GmbH

SER03/SER10/SER30_EN
www.weberusa.com

17

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
5. 4BMaintenance, adjustments

5. Maintenance, adjustments
Please refer to the maintenance plan in the appendix for maintenance intervals.
For all maintenance and adjustment works (as far as possible) driving spindle feed unit must be disconnected from the electrical and
compressed air supply and the accidental use must be prohibited.
Deviations from these instructions are only permitted if expressly detailed in the related procedures.
If the equipment remains connected to supply voltage/compressed air, a high risk of
personal danger is present. All work must be performed with extreme care and
attention by qualified personnel.
DANGER

5.1 Screwdriving head assembly


5.1.1

Cleaning of the screwdriving head assembly


Maintenance and adjustment works on the screw driving head assembly must be
performed by qualified personnel in accordance with the state-of-the-art standard
and the recognized safety rules.

ATTENTION

Illustration 1:

Screwdriving head

1 Nosepiece
2 Screwdriving head
3 Swivel arm
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SER03/SER10/SER30_EN/20/
50

WEBER Schraubautomaten GmbH

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
5. 4BMaintenance, adjustments

4
5
6
7
8
9
10
11

Guide bushing (without illustration)


Swivel arm bracket
Set collar with clamp screw
Lever
Feed tube
Connecting sleeve (quick change lining)
Air Connection for inverted screwdriving ( Air Blast )
Air Connection for prevention of contamination build up.

While dismantling screwdriving head and swivel arm, please proceed as follows:

Move bit stroke module into returned position.


Disconnect compressed air supply at maintenance unit.
Press both levers pos. 7 together and withdraw swivel arm with feed hose pos. 8 from the swivel arm bracket pos. 5.
Withdraw spring bushing of the connecting sleeve pos. 9 downwards and pull screw driving head assembly downwards off the unit.
Wash out with cold cleaner and carefully blow out the screw driving head assembly, especially the nosepiece.
Check guide sleeve in the screwdriving head, aligning jaws and the springs in the jaws for signs of wear replace if required.

5.1.2

Cleaning of the swivel arm

Unscrew male fitting pos. 3.3 and withdraw feed hose with collet chuck pos. 3.4 from the swivel arm cap pos. 3.2.
Remove snap ring pos. 3.6 from the swivel arm cap pos. 3.2.
Pins pos. 3.5, compression springs pos. 3.7 and balls pos. 3.8 fall off, dont lose
them.

NOTE

Sw ivel arm assembly:

Illustration 2 Swivel arm for hard feed hose

WEBER Schraubautomaten GmbH

SER03/SER10/SER30_EN/20/
50

19

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
5. 4BMaintenance, adjustments

3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8

20

Swivel arm
Swivel arm cap
Male fitting
Collet chuck
Bolts
Snap ring
Compression spring
Ball

SER03/SER10/SER30_EN/20/
50

WEBER Schraubautomaten GmbH

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
5. 4BMaintenance, adjustments

Wash out with cold cleaner swivel arm and small parts.
Check swivel arm for signs of wear replace if required.
Check compression springs for signs of wear replace if required.
Grease compression springs lightly and assembly them with the other parts in reverse order.
Mount feed hose to swivel arm refer also to chapter Replacing the feed hose.
Assemble the complete swivel arm in correct position to the swivel arm bracket, make sure that both levers pos. 7 engage to the set
collar pos. 6 (refer to illustration 1 above).
- Note: Recess in the swivel arm cap must face outwards.
Insert complete screwdriving head assembly into spring bushing and turn it until it engages in the correct position.
After assembly check tube connections and cables to be correctly tightened
retighten or mount again if necessary.

NOTE

5.1.3

Adjustment of the swivel arm


Loosen the adjusting ring only if required; if the fed screw doesnt load correctly
between the aligning jaws; readjust it so it does.

ATTENTION

Illustration 3
Press both levers pos. 7 together and withdraw the complete swivel arm with feed hose out from the swivel arm bracket (only
20/50) until you can loosen the clamp screw pos. 6.1.

WEBER Schraubautomaten GmbH

SER03/SER10/SER30_EN/20/
50

21

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
5. 4BMaintenance, adjustments

Shift the adjusting ring ( Pos. 6 ) on the swivel arm cap and bring the swivel arm into pre-determined position, so that the following
conditions are correct:
- The swivel arm pos. 3.1 is located under spring pressure in the slot of the screwdriving head.
- Ensure that pre-clamping force of the spring is correct.
- The swivel arm lies against the screw driving head (flat side).
- The swivel arm internal bore and the bore in the screw driving device must align correctly.
- You must ensure that swivel arm can swing out when the screw driver is moved out without the swivel arm touching the screw
driving head.
- Note: The recess in the cap facing outwards.
If these conditions are ok, tighten clamp screw pos. 6.1 firm, assemble the swivel arm in correct position to the swivel arm bracket
and make sure that both levers pos. 7 engage to the set collar.

5.2 Centering head (cleaning)


Maintenance and adjustment work on the screw driving head assembly must be
performed by qualified personnel in accordance with the state-of-the-art standard
and the recognized safety rules.
ATTENTION

Illustration 4: Guide head with quick change

1
2
3
4
5
6

Version with quick change lining (left)


Centering head
Guide bushing (not illustrated)
O-ring (2x) (not illustrated)
Locking Collar
Cheese head screw for clamping the guide bushing
Connecting sleeve with quick change lining for mounting the guide head

While dismantling the guide head please proceed as follows:

22

Move bit stroke module into returned position.


Disconnect compressed air supply at maintenance unit.
Loosen connecting sleeve pos. 6 or union nut pos. 4 and pull guide head downwards off the unit.
Blow out the guide head carefully.
Check the guide sleeve in the guide head for wear replace if necessary.

SER03/SER10/SER30_EN/20/
50

WEBER Schraubautomaten GmbH

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
5. 4BMaintenance, adjustments

5.3 Bit stroke module

Illustration 5: Bit stroke module

1
2
3
4
5

Forward bit stroke flow control (connection 6 refer to pneumatics diagram)


Return bit stroke flow control (connection 4 refer to pneumatics diagram)
Sensor bit stroke retracted position. ( home sensing )
Clamp screw for sensor
Sensor bit stroke forward position. (depth sensing )

5.3.1

5.3.2

Adjusting the forward stroke speed

Turning the adjustment screw on the flow control (pos. 1) clockwise reduces the forward stroke speed.
Turning the adjustment screw on the flow control (pos. 1) counter clockwise increases the forward stroke speed.
Adjusting the return stroke speed

Turning the adjustment screw on the flow control (pos. 2) clockwise reduces the return stroke speed.
Turning the adjustment screw on the flow control (pos. 2) counter clockwise increases the return stroke speed.

WEBER Schraubautomaten GmbH

SER03/SER10/SER30_EN/20/
50

23

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
5. 4BMaintenance, adjustments

5.3.3

Adjusting the bit stroke sensor for returned position (Home Position )

Loosen clamp screw pos. 4.


Slide sensor at pos. 3 until correct switch position is reached.
Tighten clamp screw again.
- The switch position for the sensors can be best recognized when control voltage is connected. When the correct switch position
is reached, a LED lights on the sensor.

The sensor bit stroke returned position can be reached only if the head stroke is in
returned position.

NOTE

24

SER03/SER10/SER30_EN/20/
50

WEBER Schraubautomaten GmbH

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
6. 5BDepth sensor ( Optional )

6. Depth sensor ( Optional )


6.1 High Accuracy Proximity sensor
Depending on each particular application of the assembly job, the depth sensors (magnetic field sensor) have different functions.
For this reason, your controller is individually adapted (by plc program) to your particular application.
According on delivery scope, a functional diagram or program print out have been attached. Please refer also to this sheet concerning
function and assignment.
Possible functions:

Driving depth reached,


Switching depth: for changing rotational speed, or for starting angle measurement,
Control depth: Driving depth reached, respectively exceeded,
Setting depth: for setting (starting) screw feeding, counter blast air.

Please refer for accurate adjustment values according to this sensor, to the technical data sheet of this magnetic field sensor.

1
2
3
4
5

Proximity sensor
Front proximity mounting bracket
Rear mounting bracket
Proximity switch retaining nut
Proximity shear adjuster rod

WEBER Schraubautomaten GmbH

SER03/SER10/SER30_EN

25

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
6. 5BDepth sensor ( Optional )

6.1.1

Adjustment of the depth sensor

The depth sensors have been adjusted before delivery according to your particular assembly application. Therefore, readjust depth
sensor only if:

screw, work piece, fixture, distance between driving spindle and work piece, etc. have changed,
if the driving spindle has been dismantled and assembled again.

While adjusting, proceed as follow s:

Insert the fastener (for ex. screw, nut) manually to the required depth.
Drive spindle (head stroke and bit stroke with fastening tool) to advanced (working) position. Use the Jog function key on the
controller.
Check the engagement of the tightening tool into the fastener visual control.
Loosen clamp screw pos. 1 and clamp screw pos. 3.
Slide sensor (magnetic field-sensor at pos. 4), until it detects the continuous magnetic rod. (LED lights rough positioning of the
sensor)
Tighten clamp screw pos. 3.
Slide sensor (magnetic field-sensor) pos. 4 using adjusting screw pos. 2 until the correct switch position is reached. (fine
adjustment)
Tighten clamp screw pos. 1.
Inexact adjustment of the depth sensor will result in damage to driving spindle,
fastener, work piece, or fixture. Weber cannot be held liable for any damage
resulting from such actions.
ATTENTION

After adjusting the depth sensor, check driving program (plc program). Check while using different work pieces, the correct
adjustment of the depth sensor, especially if the driving result is an O.K. one.

At an N.O.K. result, repeat adjustment procedures of the depth sensor.

26

SER03/SER10/SER30_EN

WEBER Schraubautomaten GmbH

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
7. 6BScrewdriver Pneumatic or DC Electric (Where Fitted)

7. Screwdriver Pneumatic or DC Electric (Where Fitted)

7.1 Mounting instructions

Illustration 1: insert unit into the threaded tool adapter ( CP, AC, etc ) Ensure that Quick release bit holder has the bit adaptor fitted
correctly before threading into tool adaptor

Illustration 2: make sure the unit is fully seated in adapter.

WEBER Schraubautomaten GmbH

SER03/SER10/SER30_EN

27

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
8. 7BBit / Tool change

8. Bit / Tool change

After assembly check the feed hose to be correctly tightened; mount it again if
necessary.

NOTE

While dismantling the screw driving head and tool, please proceed as follows:

Move (head stroke and) bit stroke in returned (home) position.


Disconnect compressed air supply at maintenance unit.

llustration 1

28

Pull the screwdrivers quick release bushing forward to release the bit adaptor. (Pos 1) at same time pull the bit adaptor (pos. 2)
downwards and remove it. (remove from front of spindle)
Assemble new driving tool and screwdriving head assembly or guide head in reverse order.

SER03/SER10/SER30_EN

WEBER Schraubautomaten GmbH

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
9. 8BReplacing the feed hose

9. Replacing the feed hose

Illusration 1 : Screwdriving head


1
2
3
4

Male fitting
Collet chuck or adaptor
Swivel arm cap
Feed Hose

Depending on the screw driving application, there are tw o feed hose types in use:
hard feed hose ( Shown Above )
soft feed hose

WEBER Schraubautomaten GmbH

SER03/SER10/SER30_EN

29

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
9. 8BReplacing the feed hose

9.1 Mounting of hard feed hose (with collet chuck)

Illustration 2

Loosen the male fitting (pos.1) with the pin wrench. Remove feed hose ( pos.4 ) with male fitting ( pos.1) and collet chuck ( pos.2 )
Slide the male fitting (pos.1) and collet chuck (pos. 2) correctly over the new feed hose (pos. 4). (Openings on collet chuck point
away from driving spindle).
Slide the feed hose (pos. 4) from upside completely into the swivel arm cap (pos.3) until the end stop is reached.
Tighten male fitting (pos. 1) with the pin wrench.

9.2 Mounting of soft feed hose (with hose adaptor)

Illustration 3

30

SER03/SER10/SER30_EN

WEBER Schraubautomaten GmbH

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
9. 8BReplacing the feed hose

Push feed hose (pos. 2) onto the swivel arm cap (pos. 3).
Insert male fitting (pos. 1) through the adaptor and thread it in the swivel arm cap.
Slide feed hose (pos. 4) on 2/3 of adaptors length.

The end of the feed hose must be clean and chamfered. And cut square to the hose
to prevent screw jams and inconsistent results!!!
Do not bend the feed hose particularly if it is white nylon. Is signs of bend are
evident you must replace the feed hose.
NOTE

WEBER Schraubautomaten GmbH

SER03/SER10/SER30_EN

31

Operating Instructions
WEBER Screwdriving unit SER03 / SER10 / SER30
V 1.00
10. 9BFaults

10. Faults
If a fault occurs, please try to solve it using the following troubleshooting instructions. The necessary maintenance and adjustment tasks
are explained in the chapter with the same title.
The following list of faults and measures to cure faults are not claimed to be complete.
If you cannot solve the error, remove the screwdriver and feeding unit from the mains supply (voltage) and compressed air supply,
secure the equipment against unauthorized use and contact your service representative at WEBER (please refer to preface).
The screw is ejected out of the nosepiece
Bit stroke forward speed is too high

Adjust bit stroke forward release throttle

Spring (-s) of the aligning jaws are worn out

Replace springs

Aligning jaws are worn out

Replace aligning jaws.

The screw driver finishes the driving cycle too early

Work piece is damaged

Check thread

Screws are damaged

Check/replace screws

Depth sensor incorrectly adjusted

Readjust depth sensor

Screwdriving sequence (program) at driving controller is not


programmed correctly

Change driving sequence (program) at controller (refer to


controllers manual please).

The screw driver stops the driving cycle only after monitoring time (w atch dog) has expired
Screw was spun out of the nosepiece

See above

Screwdriver bit is worn out

Replace screwdriver bit

Screw just turns without thread

Monitoring time too short

Check thread in workpiece, eventually replace it


Check thread on screw, eventually retry a new driving cycle.
(replace faulty screw first).
Readjust monitoring time

The screw jams in the screw driving head assembly


Swivel arm is incorrectly fitted

Adjust swivel arm

Swivel arm / screwdriving head / mouth piece is / are dirty

Clean swivel arm / screwdriving head / mouth piece

Feed hose not placed properly in swivel arm, not cut straight (
not chamfered), collet chuck placed in wrong direction
(openings in wrong way around)

Check feed hose and collet chuck

Incorrect fasteners from original set-up

Check with vendor of fasteners

32

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WEBER Schraubautomaten GmbH