FCC ID: 2A2B9KOMFLEX Remote adjustable tool holder

 

KOMflex precision spindle

Operating instructions

head

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KOMflex precision spindle head

Operating instructions V1.1 31.03.2021

Contents

1

Introduction ....................................................................................................................................... 1

Purpose of this document .......................................................................................................... 1

Obligations and liability ............................................................................................................. 1

2

Safety information ............................................................................................................................. 2

Operating personnel .................................................................................................................. 2

Intended use .............................................................................................................................. 2

Improper use .............................................................................................................................. 2

EC Declaration of Conformity .................................................................................................... 3

Radio Approval ........................................................................................................................... 5

3

Glossary .............................................................................................................................................. 6

KOMflex adjustment range ........................................................................................................ 6

Centre position definition .......................................................................................................... 6

VIP definition .............................................................................................................................. 6

Reinitialisation ........................................................................................................................... 7

4

5

System overview ................................................................................................................................ 8

Description of the RC66 wireless receiver ......................................................................................... 9

RC66 standby mode ................................................................................................................... 9

KOMflex mode ........................................................................................................................... 9

Pairing mode ............................................................................................................................ 10

6

Description of the KOMflex precision spindle head ........................................................................ 11

Technical data .......................................................................................................................... 11

KOMflex system description .................................................................................................... 12

Required accessories ............................................................................................................... 12

Description of the KOMflex modes .......................................................................................... 13

6.4.1

6.4.2

Manual adjustment with magnetic pen ........................................................................... 13

Automatic adjustment via NC cycle ................................................................................. 14

Emergency shutdown .............................................................................................................. 15

If the KOMflex is in an active state, but does not receive any commands from the interface IF20, the

head is deactivated after a timeout of 5 minutes and goes into standby mode. ................................ 15

Possible scenarios in which an emergency shutdown may occur ....................................................... 15

•

•

Switch-off command does not reach the KOMflex, e.g. problems with radio connection ......... 15

The emergency stop or reset of the NC is activated. ................................................................... 15

7

Getting started and tool mounting .................................................................................................. 15

Initial commissioning of the KOMflex ...................................................................................... 15

Indicating the basic settings ..................................................................................................... 16

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Manually configuring the basic settings .................................................................................. 17

Mounting.................................................................................................................................. 18

Tool mounting .................................................................................................................. 18

Tools with ABS connection ............................................................................................... 18

Tool with cylindrical shank ............................................................................................... 18

Coolant ............................................................................................................................. 19

8

Commissioning the KOMflex ............................................................................................................ 20

Presetting equipment .............................................................................................................. 20

Use of the KOMflex on the machine ........................................................................................ 22

Overview of the product range ........................................................................................ 22

Subprogram for defining the customer program ............................................................ 22

Parameter overview when calling up programs .............................................................. 24

Teaching in the KOMflex .................................................................................................. 25

Correction in automatic mode ......................................................................................... 26

Manually switching off ..................................................................................................... 27

Reinitialisation of the KOMflex ................................................................................................ 27

Extension of the machine with further KOMflex ..................................................................... 28

Changing the cutting edge ....................................................................................................... 29

Battery replacement ................................................................................................................ 30

Changing the battery ....................................................................................................... 30

Disposal of batteries ........................................................................................................ 31

KOMflex errors in machine operation ..................................................................................... 32

BLUM errors in machine operation ......................................................................................... 34

9

KOMflex recycling – Our recycling service ....................................................................................... 36

10

List of abbreviations used ............................................................................................................ 36

7.4.1

7.4.2

7.4.3

7.4.4

8.2.1

8.2.2

8.2.3

8.2.4

8.2.5

8.2.6

8.6.1

8.6.2

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KOMflex precision spindle head

Operating instructions

These operating instructions are designed to familiarise users of the KOMflex precision spindle head

with the following:

1

Introduction

Purpose of this document

• Working principles

• Operation

• Safety information

• Maintenance

Obligations and liability

• An understanding of the fundamental safety information and safety regulations is a basic

prerequisite for safe handling and trouble-free operation of the KOMflex precision spindle head.

• These operating instructions, and in particular the safety information, must be observed by all

persons who work with the KOMflex precision spindle head.

• Furthermore, the accident prevention rules and regulations applicable for the place of use must

be observed.

• The KOMflex precision spindle head is constructed according to the state of the art and

recognised safety rules. Nevertheless, dangers may arise for the user or third parties or the

KOMflex precision spindle head or other items may be damaged during use. The KOMflex

precision spindle head must therefore only be used

o

o

for its intended use

in perfect condition in terms of safety.

•

If a fault arises which could affect the safety of the KOMflex precision spindle head, it must be

shut down. Please contact the manufacturer.

• Please note that the following causes may affect the operational safety of the KOMflex precision

spindle head as well as the safety of persons working with it:

Improper use of the KOMflex precision spindle head.

Improper installation, commissioning, operation and maintenance of the KOMflex

precision spindle head.

o

o

o Operation of the KOMflex precision spindle head in a machine with faulty safety devices

or improperly attached or non-functional safety and protection devices.

o Non-compliance with the information in the operating instructions relating to transport,

storage, assembly, commissioning, maintenance and setup of the device.

Inadequate monitoring of device parts which are subject to wear.

o Unauthorised modifications to components of the KOMflex precision spindle head.

o

o Repairs carried out incorrectly.

o Catastrophes caused by external influences or force majeure.

In isolated cases and under certain circumstances, this may also lead to limitation of liability or

exclusion of liability of the manufacturer, whereby the contractual and statutory rights remain

unaffected by the above.

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Operating instructions V1.1 31.03.2021

2

Safety information

Operating personnel

Note

Intended use

Components must only be operated by trained personnel who are familiar with the working principles,

operation and safety devices of the KOMflex precision spindle head.

Always keep the operating instructions with the KOMflex precision spindle head. The instructions

must always be to hand.

The KOMflex precision spindle head is only intended for boring and boring out and over turning. The

KOMflex must only be installed and operated in the machine tools intended for this purpose.

The KOMflex precision spindle head is only to be used as intended for this purpose.

Intended use also includes complying with all the information in these operating instructions. Only

trained and instructed personnel may work with the device.

Improper use

Any other use aside from that listed above is not permitted, as improper use may result in danger

which could cause injury to persons working with or in the vicinity of the KOMflex precision spindle

head or cause damage to the device.

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Operating instructions V1.1 31.03.2021

EC Declaration of Conformity

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Operating instructions V1.1 31.03.2021

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Operating instructions V1.1 31.03.2021

Radio Approval

Japan:

R 202LSJ048

USA:

Canada:

“This device has been granted a designation number by Ministry of Internal Affairs and

Communications under „Ordinance concerning Technical Regulations Conformity

Certification etc. of Specified Radio Equipment (特定無線設備の技術基準適合証明等に

関する規則)“ Article 2-1-19.

FCC Part 15

FCC ID: 2A2B9KOMFLEX

This equipment has been tested and found to comply with the limits for a Class B digital

device, pursuant to part 15 of the FCC Rules. These limits are designed to provide

reasonable protection against harmful interference in a residential installation. This

equipment generates, uses and can radiate radio frequency energy and, if not installed

and used in accordance with the instructions, may cause harmful interference to radio

communications. However, there is no guarantee that interference will not occur in a

particular installation. If this equipment does cause harmful interference to radio or

television reception, which can be determined by turning the equipment off and on, the

user is encouraged to try to correct the interference by one or more of the following

measures:

—Reorient or relocate the receiving antenna.

—Increase the separation between the equipment and receiver.

—Connect the equipment into an outlet on a circuit different from that to which the

receiver is connected.

—Consult the dealer or an experienced radio/TV technician for help.

Changes or modifications made to this equipment not expressly approved by CERATIZIT

USA, Inc. may void the FCC authorization to operate this equipment. This device complies

with part 15 of the FCC Rules. Operation is subject to the following two conditions:(1) This

device may not cause harmful interference, and (2) this device must accept any

interference received, including interference that may cause undesired operation.

IC:27454-KOMFLEX

This device contains licence-exempt transmitter(s)/receiver(s) that comply with

Innovation, Science and Economic Development Canada’s licence-exempt RSS(s).

Operation is subject to the following two conditions: (1) this device may not cause

interference, and (2) this device must accept any interference, including interference that

may cause undesired operation of the device. This device and its antenna(s) must not be

co-located or operating in conjunction with any other antenna or transmitter. This

equipment complies with IC Canada RF radiation exposure limits set forth for an

uncontrolled environment as per RSS-102 Issue 4.

L’émetteur/récepteur exempt de licence contenu dans le présent appareil est conforme

aux CNR d’Innovation, Sciences et Développement économique Canada applicables aux

appareils radio exempts de licence. L’exploitation est autorisée aux deux conditions

suivantes (1) L’appareil ne doit pas produire de brouillage, et (2) L’appareil doit accepter

tout brouillage radioélectrique subi, même si le brouillage est susceptible d’en

compromettre le fonctionnement.

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3 Glossary

KOMflex adjustment range

The KOMflex can be adjusted between -0.25 mm and +0.25 mm in relation to the central position of

the slide.

Centre position definition

The centre position (CP) is the central position of the slide (zero point).

VIP definition

The VIP is a defined position in the KOMflex adjustment range which serves as a reference point, for

example during the trial cut or for safe changeover of the indexable insert.

VIP without offset:

The VIP must be set manually by the user, for example on the presetting equipment, before automatic

operation. The VIP can be set within the entire adjustment range of the KOMflex.

VIP with offset:

It is possible to subsequently overwrite the set VIP position by carrying out teach-in (initialisation) of the

head again via the OFFSET input parameter in the BKF_CHECKIN NC program and thereby set it again.

The VIP preset by the user is then used by the BKF_CHECKIN NC program. (See section 8.2.4)

6

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Reinitialisation

During reinitialisation, the KOMflex precision spindle head is reverted to its initial state. This means that

the KOMflex travels to the VIP and the radius wear in the tool table is reset to 0. (See section 8.3)

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System overview

4

The KOMET KOMflex compensation system consists of the following components:

• KOMET KOMflex with BLUM wireless unit

• BLUM RC66 receiver

• BLUM IF20 interface

• BLUM EM3x extension module

• BLUM software

• Any measuring unit, e.g. measuring probe

The automatic KOMflex compensation system enables process-secure boring of holes and pins on a

machine tool. The finished hole is measured with any measuring unit and compared to the target

dimension. The precision spindle head then automatically corrects the set value deviation. To do so the

dimension to be adjusted is transferred from the NC to the IF20 Interface via Ethernet or field bus. The

value is then wirelessly transferred to the KOMET KOMflex.

Machine compartment

Control cabinet

Measuring

probe

BLUM

EM3x module

KOMET

KOMflex

BLUM

RC66 wireless

receiver

BLUM

IF20 interface

Snap-on tools

Ø 1 – 120 mm

KOMflex

precision

spindle head

BLUM wireless machine equipment

+ any measuring unit

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5 Description of the RC66 wireless receiver

The RC66 is a compact wireless receiver with BRC technology which is suitable for all Blum measuring

devices and the KOMflex with wireless transmission. It enables wireless communication between the

measuring devices/the precision spindle head and the NC control. Data is transferred to the NC control

via the IF20 interface.

The meaning of the RC66 display indicators is explained below, focusing on the KOMflex-specific

operating modes.

Only the status LED (1a) is active in standby mode. This will light up red, green and blue alternately.

RC66 standby mode

The mode is set via the SET_STBY command.

t

KOMflex mode

In KOMflex mode, the MODE LED (1a) and the RX LED (1d) light up steady green and the BATTERY LED

(1b) is inactive. The display indicators can be found in the following table.

This mode can be activated with the SET_KOMFLEX_MODE command.

1e: TX:

GN

OG

1d: RX:

GN

Data transfer

KOMflex activation command

Data transfer

RD

Incorrect data received

1b: BATTERY:

Unused/inactive

1c: STATUS:

GN

KOMflex mode

1a: MODE:

GN

Connected to KOMflex

OG

RD

KOMflex activation attempt

No connection to KOMflex

(activation failed)

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Pairing mode

The MODE LED (1a) flashes white continuously in pairing mode. The TX and RX LED (1d, 1e) indicate that

data is being transferred.

Once a KOMflex has been successfully taught-in, the BATTERY and the STATUS LED (1b, 1c) flash green.

If pairing fails, due to timeout or a problem with the data transfer or an incorrect device type, for

example, then the BATTERY and STATUS LED (1b, 1c) flash red.

The mode is set via the SET_KOMFLEX_MODE command.

1e: TX:

1d: RX:

GN

Data transfer

GN

Data transfer

1b: BATTERY:

GN

Pairing successful

RD

Pairing failed

1c: STATUS:

GN

Pairing successful

RD

Pairing failed

1a: MODE:

WH

Pairing mode active

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6 Description of the KOMflex precision spindle head

The automatic precision spindle head communicates with the BLUM RC66 wireless interface and forms

a closed-loop operation (process, measure, correct, process) in conjunction with any measuring unit.

Therefore, the KOMflex enables automatic diameter correction for precision holes.

Technical data

ABS 32 /

Ø 16 mm /

Teeth

Adjustment accuracy

Adjustment range

Boring range

Max. RPM

Max. transmittable torque

Max. coolant pressure

Height

Outer diameter

Weight of head without tool

Operating temperature

Storage temperature

Interface

Protection class

Hight = 100 mm

1 µm in radius

± 0.25 mm

Dia. 1 - 120 mm

8000 RPM

16 Nm

30 bar

100 mm

63 mm

1.536 kg

+10 °C to +40 °C

-20 °C to +60 °C

ABS 50

IP67

Lithium thionyl chloride battery

2x AA Saft LS14500

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KOMflex system description

① ABS 50 adapter

② Combined tool interface

ABS 32 / dia. 16 mm / teeth

③ Slide

④

Inner and outer coolant supply

⑤ Battery compartment WAF2.5

⑥ ABS32 clamping screw WAF4 /

9-11 Nm

⑦ Battery polarity

⑧ MODE hall sensor

⑨ SET hall sensor

⑩

LED status (3x 120° = 360°)

⑪ Balance compensation

Required accessories

To operate the KOMflex in manual mode and to teach-in the precision spindle head on the machine

tool, a magnetic pen or comparable magnet is required.

Magnetic pen

Magnet

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Description of the KOMflex modes

The KOMflex can be operated in manual or automatic mode. Both modes Manual adjustment with

magnetic pen and Automatic adjustment via NC cycle are covered in more detail below.

6.4.1 Manual adjustment with magnetic pen

To operate the KOMflex in manual mode, for example on the presetting equipment, the precision

spindle head must be in standby mode (all KOMflex LEDs off). The user can then activate manual mode

with a prolonged touch of the "MODE" sensor with the magnetic pen. When the magnetic pen is

removed from the sensor and the LEDs change from yellow to orange, "Manual adjustment" mode is

active.

General information

Brief touch of the button: 20 ms < t < 1.5 s

To the + stop: LED flashing

GN

Long touch of the button: 1.5 s < t < 5 s

To the + stop: LED flashing

BU

LED

MODE

SET

MODE

"button

"

SET

"button

"

Long press

of MODE

auto

IDLE

LED

Long press

of MODE

Switch on

LED changes to LED

auto

In event of error

LED

Long

press of

SET

LED

Approach centre

position (CP)

Switch off

All LEDs off

>20 s no

action

Manual travel

ready

Manual travel

Travel by 1 µm

auto

Brief press

of MODE

LED

auto

Brief press

of SET

LED

auto

Travel by 5 µm

LED : Travel in plus direction

LED : Travel in minus direction

Long press

of MODE

auto

Change direction

of travel

LED or LED

13

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6.4.2 Automatic adjustment via NC cycle

Successful teach-in of the precision spindle head is the prerequisite for automatic operation of the

KOMflex, see section 8.2.4. In standby mode (all KOMflex LEDs off), "Automatic adjustment" mode can

be activated via the computerised numerical control (CNC). In this state, the precision spindle head

indicates the key statuses via flashing LEDs. An overview of the statuses is given below.

Application scenarios

KOMflex active and ready for adjustment, waiting for commands

KOMflex active, "ready" not yet received from the KOMET module

KOMflex active, timeout (tKOMflexReadyMax), no "Ready" received from the KOMET module

Battery status

KOMflex inactive, "low" battery status (CRITICAL). KOMET module does not carry out any actions

KOMflex inactive, "empty" battery status (BAD)

t

t

t

t

t

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Emergency shutdown

If the KOMflex is in an active state, but does not receive any commands from the interface IF20, the

head is deactivated after a timeout of 5 minutes and goes into standby mode.

Possible scenarios in which an emergency shutdown may occur

• Switch-off command does not reach the KOMflex, e.g. problems with radio connection

• The emergency stop or reset of the NC is activated.

7 Getting started and tool mounting

Initial commissioning of the KOMflex

The insulation pad located in the battery compartment must be removed for initial commissioning. Then

the precision spindle head can be put into operation.

Note

Note the correct position of the seal in the battery compartment. Keep the battery compartment

completely clean and dry. Lightly grease the sealing surface of the lid before inserting the lid.

1. Unscrew the screws on the battery compartment lid.

2. Pull both screws out and remove the battery lid.

3. Remove the insulation pad from the battery compartment.

4. Check whether the seal is correctly inserted: small, even distance of the sealing lip to the wall.

5. Fit the battery compartment lid so it is straight and secure it (Md = 0.7 Nm).

6. When screwing the battery lid on, ensure it is positioned correctly and that the O ring is in perfect

condition. If the O ring is damaged, replace it.

Pay attention to the battery

polarity!

(See housing signature)

Open battery compartment

during initial commissioning

Open battery compartment

during initial commissioning

Remove insulation pad

Remove insulation pad

Screw the battery compartment

Screw the battery

lid back into place

compartment lid back

into place

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Indicating the basic settings

Once the insulation pad has been removed/the batteries have been inserted, the basic settings are

indicated. The magnetic pen is not needed for this. Once the basic settings have been indicated, the

precision spindle head goes into standby mode.

Head active

WH

IDLE

MODE

SET

Characteristics

Transmission mode

RD

(3 x MODE - SET)

GN

Normal*

RD

Robust

• Standard setting

• Ambient conditions with radio interference

• High chip load

ON time

OG

Fast

BU

(3 x MODE - SET)

• Fast ON time

• Setting reduces the battery life

• Normal ON time

• Standard setting

• Slow ON time

• Setting increases the battery life

Device type

GN

(3 x MODE - SET)

Standard*

• Activation readinessa

• Setting reduces the battery life

EcoMode

• Activation readinessb

• Setting increases the battery life

Normal*

GN

RD

Slow

GN

OG

RD

TWIN A

BU

TWIN B

GN

O.K.

RD

Low

BU

Battery

(3 x MODE - SET)

Standby

* Standard settings

b If the KOMflex:

a The KOMflex is always ready for re-activation in standby mode.

-

-

Is outside the reception range of the wireless receiver, the system goes into EcoMode.

Is within the reception range, it is always ready for re-activation.

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Manually configuring the basic settings

The basic settings can be changed in this mode.

Note

The magnetic pen is needed to operate the KOMflex in this section.

1. Remove the batteries.

2. After 30 seconds, re-insert the batteries in the battery compartment. Pay attention to the

battery polarity. Refit the battery compartment lid.

3. The basic settings are indicated (indication phase).

4. During the indication phase, switch to programming mode:

Hold the magnetic pen on the MODE text for 5 seconds until the status LED changes from

green to violet.

Pay attention to the battery

polarity!

(See housing signature)

Insert the batteries into the

battery compartment

Indication phase for the basic

settings

Switch to programming mode

5.

In programming mode, you can perform two actions:

• Change settings (SET):

Hold the magnetic pen on the SET text.

• Switch to another menu item (MODE)

Hold the magnetic pen on the MODE text. The status LED briefly flashes violet to confirm

the menu change has been detected.

6. After the last menu item, the basic settings are repeated (3 x MODE -SET) and saved*. During

the indication phase, you can switch back to programming mode.

7. Once the basic settings have been indicated, the precision spindle head goes into standby

mode.

*The set basic settings are retained after the battery is changed.

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Mounting

7.4.1 Tool mounting

When fitting the tools, the indexable insert must point in the direction of the cutting edge shown on the

base body. The permitted maximum RPM is nper. = 8000 RPM.

The permitted RPMs depend on the tool used (mass & type). The RPMs must be adjusted in line with

the machining process and its conditions.

To achieve an ideal machining result, we recommend fine balancing the precision spindle head in the

machining position. For balancing, the M6 threads arranged on the circumference or commercially

available balancing rings can be used. Any screws or grub screws used must be secured against loosening

after balancing. The balancing ring must not be clamped on the blue jacket or in the radio range.

7.4.2 Tools with ABS connection

All existing ABS32 tools for fine machining can also be used in conjunction with the KOMflex precision

spindle head.

The clamping screw must be used to clamp ABS tools.

7.4.3 Tool with cylindrical shank

Flexibility with the overhang length: The B05 boring bars can be clamped at various lengths. These

should not rest on the bottom of the hole.

Boring bars can be axially extended to a maximum of 5 mm. Clamp the boring bar with the clamping

screw M8x1x10.

Boring bars with cylindrical shank: DIN 1835-B and E are only suitable to a certain degree; DIN1835-A

possible (no cutting edge positioning).

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7.4.4 Coolant

The precision spindle head has a thro' coolant supply.

Usage of the central coolant supply is mandatory and ensures optimal chip formation and chip

removal.

The coolant pressure must not fall below the minimum level of 5 bar. An increase in coolant pressure

to 10-20 bar improves the machining process and should therefore be the aim. The maximum coolant

pressure is 30 bar.

When using the boring bars and the serrated body, the coolant is transferred centrally, through the

inside of the boring bar body.

From a diameter of 62 mm, the filling piece for diverting the coolant must be fitted. The filling piece

prevents coolant escaping from the centre and diverts the coolant internally. The filling piece must be

retained with the clamping screw M8x1x10.

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8 Commissioning the KOMflex

Presetting equipment

Before the KOMflex precision spindle head can be taught-in with the IF20 and therefore initialised, the

VIP must be approached in manual mode, on the presetting equipment for example. This step always

needs to be carried out if:

• KOMflex is being commissioned for the first time.

• A new machining process (new VIP) is taking place.

• A new tool is being used.

Activate "Manual travel"

IDLE

Approach VIP

Standby mode

Approach

centre position

1. Activate "Manual travel"

a. The "Manual travel" mode (section 6.4.1) can be activated with a prolonged touch of the

"MODE" sensor with the magnetic pen.

2. Approach centre position

b. Approach the centre position (CP) with a prolonged touch of the "SET" sensor.

→ LEDs change from

WH

to , when the CP is reached.

YE

3. Approach new VIP

c. Approach VIP

→ Briefly touch the "MODE" sensor to move 1 µm. → LEDs are

→ Briefly touch the "SET" sensor to move 5 µm. → LEDs are

→ Use a prolonged touch of the "MODE" sensor to change direction of travel.

YE

.

.

YE

LEDs are

BU

(positive direction of travel)

GN

or (negative direction of travel).

4. Standby mode

d. If no actions are performed for 20 s, the head goes into standby mode.

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There are three ways of defining the VIP on the presetting equipment:

① Trial cut

② Without trial cut

③ Offset trial cut

No correction through offset;

value for the trial cut is

included in VIP.

Target diameter of the

cutting edge

corresponds to the

position of the VIP.

The VIP position is corrected by means

of offsets via the R-parameter in the

Global User Definition (GUD) on the

Siemens CNC.

Internal machining:

Internal machining:

Internal machining:

• VIP < target diameter

• VIP = target diameter

• VIP - R-parameter < target diameter

External machining:

External machining:

External machining:

• VIP > target diameter

• VIP = target diameter

• VIP - R-parameter > target diameter

Target diameter

Target diameter

Internal machining

Offset in

- direction

Offset in

+ direction

External machining

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Use of the KOMflex on the machine

8.2.1 Overview of the product range

Range

Description

BKF_USERPARATABn

Subprogram for defining the customer program

BKF_CONTROLLER

Subprogram for NC ←→ IF20 communication

BKF_CHECKIN

Program for teaching-in the KOMflex

BKF_CORRECTION

Program for automatic correction of the KOMflex

BKF_OFF

Program for switching off the KOMflex

Reference

Section

8.2.2

Section

8.2.4

Section

8.2.5

Section

8.2.6

BKF_REINITIALIZE

Program for reinitialising the KOMflex

Section 8.3

8.2.2 Subprogram for defining the customer program

The basic settings for the customer program can be set in the BKF_USERPARATABn program. The NC

program should be modified and adapted to the application by the machine operator before

commissioning the precision spindle head.

In addition to defining the display language, the communication module for machine control can be

defined. You can choose between a bus connection and a client server.

General parameters

Parameter

Meaning

_BKF_LANGUAGE

Language selection, for example

_BKF_IO[1]/IO[2]

Definition of the communication module

•

•

•

"GR" = German

"UK" = English

"FR" = French

• 20xxx DualPortRam(PLC)

• 30xxx direct Profibus

• 10000x Client Server

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The KOMflex tool data can also be defined in more detail in the BKF_USERPARATABn subprogram. The

following table gives further information about the most important parameters.

Definition of the tool data

Parameter

Meaning

_BKF_TOOLNAME

"NAME", if a tool name is needed.

•

•

"NUMBER", if a tool number is needed.

_BKF_TOOLD

The tool's D number

_BKF_WEAR_LIMIT Maximum wear limit of the indexable insert up to which the KOMflex makes

a correction. If this is exceeded, the indexable insert must be changed and

the KOMflex must be reinitialised.

_BKF_MIN_DELTA

Minimum correction value which must be exceeded for the KOMflex to be

adjusted in the BKF_CORRECTION program.

_BKF_LIMIT

Limit value for manual correction of the KOMflex in automatic mode

_BKF_TOOLT

Tool table

_BKF_DIAMCALL

Offset in call

• 1 = in radius

• 2 = in diameter

• 1 = in radius

• 2 = in diameter

_BKF_OPTION[0]

If the tolerance limits have been exceeded,

• 0 = the radius wear in the tool table must be manually reset to 0

and is not automatically reinitialised.

• 1 = the KOMflex is automatically reinitialised, i.e. the KOMflex moves

to the VIP position (teach-in position).

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8.2.3 Parameter overview when calling up programs

If no call parameters are

BKF_USERPARATAB1.SPF program are effective.

transferred

in

Parameter

Explanation

the program calls,

the parameters

in

the

KFID

ID number with which teach-in was carried out for the KOMflex. Up to 16 KOMflex

can be taught-in with an RC66.

|1| <= KFID <= |16|

The teach-in process can be skipped for an already taught-in KOMflex with negative

KFID.

OFFSET

Offset with which the KOMflex is taught-in in relation to its current position.

In the case of adjustment movements, the offset is added to the correction value

from the tool table.

This is to ensure, for example, that the trial cut has sufficient material for correction

when the tool is first used/after changing the indexable insert.

-0.5 <= OFFSET <= +0.5

DIR

Defines the machining direction: 0 = hole // 1 = pin

MIN_DELTA Minimum correction value which must be exceeded for the KOMflex to be adjusted

in the BKF_CORRECTION program.

MEASCUT

Measurement cut.

1 = Measurement cut is performed. The wear limit monitoring is inactive. The

reference position for a wear correction is updated.

0 = No measuring cut. The wear limit is active.

WEAR_LIMIT Maximum wear limit of the indexable insert up to which the KOMflex makes a

correction. If this is exceeded, the indexable insert must be changed and the

KOMflex must be reinitialised.

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8.2.4 Teaching in the KOMflex

In this phase, a non-taught-in KOMflex can be taught-in in IF20 or an already taught-in KOMflex can be

initialised. This means that the position of the head at the moment of teach-in is saved. If the precision

spindle head used has already been taught-in on the machine and pairing is not to take place again, then

this step can be skipped.

This cycle takes place in automatic mode.

Standby

Execute "KOMflex

teach-in" program

Pair with

KOMflex

Switch

KOMflex on

Set VIP

Approach

VIP

Standby

1. Standby mode

→ All LEDs are off.

Precision spindle head is in standby mode.

2. Execute "KOMflex teach-in" program

Call up the BKF_CHECKIN (KFID, OFFSET, DIR) program

KOMflex ID number: 1 - 16

Offset for moving the teach-in position

Defines the machining direction: 0 = hole // 1 = pin

Parameter

• KFID

• OFFSET

• DIR

Optional

• KFID

3. Pair with KOMflex

KOMflex ID number: -1 – -16

An already taught-in KOMflex can skip the teach-in process with a negative KFID.

• After calling up the program, the following command appears on the controller:

"Pair KOMflex to ID=”<<_BKF_ID<<", hold the magnetic pen on label SET! "

• To teach-in the head on the IF20, touch the "SET" sensor with the magnetic pen until:

KOMflex LED switches from

BU

to.

GN

This step is skipped with a negative KFID → continue with step 4.

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4. Switch KOMflex on

• The precision spindle head is automatically switched on after initial teach-in of a new KOMflex

or initialisation of an already taught-in KOMflex.

• Optional: VIP 2 is used in the program as the monitoring value for detecting manual

5. Set VIP

• VIP 1 is set in the program.

intervention.

6. Approach VIP

• VIP is approached.

7. Standby mode

→ All LEDs are off.

8.2.5 Correction in automatic mode

The precision spindle head is automatically switched off by the machine control after approaching

the VIP and the head goes to standby mode.

In this cycle, the KOMflex is automatically readjusted in the process. To correct the measured value, the

difference to the set value must be written in the wear parameter of the tool table for the relevant

KOMflex, using measurement software. The wear parameter is used with the transferred offset to

correct the KOMflex.

Range: BKF_CORRECTION (KFID, OFFSET, MEASCUT, WEAR_LIMIT)

Parameter

• KFID

• OFFSET

KOMflex ID number: 1 - 16

Offset for moving the teach-in position

• MEASCUT Value if a trial cut is carried out

• WEAR_LIMIT Maximum wear limit of the indexable insert

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8.2.6 Manually switching off

The KOMflex can be manually switched off with the BKF_OUT () program.

Range: BKF_OUT (KFID)

Parameter

• KFID

KOMflex ID number: 0 - 16

If the KFID = 0, the switch-off signal is sent to all KOMflex.

Reinitialisation of the KOMflex

During reinitialisation, the KOMflex can move back to its original position, set during teach-in (position

for a trial cut). This can be done manually in the case of an insert change or automatically if the wear

limit is reached. The entered radius wear for the KOMflex is always set to 0.

Range: BKF_REINITIALIZE (KFID)

Parameter

• KFID

KOMflex ID number: 1 - 16

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Extension of the machine with further KOMflex

To integrate a new KOMflex into the machine, the program must be extended with a new

BKF_USERPARATABn, whereby n is the KOMflex ID. This allows the system to be extended with ease,

without losing clarity.

The machine can be extended with up to 16 KOMflex systems.

KOMflex

tool data

NC cycles

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Operating instructions V1.1 31.03.2021

Changing the cutting edge

With the KOMflex system, the maximum wear limit for internal or external machining can be specifically

adapted to the customer application via the _BKF_WEAR_LIMIT parameter in the BKF_USERPARATABn

subprogram (section 8.2.2). If one of these values is dropped below or is exceeded, the program is

stopped and the error message "Error E7 – Out of tolerance" appears on the machine control.

As soon as the wear limit is reached, the indexable insert must be turned or replaced if there are no

more unworn cutting edges on the indexable insert.

Wear limit

New, unworn indexable insert

Indexable insert

not OK

Indexable insert

OK

When handling the indexable insert please note that it has sharp edges and therefore poses a risk of

injury. Therefore, always proceed with care when replacing the indexable insert.

To replace the indexable insert, please follow the following steps:

1. Hold the indexable insert and release the fixing screw with the key provided for this.

2. Remove both the indexable insert and the fixing screw.

3. Clean any dirt off the indexable insert.

4. Carry out a visual inspection of the indexable insert:

a.

b.

If there are unworn cutting edges on the indexable insert, then place it to one side with

the fixing screw.

If all cutting edges are worn, dispose of the indexable insert properly and place the fixing

screw to one side.

5. After assessment, clean and check the indexable insert seating for damage.

6. Then insert the new indexable insert or the unworn side of the indexable insert and secure with

the fixing screw.

7. Gently press the indexable insert against the seating contact surfaces and tighten with the key

provided for this. (Note torque specifications).

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Operating instructions V1.1 31.03.2021

Battery replacement

The KOMflex's batteries must be checked when:

• The status LED flashes red or lights up red.

• The error message 1117 – warning battery: battery voltage in critical state – appears on the CNC

control.

8.6.1 Changing the battery

Recommended type:

Type

mAh

Size

Nominal voltage

2600

3.6 V

AA

Saft Lithium LS14500

Tadiran SL-360

2400

3.6 V

AA

1. Unscrew the screws on the battery compartment lid.

2. Pull both screws out and remove the battery lid.

3. Remove the battery.

4. Carefully clean and dry the battery compartment with absorbent paper.

5.

6. Check whether the seal is correctly inserted: small, even distance of the sealing lip to the wall.

7. Fit the battery compartment lid so it is straight and secure it (Md = 0.7 Nm).

8. When screwing the battery lid on, ensure it is positioned correctly and that the O ring is in perfect

Insert new batteries. Pay attention to the battery polarity.

condition. If the O ring is damaged, replace it.

Pay attention to the battery

polarity!

(See housing signature)

Open battery compartment

Insert new batteries

Screw the battery lid back into

place

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8.6.2 Disposal of batteries

The KOMflex precision head spindle must be disposed of in compliance with national and local

regulations as part of the normal recycling process. Once it is no longer being used, statutory disposal

regulations apply. In general, observe the following during disposal: Separate components for recycling

into electronic waste, scrap iron, aluminium, plastic and battery.

In accordance with UK battery legislation, we are required to state the following

Used batteries do not belong in household waste. You can return used batteries to our dispatch

warehouse free of charge. As a consumer, you are legally obliged to return old batteries. Batteries

containing hazardous material are marked with a crossed-out wheelie bin symbol and the chemical

symbol (Cd, Hg or Pb) which determines the classification as a heavy metal containing hazardous

substances.

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Operating instructions V1.1 31.03.2021

KOMflex errors in machine operation

Code

Value Description of error

1100

1102

1103

1104

1105

1

1

2

3

1

1

20

21

28

29

31

32

33

34

35

36

37

38

39

41

42

43

Timeout: Position could not be reached in the specified time.

Absolute VIP could not be set: Index outside range.

Relative VIP could not be set: Index outside range.

"Go to VIP" requested with invalid index.

Requested position is outside the limit: Position greater than maximum.

Requested position is outside the limit: Position less than minimum.

Invalid data during input with the magnetic pen.

Invalid data during status output.

Protocol error: Missing data during the "Go to absolute position" request

(position).

Protocol error: Missing data during the "Go to absolute position" request

(internal/external machining).

Protocol error: Missing data during the "Receive VIP" request (index).

Protocol error: Missing data during the "Set absolute VIP" request (index).

Protocol error: Missing data during the "Set absolute VIP" request (position).

Protocol error: Missing data during the "Set relative VIP" request (index).

Protocol error: Missing data during the "Set relative VIP" request (value).

Protocol error: Missing data during the "Go to VIP" request (index).

Protocol error: Missing data during the "Go to VIP" request (offset).

Protocol error: Missing data during the "Go to VIP" request

(internal/external machining).

Protocol error: Missing data during the "Go to CP" request (internal/external

machining).

Invalid data for position request: Incorrect value for internal/external

machining.

Invalid data for VIP request: Index outside range.

Invalid data for "Go to VIP" request: Index outside range.

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Code

Value Description of error

1106

Plausibility error detected: Motor blocked.

Plausibility error detected: Motor overcurrent.

Plausibility error detected: Motion in opposite direction detected (positive

direction of travel expected).

Plausibility error detected: Motion in opposite direction detected (negative

direction of travel expected).

System is in an error state (battery empty for example).

Release time cannot be carried out during positioning.

Upon recognition of the release time, the CP cannot be approached.

10

Upon recognition of the release time, no motion can be detected after 3

seconds.

1109

Current position cannot be measured.

1110

1117

1118

Position detection is not available once position has been reached.

Position detection is not available during positioning.

No motion possible: Position detection is not available.

Offset cannot be adopted: Position detection is not available.

Position cannot be received: Position detection is not available.

VIP cannot be set: Position detection is not available.

Position could not be reached after the maximum number of position attempts.

Battery warning: Battery voltage at a critical level.

Incorrect status: KOMflex module is not ready.

2

3

4

5

6

8

9

1

2

3

4

5

6

7

1

-

-

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Operating instructions V1.1 31.03.2021

BLUM errors in machine operation

In the event of an error, the error number is set, and an error message appears on the screen. The

program must be interrupted with the RESET button, the cause of the error must be resolved, and the

program must be restarted.

In the event of messages (e.g. E7), the program processing is interrupted by "M0". The cycle can be

continued with "Cycle start".

E4

"Incorrect call parameters"

Description: The cycle cannot be carried out with the set call parameters.

Solution: Enter valid values for calling up the program.

Error number

Digits after point

Description of error

Check the KFID parameters

Check the OFFSET parameters

Check the DIR parameters

CALL VIP not set

CALL VIP < 4

|CALL WEAR_LIMIT| > 0.5

|MIN_DELTA| > 0.1

KFID program parameter: KOMflex not taught-in

E7

"Tool limits exceeded"

Description: KOMflex correction value exceeds the permitted limit value.

Solution: Correctly set _BKF_WEAR_LIMIT in USERPARATAB1 or in the call.

Error number

Digits after point

Description of error

Minimum tolerance violated

Maximum tolerance exceeded

4

4

4

4

4

4

4

4

7

7

.04

.09

.23

.31

.32

.44

.51

.61

.51

.52

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Operating instructions V1.1 31.03.2021

E22

"Communication error"

Description: Connection error between NC and IF20.

Solution: Ensure that a connection is established between NC and IF20.

Also check all the connecting elements between them.

Correctly configure the network or the field bus.

22

22

22

22

25

26

26

Error number

Digits after point

Description of error

.1

.2

.02010

.02011

Timeout communication

IF or EM not connected

Error RC66 timeout

Error RC66

E25

"Manual intervention"

Description: The KOMflex has been manually adjusted during automatic mode.

Solution: Execute the BKF_REINITIALIZE program.

Error number

Digits after point

Description of error

.01

Manual intervention

E26

"Incorrect tool/tool name"

Description: The tool data entered in USERPARATAB1 is incorrect.

Solution: Enter the correct tool data in USERPARATAB1.

Error number

Digits after point

Description of error

.01

.02

Incorrect tool name

Incorrect tool number

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Operating instructions V1.1 31.03.2021

9

KOMflex recycling – Our recycling service

Our joint contribution to the environment - beyond the lifetime of the tool: We take back your used

fine adjustment heads KOMflex and recondition them professionally. This saves you costs and effort

for disposal.

CNC

CP

EM

GUD

IF

IP

NC

VIP

II

10 List of abbreviations used

Abbreviation

Meaning

Computerized Numerical Control

Centre Position, slide central position

Extension module

Global User Definition

Interface

International Protection

Numeric Control

Cutting edge change position

Indexable insert

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BESCHRIFTUNG: Gr.: 12

nach: n4300850 und n4300860

INSCRIPTION:

according to: n4300850 and n4300860

CERATIZIT GROUP

MicroKom KOMflex

M04 20040

ABS50 / Ø 1-120

SN: XXXXXX

Label

8

4

0

J

S

L

-

2

0

2

R

F

C

IC:27454-K

C ID:2A2B9K

O

M

FLE

X

O

M

FLE

X



 

 

CERATIZIT USA, Inc. 11355 Stephens Road \ US-Warren, MI 48089-1833 \ USA T. +1-800-783-2280 \ +1-586-759-2280 \ F. +1-586-759-1657 E. info.usa@ceratizit.com \ www.ceratizit.com Federal Communication Commission Equipment Authorization Division, Application Processing Branch 7435 Oakland Mills Road Columbia, MD 21048 June 29, 2021 TO WHOM IT MAY CONCERN FCC ID: 2A2B9KOMFLEX We the undersigned, hereby authorize KOMET Deutschland GmbH, Zeppelinstrasse 3, Besigheim, DE 74354, Michael Renz to act on our behalf in all manners relating to application for equipment authorization, including signing of all documents relating to these matters. Any and all acts carried out by KOMET Deutschland GmbH, on our behalf shall have the same effect as acts of our own. The authorization is valid for 90 days from the date of this letter up to September 29, 2021. Sincerely, Dan Cope, VP of Sales CERATIZIT USA, Inc. 11355 Stephens Road \ US-Warren, MI 48089-1833 \ USA T. +1-800-783-2280 \ +1-586-759-2280 \ F. +1-586-759-1657 Classification: Internal \ All employees

 

 

LONG-TERM CONFIDENTIALITY REQUEST for Certification Service in the USA Federal Communication Commission Equipment Authorization Division, Application Processing Branch 7435 Oakland Mills Road Columbia, MD 21048 TO WHOM IT MAY CONCERN Pursuant to Paragraphs 0.457 and 0.459 of the Commissions Rules (47 C.F.R.) and Section 552(b)(4) of the Freedom of Information Act, we request Long-Term Confidentiality for the following product:

Check your GC here fererillcca @oyels ibrar ib pyetonslm acerenCcim @xoye(c Chek Grantee Search FCC ID 2A2B9 KOMFLEX For the product stated above, we request Long-Term Confidentiality for exhibits which contain Block Diagram, Operational Description, Parts List/Tune Up Info, Schematics, SDR Software/Security Info. The above exhibits contain our trade secrets and proprietary information that could be of benefit to our competitors. This information will not be publicly available. If you have any questions, please feel free to contact us at the address shown below Sincerely, 5omPa"Y KX OMET Deutschland GmbH Phone: +49 (0) 7143 373 0 Name:

Zeppelinstrasse 3 Fax: +49 (0) 7143 373 550 Adda, 74354 Besigheim E-mail: info@kometgroup.com DE Oietus Name:

Renz, Michael Signature:

Document Version | !

Signature Date: