02_Operating Manual.pdf

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Operating manual

F 20661

Half-automatic Printing Equipment

Keep for further use!


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Page 2 of 6602_Operating Manual.docx

Identification:

Producer: Eaton Industries (Austria) GmbH

Model: Half-automatic Printing Equipment

Type: Assembly machine

Number of order: F 20661

Year of construction: 2013

Customer: Eaton Industries (Austria) GmbH

Location: Romania

Address of producer:

Eaton Industries (Austria) GmbH

Eugenia 1

3943 Schrems

Tel: +43 (0) 50868-1228

Telefax: +43 (0) 50868-1362

E - Mail: [email protected]

Adjective Information to user manual:

Documenten- Nr.: F 20661

Version: 1.0

Created: 22. April 2013

Last change: 20. June 2013

File name: 02_Operating Manual.docx

Who did what:

Construction: Gutenthaler Manfred

Electrical plans: Poiss Harald

Program: Zlabinger Gerhard

Mechanical build-up: Langegger Franz

Electrical build-up: Hengst Markus

Operating manual: Zankl Mario

Technical documentation: Hofsttter Walter

Reprint, also in extracts, only with permission ofEaton Industries (Austria) GmbH. Copyright Firma Eaton Industries (Austria) GmbH, 2013; All rights reserved.
mailto:[email protected]:[email protected]:[email protected]


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Table of contentsOperating manual.................................................................................... 1Table of contents .................................................................................... 31 Information about the use oft he manual ........................................... 6

Purpose of the document ............................................................................. 61.1 Statement of place ....................................................................................... 61.2 Symbols of safety instructions ...................................................................... 71.3

2 Common safety instructions .............................................................. 8Intended use ................................................................................................ 82.1

Predictable abuse ................................................................................. 8

2.1.1 Technical changes ................................................................................ 82.1.2 Spare- and ware parts ........................................................................... 82.1.3 Risks during the use of the machine ............................................................ 9 2.2 Operators responsibility .............................................................................. 102.3 Staffs responsibilities................................................................................. 102.4 Safety-conscious work ........................................................................ 102.4.1 Training of Personel ................................................................................... 112.5 Security and protective devices .................................................................. 122.6

Residual risk ............................................................................................... 13

2.7 Symbols on the Machine ............................................................................ 132.8 Warning signals on the Machine ................................................................ 142.9

3 Description of the Machine .............................................................. 15Purpose of the Machine ............................................................................. 153.1

Design of the Machine ................................................................................ 163.2 Safety devices and invigilators ................................................................... 173.3 Control elements and indicators ................................................................. 183.4

Technical data ............................................................................................ 19

3.5 Declaration of Conformity .................................................................... 203.5.1 Additional Equipment ................................................................................. 203.6 Transportation and installation ................................................................... 213.7 Means of transportation ...................................................................... 213.7.1 Bevor transportation ............................................................................ 213.7.2 Transport machine .............................................................................. 213.7.3 Unpacking machine ............................................................................. 213.7.1 Setting up an mounting machine ................................................................ 223.8 Installation of the machine .................................................................. 223.8.1

Remove the transportation locks ......................................................... 223.8.2


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Supply and installation ............................................................................... 233.9 Electrical supply .................................................................................. 233.9.1 Air supply ............................................................................................ 233.9.2 Connection of the components............................................................ 243.9.34 Start of operation ............................................................................ 25

Initial operation ........................................................................................... 254.1 Reconnection ............................................................................................. 254.2

5 Operating and displaying elemens .................................................. 26Operation elements .................................................................................... 265.1 Main switch ......................................................................................... 265.1.1 Tableau ............................................................................................... 265.1.2

Control panel description of the pages ....................................................... 275.2 Starting page ....................................................................................... 275.2.15.2.1.1 Error line .......................................................................................... 285.2.1.2 Production data ............................................................................... 285.2.1.3 Type selection ................................................................................. 29

Station pages general ......................................................................... 305.2.25.2.2.1 Title bar............................................................................................ 315.2.2.2 Status of the Cylinder ...................................................................... 315.2.2.3 Options for the manual operation .................................................... 32

Circular table ............................................................................. 335.2.3 Type data .................................................................................. 355.2.4 Station data ................................................................................ 365.2.5 Production data ........................................................................ 385.2.6 Error statistics ............................................................................. 405.2.7 Machine parameters .................................................................. 415.2.8 EASY NET .................................................................................. 425.2.9 Murr micro status ................................................................................ 425.2.10

System ....................................................................................... 435.2.11 Control elements on the control panel ........................................................ 445.3

6 Adjusting and setting up .................................................................. 45General ...................................................................................................... 456.1

Changing types .......................................................................................... 466.2 Testlauf durchfhren .................................................................................. 466.3

7 Operating of the machine ................................................................ 47The switch on and switch off of the machine .............................................. 477.1 Before switch on .................................................................................. 477.1.1 Switchon the machine ....................................................................... 487.1.2 Switch-off the machine ........................................................................ 487.1.3


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Switch-off the machine in a dangerous situation ................................. 497.1.4 Switch-on the machine after an emergency stop ................................ 497.1.5 General ............................................................................................... 497.1.6 Modes ........................................................................................................ 507.2 Mode HAND ........................................................................................ 507.2.1

7.2.1.1 Requiremenst for operation ............................................................. 507.2.1.2 Select Mode ..................................................................................... 50

Mode SERVICE .................................................................................. 517.2.27.2.2.1 Requirements for operating ............................................................. 517.2.2.2 Selection of this operating mode ..................................................... 51

Mode AUTOMATIC ............................................................................. 517.2.37.2.3.1 Requirements for operating ............................................................. 517.2.3.2 Selection of this operating mode ..................................................... 51

Printing external .................................................................................. 527.2.4 Intended maintenance ................................................................................ 537.3 Safety Inspection daily ........................................................................ 537.3.1 Maintenance Schedule daily ............................................................... 547.3.2 Cleaning Schedule daily ...................................................................... 557.3.3 Maintenance Schedule weekly ............................................................ 567.3.4 General Cleaning fortnightly ................................................................ 577.3.5 Maintenance Schedule monthly .......................................................... 587.3.6 Safety Inspection quarterly .................................................................. 597.3.7 Maintenance Schedule half-yearly ...................................................... 607.3.8 Checking of the safety devices ............................................................ 617.3.97.3.9.1 Checking of the emergency stop function ........................................ 617.3.9.2 Checking of the safety light curtain .................................................. 617.3.9.3 Checking of the safety door-survey ................................................. 61

Lifetime safety components ................................................................ 617.3.10 Cleaning the equipment ...................................................................... 627.3.11 Empty condensate collector ................................................................ 627.3.128 Maintenance ................................................................................... 63

Searching and elimination of defects .......................................................... 638.1 CONTROL ON is not possible ............................................................. 638.1.1 Mainair Pressure is not reached. ...................................................... 638.1.2 Main air valve is flashing red ............................................................... 648.1.3 Spare- and wear parts ................................................................................ 648.2

9 Shutdown, storage and disposal ..................................................... 65Temporary shutdown .................................................................................. 659.1

Stoage conditions ....................................................................................... 659.2 Final Shutdown........................................................................................... 659.3

List of Figures ....................................................................................... 66


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1 Information about the use oft he manual

Purpose of the document1.1

This manual Describes the function, operating and the maintenance of the machine,

Give advices for a safe and efficient handling of the machine.

Statement of place1.2

All statements of directions and place in this manual refer to the position of theoperator.

Figure 1: Statement of place in the documentation

labeler

inkjet-coder

cabinet

workplaceoperator

screwdrivers printer

trigger test


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Symbo ls of safety inst ruct ions1.3

An icon and a warning notice characterise the safety instructions. The warningnotice describes the severity of the danger.

Danger! Imminent danger to life and health of people(severe injury or death).

Warning! Possible danger to life and health of people (severeinjury or death).

Attention! Possibly a dangerous situation(minor injury or material damage)

Information! Tips for the use of the machine and usefulinformation.

Command! Undertaking to act and react in a special way or tohandle the machine adequately.


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2 Common safety instructions

Intended us e2.1

The machine must be used only to screw off, printing and labeling of finished L9UNI Design switches.

Predictable abuse2.1.1

If damages are caused by unintended use

the operator is the only one who is responsible ,

the producer assumes no liability

Exampels of misuse:

Use of unsuitable or defective materials, improper material pairings, non-observance of the maintenance intervals and / or maintenance schedules.Any unauthorized manipulation of the machine is prohibited.

Technical changes2.1.2

It is not allowed to do any changing. Unauthorized changes or modifications willvoid any warranty.

Spare- and ware parts2.1.3

Only use original spare- and wearing parts.If damages are caused by the use of spare- and wearing parts of a

third-producer, the original producer assumes no liability.


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Risks dur ing the use of the machine2.2

While the machine is running you may come up with dangers and damages.Dangers and damages related to

the machine itself,

other material assets.

The basics of an adequate a failure-free operating of the machine, is theknowledge of the safety and user information in this manual.

Important!

Make sure that the manual has to be kept where the machine is placed.The manual has to be easily accessible for the operator and themaintenance staff.

Only instructed staff is allowed to operate the machine.If the operating staffs is not instructed to set the machine the key of theRelease off Parameters and Enable Working-Pressure has to beturned to the position 0 so that the staff is not able to change thesettings. Then the key has to be pulled out and the head-workman orthe head of production has to keep it!

Warning:

If someone works on air cylinders, it must to be turn off the appendet airvalve. (see: Figure 30)

It is possible of unexpected cylinder-moves by the recovering of airsupply.


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Operators respon sibi l i ty2.3

The operator commits itself to let only people work at the machine

which know the elementary regulations about security at work andprevention of accidents

which have been instructed in working with the machine

which have read and understood this operating manual

Staffs responsibilities2.4

All persons who work with the machine engage to:

follow the elementary regulations about security at work and prevention ofaccidents.

read and accept the chapter about security of this operating manual.

Open questions please put to the producer, as you see on page2.

Safety-conscious work2.4.1

Refrain from any unsafe work!"Strips your contribution to safety in the workplace."

This includes reading the operating instructions, especially the safety andcompliance of these instructions. Note that only authorized persons working anddanger zone of the plant.With changes (including the operating behavior) affect the safety, stop themachine immediately and report to the person responsible. Can eliminate

interference by unauthorized persons immediately.All work must be safety conscious conduct.


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Training of Personel2.5

People

activity

Special trainedstaff

Instructed staff Staff with technicaljob training

transport -- -- X

placing into operation -- -- X

rigging, setting up X -- X

operating X X X

servicing X -- X

troubleshooting X -- X

waste management -- -- X

Legend: X - allowed -- - forbidden

Special trained staffAre persons who have sufficient knowledge of powered equipment due to their trainingand experience,were instructed by the machine operator in the operation and the valid safety regulations,and with relevant state health and safety regulations, accident prevention regulations and

guidelines to such an extent that the safe working condition of power-driven equipmentcan be assessed.In addition, these persons are authorized by the machine operator transportation,commissioning, - perform advanced maintenance and disposal.

Instructed staffAre people who have been proven to be instructed to operate the machine by themachine operator in the operation and the valid safety regulations, labor regulations andaccident prevention rules.

Staff with technical job trainingAre persons who have sufficient knowledge of powered equipment due to their training

and experience,were instructed by the machine operator in the operation and the valid safety regulations,and with relevant state health and safety regulations, accident prevention regulations andguidelines to such an extent that the safe working condition of power-driven equipmentcan be assessed.


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Secur i ty and protect ive devices2.6

There are following security and protective devices installed on the machine:

Figure 2:Security devices

Do only activate the machine if all protective and safety devices exist and arefully functional!

see: Figure 6

Defective protective devices

Defective or dismantled safety devices may cause danger. Thats why:

The machine has to be turned off,

Someone has to make sure that it wont be turned on again,

If necessary, air and power supply have to be disconnected.

Checking of the safety and protective devicesAll safety and protective devices have to be checked regulary.

Inspection interval:

Safety device Inspection interval

Emergency stop Regulary to test and byretrofittingof electric components

Safety light curtain weekly with test bar

Control and locking of the protectiveand maintenance doors

weekly


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Residual r isk2.7

Caution! Risk of injury!

The local regulations and requirements for PPE are to be observed.

Symbo ls on the Machine2.8

In the environment or on the machine, the following icons may be located.

No persons withpacemakers

Risk of bodily

No entry for unauthorized

persons Wear eye protection

Warning of hot surface Wear hearing protection

Warning of hazardousarea

Wear protective gloves

Hazards of electrical

shockWear protective shoes

Pay attention to all posted

Warnings and security advices,

All other markings, i.e. turning directions or transport directions.


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Warning signals on the Machine2.9

Defects and warnings are visible on the Control panel (station : step) and by theblinking quit button, after the elimination of the failure press the button quit (Control

panel) or switch over from Hand to Auto (the switch on the station with thefailure). (Figure 31)

The following warning signals are installed:

Quit button flashes blue, if a defect exists it is to remove the failure.

The quit button shines blue, if the failure has been eliminated but not quitted.

Figure 3: Tableau

Quit button


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3 Description of the Machine

This chapter gives an overview of the construction and the function of the machine.

If possible read this chapter next to the machine. Thats the ideal way to makeyourself familiar with it.

Purpo se of the Machin e3.1

The machine must be used only to screw off, printing and labeling of finished L9UNI Design switches.

Figure 4: Finished switches

Print oft he date

Terminaldisignation

Side label

Ordernumberwith Inkjet


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Design of the Machin e3.2

Figure 5 gives an overview of the most important components and devices andshows where they are installed:

1 Cabinet 4 Printer

2 Inkjet-Coder 5 Frigger test

3 Screwdrivers 6 Labeler

Figure 5: Construction and Components

3

2

4

1

5

6


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Safety devices and inv igi lators3.3

Figure 6gives an overview of the most important safety and monitoring devicesand displays their installation on the machine.5 Emergency stop switch (2 on the back), and safety switches are located at theaccess points on the machine.

Figure 6: Safety devices and invigilators


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Contro l elements and indicators3.4

Figure 7 gives an overview of the most important control elements and indicatorsand showes where they are installed:

Figure 7: Control elements and indicators

TableauMain-switch

Brake release

Pneumatic maintenance unit

Switchbar

Printer

Keyboard and MousePC

Labeler


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Techn ical data3.5

Mechanical date

Dimensions L = 1950 mmB = 1300 mm

H = 2050 mm

Weight ca. 1500kg

Electrical data

Operating voltage: 230V / 400V AC

Frequency: 50Hz

Control voltage: 24V DC

Nominal current: 13A

Main fuse: 16A

Air supply

Air pressure 6 bar

Reduced air pressure max. 2 bar

Quality of Air not oiled

Noise


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Declaration of Conformity3.5.1

Add it ional Equipment3.6

Detailed technical specifications, see separate manual. This is

located in the Documentation folder of the machine.


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Transportat ion and ins tal lat ion3.7

There are only locked the pneumatic axis.

The electrical axis are not locked, because they cannot move autonomous, theinterance of the engines is to high.

Means of transportation3.7.1

For the transportation of the machine the fllowing means of transportation arenecessary:

a crane with two crabs

adepted cables

fork lift truck

elevating truck.

Bevor transportation3.7.2

Information!

You will find the exact position of the installation of th ecomponents in theinstallation plan. This plan is in the documentation-folder of the machine.

The connections

for the electric current is at the bottom of the switch case,

for the air supply at the air service unit on the backside of themachine.

Fix and mark the place of installation. Fix the route of transportation and remove possible barriers.

Unauthorised people have to stay away from the route of transportatinand the installation location. The area has to be blocked.

Transport machine3.7.3

No Abidance

In danger areas

Beyond pending encumbrances

Lift the machine only a little and keep balanced. Drop down the machine slowlyand carefully.

Unpacking machine3.7.1

The machine may be damaged by unpacking improperly.

Advice!

Please help us to decrease the pollution of environmentand put thewrapping to the right waste containers.


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Sett ing up an mount ing m achine3.8

Installation of the machine3.8.1

The machine has to be placed horizontally. Therefore adjustable levelingelements are mounted at the base frame of the machine.

Figure 8: Leveling element

1. First all components have to be placed as it is shown in the installationplan.

2. Put a water level on the base frame of the machine.

3. Untighten all counter nuts of the levelling elements.

4. Use the hexagon nut to adjust the hight.

5. Clockwise rotation: up

6. Counter clockwise rotation: down

7. Turn the water level 90.

8. Then adjust the machine this way.

9. Turn the water level again 90. Check whether the machine is stillhorizontal and adjust once again if necessary.

10. If the element is exactly horizontal then tighten the counter nuts.

Remove the transportation locks3.8.2

Remove all protection films and cable ties which are used for fixing movingparts.


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Supp ly and instal lat ion3.9

Adjusting and servicing only by special trained stuff.

Test ground fault circuit interrupter in regular intervals.Check the local circumstances with the above-mentioned technicalconnection conditions.

Electrical supply3.9.1

The electrical input lead has to be fixed in the switch case.

They have to be connected at the installation location in accordance with validstandards and regulations and with the connection diagram. Voltage and currentconsumption see chapter 3.5

Procedure

1. Put the input lead through the loophole at the underside of the switchcase into the switch case.

2. Connect the input lead to the marked terminalship in the switch case.

3. Check the power supply.

Air supply3.9.2

The connection of the air supply is exactly where the air service unit is placed.

The positions of the air service unit see at this photo.

Procedure

1. Connect the supply lead2. Adjust the air pressure with the pressure regulator

3. Check the air pressure on the manometer

Figure 9: Air service unit

manometer


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Connection of the components3.9.3

Electrical connections

The components have to be connected as it is described in theconnection diagramm

Avoid single loose cables that make people tripe

Protect the cables from demages

Pneumatical connections

See descriptions of the original devices.


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4 Start of operation

Init ial operat io n4.1

Advice!

In principle machines or equipments of Co. Eaton Industries (Austria) GmbH areset up and putted into operation by our own employees. It is suggested thatsetting up and putting into operation is the duty of the producer.

For initial operation there is necessary:

Checking location.

Checking energy supply.

Removing corrosion protection and cleaning.

Check or fill in operating supplies.

Switch on machine.

Adjusting machine.

Test run.

Information!

For the starting up of components that are bought additionally lookinto the separate manual. You will find it in the documentationfolder of the machine.

Reconnect ion4.2

After a longer term of storage you have to put into operation in the same way asinitial operation.


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5 Operating and displaying elemens

Operat ion elements5.1

Main switch5.1.1

Switch-on or -off the power supply. In possition 0 the main switch can be lockedwith a separate padlock.

position 0: power supply off

position 1: power supply on

Figure 10: Main switch

The main switch must be ensured during maintenance and repair work, such ascleaning with a padlock to prevent unauthorized reconnection.

Tableau5.1.2

Figure 11: Tableau


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Contro l panel descr ipt io n of the pages5.2

If one of the buttons is filled with a checkerboard pattern or deposited grey, so isthis function not available for the moment! (e.g. key switch for the Release ofparameters is switched off at theControl panel)

Starting page5.2.1

This page is displayed after switching on the system. The site provides an overviewof the current machine status. From here, various functions can be selected.

branched directly into stations

switching ON or OFF the stations, if possible

see the production data (piece numberand times)

see error statistics

to call the configurations menu

branched to the station data menu

see directly an active error

Figure 12: Starting page


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5.2.1.1 Error line

Figure 13 demonstrate the error line. This line is to see on the bottom of allpages of the terminal. But it is only to see, when an error or a caution is to be

available. Furthermore, errors or cautions are descriped at Station numberand error text.

Figure 13: Error line

5.2.1.2 Production data

Production time: this is the time with effectiv production

Working shift counter: The amount of the pieces that have to be producedper shift. A Reset is possible at any time.

Cycle time: By changing the cycle time you can manipulate the productivecapacity of the production ine in the long term. The minimal cycle time, thatone material remains in one cycle (one station) of the production line for theprocessing. So if you feed one material to the production line during theminimal cycle time then one material can be completed during this period.Then the production line delivers the maximum rate or the maximumproduction capcity.

Slowest station: Is the station what need a long time to finish a workprocess.

Figure 14: Production data

This area changes the colour:

RED = error

ORANGE = warning

GRAY = advice

Status display (station number : step)


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5.2.1.3 Type selection

After selection of a new type, the key "load" must be pressed to activate thetype.

Figure 15: Type selection

active: shows the currently loaded type

up/down: To select the desired type (next higher / lower)

load: To load the selected type. This function is only available when the

system is emptied and stopped.

Typedata: To continue in the sub Typedata. In this menu types can becreated, deleted, modified and loaded.


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Station pages general5.2.2

This pages are shown after the particular station has been chosen. All stationhave their ones page.

What you can do/see on this page:

the name of the stationand the time

the Occupation Code, the sequence number and the mode of operation

branched directly to the different stations or an overview of the stations

the final position of the cylinder and the appropriate error messages

the options of the manual operation

the status of the stations (defect/warning)

branched into the drive-menu of the circular table

branched to the menuBasic Data (Machine Parameters)

Figure 16: Menue page station 3

Status oft he Cylinder

Options fort he manual operation


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5.2.2.1 Title bar

Figure 17: Title bar

Step Number: The step number tells you which step of the whole procedureis the current one.

Operating mode: Is the mode of the station (SERVICE-HAND-AUTO)

5.2.2.2 Status of the Cylinder

Figure 18: Cylinder

End switch of the cylinder: When a cylinder achieved the end possition, is itsignalled yellow .

Error indication of the end position of the cylinder: If the end position isnot reached after a certain time the error window including the designation ofthe operating resources starts to flash. If the end position is OK because of arepair or because of a delay of the cylinder, the error window and the errormessage can be quitted.

Name of the station Operation mode

end switch of thecylinder

Status of cylinder


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Status of the cylinder: It is to show the status of the cylinder. The directionof the neutral stroke or basic position is pictured with an blue arrow. The

colour of the arrow changes to yellow and it is to signal the direction

of the working stroke of the cylinder.

Operating interface of the cylinder: At the Test-mode the particular cylinderis to move by use of the key-switch or closed guard doors. Therefor touch thepush button of the cylinder. If this push button isnt to see, this function isntallowed.

5.2.2.3 Options for the manual operation

To use the operating interface, the mode-switch must to be switched onHAND-mode. Furthermore the safety must to be warranted (safety doorsclosed).

Figure 19: Operating interface

Step: When push this button the process of this station is done step by step.

Cycle: When push this button one cycle of the station is carried on.

Reset: When push this button a reset of the station is carried out and thecylinders move to the basic position.

Set to empty: When push this button the station is to deplete, (in theOccupation Code of the station is to be inscribed 0, that is the retainers arenot engaged.

Warning!!! Deplete retainers


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Circular table5.2.3


the Occupation Code (state of machining) of all stations (only changeablewith extended authorisation)

the error-code of the stations

the status of the circular table

select the rotational speed of the circular table (only changeable withextended authorisation)

branched to the station data, see chapter5.2.5

branched to the HELP-menu

Figure 20: Menu page circulat table

Occupation Code: At the Occupation Code is to see the state of machining ofthe circular table retainers, which to be located in the relevant station.

All stations fill in their code after successful work. The retainer is empty, if 0filled in at the code. When filled in a number which is not used for a state ofmachining (e.g.: 99 oder 255), so can not handle the stations this retainerandthis retainer is to remove from the circular table (to screw off).


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Error-code: The error-code shows a defective piece into the retainer.

The station what has found or created this error usually filled in their numberatthis code. Is here filled in a value unlike 0 , so will be the part into the retainer

ejected as bad part.

Status of the circular table: The status of the circular table is the summation of

all stations (see chapter5.2.5 Station data )

Safety lost ST: The safety of the stations is controlled during the moving of thecircular table (cylinders shouldnt engage into the circular table). If a stationlosing here safety (position switch of a cylinder), so stop the circular table at themoment and it is to see 91:13 Safety lost (Position) on the error-display. It ispossible to read here the station number (which losing safety) This error is onlyto quit at Hand-mode of the circular table.


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Type data5.2.4

The type data can be set or changed here, even the creation of new types and atype change are possible. For some applications, the a password is required.

Figure 21: Menu page type data


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Station data5.2.5


the status of all stations (coloured symbols) the mode of the stations

change to the stations

branched to the drive-menu of the circular table

branched to the HELP

Figure 22: Menu page station data

Meaning of the coloured symbols:

safety yes

Is to see, if it isnt engaged a cylinder of the station to the retainer and theposition-switches signal exact.

safety noIs to see, if it is engaged a cylinder of the station to the retainer or a position-switches dont signal exact. (e.g. cylinder is in end-position but position-switchdont signal).

blocked yesIs to see, if the station is to blocked the turning of the circular table. If the mode-switch isnt at position AUTO!

mode

SERVICE

HAND

AUTO

description of the colouredsymbols see at the next page

(also in the HELP menu)

access

readyblocked

safety

Back to circulartable menu

Station ON-

or OFF-


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blocked noIs to see, when the station dont blocked the turning of the circular table. If themode-switch is at position AUTO!

ready yesIs to see, if the station dont to process this retainer. (the process is finished or itshouldnt be processed).

ready noIs to see, when the retainer should be processed by the station.

access yesIs to see, when the control is to be working in a machining cycle of a retainer.

access noIs to see, when the control isnt to be work in a machining cycle of a retainer.ist.

In order that the circular table could be move must to be display the station-status!


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Production data5.2.6

The production data are used to represent the achievements quantities sheetpiece counter and time tracking.

Figure 23: Menu page production data

Total Count: Here are counted all pieces or switches which leaving themachine, no matter good or amiss pieces. (Reset of this counter is not possible)

Total Count Pass: Here are counted all good pieces or switches which leavingtne machine. (Reset of this counter is not possible).

Total Count Fail: Here are counted all amissed pieces or switches whichleaving tne machine. (Reset of this counter is not possible)

Order Count Pass: This counter can be used for counting the charge pieces.This counter is resettable.

Lschtasten

Auswahl dergewnschten

Stckzahl


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Preselect Count Reference: At this counter is to setting up the pieces whatshould be manufactured (by dint of charge)

Preselect Count Actual: This counter is connected with the Preselect CountReference and stop the machine if this piece number is achieved (PreselectCount Actual=Preselect Count Reference). This counter is resettable anytime.

Shift Count: This counter counts the produced pieces of a shift (or in space ofan appointed time). This counter is resettable anytime.

Acquisition Time: This time is comprised of Production Time and Down Time.This counter is resettable anytime.

Down Time: This time is comprised of Fault Time and Hand Time.

Fault Time: This time is active, if exist an error message.

Hand Time: This time is active, if a mode-switch in position Hand.

Wait Time: This time is active, if a station must to be wait to a retainer for thenext work.


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Error statistics5.2.7

Here are to see the last 4096 messages (error , warning,....).

Figure 24: Menu page error statistics

Clear the error list (pressmore than 2 sec)To toggle active error

and error list


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Machine parameters5.2.8

Here is to setting up the way and the speed of the servo drive.

An extended authorisation is necessary therefore. The setting of the revolution ofthe screws is possible without extended authorisation.

Figure 25: Menu page machine parameters


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EASY NET5.2.9

The status of security controls is displayed.

Figure 26: Menu page easy net

Murr micro status5.2.10

The status of the Murr Micro switches is displayed.

Figure 27: Menu page Murr Micro status


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System5.2.11

The system settings can be changed here. You must enter a password to makechanges.What you can do/see on this page:

Entering of the date and time

Selection of the IP-address of the terminal

Entering of the password for an advanced authorisation

Reading back of the system information

Exit the program and go back to WIN-CE

Restarting of the terminal

Figure 28: Menu page system

To networkconfiguration

Restart the teminal

Reading backsysteminformations

entering password

entering of date andtime

Exit the terminal

Change language


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Control elements on the control p anel5.3

Figure 29: Control panel

1. Emergency stop button: Immediately switches off all movements of themachine and cuts off all supply voltages. Except fort he supply voltage ofthe control 24V inputs and of the control panel.see chapter7.1.4 Switch-off the machine in a dangerous situation

2. Control ON: switches on the control voltage, quit emergency stopsignal lamp off function switches off asignal lamp on function switches on

3. Control OFF: switches off the copntrol voltage

4. Release of parameters: Permits the changing of important parameters ofthe machine. The key shouldnt pluged in at the control panel!

5. Mode switch: Station 3




9. Printing external: for the manual printing with the labelprinter

10. Enable Working Pressure: To enable the high working pressure in therotary table area when the doors are opened

11. Quit button: With this button you can quit failures provided that they arequitable. That means that failures that are still active are signalled by theblinking of the quit button. These failures have to be eliminated first. Ifthese failures are eliminated the quit button stop blinking and shines. Thenthe failure can be quitted.

1

8 10

97

6

54

3

2

11


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6 Adjusting and setting up

General6.1

The equipment must be used only by instructed staffs!!

Only instructed stuff is allowed to operate the machine.

If the operating staff is not instructed to set the machine the key of the EnableWorking pressure (Figure 29) has to be turned to the position 0 so that the staff isnot able to change the settings. Then the key has to be pulled out and the head-workman or the head of production has to keep it!

The same thing has to be done with the key Release of Parameters!

Watch out:

If someone wants to work on a cylinder the air supply has to bestopped. (see Figure 30)

If the air supply starts again, cylindermoves are possible.

Figure 30: valve terminal

During setting, it may happen that pneumatic cylinder must be pressurized withcompressed air. In this case the cylinder can be moved with a reduced pressure

on the open doors. This requires that the exporting specialist is trained for thiswork demonstrated, aware of the potential dangers of the machine and possibleprotective measures applied (eg wearing of PPE).To establish the control of the air valve terminals, control air must be released tothe respective valve island. Now we can proceed with the cylinders by means ofmanual override of the valves. This function is automatically reset when theprotection is closed.

Gate valve


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Changing types6.2

There are to change the different types (order number) on the PC at the respectiveprogram (Bluhm Linx, Easylabel).

The inscription must to be controlled after changing the type.

Test lauf durc hfhren6.3

After the setting-up and before production starts it is to make a test-run.

PurposeThe correct settings of the machine should be checked.

Requirements

Machine is ready to operate. Machine is fully set.

Right switches for insert are available.

Procedure

Switch on the machine.

Select thje operating mode AUTOMATIC.

Insert the right switches for work.

Start the automatic cycle.

Eject the swiches and check the machining result. Correct the settings if necessary.

Execute more switches and check the result.


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7 Operating of the machine

Setting-up and servicing only by instructed staffs.

The switch on and sw itch of f of the machine7.1

Before switch on7.1.1

Only instructed staff is allowed to operate the machine!!

The training-record at the instructet staffs are to see into the electricaldocumentation.

If the operate staff is not instructed to set the machine the key of the EnableWorking-ressurehas to be turned to the position 0(Figure 29) so that the staffis not able to change the settings. Then the key has to be pulled out a d thehead-workman or the head of production has to keep it!

The same thing has to be done with the key for the Release of Parameters!

Watch out:

If someone works on air cylinders, it must to be turn off the appendet airvalve. (see Figure 30)

It is possible of unexpected cylinder-moves by the recovering of air supply.

Send unauthorised people away from the machine.

Make a visual check of the whole machine and the tools.

Check the level of the lubricants and adjuvants.

Unlock all emergency stopbuttons.


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Switchon the machine7.1.2

1. Switch on the main switch.2. Switch on the control. Therefore press the button Control ON at the

Control panel .3. The control voltage is switched on, the signal lamp control ON shines.4. Please wait, to the operable of the control (approx. 5 minutes) (the

opening image is to see at the Control panel) Quit possibly errormessages.

Switch-off the machine7.1.3

1. Stop the machine (press the button Stop at the control panel)

2. Wait untilthe machine has sttopped.

The release for starting is switched off, the signal lamp START

doesnt shine.The button STOP shines.

3. Switch off the control. Therefore press the button Control off at thecontrol panel.

The control voltage is switched off, the signal lamp Control ondoesnt shine.

4. Switch off the main switch.

The machine is switched off.


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Switch-off the machine in a dangerous situation7.1.4

Beside the regular switch off of the machine it is also possible to switch it offimmediately.

Press one of the 5 emergency stop buttons)

Control panel 1

emergency stop button 4

If one of the emergency stop buttons is pressed all power supplies are cut off.

For more information see the electrical connection diagram.

The current supply of the control and the control panel are not cut off.

(for the error analyses)

If an emergency stop button was pressed an error message is visible on theControl panel . (Emergency stop button pressed)

Switch-on the machine after an emergency stop7.1.5

Important!

Before the restart of the machine after an emergency stop

Find out the reason of the emergency stop,

Eliminate the danger.

1. Once again make sure that all dangers are eliminated.

2. Check the intakes and the stations. The intakes or stations that wereactive at the time of the emergency stop may be damaged.

3. Unlock the pressed emergency stop button by pulling out the button.

4. Switch on the release forstarting. Therefore press the button Control onat the control panel.

5. See point 2 in chapter7.1.2Switchon the machine

Now you can continue the normal operating procedure.

General7.1.6

If the machine was stopped with an emergency stop button or without theheaded switch-off or deplete of the machine, there are checked the stations forswitches to lie about (build the initial condition).

Than is it allowed to restart the machine.

For remove an emergency stop press the button Control on.

The air supply is switched on (protective-doors must to be closed!) and it ispossible to quit the emergency stop report.


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Modes7.2

The mode for the station is to choose with the Service Hand Auto switch.

It is allowed only one mode switch at position Hand, otherwise it is to lay out theerror message 00:01 (many switches are switched on Hand). Hand-mode is notpossible in this moment.

At the postion Service is it possible to move cylinders apart (by closed protective-doors).

It is a RESET at the station by switching of the Mode-switch from position Serviceto Hand.

Furthermore quits the switching from position Hand to Auto all station failure, andthe message open door.

By switching from Auto to Hand stops the auto mode directlyand it is to seestation number : step numberat the control panel.

Mode HAND7.2.1

In the "HAND" mode, the movements of the machine are performed individually.

7.2.1.1 Requiremenst for operation

Machine is switched on

No error message is active

Doors are closed

Type is set

7.2.1.2 Select Mode

Switch on machine

Position the switch to HAND.

With the Step button is it able to execute step by step.

The Cycle button starts a complete work cycle.

The Reset button takes the Station

into a defined basic position.

With the Set to empty button is it able to deplete theretainers.

Figure 31: Mode-HAND


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Mode SERVICE7.2.2

The service-mode permits that the cylinders can be switched manually on theControl panel.

7.2.2.1 Requirements for operating

Machine switched on

No error message active

Safety doors closed

Operation mode switch is in position Service

7.2.2.2 Selection of this operating mode

Switch on the machine

Switch on the operation mode switch on the panel inposition Service

The buttons of the individual cylinders are selectable

Proceed the functions

Figure 32: Mode SERVICE

Mode AUTOMATIC7.2.3

The position AUTO enables an automatic mode.

7.2.3.1 Requirements for operating

Machine switched

Safety doors closed

Machine in basic position


7.2.3.2 Selection of this operating mode

Machine switched on


Sfety doors closed

Operation mode switch in position Auto

Type selected

Figure 33: Mode AUTO


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Printing external7.2.4

Switch the mode switch for External Printing at theControlpanel.Turn out the label printer with the device.

Shut out the safety switch with a safety key.Press the footswitch and start the printing cycle of the label printer.

Figure 34: Mode External Printing

Attention:

The use of a Safety key is only allowed by External Printing mode. Thesafety doors must to be closed by changing to Automatic mode.


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Intended maintenance7.3

Safety Inspection daily7.3.1

Step

Execution Other Time

1Operator

at the beginning of the

early shift

Machine

run1 min

2Operator


early shift

Machine

run1 min

3Operator


early shift

Machine

run1 min

4Operator


early shift

Machine

run1 min

Total time: 4 min

Visual inspection of the light guard for

damage and presence.(SG_number_safety_devices_01_index_a)

Machine number:

F20661

Protective equipment:

Safety shoesQuality control

MESH - Safety Inspection daily

Machine: Half-automatic Printing Equipmen

Location: Romania

Visual inspection of the protective glazing

for damage and presence.

Security check

Visual inspection of the emergency stop

switches for damage and presence.(SG_number_safety_devices_01_index_a)

Visual inspection of the safety door switch

for damage and presence.(SG_number_safety_devices_01_index_a)

Activity

1 2

3

4


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Maintenance Schedule daily7.3.2

Step


1 Operatorat the end of the shiftMachine

stop 3 min

2Operator

at the end of the shift

Machine

stop1 min

3

4

5

Total time: 4 min

Visual inspection of all machine

components for damage

Security check

Pay attention to leaks in the compressed air

systems

Activity

Machine number:

F20661



Maintenance Schedule dailyMachine: Half-automatic Printing Equipmen

Location: Romania

1

2


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Cleaning Schedule daily7.3.3

Step


1Operator


Machine

stop 2 min

2Operator


Machine

stop2 min

3Operator


Machine

stop7 min

4

5

Total time: 11 min

Remove parts lying around in the work area

of the machine

Security check

Blow off stations and rotary table

Clean machine environment

Activity

Machine number:

F20661


Safety shoes, protective gogglesQuality control

Cleaning Schedule dailyMachine: Half-automatic Printing Equipmen

Location: Romania

2

3

1


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Maintenance Schedule weekly7.3.4

Step


1 Operatorat the end of the shiftMachine

stop 3 min

2Operator


Machine

stop1 min

3Operator


Machine

stop2 min

4

5

Total time: 6 min

Check all pneumatic components

Security check

Empty the condensate and clean the filter

cartridge at the air service unit

Check switch holder for damage and

smooth

Activity

Machine number:

F20661



Maintenance Schedule weeklyMachine: Half-automatic Printing Equipmen

Location: Romania

1

2

3


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General Cleaning fortnightly7.3.5

Step

Other Time

1 Machinestop

2 min

2Machine

stop5 min

3Machine

stop4 min

4Machine

run5 min

5Machine

run7 min

Total time: 23 min

Blow out all the hard to reach places in the work area

Wipe all surfaces in the work area

Clean the inside of the glazing

Clean the switching panel and the outside of the glazing

Clean the underframe, tableau and the cabinet

Activity

Machine number:

F20661



General cleaning fortnightly


Execution: Operator + Cleaneron Monday at 08:00 clock in every week with an even number

Security check

1

2

34

5


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Maintenance Schedule monthly7.3.6

Step


1 Operatorat the end of the shift

Machinestop

10 min

2

3

4

5

Total time: 10 min

Machine number:

F20661



Maintenance Schedule monthly


Location: Romania

Check all exposed cables for damage

Security check

Activity

1

1


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Safety Inspection quarterly7.3.7

Step


1 Operator andSupervisor

Machinestop

5 min

2Operator and

Supervisor

Machine

stop5 min

3Operator and

Supervisor

Machine

stop2 min

4

Total time: 12 min

Inspection of the emergency stop switches(SG_number_safety_devices_01_index_a)

Security check

Inspection of the safety door switches(SG_number_safety_devices_01_index_a)

Activity

Inspection of the light guard(SG_number_safety_devices_01_index_a)

Machine number:

F20661



MESH - Safety Inspection quarterlyMachine: Half-automatic Printing Equipmen

Location: Romania

1

2

2

1 3

3


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Maintenance Schedule half-yearly7.3.8

Step


1Operator


Machine

stop5 min

2Operator


Machine

stop3 min

3

4

5

Total time: 8 min

Machine number:

F20661



Maintenance Schedule half-yearlyMachine: Half-automatic Printing Equipmen

Location: Romania

Check the air filters in the control cabinet,

Air service unit and air manifolds

Security check

Check the fan on the drive motors for dirt

and function

Activity

1

1

1


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Information!

Some of the operations that were mentioned above depend on the use andon the conditions of the surrounding. The cycles that were named above are

minimum specifications. In particular cases different maintenance cycles arepossible.

Correct the specifications in the manual, and instruct the operating stuff.

Checking of the safety devices7.3.9

All emergency stop buttons and safety doors have to bechecked separately.

If one of the safety devices is defective the machine has to bestopped immediately and must not restarted again..

7.3.9.1 Checking of the emergency stop function1. Switch on the machine

2. Press an emergency stop button

When the emergency stop button is pressed all functions of the machinehave to stop:

Release for starting

engines

pneumatically activated parts

7.3.9.2 Checking of the safety light curtain

1. Switch on the maschine

2. by using of the foots witch turn the circular table

3. break the with a test bar the safey light curtain the turning of the circulartable must to be stopped

7.3.9.3 Checking of the safety door-survey

1. open safety door

2. Switch on the machine

3. Press START button

If a safety door is open Hand mode is not possible.

Engines and pneumatically activated parts can not run.

Circular table move is not possible.

Lifetime safety components7.3.10

The Lifetime of the light guard contactors under normal use ofthe machine is 3 years before they must be replaced.Exact details can be found in the service plan and the wiringdiagram of the machine.


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Cleaning the equipment7.3.11

See the above named maintenance schedule

Empty condensate collector7.3.121. Disconnect air pressure see manual of the air service unit

2. Put a canister beyond the condensate collector

3. Open the drain screw

4. Let out the condensation water

5. Close the drain screw again.

Figure 35: Air service unit

Advice!

Some of the works named above are dependent on the using and theambient conditions. The above named intervals are minimumspecifications. In certain cases the maintenance intervals may deviate fromthis maintenance schedule. In that case inform the operating staff.


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8 Maintenance

Adjusting and servicing only by special trained staff!

Check ground fault circuit interrupter in regular intervals!

Only trained and instructed staff is allowed to do adjusting and to operate the machine.

Dont put your hands inside the machine by connecting the air supply.

Searchin g and el iminat ion of defects8.1

The following overview informs of defects, the reasons and correctives.

In case of a defect

Inform trained service staff.

If necessary inform the customer service of the producer..

CONTROL ON is not possible8.1.1

If the control cant be switched on.

Possible reasons Correctives

Voltage supply non existent. Find out the reason fort he missing voltagesupply.Supply with voltage.

Motor-circuit switch or fuse releasesMotor defectiveMecanic blockedWire defective

Find out the reason for the release.Eliminate the error.Switch on the motor-circuit.Switch on the fuse.

Error in the control Inform the customer service of the producer.Inform a worker that is skilled in electricalcontol engineering.

Mainair Pressure is not reached.8.1.2


Air service unit set too littlepressure

Set Working pressure (6 bar).

Insufficient air supply from thesupply line

Check supply line

Pneumatic leak Search for and fix leaks


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Main air valve is flashing red8.1.3

The main air valve are one red and one green LED attached to the controlcondition. If there are no errors, the green LED flashing or glowing state. Once a

fault of the main air valve is diagnosed, the green LED goes off and the red LEDstarts to flash.


Error of the Main air valve Disconnect the power supply,by switching off and on again the power switch,reset the valve is performed.

Error of the compressed airsupply

Check maintenance unit and compressed airsupply, perform reset using the main switch.

Figure 36: Main air valve

Spare- and w ear parts8.2Look into the list of the documentation folder!

For wear parts see the identification into the parts list.

Drawings!


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9 Shutdown, storage and disposal

Temporary shutdow n9.1

Switch off the machine and all connected components

Stop the air supply of the machine.

Clean and maintain the machine.

Information!

After a temporary shut-down a restarting-up has to beproceeded.

Stoage con di t ions9.2

Short or mediun-term storage (until 2 years) is possible without special measures.But still the surrounding conditions that were specificated in the technical data haveto be kept in mind.

For long term storage measures for corrosion protection are needed.

Final Shutdow n9.3

1. Switch off the machine, see chaper7.1.3

2. Pinch off the power supply witch is on the switching case or pull out theplug and roll up the supply wire and safely fix it on the machine.

3. Stop the air supply and pinch off the suppy.

4. Empty the adjuvant.

5. Seperating the machine parts and the electric components and dispose itprofessional.

Important!

All parts, adjuvants and lubricants of the machine have to beseperated accurately and you have to dispose of these artsaccording to the local instructionsand principals.

Information!

If there are any questions open concerning the disposalplease ask the producer!


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List of FiguresFigure 1: Statement of place in the documentation .................................................... 6Figure 2:Security devices ......................................................................................... 12Figure 3: Tableau ..................................................................................................... 14Figure 4: Finished switches ...................................................................................... 15Figure 5: Construction and Components .................................................................. 16Figure 6: Safety devices and invigilators .................................................................. 17Figure 7: Control elements and indicators ................................................................ 18Figure 8: Leveling element ....................................................................................... 22Figure 9: Air service unit ........................................................................................... 23Figure 10: Main switch .............................................................................................. 26Figure 11: Tableau ................................................................................................... 26Figure 12: Starting page ........................................................................................... 27Figure 13: Error line .................................................................................................. 28Figure 14: Production data ....................................................................................... 28Figure 15: Type selection ......................................................................................... 29Figure 16: Menue page station 3 .............................................................................. 30Figure 17: Title bar ................................................................................................... 31Figure 18: Cylinder ................................................................................................... 31Figure 19: Operating interface .................................................................................. 32Figure 20: Menu page circulat table ......................................................................... 33Figure 21: Menu page type data ............................................................................... 35Figure 22: Menu page station data ........................................................................... 36Figure 23: Menu page production data ..................................................................... 38Figure 24: Menu page error statistics ....................................................................... 40Figure 25: Menu page machine parameters ............................................................. 41Figure 26: Menu page easy net ................................................................................ 42Figure 27: Menu page Murr Micro status .................................................................. 42Figure 28: Menu page system .................................................................................. 43Figure 29: Control panel ........................................................................................... 44Figure 30: valve terminal .......................................................................................... 45Figure 31: Mode-HAND ............................................................................................ 50Figure 32: Mode SERVICE ....................................................................................... 51Figure 33: Mode AUTO ............................................................................................ 51Figure 34: Mode External Printing ............................................................................ 52Figure 35: Air service unit ......................................................................................... 62Figure 36: Main air valve .......................................................................................... 64

Documents

02_Operating Manual.pdf