0026215_4_BA_Gamma_333_PC_PCB_EN

Operating instructions Fully automatic crimping machine

Gamma 333 PC Gamma 333 PC – B

Art.No. 0026215 0026215 – Version Version 4

Publisher

Komax AG Industriestrasse 6 CH-6036 Dierikon-Lucerne, Switzerland Phone Fax E-mail Internet

+41 41 455 0 455 +41 41 450 4 266 [email protected] www.komaxgroup.com

Date issued

Version number

Pages with changes

1998 June 2003 June 2004 January 2007 March 2009

Version 1 Version 2 Version 2.1 Version 3 Version 4

None; first version completely complete ly revised Chapter 10 / page 10–14 revised completely complete ly revised completely complete ly revised

Reproduction of these instructions or parts of them in whatever form is not permitted withReproduction out express written permission from the publisher. Komax reserves the right to make technical changes necessary to improve the machine that could diverge from figures and information in these instructions.

© 2009 by Komax AG, Wire Processing Systems

lu

Table of contents

Part A Information for every machine user

Part B Information for the machine operator

Part C Information for the service technician

Part A 1. Product description............................................................................................. ..................... .....................1–3 1–3

1.1 The operating instructions .............................................................................................1–4 1.1.1 Layout of of the instructions ................................................................................ 1–4 1.1.2 Size of the instructions......................................................................................1–4 1.1.3 Updating of the instructions .............................................................................1–5 1.2 Other types of documentation ................................................................................ ......1–5 1.3 Personnel Personnel qualifications qualifications and training training ............................................................................ 1–6 1.3.1 Personnel qualifications .................................................................................... 1–6 1.3.2 Training .............................................................................................................1–6 1.4 Machine identification .............................................................................................. ......1–7 1.5 Technical Technical data / scope of performance .................... ..................................................... 1–8 1.6 Conformity......................................................................................................................1–9 Conformity......................................................................................................................1–9 1.7 Accessories ............................................................................... ................................... 1–10

2. Safety .................................................................................... ..................................................... 2–3

2.1 Explanation of notes ......................................................................................................2–3 2.2 Safety notes ...................................................................................................................2–3 2.2.1 Personal protection..................................................................................... ......2–3 2.2.2 Machine protection ..................................................................................... ......2–5 2.2.3 General safety notes ........................................................................................2–5 2.3 Safety features ...............................................................................................................2–6 2.4 The RCS safety system ............................................................................................ ......2–8

3. Transport Transport ................................................................................................................................... 3–1

4. Items included in the delivery / incoming inspection ........................................................... 4–1

OI Gamma 333 PC / Gamma 333 PC – B Version Versio n4

Table of contents

0–3

5. Installation ............................................................................................ ..................................... 5–3

5.1 Installation site ...............................................................................................................5–3 5.2 Installation ................................................................................. ..................................... 5–4

Part B 6. Machine overview and functions ...................................................................................... ......6–3

6.1 Basic machine ........................................................................................... ..................... .....................6–3 6–3 6.1.1 Straightening unit ........................................................................................ ......6–5 6.1.2 Transport Transport unit .................................................................................................... 6–5 6.1.2.1 Gamma 333 PC ...................................................................................6–5 6.1.2.2 Gamma 333 PC-B ...............................................................................6–5 6.1.2.3 Encoder ...............................................................................................6–6 6.1.2 Swivel and pull-off unit on side 1 ...................................................................... 6–6 6.1.3 Cutting head .....................................................................................................6–8 6.1.4 Swivel and pull-off unit on side 2 ...................................................................... 6–9 6.1.4.1 Good/bad sorting...............................................................................6–10 6.1.5 Hold-up device ...............................................................................................6–10 6.1.6 Wire deposit system and conveyor conveyor belt ..................................................... ....6–11 6.1.7 Maintenance unit ............................................................................................6–11 6.2 Control system .......................................................................................... ................... ...................6–12 6–12 6.2.1 Control cabinet ...............................................................................................6–12 6.3 Front control panel ......................................................................................................6–15 6.4 Sensors ........................................................................................................................6–16

7. Machine operation ...................................................................................................................7–3

7.1 Checks prior to startup ..................................................................................................7–3 7.2 Switching the machine machine ON and OFF ............................................................................. 7–4 7.3 Selecting the operating mode ................................................................ ...................... 7–4 7.4 Safety cover ............................................................................................. ..................... .....................7–5 7–5 7.5 Preparing Preparing the machine machine for production production .......................................................................... 7–5 7.5.1 Knot detection ........................................................................................... ......7–5 7.5.2 Straightening unit ........................................................................................ ......7–5 7.5.3 Wire guide parts .......................................................................................... ......7–6 7.5.4 Wire draw-in ................................................................................ ...................... 7–7 7.5.5 Pull-off Pull-off unit on side 1 and side 2 ...................................................................... 7–7 7.5.6 Crimping module ..............................................................................................7–8 7.6 The tool drawer ..............................................................................................................7–9

0–4

Table of contents

OI Gamma 333 PC / Gamma 333 PC – B Version Versi on 4

8. Software instructions ......................................................................................... ............................

The machine operator will need the software instructions most often for his daily work. They describe actual production and setup operations. These instructions have their own table of contents.

Part C 9. Maintenance .............................................................................................................................9–3

9.1 Notes on maintenance ............................................................................................. ......9–3 9.2. Maintenance plan ..................................................................................... ..................... .....................9–4 9–4 9.2.1 Daily maintenance....................................................................................... ......9–4 9.2.2 Weekly maintenance ................................................................................... ......9–4 9.2.3 Monthly maintenance maintenance........................................................................................9–6 ........................................................................................9–6 9.2.4 Maintenance Maintenance every six months ......................................................................... 9–7 9.3 Explanation of maintenance procedures........................................................................ procedures........................................................................ 9–9 9.3.1 Maintenance unit ..............................................................................................9–9 9.3.2 Cutting head ...................................................................................................9–10 9.3.3 Grippers on side 1 and side 2 ......................................................................... 9–10

10. Settings and adjustments................................................................................ .................... ....................10–3 10–3

10.1 Blade blocks and blades ........................................................................................ ....10–3 10.1.1 Disassembling the blade blocks ................................................................... 10–3 10.1.2 Assembling the blade blocks ........................................................................ 10–3 10.1.3 Changing the blades ................................................................................. ....10–4 10.2 Mechanical settings and adjustments........................................................................ adjustments........................................................................ 10–5 10.2.1 Guide parts and bearings .............................................................................10–5 10.2.2 Toothed Toothed belts ............................................................................. ................... ...................10–6 10–6 10.2.2.1 Mounting Mounting a toothed belt .................................................................. 10–7 10.2.2.1.1 Toothed Toothed belt for transport unit on Gamma 333 PC ...................... 10–7 10.2.2.1.2 Toothed Toothed belt for transport unit on Gamma 333 PC-B................... 10–8 10.2.2.1.3 Replacing the drive belt for the swivel head on side 1 and side 210–9 210–9 10.2.2.1.4 Replacing the drive belt for the cutting head.............................. 10–10 10.2.2.2 Operating problems associated with toothed belt drives .............. ..............10–10 10–10 10.2.3 Setting the guide for the pull-off unit on side 2 .......................................... 10–11 10.2.3.1 Positioning the toothed rack (user side) ........................................ 10–11 10.2.3.2 Positioning the counter guide (at the back) ................................... 10–12 10.2.3.3 Final step and setting-check setting-check ........................................................ 10–12


Table of contents

0–5

10.2.4 Calibrating the machine ..............................................................................10–14 10.2.4.1 Calibrating the axes (mechanical) .................................................. 10–14 10.2.4.2 Calibrating the axes under TopWin TopWin ................................................ 10–14 10.2.4.3 Calibration procedure ...................................................................10–15 10.2.5 Wire feed unit .............................................................................................. 10–17 10.2.5.1 Gamma 333 PC ............................................................................. 10–17 10.2.5.2 Gamma 333 PC-B ......................................................................... 10–18 10.2.6 Lifting device ............................................................................................ ..10–18 10.2.7 Wire guide gripper ......................................................................................10–19 10.2.8 Conveyor belt ............................................................................................ ..10–20 10.2.9 mci 711 options .......................................................................................... 10–21 10.2.10 Safety cover ............................................................................................ ..10–21 10.3 Electrical settings and adjustments ......................................................................... 10–22 10.3.1 Sensors ...................................................................................... ................. .................10–22 10–22 10.3.1.1 Laying sensor cables ..................................................................... 10–22 10.3.1.2 Inductive sensors ........................................................................... 10–25 10.3.1.3 Hybrid light barriers .......................................................................10–25 10.3.2 Electric fuses in control control cabinet ................ ................................................. 10–26 10.3.3 BIO PCB..................................................................................... ................. .................10–27 10–27 10.3.4 Output stages of the stepping stepping motors ....................................................... 10–28 10.4 Pneumatic Pneumatic settings and adjustments .................................................... .................. ..................10–30 10–30 10.4.1 Operating pressure .................................................................................. ..10–30 10.4.2 Throttle non-return valves ........................................................................... 10–30 10.5 Setup of processing stations ................................................................................. ..10–31 10.5.1 Crimp module setup ...................................................................................10–31 10.5.2 Setup of mci 761 seal module .................................................................... 10–32 10.5.3 Setting up non MCI modules ......................................................................10–33 10.5.4 MRS PCB ................................................................................... ................. .................10–34 10–34

11. Pneumatic and electrical diagrams ................................................................................ ............

You will find the diagram for the pneumatic system of the machine here. The electrical diagram is enclosed separately along with each machine delivery and must be inserted in this chapter of the operating instructions.

12. I/O list ................................................................................. ...........................................................

The I/O list is enclosed separately along with each machine delivery and must be placed in this chapter of the operating instructions.

0–6

Table of contents


13. Annex .................................................................................. ...........................................................

This chapter is reserved for training materials, technical data sheets, etc. 13.1

_____________________________________________________________________ ______________________________________________ _______________________

13.2

_____________________________________________________________________ ______________________________________________ _______________________

13.3

_____________________________________________________________________ ______________________________________________ _______________________

13.4

_____________________________________________________________________ ______________________________________________ _______________________

14. Accessories ..................................................................................................................................

Place the operating instructions for all your accessories in this chapter so you have the instructions for the entire machine configuration together in a single place. 14.1

_____________________________________________________________________ ______________________________________________ _______________________

14.2

_____________________________________________________________________ ______________________________________________ _______________________

14.3

_____________________________________________________________________ ______________________________________________ _______________________

14.4

_____________________________________________________________________ ______________________________________________ _______________________

15. Putting the machine out of operation, storage and disposal ...................................... ....15–1

15.1 Putting the machine out of operation......................................................................... 15–1 15.2 Storage .................................................................................... ................................... 15–1 15.3 Disposal .....................................................................................................................15–1


Table of contents

0–7

0–8

Table of contents


1. Produktebeschreibung 1.1 The operating instructions .................................................................................................4 1.1.1 Layout Layout of the instructions instructions ................................................................................ ....4 1.1.2 Size of the instructions..........................................................................................4 1.1.3 Updating of the instructions instructions ................................................................................. 5 1.2 Other Other types of documentation ...................................................................................... ....5 1.3 Personnel Personnel qualifications and and training ................................................................................ 6 1.3.1 Personnel qualifications .................................................................................... ....6 1.3.2 Training Training .............................................................................. ...................................6 1.4 Machine identification ..................................................................................... ...................7 1.5 Technical Technical data / scope of performance ........................... ..................................................8 1.6 Conformity..........................................................................................................................9 Conformity..........................................................................................................................9 1.7 Accessories ..................................................................................... .................................10


Product description

1–1

1–2

Product description


1. Product description The Komax Gamma 333 PC / 333 PC – B is an expandable, fully automatic crimping machine with up to three individual processing stations. The Komax Gamma 333 PC / 333 PC – B is intended for the following wire processing applications if operated according to the technical specifications (see Chapter 1.5):

Application

Cutting wire to size / Stripping Marking Crimping Seal application, one end Tinning Length measurement Seal monitoring (on/off) Crimp force analysis Splice monitoring Conveyor-belt Conveyor -belt deposition of wire Good/bad sorting Sequences Batch sorting Split cycle Double crimping

Sleeves fig 1.1 Scope of application for the Gamma 333 PC

This list assumes that the machine is used to process only the materials (conductors, contacts, etc.) specified in the technical data.

Please take a moment now and read through the operating instructions carefully. carefully. They will guide you step by step through Komax Gamma 333 PC / 333 PC – B operations, enabling you to be running it successfully in no time at all.


Product description

1–3

1.1 The operating instructions These operating instructions are valid for the Komax Gamma 333 PC / Gamma 333 PC – B and are available in German, English, French, Italian, Spanish and Portuguese; other languages are available on request. The instructions contain all technical specifications as well as complete infor infor-mation on the controls, the handling procedures for the entire machine, maintenance and adjustment/setting work. These operating instructions form an integral part of the Gamma 333 PC / 333 PC – B. Always keep them nearby so you can refer to them readily any time you need this information. All aspects of these instructions instructions must be thoroughly thoroughly understood understood and heeded by anyone anyone responsible for transporting, installing, operating and repairing the machine.

1.1.1 Layout of the instructions 

of these instructions, Chapters 1 to 5, contains information you usually need note only Part A of once, except for Chapter 2 on safety notes.



Part B, Chapters 6 to 8, features information on operations and on settings/adjustments. This section is intended for the individuals actually operating the machine.



Part C, Chapters 9 to 12 , covers maintenance, machine settings, diagrams, etc., in other words, topics of importance to service technicians.



Read through these instructions carefully! Do not begin to work until you understand all the work steps in the chapters intended for you.

Pay particularly close attention to Chapter 2 on safety notes.

1.1.2 Size of the instructions These operating instructions have 15 chapters. Below is a list of the valid pages in each chapter: Chapter 0 Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9 Chapter 10 Chapter 11 Chapter 12 Chapter 13 Chapter 14 Chapter 15

1–4

8 pages, consecutively numbered from page 0 - 1 to page 0 - 8 12 pages, consecutively numbered from page 1 - 1 to page 1 - 12 8 pages, consecutively numbered from page 2 - 1 to page 2 - 8 Page 3 - 1 Page 4 - 1 8 pages, consecutively numbered from page 5 - 1 to page 5 - 8 18 pages, consecutively numbered from page 6 - 1 to page 6 - 18 10 pages, consecutively numbered from page 7 - 1 to page 7 - 10 Software instructions The valid pages are listed right in the instructions. 10 pages, consecutively numbered from page 9 - 1 to page 9 - 10 36 pages, pages, consecutively consecutively numbered numbered from from page 10 - 1 to page 10 - 36 Diagram of compressed air system Electrical diagram (delivered separately) I/O list (delivered separately) Annex: Customer-speci Customer-specific fic sets of documentat documentation ion Accessories: Customer Customer-specific -specific sets of documentation 2 pages, pages, consecutively consecutively number from page 15 15 - 1 to page 15 - 2

Product description


1.1.3 Updating of the instructions Each footer in these instructions contains a version number, e.g. Version 1.0. The number 1.0 designates the first version of the operating instructions. Main number Subordinated Subordinate d number If individual pages in the instructions change, only the subordinated number on those pages is increased, e.g. from 1.0 to 1.1. If the entire operating instructions are newly reissued, the main number also changes, e.g. from 1.3 to 2.0.

1.2 Other types of documentation The overall documentation for the Komax Gamma 333 PC / 333 PC – B is divided into different types of instructions. Operating instructions The following sets of documentation are integrated into the operating instructions: 

Software instructions

under Chapter 8

Set of diagrams for compressed air system under Chapter 11 Set of electrical diagrams

under Chapter 11

Input / output lists

under Chapter 12

Operating instructions for accessories

under Chapter 14

The operating instructions for the accessories are enclosed with each device. Make sure not to mislay these instructions when unpacking and setting up the device; keep them in the main machine documentation.

Training materials All training materials, materials, personal notes, and customercustomer-specific specific documents can can also be filed in these these operating instructions (under Chapter 13). Spare parts catalog The spare parts catalog lists all spare and wearing parts for the basic machine. All spare parts lists for accessories can also be filed here. 

If you need additional copies of the sets of documentation, just contact your Komax dealer.


Product description

1–5

1.3 Personnel qualifications and training 1.3.1 Personnel qualificatio qualifications ns Machine operators Machine operators must be sufficiently familiar with the machine to be able to operate it and its accessories and peripheral devices in production without any trouble. This requires a good technical understanding of the machine and knowledge of the software used in operating it. Service technicians Service technicians must have extensive knowledge of the machine. Aside from machine operations, they must be able to locate errors and take the appropriate steps to remedy them. Service technicians must also be able to maintain the machine correctly so that its service life and availability is increased. They must also have complete mastery of the software, so that optimum use can be made of the machine in production. To carry out these tasks, technicians must have experience in wire processing and crimp technology.. They must also have completed formal mechanical or electronics training and be able to nology demonstrate a solid understanding of the Komax Gamma 333 PC.

1.3.2 Training Komax offers individually adapted courses for all, from operators and setup engineers to maintenance and service technicians. You You become more familiar with your product, the accessories and the peripherals and learn how to use them to optimum effect in the production process. Greater knowledge about maintenance maintenance and repairs helps you to increase the availability and service life of the machine. After successfully completing the training, each participant receives a certificate. Courses and their contents The training program is divided into machine-specific and module-specific units. Basically speaking a training course consists of the following topics:  Tour of Komax  Machine layout  Machine maintenance  Mechanical system  Electrical system  Pneumatic system  Software  Practical exercises  Trouble-shooting  Wrap-up discussion General information on the way courses are set up Depends on machine, 1 to to 5 days, or or as agreed  Duration of training: Training center at Komax in Dierikon or at customer customers’ s’ premises  Venue: We are happy to make hotel reservations (in downtown Lucerne)  Accommodations: for you. Customer Service at Komax in Dierikon  Training organizer: German or English  Languages: The class size is limited to at most three persons.  Class size: All materials are distributed on the first day of training.  Training materials:

1–6

Product description


1.4 Machine identification Example of a nameplate Machine number

Machine type

Voltage Vo ltage version

Power input

A nameplate 1 is located on the frame of the machine.

1 fig 1.01 Machine overview of Gamma 333 PC / 333 PC – B


Product description

1–7

1.5 Technical Technical data / scope of performance Length range

60mm – 10000mm, optionally from 30mm

Length accuracy

+/- 1mm or <0.2%, depending on wire length

Length measurement

with measuring encoder

Stripping lengths

0.1 – 15mm, on side 1, (optionally from 30mm) 0.1 – 15mm, on side 2

Wire cross section

0.125 – 5.0mm2 AWG26 – AWG10

Piece output

see fig 1.02

Feed speed

max. 6m/s (Gamma 333 PC) / max. 10m/s (Gamma 333 PC – B)

Electrical connection

3 x 208 – 480V 480V,, N, PE; 50/60Hz; 6000VA 2 5 × 4mm ; 25A fuse

Compressed air connection

4 – 6bar

Noise level

< 75dBA (without presses)

Air consumption

6.5m3 /h (without accessories) accessories)

Weight

1030kg with two mci 711 crimp presses

Piece number [pcs/h] 4500

mci 721 at 60°

mci 721 at 35°

1

4000

3500

2

mci 721 at 60°

3000

mci 721 at 35°

2 3

2500

1

2000

mci 721 at 60° 1500

mci 761 at 35°

3

1000 0

1000

2000

3000

4000

5000

6000

7000

8000

9000

mci 721 at 90°

10000

Wire length (mm) Configuration of 333 PC

Conductor Pneumatic pressure Speed Acceleration Quality monitoring Press optimization Crimping modules

Configuration Configurati on of 333 PC-B

FLRY 0.75mm2 6bar (87psi) 6m/s (19.7ft/s (19.7ft/s)) 40m/s (131ft/s2) (131ft/s2) active yes mci 721

Conducto r Conductor Pneumatic pressure Speed Acceleration Quality monitoring Press optimization Crimping modules

FLRY 0.75mm2 6bar (87psi) 10m/s (32.8ft (32.8ft/s) /s) 50m/s (164ft/s2) (164ft/s2) active yes mci 721

fig 1.02 Recommended values for piece output on Gamma 333 PC/333 PC – B

1–8

Product description


1.6 Conformity

If used in accordance with the operating documents and specifications (operated exclusively with the stipulated protective, safety, and operating devices), this machine is in conformity with 

Directive 89/392/EEC 89/392/EEC as amended by Directives 91/368/EEC, 91/368/EEC, 93/44/EEC 93/44/EEC and 93/68/EEC (Machinery Directive).



Directive 89/336/EEC 89/336/EEC as amended by Directives 91/263/EEC 91/263/EEC and 92/31/EEC 92/31/EEC (EMC Directive).



Directive 73/23/EEC 73/23/EEC as amended by Directive 93/68/EEC 93/68/EEC (Low Voltage Voltage Directive).

In addition, we confirm that the machine complies with the following standards: 

EN 50 081-2

Electromagnetic Compatibility (EMC) Electromagnetic Basic Specification on Emitted Interference, Industrial Area



EN 50 082-2

Electromagnetic Compatibility (EMC), Draft Electromagnetic Basic Specification on Emitted Interference, Industrial Area


Product description

1–9

1.7 Accessories With the many accessories, the Komax Gamma 333 PC / 333 PC – B can be tailored perfectly to your specific application yet remains open to accommodating future requirements. The following list gives a quick overview of the possibilities provided by the individual devices.

Blades Cutting head         

Set for stripping lengths up to 30mm on side 1 V form stripping blade R 0.1 1 V form stripping blade R 0.5 1 V form stripping blade R 0.75 1 V form stripping blade R 1.0 1 V form stripping blade R 1.5 1 V form stripping blade R 2.0 1 Cutting blade 2 3 Bad wire cutting blade

1 3

2

fig 1.03 Blade head

Wire guides

Various wire guides (arrows) Various (arrows) can be used to ensure optimum wire guidance. Special guides are available on request. 1 Wire guide 2 Guide hose 3 Wire guide tube, short/long

short

long

× × × × × × × × × ×

× × × × × ×

Ø1.3 Ø1.5 Ø1.7 Ø2 Ø2.5 Ø3 Ø3.5 Ø4 Ø5 Ø5.5

×

1 2

3

fig 1.04 Wire guides on the swivel unit, side 1

× × ×

Grease: Standard

1 – 10

Product description


Transport rollers (Gamma 333 PC)

You can use different transport rollers (arrow) to adjust the roller drive to wires with different characteristics.  







Elastomer transport rollers Steel transport transport rollers, rollers, diagonally knurled, fine (optional) Steel transport transport rollers, rollers, diagonally knurled, medium (optional) Steel transport transport rollers, rollers, diagonally knurled, coarse (optional) Plasma-coated transport rollers (optional)

Processing stations

fig 1.05 Roller drive

Press accessories  



 

Fixed press positioning Lever-operated Leveroperated quick quick clamping clamping system for mini applicators Contact feed feed plates for for side 1 and side 2, side-feed and back-feed Contact strip cutter, cutter, K 455 Paper strip take-up device, K 496

fig 1.06

Monitoring 

The wire end check is done in the wire drive with an encoder. (fig 1.07 shows the encoder in the roller drive for the Gamma 333 PC.)

fig 1.07 Monitoring units prior to wire draw-in


Product description

1 – 11



Crimp force analysis is integrated in the mci 711 crimp modules.

fig 1.08 Crimp force analysis

Wire deposition

Standard: 1.5m conveyor belt Optional: 2m extension for conveyor belt, K 419 4m extension for conveyor belt, K 420

fig 1.09 Deposit unit, 1.5m

1 – 12

Product description


Sicherheit Hinweiserklärung GEFAHR Bezeichnet eine Gefahr mit hohem Risiko. Wenn sie nicht gemieden wird, sind Tod oder schwerste Verletzungen die Folge. WARNUNG Bezeichnet eine Gefahr mit mittlerem Risiko. Wenn sie nicht gemieden wird, können Verletzungen die Folge sein. VORSICHT Bezeichnet eine Gefahr mit geringem Risiko. Wenn sie nicht gemieden wird, können Sachschäden die Folge sein. HINWEIS Bezeichnet Anwendertipps und andere nützliche Informationen. Es ist kein Signalwort für Gefahren.

Im Weiteren werden folgende Symbole für spezifische Gefahren der Maschine verwendet: Gefahr durch Strom

Verbrennungsgefahr Verbrennungsge fahr durch heisse Oberflächen

Einzugsgefahr für Finger oder Hände

Gefahr durch Laser

Quetschgefahr für Finger oder Hände

Verletzungsgefahr für Augen Verletzungsgefahr durch Kabel und Litzen

Schnittgefahr für Finger oder Hände

Gefahr durch Zinnspritzer

Gefahr durch ESD (Elektrostatische (Elektros tatische Entladung)

Gefahr durch Explosion

h c s t u e D

h c s t u e D

Allgemeine Sicherheitshinweise Betriebsanleitung Die Betriebsanleitung ist ein Bestandteil der Maschine. Bevor Sie mit der Maschine arbeiten, muss die Betriebsanleitung gelesen und verstanden werden. Beachten Sie insbesondere die Sicherheits- und Warnhinweise.

Anleitungen Zubehör Beachten Sie neben den Sicherheitshinweisen in dieser Betriebsanleitung auch die Sicherheitshinweise in den Anleitungen des Zubehörs.

Personensicherheit Die Personensicherheit ist nur für einen einzigen Bediener gewährleistet. Personen die an der Maschine arbeiten, müssen sich stets vergewissern, dass durch ihr Handeln keine Personen gefährdet werden.

Personalqualifikation Die Maschine darf nur von Personen welche die entsprechenden Qualifikationen mitbringen bedient, eingestellt und gewartet werden.

Technischer Zustand der Maschine Gefahrloser Betrieb Wenn anzunehmen ist, dass ein gefahrloser Betrieb der Maschine nicht mehr gewährleistet ist, muss die Maschine ausgeschaltet und gegen unbeabsichtigtes Einschalten gesichert werden.

Sicherheitseinrichtungen Die Maschine darf nur mit funktionierenden Sicherheitseinrichtungen betrieben werden. Sicherheitseinrichtungen, inbesondere die Schutzhaube, dürfen nicht entfernt, überbrückt oder in irgendwelcher Form manipuliert werden.

Wartung Die Maschine muss nach den angegebenen Zeitintervallen gewartet werden. Wird die Maschine nicht regelmässig gewartet, können Maschinenschäden die Folge sein.

Ersatzteile Defekte Teile Teile dürfen nur durch Originalersatzteile ersetzt werden. Die Originalersatzteile können bei Komax bezogen werden.

Umbauten Die Maschine darf grundsätzlich nicht umgebaut werden. Sollten Umbauten notwendig sein, dürfen diese nur nach Rücksprache mit Komax ausgeführt werden.

Softwaremodifikationen Jegliche Modifikation der Software ist untersagt.

h s i l g n E

Safety Explanation of notes DANGER Indicates a danger involving a high risk. Not avoiding it results in death or serious injury. WARNING Indicates a danger involving a medium risk. Not avoiding it could result in injuries. CAUTION Indicates a danger involving a low risk. Not avoiding it could result in property damage. NOTE Indicates user tips and other useful information. It is not a word that signals dangers.

The following symbols are used hereafter to indicate the specific dangers posed by the machine: Danger from electrical shock

Danger of burns from hot surfaces

Danger of fingers or hands being drawn in

Danger from laser

Danger of fingers or hands being crushed

Risk of injury to eyes from cables and strand wires

Danger of fingers or hands being cut

Danger from tin splatters

Danger from ESD (electrostatic discharge)

Danger from explosion

h s i l g n E

General safety instructions Operating instructions The operating instructions are an integral part of the machine. You must read the operating instructions and make sure you understand them before working with the machine. Pay especially close attention to the safety and warning instructions.

Instructions for accessories Besides heeding the safety instructions in these operating instructions, make sure to obey the safety instructions in the instructions for the modules and accessories.

Safety of persons Personal safety is guaranteed only for a single machine operator. Anyone working on the machine must always be careful not to enter a command that puts others in danger.

Personnel qualifications Only individuals with the appropriate qualifications are allowed to operate, set up, and maintain the machine.

Technical condition of the machine Safe operation If you have reason to believe the machine can no longer be operated safely, you must put it out of operation and secure it against being switched on unintentionally.

Safety devices The machine may only be operated with properly functioning safety devices. It is not permitted to remove or bridge safety devices or tamper with them in any way way..

Maintenance The machine must be serviced at the indicated time intervals. Machine damage could occur if the machine is not serviced regularly regularly..

Spare parts Defective parts must be replaced with original spare parts. These original spare parts are available for purchase from Komax.

Modifications Basically speaking, the machine is not n ot allowed to be modified. If modifications prove necessary,, you may not carry them out without first consulting Komax. necessary

Software modifications It is forbidden to modify the software in any way way..

Sécurité Explication des remarques DANGER Désigne un danger à grand risque. Si on ne l’évite pas, il peut entraîner la mort ou de très graves blessures. blessures. AVERTISSEMENT AVERTISSEMENT Désigne un danger à risque moyen. Si on ne l’évite pas, il peut entraîner des blessures. blessures. PRECAUTION Désigne un danger à faible risque. Si on ne l’évite pas, il peut entraîner des dommages matériels. matériels. REMARQUE Désigne des conseils pour utilisateurs et autres informations utiles. Ce n’est pas un mot-clé signalant des dangers.

Par ailleurs, les symboles suiants sont utilisés pour désigner des dangers spécifiques à la machine: Danger: courant électrique

Risque de brûlure: surfaces très chaudes

Risque de saisisssement des doigts ou des mains

Danger: laser

Risque d’écrasement des doigts ou des mains

Risque de lésions oculaires dues aux câbles et aux torons

Risque de se couper les doigts ou les mains

Danger: projections d’étain

Danger: décharges électrostatiques électros tatiques (ESD)

Danger: explosion

s i a ç n a r F

Consignes générales de sécurité s i a ç n a r F Instructions de service

Les instructions de service font partie intégrante de la machine. Avant de travailler avec la machine, les instructions de service doivent avoir été lues et comprises. Observez particulièrement les consignes de sécurité et d’avertissement.

Instructions de service des accessoir accessoires es Outre les consignes de sécurité des présentes instructions de service, veuillez également observer les consignes de sécurité des instructions de service des accessoires.

Sécurité des personnes

La sécurité des personnes n’est n ’est garantie que pour un seul utilisateur. utilisateur. Les personnes travaillant sur la machine doivent toujours s’assurer qu’aucune personne n’est en danger du fait d’une entrée erronée.

Qualification du personnel La commande, le réglage et la maintenance de la machine ne doivent être réalisés que par des personnes disposant des qualifications correspondantes.

Etat technique de la machine Fonctionnement sans risque Lorsqu’on peut supposer qu’un fonctionnement sans danger de la machine n’est plus garanti, la machine doit être mise hors circuit et protégée contre une mise en circuit involontaire.

Dispositifs de sécurité La machine ne doit être mise en service que lorsque les dispositifs de sécurité fonctionnent correctement. Les dispositifs de sécurité, et notamment le capot de protection, ne doivent pas être enlevés, pontés ou manipulés de quelque manière que ce soit.

Maintenance La maintenance de la machine doit être réalisée après les intervalles de temps indiqués. Lorsque la maintenance de la machine n’est pas réalisée régulièrement, cela peut entraîner des dommages sur la machine.

Pièces de rechange Les pièces défectueuses ne doivent être remplacées que par des pièces originales. Les pièces de rechange originales peuvent être achetées chez Komax.

Transformations Par principe, la machine ne doit pas subir de transformation. Si des transformations devaient être nécessaires, elles ne doivent être exécutées qu’après consultation de Komax à ce sujet.

Modifications du logiciel Toute modification du logiciel est interdite.

Sicurezza Spiegazione delle avvertenze PERICOLO Contrassegna un pericolo ad alto rischio. Se non viene evitato, la conseguenza possono essere la morte o gravi ferite. AVVISO Contrassegna un pericolo di medio rischio. Se non viene evitato, come conseguenza si possono subire delle lesioni. CAUTELA Contrassegna un pericolo di basso rischio. Se non viene evitato, possono verificarsi verificarsi danni materiali. NOTA Indica suggerimenti per l’utente ed altre utili informazioni. Non è una parola che segnala dei rischi.

Inoltre, vengono impiegati i seguenti simboli per rischi specifici della macchina: Pericolo da corrente elettrica

Rischio di scottarsi contro superfici surriscaldat surriscaldatee

Rischio di impigliare dita o mani

Rischio da laser

Rischio di schiacciare dita o mani

Rischio di ferirsi gli occhi con cavi e trefoli

Rischio di tagliare dita o mani

Rischio di schizzi di stagno

Rischio di scariche elettrostatiche

Rischio di esplosioni

o n a i l a t I

o n a i l a t I

Avvertenze generali sulla sicurezza Istruzioni per l’uso Le istruzioni per l’uso sono parte integrante della macchina. Prima di lavorare con la macchina, le istruzioni per l’uso devono essere lette e comprese. Rispettate in particolare le avvertenze e gli avvisi sulla sicurezza.

Istruzioni degli accessori Oltre alle avvertenze sulla sicurezza contenute in queste istruzioni per l’uso, si deve tener conto anche delle avvertenze sulla sicurezza nelle istruzioni dei moduli e degli accessori.

Sicurezza personale La sicurezza personale è garantita solo per un unico operatore. Le persone che lavorano sulla macchina devono sempre accertarsi di non mettere in pericolo altre persone con le loro azioni.

Qualificazione del personale La macchina può essere comandata, regolata ed assoggettata a manutenzione solo da persone dotate di adeguate qualifiche.

Stato tecnico della macchina Funzionamento esente da rischi Se si ritiene che non sia più garantito un funzionamento fu nzionamento della macchina esente da rischi, questa deve essere messa fuori servizio ed assicurata contro l’inserimento accidentale.

Dispositivi di sicurezza La macchina può essere fatta funzionare f unzionare solo con dispositivi di sicurezza operativi. I dispositivi di sicurezza, in particolare la copertura di protezione, non devono essere rimossi, messi in derivazione o manipolati in qualsivoglia forma.

Manutenzione La macchina deve essere assoggettata a manutenzione agli intervalli di tempo indicati. Se la macchina non viene assoggettata a manutenzione regolarmente, può subire dei danni.

Parti di ricambio I componenti difettosi possono essere sostituiti solo da ricambi originali. I ricambi originali possono essere acquistati presso la Komax.

Trasformazioni La macchina in linea di massima non deve essere sottoposta a trasformazioni. Qualora si rendano necessarie delle trasformazioni, queste si possono eseguire solo dopo aver consultato la Komax.

Modifiche del software Qualsivoglia modifica del software è vietata.

l o ñ a p s E

Seguridad Explicación de las indicaciones PELIGRO Designa un peligro de elevado riesgo. Si no se evita, provoca la muerte o heridas graves. ADVERTENCIA Designa un peligro de riesgo mediano. Si no se evita, puede provocar heridas. CUIDADO Designa un peligro de riesgo reducido. Si no se evita, puede provocar daños materiales. materiales. AVISO Designa avisos para el usuario y otras informaciones provechosas. provechosas. No es ningún aviso sobre un peligro.

Por lo demás, se emplean los siguientes símbolos para peligros específicos de la máquina: Peligro por corriente

Peligro de quemaduras por superficientess calientes superficiente

Peligro de atrapamiento de dedos o manos

Peligro por láser

Peligro de aplastamiento de dedos o manos

Peligro de heridas oculares por cables y cordones

Peligro de corte de dedos o manos

Peligro por salpicaduras de estaño

Peligro por ESD (descarga electrostática)

Peligro por explosión

l Indicaciones generales de seguridad o ñ a p s E Instrucciones de servicio

Las Instrucciones de servicio son parte integrante de la máquina. Antes de trabajar con la máquina debe haber leído y entendido las instrucciones de servicio. Observe especialmente los avisos de seguridad y las advertencias.

Instrucciones de accesorios

Observe aparte de los avisos de seguridad en las presentes instrucciones de servicio también los avisos de seguridad en las instrucciones de accesorios.

Seguridad de personas

La seguridad de personas sólo viene garantizada para un solo operador operador.. Las personas que trabajan en la máquina deben cerciorarse siempre que la entrada de un comando no pueda exponer a peligros a otras personas.

Calificación del personal La máquina sólo debe ser operada, ajustada y mantenida por personas que satisfagan las calificaciones correspondientes.

Estado técnico de la máquina Operación exenta de peligros Cuando es de suponer que ya no está garantizado un funcionamiento de la máquina exento de peligros, ésta debe ponerse fuera de servicio y asegurarse contra la conexión involuntaria.

Dispositivoss de seguridad Dispositivo La máquina sólo debe operarse con los dispositivos de seguridad en funcionamiento. Los dispositivos de seguridad, especialmente la cubierta de protección, no deben quitarse, puentearse o manipularse de otra manera.

Mantenimiento La máquina debe ser mantenida conforme a los intervalos de tiempo indicados. Si la máquina no es mantenida periódicamente, pueden surgir daños de la misma.

Piezas de repuesto Las piezas defectuosas sólo deben ser sustituidas por piezas de repuesto originales. Las piezas de repuesto originales pueden obtenerse de Komax.

Modificaciones Modificacio nes constructivas En principio, no deben efectuarse modificaciones constructivas de la máquina. Si éstas fueran necesarias, no obstante, debe consultar previamente a Komax.

Modificaciones del software Se prohíbe toda modificación del software.

Segurança Esclarecimentos sobre as instruções PERIGO Indica um perigo elevado. Se não for evitado, a consequência será a morte ou ferimentos gravíssimos. gravíssimos. ADVERTÊNCIA Indica um perigo médio. Se não for evitado, pode provocar ferimentos. CUIDADO Indica um perigo baixo. Se não for evitado, pode provocar provocar danos materiais. NOTA Indica dicas de aplicação e outras informações úteis. Não é um sinal de perigo.

Para além disso, serão utilizados os seguintes símbolos para perigos específicos da máquina: Perigo causado por corrente eléctrica

Perigo de queimadura causado por superfícies quentes

Perigo de os dedos e as mãos serem puxados

Perigo causado por laser

Perigo de esmagamento para os dedos ou as mãos

Perigo de ferimento aos olhos por cabos ou condutores multifilares

Perigo de corte aos dedos ou às mãos

Perigo causado por salpicos de estanho

Perigo causado por DEM (descarga electromagnética)

Perigo causado por explosão

s ê u g u t r o P

s Instruções gerais de segurança ê u g u t r o P Manual de instruções

O manual de instruções é um componente da máquina. Antes de operar a máquina, é preciso ler e compreender o manual de instruções. Respeite sobretudo as instruções de segurança e as advertências.

Manuais de instruções dos acessórios Observe, para além das instruções de segurança deste manual de instruções, também as instruções de segurança dos manuais de instruções dos acessórios.

Segurança do pessoal

A segurança do pessoal só está garantida garantida para um único operador. operador. Pessoas que trabalhem na máquina devem certificar-se continuamente que as suas acções não põem outras pessoas em perigo.

Qualificação do pessoal Apenas pessoal que disponha da respectiva respectiva qualificação está autorizado a operar operar,, ajustar e efectuar trabalhos de manutenção na máquina.

Estado técnico da máquina Funcionamento isento de perigo Se houver justa causa para supor que não se pode garantir um funcionamento da máquina isento de perigo, é preciso pôr a máquina fora de serviço e protegê-la para que não seja ligada acidentalmente.

Dispositivoss de segurança Dispositivo Só é permitido operar a máquina se os dispositivos de segurança estiverem a funcionar perfeitamente. É proibido remover, remover, curto-circuitar ou manipular de qualquer outra forma os dispositivos de segurança, principalmente a cobertura de protecção.

Manutenção Os trabalhos de manutenção devem efectuar-se na máquina de acordo com os intervalos especificados. Se os trabalhos de manutenção não forem efectuados regularmente na máquina, há perigo de danos à máquina.

Peças sobressa sobressalentes lentes Peças defeituosas só podem ser substituídas por peças sobressalentes originais. As peças sobressalentes originais podem ser encomendadas à firma Komax.

Transformações É proibido realizar todo e qualquer tipo de transformações na máquina. Se for necessário fazer transformações na máquina, elas só podem ser realizadas após consulta prévia à firma Komax.

Modificações no software É proibido realizar toda e qualquer modificação no software.

Sikkerhed Symbolforklaring FARE Angiver fare med med høj risiko. Hvis ikke den undgås, er følgen død eller alvorlige kvæstelser. ADVARSEL Angiver fare med med mellemhøj risiko. risiko. Hvis ikke den undgås, kan følgen være kvæstelser. FORSIGTIGHED PÅBUDT Angiver fare med med lav risiko. risiko. Hvis ikke den undgås, kan følgen være skader på ting. OBS! Angiver brugerinformationer brugerinformationer og og andre nyttige nyttige oplysninger oplysninger.. Er ikke en faresignalbetegnelse. faresignalbetegnelse.

Desuden anvendes følgende symboler for specifikke risici ved maskinen: Fare på grund af strømførende dele

Forbrændingsfare på grund af Forbrændingsfare varme overflader

Fare for indtrækning af fingre eller hænder

Fare på grund af laserstråling

Fare for kvæstelser på fingre eller hænder

Fare for øjenkvæstelser på grund af kabler og ledninger

Fare for snitkvæstelser på fingre eller hænder

Sprøjterisiko Sprøjteris iko fra tin

Fare for ESD (elektrostatisk afladning)

Eksplosionsfare

k s n a D

k Generelle sikkerhedsanvisninger s n a D Driftsvejledning

Driftsvejledningen er en del af maskinen. Før der arbejdes med maskinen, skal driftsvejledningen gennemlæses og indholdet forstås. Opmærksomheden henledes særligt på sikkerhedsinstruktioner og advarsler advarsler..

Vejledninger Vejle dninger for tilbehør tilbehør

Ud over sikkerhedsinstruktionerne i nærværende driftsvejledning skal også sikkerhedsinstruktionerne i dokumentationerne for tilbehøret overholdes.

Personlig sikkerhed Den personlige sikkerhed kan kun garanteres for en enkelt operatør operatør.. Personer, der arbejder ved maskinen, skal altid overbevise sig om, at deres handlinger ikke indebærer risiko for andre personer.

Uddannelse Maskinen må kun betjenes, indstilles og vedligeholdes af personer med den relevante uddannelse.

Maskinens tekniske tilstand Risikofri drift Hvis der opstår tvivl om maskinen kan køre uden sikkerhedsrisiko eller ej, skal maskinen tages ud af drift og sikres mod utilsigtet genindkobling.

Sikkerhedsanordninger Maskinen må kun ku n anvendes med fungerende sikkerhedsanordninger. sikkerhedsanordninger. Sikkerhedsanordninger,, specielt sikkerhedshætten, må ikke fjernes, frakobles eller på Sikkerhedsanordninger nogen måde manipuleres.

Vedligeholdelse Ved ligeholdelse Maskinen skal vedligeholdes iht. de anførte tidsintervaller tidsintervaller.. Vedligeholdes Vedligeho ldes maskinen ikke regelmæssigt, kan der opstå skader på maskinen.

Reservedele Defekte dele må kun udskiftes med originale reservedele. Originale reservedele kan bestilles hos Komax.

Modifikationer Maskinen må principielt ikke modificeres. Hvis modifikationer skulle være nødvendige, må disse kun udføres efter konsultation med Komax.

Softwaremodifikationer Modifikation af software er ikke tilladt.

Veiligheid Toelichting op de aanwijzingen GEVAAR Betekent een gevaar met groot risico. Indien dit niet gemeden wordt, zijn de dood of ernstige verwondingen het gevolg. WAARSCHUWING Betekent een gevaar met middelgroot risico. Indien dit niet gemeden wordt, kunnen verwondingen het gevolg zijn. PAS OP Betekent een gevaar met gering risico. Indien dit niet gemeden wordt, kan materiële schade het gevolg zijn. AANWIJZING Betekent gebruikerstips en andere nuttige informatie. Het is geen waarschuwing voor gevaar.

Hieronder worden de volgende symbolen voor een specifiek gevaarlijke machine gebruikt: Gevaar door stroom

Verbrandingsgevaar Verbrandingsgev aar door hete oppervlakken

Intrekgevaar voor vingers of handen

Gevaar door laser

Gevaar voor bekneld raken van vingers of handen

Gevaar voor oogletsel door kabels en draden

Snijgevaar voor vingers of handen

Gevaar door spatten tin

Gevaar door ESD (elektrostatische (elektro statische ontlading)

Gevaar door explosie

s d n a l r e d e N

s Algemene veiligheidsinstructies d n a l r e d e N Handleiding

De handleiding vormt een bestanddeel van de machine. Voordat u met de machine werkt, moet de handleiding gelezen en begrepen worden. Let met name op de veiligheidsinstructies en waarschuwingen.

Handleiding accessoires

Let naast de veiligheidsinstructies in deze handleiding ook op de veiligheidsinstructies in de handleidingen voor de accessoires.

Veiligheid Veil igheid van personen personen

De veiligheid van personen is uitsluitend gewaarborgd voor één enkele operator. operator. Personen die aan de machine werken, moeten zich er steeds van vergewissen, dat door hun handelen geen personen in gevaar worden gebracht.

Kwalificatie van het personeel De machine mag uitsluitend door hiertoe gekwalificeerde personen bediend, ingesteld en onderhouden worden.

Technische toestand van de machine Ongevaarlijke werking Indien kan worden aangenomen dat een gevaarloze werking van de machine niet meer gewaarborgd is, moet de machine uitgeschakeld en tegen onopzettelijk opnieuw inschakelen beveiligd worden.

Veiligheidsvoor Veil igheidsvoorzieningen zieningen De machine mag uitsluitend met goed functionerende veiligheidsvoorzieningen worden gebruikt. Veiligheidsvoorzieningen, Veilighei dsvoorzieningen, met name de beschermkap, mogen niet verwijderd, overbrugd of in welke vorm dan ook gemanipuleerd worden.

Onderhoud De machine moet volgens de aangegeven termijnen onderhouden worden. Indien de machine niet regelmatig onderhouden wordt, kan machineschade het gevolg zijn.

Onderdelen Defecte onderdelen mogen uitsluitend door originele onderdelen worden vervangen. De originele onderdelen kunnen bij Komax worden gekocht.

Ombouwen De machine mag in principe niet worden omgebouwd. Mocht ombouwen noodzakelijk zijn, dan mag dit uitsluitend in overleg met Komax worden uitgevoerd.

Softwaremodificaties Iedere modificatie van de software is verboden.

Turvallisuus Merkkien selitys VAARA Merkitsee suuren riskin vaaraa. Vaaran Vaar an seurauksena voi voi olla kuolema tai tai vakava tapaturma. tapaturma. VAROITUS Merkitsee keskisuuren riskin vaaraa. Vaaran Vaar an seurauksena voi voi olla tapaturma. tapaturma. HUOMIO Merkitsee pienen riskin vaaraa. Vaaran Vaar an seurauksena voi voi olla esinevahingot. esinevahingot. OHJE Merkitsee vinkkejä käyttäjälle ja muuta hyödyllistä tietoa. Ei viittaa mahdolliseen vaaratilanteeseen.

Lisäksi koneen mahdolliset vaarapaikat on merkitty seuraavilla symboleilla: Sähköiskun vaara

Palovammojen vaara kuumien Palovammojen pintojen johdosta

Sormien ja käsien koneeseen vedetyksi tulemisen vaara

Laserin aiheuttama vaara

Sormien ja käsien puristumisvaarasormien puristumisvaa rasormien ja käsien koneeseen vedetyksi Sormien ja käsien viiltovammojen viiltovammo jen vaarasormi vaarasormien en ja käsien koneeseen koneeseen vedetyksi Sähköstaattisen purkauksen Sähköstaattisen aiheuttama vaara

Silmien vahingoittumi vahingoittumisvaara svaara kaapelien ja johdinten vuoksi Tinaruiskun aiheuttama vaara

Räjähdysvaara

i m o u S

i Yleisiä turvallisuusohjeita m o u S Käyttöohje

Käyttöohje on osa konetta. Käyttöohje on luettava huolellisesti ja sen sisältö ymmärrettävä ennen koneen käyttämistä. Perehdy erityisesti turvallisuusohjeisiin ja varoituksiin.

Lisävarusteidenn ohjeet Lisävarusteide

Noudata tämän käyttöohjeen turvallisuusohjeiden lisäksi myös lisävarusteiden turvallisuusohjeita.

Henkilöturvallisuus Henkilöturvallisuus on taattu vain yhdelle ainoalle käyttäjälle. k äyttäjälle. Koneella työskentelevien henkilöiden on varmistettava, että he eivät vaaranna toiminnallaan muiden henkilöiden turvallisuutta.

Henkilökunnan pätevyys Konetta saavat käyttää, säätää ja huoltaa vain henkilöt, joilla on tähän soveltuva pätevyys.

Koneen tekninen kunto Vaaraton Vaar aton käyttö Kun on epäiltävissä, että koneen vaaratonta käyttöä ei enää voida taata, kone on kytkettävä päältä ja on varmistettava, että sitä ei voida tahattomasti kytkeä päälle.

Turvalaitteet Konetta saa käyttää vain, kun turvalaitteet toimivat. Turvalaitteita, erityisesti suojusta, ei saa poistaa, ohittaa eikä käsitellä millään tavoin.

Huolto Konetta on huollettava ohjeiden mukaisin aikavälein. Jos konetta ei huolleta säännöllisesti, kone saattaa vioittua.

Varaosat Vara osat Vioittuneet osat on vaihdettava alkuperäisiin varaosiin. Alkuperäisiä varaosia voi tilata Komaxilta.

Muutokset Konetta ei saa muuttaa. Jos muutoksia tarvitaan, näistä on neuvoteltava ensin Komaxin kanssa.

Ohjelmiston muokkaaminen Ohjelmiston muokkaaminen on kielletty kielletty..

Säkerhet Förklaring FARA Indikerar fara med hög risk. Om varningen inte tas på allvar, kan det leda till att livshotande skador uppstår. VARNING Indikerar fara med medelrisk. Om varningen inte tas på allvar, kan det leda till att skador uppstår. FÖRSIKTIGHET Indikerar fara med låg risk. Om varningen inte tas på allvar, kan det leda till att sakskador uppstår. INFORMATION Indikerar användartips och annan värdefull information. Detta är inte ett varningstecken.

Nedan visas symboler för specifika faror som kan uppstå i samband med att maskinen används: Risk för elchock

Risk för brännskada på grund av heta områden

Risk för att fingrar och händer fastnar och dras in

Fara på grund av laser

Risk för att fingrar och händer kläms fast

Risk för ögonskada på grund av kablar och tränsar

Risk för skärskador på fingrar och händer

Risk för tennstänk

Risk för elektrost elektrostatisk atisk urladdning (ESD)

Fara på grund av explosionsr explosionsrisk isk

a k s n e v S

a Allmänna säkerhetsanvisningar k s n e v S Bruksanvisning

Bruksanvisningen hör till maskinen. Innan arbetet med maskinen påbörjas, är det viktigt att läsa och förstå innehållet i bruksanvisningen. Var extra uppmärksam på säkerhets- och varningsanvisningarna.

Tillbehörsanvisningar

Förutom säkerhetsanvisningarna i den här instruktionsboken ska även tillbehörens säkerhetsanvisningar följas.

Personsäkerhet

Personsäkerheten kan endast garanteras för en användare. Personer som arbetar vid maskinen måste alltid se till att ingen annan person skadas genom arbetet.

Personalkvalifikationer Maskinen får endast hanteras, ställas in och underhållas av personer med lämpliga kvalifikationer.

Maskinens tekniska skick Drift utan risk för fara Om maskinen inte kan köras utan att det medför fara, måste maskinen stängas av och säkras mot att någon råkar starta den av misstag.

Säkerhetsanordningar Maskinen får endast köras med fungerande säkerhetsanordningar. säkerhetsanordningar. Säkerhetsanordningarna, särskilt skyddskåpan, får inte avlägsnas, förbikopplas eller manipuleras på något sätt.

Underhåll Underhåll ska utföras på maskinen i enlighet med de angivna tidsintervallen. Om maskinen inte underhålls regelbundet, kan det leda till att maskinskador uppstår uppstår..

Reservdelar Defekta delar får endast bytas ut mot originalreservdelar. originalreservdelar. Originalreservdelarna kan beställas från Komax.

Ombyggnad Maskinen får aldrig byggas om. Om ombyggnad ändå skulle krävas, får det ske endast efter överenskommelse med Komax.

Programvarumodifieringar Alla former av modifiering av programvaran programvaran är förbjudna.

Безопасност Обяснение на символите за безопасно безопасност ст ОПАСНОСТ Обозначаваа опасност с висок риск. Обозначав Ако не се избегне, може да доведе до смърт или тежки наранявания. ПРЕДУПРЕЖДЕНИЕ Обозначаваа опасност със среден риск. Обозначав Ако не бъде избегната, може да доведе до наранявания. ВНИМАНИЕ Обозначаваа опасност с малък риск. Обозначав Ако не бъде избегната, може да доведе до материални щети. ЗАБЕЛЕЖКА Обозначава съвети за потребителя и друга полезна информация. Не е дума, сигнализираща за опасност.

По-нататък са използв използвани ани следните символи за конкретни опасности, свърз свързани ани с машината: Опасност от електрически ток

Опасност от изгаряне от горещи повърхности

Опасност от увличане или захващане на пръстите или ръцете

Опасност от лазерно лъчение

Опасност от притискане на пръстите или ръцете

Опасност от нараняване на очите от кабели и проводници

Опасност от порязване на пръстите или ръцете

Опасност от пръски калай

Опасност от електростатичен е лектростатичен разряд

Опасност от експлозия

и к с р а г л ъ Б

и к с р а г л ъ Б

Общи инструкции за безопасност Ръководство за експлоатация Ръководството за експлоатация е част от машината. Преди да започнете работа с нея, Ръководството трябва да сте го прочели и разбрали. Обърнете специално внимание на инструкциите за безопасност и предупрежденият предупрежденията. а.

Ръководства за принадлежностите Освен инструкциите за безопасност, съдържащи се в това ръководство за експлоатация, съблюдавайте също инструкциите за безопасност в ръководствата за принадлеж ностите.

Лична защита Личната защита е осигурена само за един единствен оператор. Лицата, които работят по машината, трябва винаги да се уверяват, че другите хора не са застрашени от техните действия.

Квалификация на персонала Машината може да се регулира и поддържа само от лица, които притежават съответ ната квалификация.

Техническо състояние на машината Безопасна експлоатация Когато се предполага, предполага, че безопасна безопасната та експлоатация на машината не може да бъде осигурявана повече, повече, тя трябва да се изключи и да се защити срещу неволно включване.

Защитни устройства С машината трябва да се работи само при функциониращи защитни устройства. Защитните устройства и по-специално защитния капак не трябва да се отстранява отстраняватт, припокриват или подлагат подлагат на манипулаци манипулация я по някакъв друг начин.

Техническа поддръжка Машината трябва да се поддъ поддържа ржа през определ определените ените интервали от време. Ако не се извършва извършва редовна поддръжка поддръжка на машината, това това може да доведе доведе до възник възник ване на повреди.

Резервни части Дефектните части трябва да се заменят само с оригинални резервни части. Оригиналните резервни части могат могат да се закупят от Komax.

Преустройства Машината по принцип не бива да се преустройва. Ако се налагат преустройства обаче, те могат да бъдат извършени само след консултация с Komax.

Модификации Модификаци и на софтуера Забранени се всякакви модификации на софтуера.

Bezpečnost Vysvětlení pokynů NEBEZPEČÍ Označuje nebezpečí s vysokým rizikem. Pokud se nebezpečí nezamezí, jsou následkem smrt nebo nejtěžší poranění. VÝSTRAHA

Označuje nebezpečí se středním rizikem. Pokud se nebezpečí nezamezí, může způsobit zranění. POZOR

Označuje nebezpečí s nízkým rizikem. Pokud se nebezpečí nezamezí, může způsobit věcné škody. UPOZORNĚNÍ Označuje rady pro uživatele a jiné užitečné informace. Není to výstražný text pro ohrožení.

V další části budou použity následující symboly pro specifická nebezpečí stroje:

Nebezpečí elektrickým proudem

Nebezpečí popálením horkými plochami

Nebezpečí vtažení prstů nebo rukou

Nebezpečí působením laseru

Nebezpečí rozdrcení prstů nebo rukou

Nebezpečí zranění očí kabelem nebo vodiči

Nebezpečí pořezání prstů nebo rukou

Nebezpečí rozstříknutým cínem

Nebezpečí vlivem elektrostatického vybíjení

Ohrožení výbuchem

y k s e Č

bezpečnostní pokyny y ObecnéNávod k provozu k Návod k provozu je součástí stroje. Před zahájením práce na stroji si musíte návod s k provozu pročíst a porozumět mu. Dodržujte zvláště bezpečnostní a výstražné pokyny. e Návody příslušenství Č Kromě bezpečnostních pokynů v tomto návodu k provozu respektujte rovněž bezpečnostní pokyny v návodech pro příslušenství.

Osobní bezpečnost Osobní bezpečnost je zajištěna jen pro jediného operátora. Osoby, které na stroji pracují, se musejí vždy přesvědčit, zda nejsou jejich jednáním ohroženy žádné další osoby.

Kvalifikace personálu Stroj smí obsluhovat, nastavovat a udržovat jen osoby, které mají odpovídající kvalifikaci.

Technický stav stroje Bezpečný provoz Pokud se předpokládá, že již není zaručen bezpečný provoz stroje, musí se zařízení vypnout a zajistit proti neúmyslnému opětovnému zapnutí.

Bezpečnostní zařízení Stroj se smí uvést do provozu jen s fungujícím bezpečnostním zařízením. Bezpečnostní zařízení, zvláště ochranný kryt, se nesmí odstranit, překlenout nebo se s nimi nesmí jakýmkoliv způsobem manipulovat.

Údržba Na stroji se musí podle zadaných časových intervalů provést údržba. Jestliže se stroj pravidelně neudržuje, může být následkem jeho poškození.

Náhradní díly Vadné díly se smějí nahradit výhradně originálními náhradními díly. Originální náhradní díly je možno zakoupit u firmy Komax.

Úpravy Stroj se zásadně nesmí upravovat. Pokud by byly úpravy nutné, smějí se provést jen po dohodě s firmou Komax.

Modifikace softwaru Jakákoliv modifikace softwaru je zakázána.

Ασφάλεια

Επεξήγηση συμβόλων ΚΙΝΔΥΝΟΣ Αυτό το σύμβολο σας προειδοποιεί ότι εγκυμονεί υψηλός κίνδυνος. Εάν αγνοήσετε την προειδοπ προειδοποίηση οίηση θα επέλθουν θανάσιμοι ή βαριοί τραυματισμοί. ΠΡΟΕΙΔΟΠΟΙΗΣΗ Αυτό το σύμβολο σας προειδοποιεί ότι εγκυμονεί κίνδυνος. Εάν αγνοήσετε την προειδοπ προειδοποίηση οίηση ενδέχεται να επέλθουν τραυματισμοί. ΠΡΟΣΟΧΗ Αυτό το σύμβολο σας προειδοπ προειδοποιεί οιεί ότι εγκυμονεί χαμηλ χαμηλός ός κίνδυνος. Εάν αγνοήσετε την προειδοπ προειδοποίηση οίηση ενδέχεται να επέλθουν υλικές ζημιές. ΣΥΜΒΟΥΛΗ Αυτό το σύμβολο σας δίνει συμβουλές και άλλες χρήσιμες πληροφορίες. Δεν προειδοποιεί για τυχόν κινδύνους.

Επεξήγηση των παρακάτω συμβόλων σχετικά με συγκεκριμένους κινδύνους των μηχανών: Κίνδυνος ηλεκτροπ ηλεκτροπληξίας ληξίας

Κίνδυνος εγκαύματος από επαφή με θερμές επιφάνειες

Κίνδυνος μαγκώματος των δαχτύλων ή χεριών

Κίνδυνος από Laser

Κίνδυνος σύνθλιψης των δαχτύλων ή χεριών

Κίνδυνος τραυματισμού των ματιών από συρματόσχοινα και καλώδια

Κίνδυνος τραυματισμού των δαχτύλων ή χεριών

Κίνδυνος από εκτόξευση κασσίτερου

Κίνδυνος από ηλεκτροστατική εκφόρτιση

Κίνδυνος έκρηξης

ά κ ι ν η λ λ Ε

ά κ ι ν η λ λ Ε

Γενικές υποδείξεις ασφαλείας Εγχειρίδιο χρήσης Το εγχειρίδιο χρήσης αποτελεί μέρος της μηχανής. Προτού θέσετε σε λειτουργία τη μηχανή, βεβαιωθείτε ότι έχετε διαβάσει και κατανοήσει πλήρως τις οδηγίες του εγχειρίδιου χρήσης. Δώστε ιδιαίτερη προσοχή στις υποδείξεις ασφαλείας και στις προειδοποιήσεις.

Οδηγίες παρελκο παρελκομένων μένων Πέρα από τις υποδείξεις ασφαλείας που αναφέρονται στο εγχειρίδιο χρήσης, δώστε προσοχή και στις υποδείξεις ασφαλείας που αναφέρονται στις οδηγίες των παρελκομένων.

Ατομική ασφάλεια Η ατομική ασφάλεια διασφαλίζεται για έναν μόνο χειριστή. Οι χειριστές της μηχανής πρέπει πάντοτε να βεβαιώνονται ότι δεν εκθέτουν σε κίνδυνο τρίτα άτομα.

Ειδίκευση προσωπικο προσωπικούύ Ο χειρισμός, η ρύθμιση και η συντήρηση της μηχανής επιτρέπεται να γίνεται μόνο από Εξουσιοδοτημένο ή από εξειδικευμένο προσωπικό.

Τεχνική συντήρηση της μηχανής Ακίνδυνη λειτουργία Εάν υπάρχει υπόνοια ότι δεν διασφαλίζεται πλέον η ακίνδυνη λειτουργία της μηχανής, τότε πρέπει να τεθεί εκτός λειτουργίας και να ασφαλισθεί έναντι μη ακούσιας εκκίνησης.

Διατάξεις ασφαλείας Η μηχανή τίθεται σε λειτουργία μόνο όταν οι διατάξεις ασφαλείας της λειτουργούν σωστά. Μην απομακρύνετε, καλύπτετε ή επεμβαίνετε με οποιονδήποτε τρόπο στις διατάξεις ασφαλείας, ειδικά το προστατευτικό κάλυμμα.

Συντήρηση Πρέπει να γίνεται συντήρηση της μηχανής ανά τακτά χρονικά διαστήματα. Εάν δεν γίνεται τακτική συντήρηση, ενδέχεται να επέλθουν ζημιές στη μηχανή.

Ανταλλακτικά Τα ελαττωματικά μέρη πρέπει να αντικαθιστούντ αντικαθιστούνται αι μόνο από πρωτότυπα ανταλλακτικά. Για παραγγελίες πρωτότυπων ανταλλακτικών απευθυνθείτε στην Komax.

Μετατροπές Είναι αρχή μας να μην επιτρέπουμε μετατροπές στις μηχανές. μηχανές. Σε περίπτωση όμως που κρίνεται αναγκαίο, επιτρέπεται να γίνουν μετατροπές μόνο κατόπιν αναφοράς τους στη Komax.

Μετατροπές λογισμικού Απαγορεύεται οποιαδήποτε οποιαδήποτε μετατροπή μετατροπή στο λογισμικό. λογισμικό.

Biztonság Megjegy Me gjegyzé zések sek leírása VESZÉLY Nagy Na gy kockázatú veszélyt jelöl. Amenn Am enn yi yiben ben nem ker kerül ül i el, el , halálh hal álh oz vagy v agy sú súly lyos os sér sérül ül ések ésekhez hez v ezeth ezethet. et. FIGYELMEZTETÉS Közepes kockázatú veszélyt jelöl. Ha nem kerüli el, sérüléshez vezethet. VIGYÁZAT Kis ko ckáza ckázatú tú veszélyt jelöl. Ha nem nem kerül i el, dolog i kárho z vezethet. vezethet. MEGJEGYZÉS Felhasználói Felha sználói tanácsokat és egyéb hasznos info rmációkat jelöl. Veszélyt nem jelöl.

Továbbá a következő szimbólumok kerülnek használatra a gép specifikus veszélyeire: Áram Ár am ál tal talii veszél v eszélyy

For ró fel ül ületek etek ált általi ali égés ves veszély zély

Ujjak vagy kezek behúzásának veszélye

Lézer általi veszély

Ujjak vagy kezek zúzódásának veszélye

Szem kábelek és pászmák ált ali Szem sérülésének v eszé eszélye lye

Uj j ak v ag y k ezek v ág ás v es zél y e

Ón f r ö c c s en és ál t al i v es zél y

ESD (elektrosztatikus kisülés)

Robbanás általi veszély

általi veszély

r a y g a M

r Általános biztonsági utasítások Üzemeltetési útmutató a y útmutatót, mielőtt a géppel dolgozna. Különösen a biztonsági és figyelmeztető utasításokat g vegye figyelembe. a Tartozékok útmutatói A jelen üzemeltetési útmutatóban szereplő biztonsági utasítások mellett vegye figyelembe a M tartozékok útmutatóiban szereplő biztonsági utasításokat is. Személyi Sz emélyi b iztonság

A személyi biztonság csak egyetlen kezelő számára biztosított. A gépen dolgozó személyeknek mindig meg kell győződniük arról, hogy az általuk végzett kezelés más személyeket nem veszélyeztet. Személyzet képzettsége

A gépet kizárólag a megfelelő képesítéssel rendelkező személyek kezelhetik, állíthatják be és tarthatják karban.

A gép műszaki állapota Veszélytelen működés Amennyiben feltételezhető, hogy a gép veszélytelen működése többé nem biztosított, a gépet ki kell kapcsolni és az akaratlan bekapcsolás ellen biztosítani kell. Biztonsági berendez berendezések ések

A gépet kizárólag működő biztonsági berendezésekkel szabad üzemeltetni. A biztonsági berendezéseket, különösen a védőfedelet nem szabad eltávolítani, áthidalni vagy bármilyen egyéb formában manipulálni. Karbantartás

A gépet a megadott időintervallumok szerint kell karbantartani. Ha a gép nem kerül rendszeresen karbantartásra, úgy ennek gépkár lehet a következménye. Pótalkatrészek

A hibás alkatrészeket csak eredeti pótalkatrészekkel szabad pótolni. Az eredeti alkatrészek a Komax cégnél szerezhetők be. Átépít Át épít ések

A gépet alapvetően nem szabad átépíteni. Amennyiben mégis szükségesek lennének átépítések, úgy ezeket csak a Komax vállalattal történt egyeztetés után szabad elvégezni. Szoftvermódosítások

A szoftver mindennemű módosítása tilos.

Ohutus

Märku Mä rkuse se selgitus OHT Tähistab Tä histab kõr ge riskiga oht u. Kui s eda ära ära ei hoita, on tagajärjeks tagajärjeks su rm v õi r aske asked d vig astused. HOIATUS Tähistab Tä histab keskmise ri skiga ohtu. Kui seda ära ei hoita, võivad tagajärjeks olla vigastused. HOIATUS Tähistab Tä histab keskmise ri skiga ohtu. Kui seda ära ei hoita, võib tagajärjeks olla materiaalne kahju. MÄRKUS Tähistab näpunäiteid kasutajale ja muud kasulikku teavet. Ei märgista ohte.

Masina spetsiifiliste ohtude kohta kasutatakse edaspidi järgmisi sümboleid: Elektrioht

K m ad es es t pi p i n da dad es t titi n g itit d p l et s o h t

S r m ed e v i k t e s i s s et m b eo h t

L as er i o h t

S r m ed e v i k t e m l j m i s o h t

Kaablite Kaabl itest st ja traat traatide idest st tingit d silma sil made de vig viga ast soht

S r m ed e v i k t e v i g as t s o h t

Ti n ap r i t s m et e o h t

El ek t r o s t aat i l i s e l aen g o h t

Pl ah v at s o h t

i t s e E

i t s e E

l d i s ed o h t s j h i s ed K as t s j h en d

Tar vi vi k t e j h en en di di d

Per s o n al i o h t s

Personali kvalifikatsioon Masinat tohivad kasutada, seadistada ja hooldada ainult vastava kvalifikatsiooniga isikud.

Masina te tehnil hniline ine se seis is nd h t töö

Kaitseseadised

Ho o l d s

Var o sa s ad

mbe mb ere rehi hitt se sed d

Tarkvara modifikatsioonid Tarkvara igasugune modifitseerimine on keelatud.

u

Pastabų išaiškinimas PAVO US

Žymi pavojų, susijusį su didele rizika. Jeigu jos nevengiama, gali ištikti mirtis arba sunkus kūno sužalojimas. ĮSPĖJIMAS Žymi pavojų, susijusį su vidutine rizika. Jeigu jos nevengiama, galite susižaloti. ATSARGIAI Žymi pavojų, susijusį su nedidele rizika. Jeigu jos nevengiama, gali būti padaryta materialinė žala. PA STA A

Žymi naudojimo patarimus ir kitą naudingą informaciją. Tai ne įspėjimas apie pavojų.

Toliau specifiniams mašinos keliamiems pavojams žymėti naudojami šie simboliai: Elektros srovės keliamas pavojus

Karšti paviršiai – galima nusideginti

Pirštų ir rankų įtraukimo pavojus

Lazerio spinduliuotės keliamas pavojus

Pirštų ir rankų suspaudimo pavojus

Kabeliai ir laidų gyslos kelia akių sužalojimo pavojų

Pirštų ir rankų įsipjovimo pavojus

Cinko purslų keliamas pavojus

Elektros iškrovos keliamas pavojus

Sprogimo pavojus

. k ų i v u t e i L

. Bendrieji saugos nurodymai k Eksploatavimo instrukcija ų i v Priedų instrukcijos u t e i Asmenų sauga L

Eksploatavimo instrukcija yra neatsiejama mašinos dalis. Prieš pradėdami dirbti su mašina, turite perskaityti ir suprasti eksploatavimo instrukciją. Ypatingą dėmesį skirkite saugos nurodymams ir įspėjimams.

Be saugos nurodymų šioje eksploatavimo instrukcijoje atsižvelkite ir į saugos nurodymus priedų instrukcijose.

Užtikrinama tik operatoriaus sauga. Asmenys, dirbantys su mašina, visada turi įsitikinti, kad jų veikla nekelia pavojaus kitiems asmenims.

Personāla kvalifikācija Mašiną valdyti, derinti ir atlikti jos techninę priežiūrą gali tik asmenys, turintys atitinkamą kvalifikaciją.

Techninė mašinos būklė Nekeliantis pavojaus eksploatavimas Jeigu yra priežasčių manyti, kad užtikrinti nekeliančio pavojaus mašinos eksploatavimo nebegalima, mašiną reikia išjungti ir apsaugoti nuo netyčinio įjungimo.

Apsauginiai įrenginiai Mašiną galima eksploatuoti tik su veikiančiais apsauginiais įrenginiais. Apsauginių įrenginių, ypač apsauginio gaubto, negalima nuimti, šuntuoti arba keisti bet

Techninė priežiūra Techninę mašinos priežiūrą reikia atlikti praėjus nustatytam laikui. Jeigu reguliariai neatliekama techninė mašinos priežiūra, ji gali sugesti.

Atsarginės dalys Sugedusias dalis galima keisti tik originaliomis atsarginėmis dalimis. Atsargines dalis galite įsigyti iš Komax.

Modifikavimas Mašiną modifikuoti griežtai draudžiama. Jeigu mašiną reikia modifikuoti, tai galima atlikti tik suderinus su Komax.

Programinės įrangos modifikavimas Griežtai draudžiamas bet koks programinės įrangos modifikavimas.

Drošība Norādījumu skaidrojums BĪSTAMI Apzīmē bīstamību ar augstu riska pakāpi. Ja no tās neizvairās, iestājas nāve vai var gūt nopietnas traumas. BRĪDINĀJUMS Apzīmē bīstamību ar vidēju riska pakāpi. Ja no tās neizvairās, var gūt traumas. UZMANĪBU Apzīmē bīstamību ar zemu riska pakāpi. Ja no tās neizvairās, var rasties materiālie zaudējumi. NORĀDE Apzīmē padomus lietotājam un citu lietderīgu informāciju. Tas nav risku signālvārds.

Turpmāk norādīti simboli, kurus izmanto iekārtas iekā rtas specifisko risku apzīmēšanai: Risks, ko rada elektriskā strāva

Apdeguma risks, ko rada karstas virsmas

Pirkstu vai roku ievilkšanas risks

Risks, ko rada lāzers

Pirkstu vai roku saspiešanas

Acu traumu risks, ko rada kabeļi un troses

risks

Pirkstu vai roku sagriešanas risks

Risks, ko rada ESD (elektrostatiskā izlāde)

Risks, ko rada alvas izšļakstīšanās Risks, ko rada eksplozija

i k s i v t a L

i Vispārējie drošības norādījumi k Ekspluatācijas instrukcija s Ekspluatācijas instrukcija ir iekārtas daļa. Pirms sākt strādāt ar iekārtu, jāizlasa un jāizprot i ekspluatācijas instrukcija. Īpašu vērību pievērsiet drošības norādījumiem un brīdinājuma norādēm. v t Piederumu instrukcijas a Līdzās drošības norādījumiem šajā instrukcijā ņemiet vērā arī drošības norādījumus, kas sniegti piederumu instrukcijās. L Personu drošība Personu drošība ir garantēta tikai pašam operatoram. Personām, kuras strādā ar iekārtu, vienmēr jāpārliecinās, vai viņu darbība neapdraud citas personas.

Personāla kvalifikācija Iekārtu drīkst vadīt, iestatīt un apkopt tikai personas ar atbilstošu kvalifikāciju.

Iekārtas tehniskais stāvoklis Neapdraudēta ekspluatācija Ja pieņem, ka vairs netiek garantēta iekārtas neapdraudēta ekspluatācija, iekārta ir jāizslēdz un jānodrošina pret nejaušu ieslēgšanu.

Drošības mehānismi Iekārtu drīkst izmantot tikai tad, ja darbojas drošības mehānismi. Drošības mehānismus, sevišķi aizsargpārsegu, nedrīkst noņemt, šuntēt vai citādā veidā ar tiem manipulēt.

Apkope Iekārtai jāveic apkope pēc norādītajiem laika intervāliem. Ja neveic regulāru apkopi, iekārtai var rasties bojājumi.

Rezerves daļas Bojātās detaļas drīkst nomainīt tikai ar oriģinālajām rezerves daļām. Oriģinālās rezerves daļas var iegādāties uzņēmumā Komax.

Pārbūves Principā iekārtu pārbūvēt nedrīkst. Ja nepieciešams veikt pārbūvi, tās izpilde noteikti jāsaskaņo ar uzņēmumu Komax.

Programmatūras modifikācijas Jebkāda programmatūras modificēšana ir aizliegta.

Bezpieczeństwo Objaśnienie wskazówek NIEBEZPIECZEŃSTWO Oznacza zagrożenie o wysokim stopniu ryzyka. Jeśli się go nie uniknie, konsekwencją może być śmierć lub ciężkie obrażenia. OSTRZEŻENIE Oznacza zagrożenie o średnim stopniu ryzyka. Jeśli go się nie uniknie, konsekwencją mogą być obrażenia ciała. OSTROŻNIE Oznacza zagrożenie o niskim stopniu ryzyka. Jeśli go się nie uniknie, konsekwencją mogą być szkody rzeczowe. WSKAZÓWKA Oznacza wskazówki dotyczące użytkowania i inne pożyteczne informacje. Nie oznacza zagrożenia.

W instrukcji zastosowano następujące symbole specyficznych zagrożeń związanych z eksploatacją maszyny: Niebezpieczeństwo wywołane przez prąd elektryczny

Niebezpieczeństwo poparzenia przez gorące powierzchnie

Niebezpieczeństwo wciągnięcia palców lub dłoni

Niebezpieczeństwo wywołane przez laser

Niebezpieczeństwo zmiażdżenia palców lub dłoni

Niebezpieczeństwo skaleczenia oczu przez kable i druty

Niebezpieczeństwo przecięcia palców lub dłoni

Niebezpieczeństwo wywołane odpryskami cyny

Niebezpieczeństwo wywołane przez wyładowania elektrostatyczne

Niebezpieczeństwo wywołane wybuchem

i k s l o P

i Ogólne wskazówki bezpieczeństwa k Instrukcja eksploatacji Instrukcja eksploatacji stanowi część składową maszyny. Przed przystąpieniem do użyt s kowania maszyny należy ze zrozumieniem przeczytać niniejszą instrukcję eksploatacji. W l szczególności należy przestrzegać wskazówek bezpieczeństwa i wskazówek ostrzegaw o czych. P Instrukcje wyposażenia dodatkowego Oprócz wskazówek bezpieczeństwa zawartych w niniejszej instrukcji eksploatacji należy przestrzegać również wskazówek bezpieczeństwa w instrukcjach wyposażenia dodatko wego.

Bezpieczeństwo osób Bezpieczeństwo osób zagwarantowane jest tylko dla jednego operatora. Osoby pracujące przy maszynie muszą stale pilnować, aby przez swoje działanie nie stwarzać zagrożenia dla innych osób.

Kwalifikacje personelu Obsługi, ustawień i konserwacji maszyny mogą dokonywać tylko osoby posiadające odpo wiednie kwalifikacje.

Stan techniczny maszyny Bezpieczna eksploatacja W przypadku stwierdzenia, że nie można dłużej zapewnić bezpiecznego użytkowania maszyny,, maszynę należy wyłączyć i zabezpieczyć przed przypadkowym włączeniem. maszyny

Urządzenia odpowiedzialne za bezpieczeństwo Maszynę należy użytkować wyłącznie ze sprawnymi urządzeniami zabezpieczającymi. Nie wolno demontować i mostkować urządzeń zabezpieczających - w szczególności dotyczy to pokrywy ochronnej - ani manipulować nimi w jakikolwiek sposób.

Konserwacja Maszyna wymaga konserwacji w podanych okresach przeglądowych. Jeżeli maszyna nie będzie regularnie konserwowana, konsekwencją może być jej uszko dzenie.

Części zamienne Uszkodzone części należy wymieniać tylko na oryginalne części zamienne. Oryginalne części zamienne można nabyć w firmie Komax.

Przebudowa Zasadniczo nie zezwala się na przebudowę maszyny. Jeżeli jednak przebudowa maszyny jest niezbędna, wolno ją wykonywać wyłącznie po konsultacji z firmą Komax.

Modyfikacje oprogramow oprogramowania ania Jakakolwiek modyfikacja oprogramowania jest zabroniona.

Siguranţa Explicaţia indicaţiilor Legendă PERICOL Indică un pericol cu risc ridicat. Dacă nu poate fi evitat, implică vătămări grave sau chiar decesul. AVERTI ARE

Indică un pericol cu risc mediu. Dacă nu poate fi evitat, poate să cauzeze vătămări vătă mări grave. ATENŢIE Indică un pericol cu risc redus. Dacă nu poate fi evitat, poate să cauzeze pagube materiale. INDICAŢIE Indică recomandări pentru utilizator şi alte informaţii utile. Nu reprezintă o formulă de semnalizare a pericolelor pericolelor..

În continuare, pentru pericolele pericolele specifice utilajului se vor utiliza următoarele următoarele simboluri: Pericol de natură electrică

Pericol de arsuri reprezentat de suprafeţele fierbinţi

Pericol de prindere a degetelor sau a mâinilor

Pericol reprezentat de laser

Pericol de strivire a degetelor sau a mâinilor

Pericol de vătămare a ochilor reprezentat de cabluri şi liţe

Pericol de tăiere a degetelor sau a mâinilor

Pericol reprezentat de stropii de cositor

Pericol reprezentat de ESD (încărcare electrostatică)

Pericol reprezentat de explozii

ă n â m o R

generale referitoare la siguranţă ă Instrucţiuni Manualul de exploatare n â m Instrucţiuni referitoare la accesorii o R

Manualul de exploatare constituie o parte integrantă a utilajului. Înainte de a utiliza utilajul, trebuie să citiţi şi să înţelegeţi manualul de exploatare. Acordaţi atenţie specială instrucţiunilor de siguranţă şi de avertizare.

Pe lângă instrucţiunile de siguranţă din cadrul acestui manual de exploatare, ţineţi cont şi de instrucţiunile de siguranţă din manualele referitoare la accesorii.

Siguranţa persoanelor

Siguranţa persoanelor se asigură numai pentru un singur operator. Personalul care exploatează utilajul trebuie întotdeauna să se asigure că prin operarea acestuia nu expune la pericole alte persoane.

Calificarea personalului Exploatarea, reglarea şi întreţinerea utilajului se asigură numai de către personal cu calificare corespunzătoare.

Starea tehnică a utilajului Funcţionarea în siguranţă Dacă se consideră că nu se mai asigură o funcţionare a utilajului în siguranţă, trebuie să se oprească utilajul şi să se asigure împotriva conectării accidentale.

Dispozitive de siguranţă Se permite exploatarea utilajului numai cu dispozitivele de siguranţă în stare de funcţionare. Dispozitivele de siguranţă, în special capacul de protecţie, nu trebuie îndepărtate, şuntate sau manipulate în orice stare.

Întreţinere Întreţinerea utilajului trebuie să se efectueze la intervalele de timp specificate. Dacă întreţinerea nu se realizează periodic, atunci pot să apară defecţiuni ale utilajului.

Piese de schimb Piesele defecte trebuie înlocuite numai cu piese de schimb originale. Aveţi posibilitatea să obţineţi piese de schimb originale de la Komax.

Modificări constructive De regulă, nu se permit modificări de natură constructivă ale utilajului. Dacă modificările sunt necesare, atunci efectuarea acestora se permite numai cu acordul Komax.

Modificări referitoare la software Se interzice orice tip de modificare a software-ului.

Bezpečnosť V s v et l en i e p o k n o v NEBEZPEČENSTVO Označuje nebezpečenstvo s vysokým rizikom. Ak mu nepredídete, môže mať za následok smrť alebo najťažšie úrazy. UPOZORNENIE Označuje nebezpečenstvo so stredným rizikom. Ak mu nepredídete, môže mať za následok úraz. POZOR Označuje nebezpečenstvo s nízkym rizikom. Ak mu nepredídete, môže mať za následok úraz. INFORMÁCIA Označuje tipy na používanie a iné užitočné informácie. Nie je to slovo signalizujúce nebezpečenstvá.

Ďalej v texte sa budú používať nasledujúce symboly symboly pre špecifické nebezpečenstvá stroja: Nebezpečenstvo spôsobené elektrickým prúdom

Nebezpečenstvo popálenia na horúcich povrchoch

Nebezpečenstvo vtiahnutia prsta alebo ruky

Nebezpečenstvo spôsobené laserom

Nebezpečenstvo pomliaždenia prstov alebo rúk

Nebezpečenstvo poranenia očí káblom a holým vodičom

Nebezpečenstvo porezania prstu alebo ruky

Nebezpečenstvo od odstrekujúceho cínu

Nebezpečenstvo ESD (elektrostatického výboja)

Nebezpečenstvo výbuchu

k s n e v o l S

k s n e v o l S

Všeobecné bezpečnostné pokyny Návod na obsluhu Návod na obsluhu je súčasťou stroja. Pred začatím práce na stroji si návod na obsluhu musíte najprv preštudovať a porozumieť mu. Rešpektujte predovšetkým bezpečnostné a varovné pokyny pokyny..

Návody na príslušenstvo Spolu s bezpečnostnými pokynmi tohto návodu na obsluhu rešpektujte aj bezpečnostné pokyny návodov dodávaných s príslušenstvom.

Osobná bezpečnosť Osobná bezpečnosť je zaručená len pre jedného pracovníka obsluhy. Osoby, Osoby, ktoré na stroji pracujú, sa vždy musia presvedčiť, že svojim počínaním neohrozujú žiadne osoby osob y.

Kvalifikácia personálu Stroj môžu obsluhovať, nastavovať a udržiavať iba osoby s potrebnou kvalifikáciou.

Technický stav stroja Prevádzka bez nebezpečenstva Ak možno predpokladať, že prevádzku stroja bez vzniku nebezpečenstva nie je možné naďalej zaručiť, stroj sa musí vypnúť a zaistiť proti náhodnému zapnutiu.

Bezpečnostné zariadenia Stroj sa môže uvádzať do prevádzky iba s fungujúcimi bezpečnostnými zariadeniami. Bezpečnostné zariadenia, predovšetkým ochranný kryt, sa nesmú demontovať ani vyradiť z činnosti. Nesmie sa s nimi akýmkoľvek spôsobom manipulovať.

Údržba Údržba stroja sa musí vykonávať v tu uvedených časových intervaloch. Ak údržba stroja nie je pravidelná, môže to spôsobiť poškodenie stroja.

Náhradné diely Chybné diely možno nahradiť iba originálnymi náhradnými dielmi. Originálne náhradné diely si možno objednať u spoločnosti Komax.

Prestavby a úpravy Prestavby stroja sú zo zásady zakázané. Ak by boli potrebné akékoľvek prestavby alebo úpravy, môžu sa vykonať iba po dohode so spoločnosťou Komax.

Úpravy softvéru Akákoľvek úprava softvéru je zakázaná.

Uyarılara İlişkin Açıklamalar TEHLİKE Yüksek risk taşıyan bir tehlikeye işaret eder. Önlenmedikleri takdirde sonucunda ölüm ve ağır a ğır yaralanma meydana gelir. UYARI Orta derecede risk taşıyan bir tehlikeye işaret eder. Önlenmedikleri takdirde sonucunda ağır yaralanma meydana gelir. DİKKAT Düşük derecede risk taşıyan bir tehlikeye işaret eder. Önlenmedikleri takdirde sonucunda maddi hasarlar meydana gelebilir. UYARI Kullanıcı önerilerine ve diğer yararlı bilgilere işaret eder. Tehlike sinyali için i çin kullanılan bir kelime ke lime değildir.

Bunların dışında aşağıdaki semboller makinenin spesifik tehlikeleri için kullanılır: Akımın yol açtığı tehlike

Sıcak yüyezlerin neden olduğu yanma tehlikesi

Parmakların ve ellerin kaptırılma tehlikesi

Lazerin neden olduğu tehlike

Parmakların ve ellerin sıkıştırılma tehlikesi

Kabloların ve kordonların yol açtığı göz yaralanmaları tehlikesi

Parmakların ve ellerin kesilme tehlikesi

Kalay enjektörlerinin neden olduğu tehlike

ESD (Elektrostatik Deşarj) sonucunda meydana gelen tehlike

Patlamanın neden olduğu tehlike

e k r ü T

Uyarıları e Genel Güvenlik Kullanım Talimatı Kullanım talimatı makinenin bir parçasıdır. Makineyle çalışmaya başlamadan önce kullanım k talimatının okunması ve anlaşılması gerekir. Özellikle de güvenlik uyarılarını ve önerilerini r dikkate alınız. ü Aksesuar Talimatı T Bu kullanım talimatındaki güvenlik uyarılarının yanında aksesuarların talimatlarındaki güvenlik uyarılarını da dikkate alınız.

Kişi Güvenliği Kişi güvenliği sadece tek bir kullanıcı için sağlanmıştır. Makine başında çalışan kişilerin, çalışmalarından dolayı insanları tehliye sokmadıklarından emin olmak zorundadırlar.

Personel Vasıfları Makine sadece vasıflı kişiler tarafından kullanılabilir, ayarlanabilir ve bakımı yapılabilir.

Makinenin Teknik Durumu Tehlikesiz Kullanım Eğer makinenin artık tehlikesiz kullanımı mümkün görünmüyorsa, makinenin kapatılması ve kazayla açılmasına karşı güvenliğinin sağlanması gerekir.

Güvenlik Tertibatları Makine sadece fonksiyonunu yerine getirebilen güvenlik tertibatları ile kullanılabilir. Güvenlik tertibatları, özellikle de koruyucu kapak çıkartılamaz, birleştirilemez ya da herhangi bir biçimde değiştirilemez.

Bakım Makinenin belirtilen periyotlarda bakımının yapılması gerekir. Eğer makinenin bakımı düzenli olarak yapılmazsa sonucunda makine hasarları hasar ları meydana gelebilir.

Yedek Parçalar Hasarlı parçalar sadece orijinal yedekleri ile değiştirilebilir. Orijinal yedek parçalar Komax’tan temin edilebilir.

Modifikasyon Makine özünde modifiye edilemez. Eğer modifikasyonlar gerekli olacak olursa, bunlar sadece Komax ile görüşülerek gerçekleştirilebilir.

Software Modifikasyonları Software’de her türlü modifikasyonun yapılması yasaktır.

Varnost

Razlaga simbolov EVAR OST

Označuje nevarnost z visoko stopnjo tveganja. Če se je ne izognete, so njena posledica smrt ali težke poškodbe. OPO ORILO

Označuje nevarnost s srednjo stopnjo tveganja. Če se je ne izognete, so njena posledica lahko poškodbe. PO OR

Označuje nevarnost z nizko stopnjo tveganja. Če se je ne izognete, so njena posledica lahko poškodbe predmetov. APOTEK

Označuje napotke za uporabnika in druge uporabne informacije. Ni signalna beseda za nevarnost.

V nadaljevanju se za specifične nevarnosti strojev uporabljajo naslednji simboli: Nevarnost toka

Nevarnost opeklin zaradi vročih površin

Nevarnost vpotega prstov ali rok

Nevarnost laserske svetlobe

Nevarnost zmečkanja prstov ali rok

Nevarnost poškodb oči zaradi kablov in jeklenih vrvi

Nevarnost vreza prstov ali rok

Nevarnost brizganja kositra

Nevarnost elektrostatične razelektritve

Nevarnost eksplozije

a n i č š n e v o l S

varnostni napotki a SplošniNavodila za uporabo n i č Navodila za dopolnilno opremo š n e Varnost oseb v o l Kvalifikacija oseb S

-

bljajo, se morajo vedno prepričati, da s svojim ravnanjem ne ogrožajo drugih oseb.

Stroj lahko upravljajo, nastavljajo in vzdržujejo samo osebe, ki imajo ustrezno kvalifikacijo.

Tehnično stanje stroja Nenevarno delovanje Če domnevate, da varno delovanje stroja ni več zagotovljeno, morate stroj izklopiti in ga

Varnostna oprema Stroj lahko obratuje le z delujočimi varnostnimi napravami. Varnostnih naprav, še posebej zaščitnega pokrova, ne smete odstranjevati, premostiti ali na kakršen koli način z njimi manipulirati.

Vzdrževanje Stroj morate vzdrževati glede na navedene časovne intervale. Če stroja ne vzdržujete redno, so posledica nevzdrževanja lahko okvare stroja.

Nadomestni deli -

Predelave Stroja v osnovi ne smete predelati. Če je predelava nujna, se jo lahko izvede le po posvetu

Modifikacije programske opreme Prepovedana je vsakršna modifikacija programske opreme.

rt

Sp j eg a j o n i t an n o t i PERIKLU

Jindika periklu li jinvolvi riskju għoli. Jekk ma tevitax jirriżulta f’mewt jew ferriment serju. T ISSIJ A

Jindika periklu li jinvolvi riskju medju. Jekk ma tevitax jirriżulta fi ġrieħi. K A TEL A

Jindika periklu li jinvolvi riskju baxx. Jekk ma tevitax jista’ jirriżulta fi ħsara lil proprjetà. N TA

Jindika għajnuniet u informazzjoni utli oħra. Mhux kelma li turi li hemm xi ħsarat.

Is-simboli li ġejjin jintużaw biex jindikaw perikli speċifiċi attribwiti mal-magna: Perikl minn okk ele lettri ttrikk

Periklu ta’ ħruq minn superfiċji sħan

Periklu li s-swaba jew l-idejn jinġibdu ’l ġewwa

Perikl minn la lase ser r

Periklu li s-swaba jew l-idejn jitgħaffġu

Riskju ta’ ħsara lil għajnejn minn kejbils u wajers mibrumin

Periklu li s-swaba jew l-idejn jistgħu jinqatgħu

Periklu minn qtugħ tal-landa

Peri rikl kl mi minn nn sk ska arg rga ar ES ES skargar elettrostatik

Periklu minn splużjoni

i t l a M

i Struzzjonijiet ta’ sigurtà ġenerali t Struzzjonijiet ta’ tħaddim l L-istruzzjonijiet ta’ tħaddim huma parti integrali tal-magna. Għandek taqra l-istruzzjonijiet ta’ a tħaddim u tkun żgur li tifhimhom qabel ma tibda taħdem fuq il-magna. Oqgħod attent b’mod speċjali għall-istruzzjonijiet dwar is-sigurtà u ta’ twissija. M Struzzjonijiet għal aċċessorji Barra milli għandek timxi mal-istruzzjonijiet dwar is-sigurtà f’dawn l-istruzzjonijiet ta’ tħaddim, kun żgur li ssegwi l-istruzzjonijiet dwar is-sigurtà għall-moduli u l-aċċessorji.

Sigurtà ta’ persuni Is-sigurtà personali hija garantita biss għal operatur wieħed tal-magna. Kull persuna li jaħdem fuq il-magna għandha tkun żgur li ma ddaħħalx xi kmand li jpoġġi lil oħrajn f’periklu.

Kwalifiċi tal-personel Individwi li għandhom l-kwalifiċi xierqa biss għandhom jitħallew joperaw, jimmontaw u jagħmlu manutenzjonijiet fuq il-magna.

K ndi ndizzzjon jonii te tekni knika ka ta tall ma magna gna Tħaddim sikur Jekk għandek raġuni biex taħseb li l-magna ma tistax titħaddem b’mod sikur, m’għandekx tħalliha taħdem u għandek tiżgura li ma tistax tinxtegħel mingħajr ħsieb.

Tagħmir ta’ sigurtà Il-magna għandha titħaddem b’tagħmir tas-sigurtà li jkun qed jaħdem sew. Mhux permess li tneħħi jew tibbriġja t-tagħmir tas-sigurtà jew tbagħbashom b’xi mod. Man te tenz nzjon jonii

Il-magna għandha tiġi servisjata fl-intervalli fl- intervalli ta’ żmien indikat. Ħsara lil magna tista’ sseħħ jekk il-magna ma tiġix servissjata regolarment. Spare parts

Partijiet difettużi għandhom jiġi mibdula bi spare parts oriġinali. Dawn l-ispare parts oriġinali huma disponibbli biex jinxtraw m’għand Komax.

Modifikazzjonijiet B’mod ġenerali, mhux permess li l-magna tiġi modifikata. Jekk modifikazzjonijiet huma meħtieġa, ma tistax taqbad tagħmilhom mingħajr ma tikkonsulta qabel ma’ Komax.

Modifikazzjonijiet tas-softwer Huwa pprojbit li timmodifika s-softwer b’xi mod

Безопасность Пояснения ОПАСНОСТЬ Обозначает опасность с высокой степенью риска. Пренебрежениее опасностью приводит к смерти или тяжелейшим травмам. Пренебрежени ПРЕДУПРЕЖДЕНИЕ Обозначает опасность со средней степенью риска. Пренебрежениее опасностью может привести к травмам. Пренебрежени ОСТОРОЖНО Обозначает опасность с невысокой степенью риска. Пренебрежение опасностью может привести к материальному ущербу. УКАЗАНИЕ Обозначает советы и рекомендации по использованию и другую полезную информацию. Не указывает на опасность.

Для обозначения специфических специфических видов опасности опасности машины используются используются следующие символы: Опасность электрического поражения

Опасность ожога горячей поверхностью

Опасность втягивания пальцев или кистей рук

Опасность лазерного ла зерного излучения

Опасность зажатия пальцев или кистей рук

Опасность травмирования глаз кабелями или проводами

Опасность пореза пальцев или кистей рук

Опасность разбрызгиван разбрызгивания ия олова

Опасность электростатического электро статического разряда

Опасность взрыва

й и к с с у Р

й и к с с у Р

Общие указания по безопасности Руководство по эксплуатации Руководство по эксплуатации является составной частью машины. Перед работой с машиной следует прочитать прочитать и понять Руководство по эксплуатации. Особое внимание в нимание следует обращать на указания по технике безопасности и предупреждения.

Указания по использ использованию ованию принадлежностей Наряду с указаниями по технике безопасности в Руководстве по эксплуатации обратите внимание на указания по безопасному использованию принадлежностей. принадлежностей.

Безопасность для людей В плане безопасности для людей гарантируется гарантируется безопасность только для оператора машины. Операторы машины должны эксплуатировать машину таким образом, о бразом, чтобы не подвергать опасности других людей.

Квалификация персонала Использование и монтаж машины, а также ее техническое обслуживание допускается только персоналом, обладающим соответствующей соответствующей квалификацией.

Техническое состояние машины Безопасная эксплуатация В случае невозможности дальнейшего обеспечения безопасной эксплуатации машины она должна быть выключена. При этом должна быть исключена возможность непреднамеренного включения машины.

Оборудование Оборудов ание для обеспечения безопасности Машину разрешается использовать только с действующим оборудованием для обеспечения безопасности. Не допускается удаление и шунтирование оборудования для обеспечения безопасности - и прежде всего защитного кожуха - а также любые виды манипулирования ими.

Техническое обслуживание Через указанные промежутки времени машина должна проходить техническое техническое обслу живание. Пренебрежение регулярным техническим обслуживанием может привести к повреждению машины.

Запасные детали Поврежденные детали разрешается заменять исключительно на оригинальные запасные детали. Оригинальные запасные детали могут быть приобретены через Komax.

Переделки Любые переделки в машине принципиально недопустимы. При возникновении необходимости в переделках они должны быть согласованы с Komax.

Модификации программного обеспечения Запрещена любая модификация программного обеспечения.

2. Safety 2.1 Explanation of notes ..........................................................................................................3 2.2 Safety notes .................................................................................... ...................................3 2.2.1 Personal protection........................................................................................... ....3 2.2.2 Machine protection ........................................................................................... ....5 2.2.3 General safety notes ............................................................................................5 2.3 Safety features ................................................................................ ...................................6 2.4 The RCS safety system ................................................................................... ...................8


Safety

2–1

2–2

Safety


2. Safety 2.1 Explanation of notes The note boxes in these instructions are marked with three symbols you must understand and obey. The symbols have the following meanings:

This symbol marks a safety note regarding all work procedures posing a hazard to you or other persons. persons. Heed these warnings warnings and exercise exercise particular caution in these situations. Also pass these warnings on to other users.

This symbol is next to all work procedures where special care must be taken to prevent machine damage. Pass these safety notes on to other machine users.

This symbol signals useful tips and draws your attention to correct procedures procedures and behavior. Heed these remarks and you will save yourself a lot of time and unnecessary headaches. Komax AG accepts no liability whatsoever in the event of non-compliance with instructions marked on the machine or in these notes.

2.2 Safety notes 2.2.1 Personal protectio protection n

Danger: High voltage ! Touching live parts is dangerous! Safety devices may be removed only when the machine is stopped and the power to it is shut off. Only duly trained persons are allowed allowed to remove housings and covers in particular. particular.

Danger: Wire draw-in ! There is a wire draw-in point where the wire is fed into the machine. Take care that there are not wire loops that people can trip on or become otherwise tangled up in.


Safety

2–3

Danger: Moving parts ! Anyone who gets close close to the moving parts of the machine could get pinched. All parts of the machine must be switched off and secured against unauthorized switch-on before any installation, maintenance and repair work is carried out.

Danger of injury ! The blades can cause cuts even when not in operation. Prior to working on the cutting head or blades, ALWAYS turn the main power switch on the machine to OFF.

Potential sources of danger Processing stations

Cutting head

Wire draw-in Control cabinet Wire drive

Feed belt and wire deposit tray

Swivel and pull-off units fig 2.01 Potential sources of danger

2–4

Safety


Safety devices Before starting the machine, ALWAYS check to see that all safety devices, especially covers, are properly attached and functioning.

Safety requirements The safety requirements are not met unless the safety devices are functioning properly. Moreover, the machine must be operated according to the scope of application described in Chapter 1 and to the technical specifications. Make sure it is not used for any purpose other than the one stipulated.

2.2.2 Machine protection Training Thorough training of operating staff is a crucial part of preventing machine damage. Non-compliance with the operating instructions can result in the destruction of parts of the system. Aside from reading the software instructions, all staff must read these operating instructions as part of their training.

2.2.3 General safety notes Authorized personnel Only authorized and trained personnel familiar with the safety features of the machine are allowed to operate, maintain and repair it.

Danger to other persons Machine safety is guaranteed only for operators. Machine operators must be very careful not to enter a command that puts others in danger.

Safe operations not guaranteed If you have reason to believe that the machine can no longer be operated safely, disconnect it and secure it from being unintentionally switched back on.

Reading these instructions Read through these instructions carefully before operating operating the machine for the first time.

General rules of safety and accident prevention Aside from the advice in these instructions, instructions, always observe general general rules of safety and accident prevention.


Safety

2–5

2.3 Safety features The Komax Gamma 333 PC / 333 PC – B is built in compliance with the latest safety engineering standards and has the following safety and protection devices as standard features:

fig 2.02 Safety devices

Main power switch for machine The main switch cuts off the electricity supply for the entire system.

Emergency stop switch Pressing the emergency stop switches on the front control panel and at wire drawin stops all machine movements and cuts off the power supply to the processing stations. Pressing an emergency emergency stop switch shuts off off the main air valve. 

Approval switch switch When entering a command in setup mode that triggers a machine movement, you must press the approval switch at the same time or the command will not be executed.

Main stopcock for pneumatic system The pneumatic stopcock interrupts the air feed to the entire pneumatic system.

2–6

Safety


Safety cover completely closed

The cover which opens upward and the separate safety cover for the Wire drive are each monitored by two circuit breakers. Opening a safety cover in production mode causes the machine to stop immediately and the on-load voltage to be cut off. During machine setup, the operating voltage must be on so that adjustments can be made inside the machine. However, when entering a command in setup mode that triggers a machine movement, you must press the approval switch at the same time. The approval switch is deactivated in production mode.

fig 2.03 Safety covers

When closing the machine cover, make sure no one can reach into the machine chamber; otherwise, he or she could get pinched.

Accessible operating operating elements All operating elements elements are clearly labeled and readily readily accessible. Quiet operation The noise level without presses is less than 75 dBA.

The machine may be hazardous if operated improperly by untrained persons.


Safety

2–7

2.4 The RCS safety system Energy feed

Power switch-on A Approval A

Logic safety circuit circuit A Feedback A

Feedback B Approvall B Approva

Logic safety circuit circuit B Power switch-on B

Hazardous components

fig 2.04 RCS safety system

The RCS safety system (Redundant Control System) operates with two separate channels. Each safety cover is fitted with two switches. Both channels have to give their approval before certain actions are carried out, e.g. before a crimp module is triggered.

This machine must NEVER be used with the safety covers bridged.

2–8

Safety


3. Transport Transport

When transporting the machine, please follow the instructions below and heed general rules of safety and accident prevention. prevention.

The Komax Gamma 333 PC / 333 PC – B is prepared for shipping as a single unit. Dimensions of the packaging (WxHxD): Weight incl. packaging:

274 x 184 x 201cm approx. 1130kg (machine alone: approx. 840kg)

Pay close attention to the handling symbols on the packaging:

Up

Keep dry

Keep cool

Delicate electronic appliance Do not load cover

Delicate electronic appliance

Fragile

Weight is not in balance

Weight is no t in balance Weight is not in balance

Corrosion protection

To protect the machine from corrosion, a special mat containing inhibitors is placed in the pakkaging. When the inhibitors vaporize, they protect the metal surfaces. Please note: 

Prevent this protective protective atmosphere from escaping.



Reseal any tears or damage damage to packaging packaging immediately immediately..



Do not open the package until until you use the machine.



For control purposes, purposes, the outer covering can can be opened briefly, briefly, but it should be resealed resealed immediately thereafter. thereafter. The protective atmosphere is replenished automatically after the pakkaging is sealed.


Transport

3–1

Please note the following points when transporting the system: 

Transport the system with great great care to prevent prevent damage from excessive excessive force or careless careless loading and unloading.



The delivery documents documents are attached in a highly visible spot on the outside of the cardboard cardboard packaging in a plastic envelope.



Immediately check check the machine machine for transport damage when it arrives. Report any problems or shortcomings to us immediately.

3–2

Transport


4. Items included in the delivery / incoming inspection

Check the items delivered against the delivery documents to be sure everything was sent that was supposed to have been.

Please report any missing or defective parts immediately to Komax AG or the nearest Komax dealer.


Items included in the delivery

4–1

4–2

Items included in the delivery


5. Installation 5.1 Installation site ...................................................................................................................3 5.2 Installation ....................................................................................... ...................................4


Installation

5–1

5–2

Installation


5. Installation 5.1 Installation site Prior to installing your Komax Gamma 333 PC / 333 PC – B, check the following points: Floor: Even, solid surface free of vibration Does the floor have sufficient loading capacity? Machine weighs weighs approx. 840 kg; with two mci 711 crimp presses, approx. approx. 1030kg Avoid rooms rooms with high humidity! humidity! Ambient temperature temperature should be be neither too high high nor too low Power connection 3x208–480V,, N, PE; 50 – 60Hz 6kVA 3x208–480V 5×4mm²; 25A fuse

Attention: Heed the connected load! load!

The machine may be operated only if it has a connected ground conductor.

Compressed air supply 4–6bar Gamma 333 PC → 3137 mm (123.5 inch)

Space required for basic machine?

Gamma 333 PC-B → 3320 mm (130.7 inch)

fig 5.01 Space required by Gamma 333 PC / 333 PC – B basic machine

Figure in extra space to accommodate wire wire feed systems, wire deposit system, pre-processing pre-pro cessing stations, etc.


Installation

5–3

5.2 Installation The machine must be installed and put into operation by an experienced technician.

Observe general rules of safety and accident prevention during installation.

The center of gravity is not in the middle of the machine.

Proceed as follows to install the machine: 

Take the machine out of its packaging.



Lay the boxes and unattached machine parts off to the side.



Make sure sure the surface on which the machine will be set up is clean. Use a water level to level the machine.



Adjust the feet of the machine (5 in all) as required, taking care not to unscrew them too far fa r. fig 5.02 Leveling the machine

The weight must be distributed equally among each of the five feet. The less you unscrew the feet, the more stable the machine will be.

Make sure to tighten the lock nuts on the threaded rods of the feet.

This will ensure that the additional vibrations of the machine do not cause the stepping motors to malfunction, e.g., to fall „out of step“.

5–4

Installation


When laying the compressed air hoses, be careful not to create any kinks in them. In hazardous areas around moving parts, the hoses must be secured to keep them from being abraded and pinched. Select hose lengths that do not impair the movements of the components involved. involved.



With the air air hose included included in the delivery delivery,, hook up the maintenance unit to the compressed air supply (arrow).

fig 5.03 Maintenance unit 

Power to the machine machine must be supplied via a power cable with a cross cross section of at least 2 5×4mm (25 A fuse on supply side). Be careful never to switch around the phase and PEN conductors when connecting the power!

fig 5.04 Main power supply X01


Installation

5–5

Ensure that no wires are pinched in the control cabinet.



Take the monitor, PC, mouse and keyboard out of their boxes.



Place the PC PC on the mount provided provided for it on the door of the control cabinet and fix into place with the adjustable fastening brackets.

fig 5.05 PC mounted on door of control cabinet



Place the monitor on the control control cabinet and run the two monitor cables through the opening in the back of the control cabinet.



Connect the cable to the PC.

fig 5.06 Control cabinet with monitor, keyboard and mouse

The PC connections and the terminal assignments are covered covered in two separate documents (document Komax PC connection diagram, doc Komax PC hardwar hardware e overview). The documents are included in the delivery in a separate package. The documentations contain the connection diagrams and indicate the assignments of the PC ports.

5–6

Installation


Mounting the conveyor belt extension 

Remove baffle plate 1 from the end of the basic conveyor belt module and reinstall it at the end of the extension module.



To ensure better accessibility, accessibilit y, remove the cover plate from the extension module.



Detach the wire ramp from from the end of the extension module and screw ramp 2 to the end of the basic module.

1

2

fig 5.07 Baffle plate and wire ramp 

Lower the rollers on the extension extension frame to the position they were in before before and move the conveyor belt extension up to the basic module. Align the extension module with the basic module, making sure it is flush in the vertical and the horizontal. Make sure the ramp does not touch any part of the belt.



Screw the conveyor conveyor belts with the two connectors provided provided and attach the tipping tipping trays as well as the sections of the deposit trays for the basic and extension modules.

3

4

5

fig 5.08 Conveyor belt for extension module

3 Attachment of tipping trays 4 Attachment of deposit tray section 

Now remount remount the cover plate on the extension module. module.



Compressed air is supplied at connection 5 (fig 5.08).


Installation

5–7



Power is supplied to the first extension directly directly from the control cabinet cabinet (connection X07). X07).



Power is supplied to the the second extension extension and any further extensions extensions via the electrical electrical box of the previous extension.



This completes the installation of the the Komax Gamma 333 333 PC / 333 PC – B itself. itself. The installation of the processing stations and the accessories is described in the set of instructions for each respective device.



The operating and and software instructions instructions and the spare spare parts catalog must be stored stored in a suitable spot. This also applies to the electrical and mechanical accessories. File away the diagrams for the compressed air system and the electrical system as well as the I/O list in the operating instructions under Chapter 11 and Chapter 12.



Dispose of the packaging packaging and pallet in an ecological manner manner when you finish. finish.

5–8

Installation


6. Machine overview and functions 6.1 Basic machine................................................................................. ...................................3 6.1.1 Straightening unit ............................................................................... ...................5 6.1.2 Transport unit ..................................................................................... ...................5 6.1.2.1 Gamma 333 PC ................................................................................... ....5 6.1.2.2 Gamma 333 PC-B ...................................................................................5 6.1.2.3 Encoder ...................................................................................................6 6.1.2 Swivel and pull-off unit on side 1 .......................................................................... 6 6.1.3 Cutting head .........................................................................................................8 6.1.4 Swivel and pull-off unit on side 2 .......................................................................... 9 6.1.4.1 Good/bad sorting...................................................................................10 6.1.5 Hold-up device ...................................................................................................10 6.1.6 Wire deposit system and conveyor conveyor belt ............................................ .................11 6.1.7 Maintenance unit ................................................................................................11 6.2 Control system ................................................................................ .................................12 6.2.1 Control cabinet ...................................................................................................12 6.3 Front Front control panel ......................................................................................... .................15 6.4 Sensors ........................................................................................... .................................16


Machine overview and functions

6–1

6–2



6. Machine overview and functions 6.1 Basic machine 7

8

9

14

15

16

17 18

6 19

10

11 1

2

3

12

4

13

23

22 22

21 21

20

5 fig 6.01 Machine overview of Gamma 333 PC / 333 PC – B basic machine

1 Straightening unit Straightens the wire

2 Wire drive Wire feed, length measurement and wire-end monitoring

3 Swivel and pull-off unit side 1 Swivels and positions wire on side 1 at the first processing station

4 Cutting head Cuts the wire to the desired length or makes a cut in the insulation in preparation for stripping; cuts off bad wire

5 Swivel and pull-off unit side 2 Swivels and positions wire on side 2 at the second processing processi ng station

6 Machine side 1 Processing of the lead end of the wire

7 Connector feed side 1, side feed Feeds connectors from reels

8 Processing station, side 1 Crimping module configuration

9 Connector feed side 1, back feed Feeds connectors from reels

10 Machine side 2 Processing Processi ng of the trailing end of the wire


11 Connector feed side side 2, back feed Feeds connectors from reels

12 Processing station side 2 Crimping module configuration

13 Connector feed side side 2, side feed Feeds connectors from reels

14 Power connection connection 15 Control cabinet Contains the power supply and the control system (PC)

16 Monitor 17 Operator’s station Machine controls and station for the machine operator

18 Keyboard 19 Mouse 20 Conveyor belt with wire deposit system and batch separation Picks up the processed wires and carries them away them from the machine

21 Machine operator operator at work 22 Compressed air supply 23 Safety cover


6–3

7

8

9

10 11 12 13 14 15 16 17

18 19 20

A 21

22

23

Detail A 25

24 C P 3 3 3 a m m a G

1

2

3

4

5

B – C P 3 3 3 a m m a G

4

3

5

6

1

2

fig 6.02 Front view of Gamma 333 PC / 333 PC – B

Wire advance button Approval button Manometer for applied pressure Control system for applied pressure Emergency off switch Button for opening the belt drive Pressure regulation valve for for wire wire gripper on side 1 pressure regulation valve on 8 Manometer for pressure side 1 pressure regulation valve on 9 Manometer for pressure side 2 10 Pressure regulation valve for wire gripper on side 2 11 Approval button 12 Start button (to switch on load voltage) 1 2 3 4 5 6 7

6–4


13 Stop button (to switch off load voltage) 14 Monitor 15 Keyboard 16 Start button 17 Stop button 18 Emergency off switch 19 Opening the safety cover 20 Closing the safety cover 21 Mouse 22 Main switch 23 Control cabinet 24 Contact rollers 25 Waste container (at back)


6.1.1 Straightening unit

1

4

1 Protection pane 2 Perforated disk 3 Straightening device with quick-action release 4 Installation site for splice detection (optional) 5 Toolbox

Please consult Chapter 7.5.2 for an explanation on how to set the straightening units correctly.

2

3

5

fig 6.03 Straightening unit

6.1.2 Transport unit 6.1.2.1 Gamma 333 PC 1 2 3 4 5 6 7 8

6

Wire advance button Approval button Manometer for applied pressure Control system for for applied pressure in roller roller drive Emergency off switch Transpor ransportt rollers Wire guide Encoder 1

2

7

3

8

4

5 fig 6.04 Roller drive

6.1.2.2 Gamma 333 PC-B 1 Control system for applied pressure 2 Manometer for applied pressure 3 Emergency off switch 4 Button for opening the belt drive 5 Wire advance button 6 Approval button 7 Wire inlet 8 Wire drive driven by toothed belt 9 Pressure cylinder 10 Encoder pressure wheel 11 Encoder for length measurement 12 Wire outlet


7

8

9

10 11 12

1

2

3

4

5

6

fig 6.05 Belt-driven wire drive


6–5

6.1.2.3 Encoder The transport unit has a brushless AC servomotor with length measurement and slip control. The ASS automatic slip control compares the two values of the motor encoder and the length measurement encoder. encoder. The roller drive stops if the maximum value that can be set in the parameters is exceeded.

fig 6.06 ASS automatic slip control

6.1.2 Swivel and pull-off unit on side 1 1 Guide tube 2 Swivel unit 3 Wire guide tube, short/long

1

2

3

The swivel and pull-off unit pulls off the insulation after it has been cut into and then approaches the processing stations. The gripper on the swivel and pull-off unit on side 1 is pressed down to the crimp tool during crimping.

Fig 6.07 Swivel and pull-off unit

6–6



Operating cycle of the swivel and pull-off unit on side 1

After the wire is cut cut to length and a cut cut is made in the insulation, the pull-off unit withdraws, stripping the wire as it does so.

Side 2 Side 1

The unit then swivels to the processing station.

The pull-off unit moves forward, so the wire can be fed to processing station 1 for processing.

After processing, processing, the pull-off unit moves the wire back to the wayback position.

The unit swivels back to the cutting head.



6–7

6.1.3 Cutting head 1 2 3 4 5

Cutting blade, bottom V stripping blade side 1, top V stripping blade side 1, bottom Blow-off air connection Bad-wire cutting blade

1

5 4

2 3 fig 6.05 Cutting head with top and bottom blade block

Operating cycle of cutting head

The cutting blade cuts the wire.

The pull-off units on side 1 and 2 move the two wire ends to the stripping position.

The V stripping blades cut the insulation down to the stranded conductor.

The V stripping blades withdraw by a pre-programme pre-programmed d distance so the stranded conductors are not damaged during pull-off.

The pull-off units on side 1 and 2 withdraw, pulling off the insulation. A blow-off unit clears away any stripping scraps.

The entire cutting head opens up, ending the stripping cycle.

6–8



6.1.4 Swivel and pull-off unit on side 2 1 2 3 4

Wire gripper Pull-off unit Swivel unit Drive belt for the swivel unit

1

2

3

4

fig 6.06 Swivel and pull-off unit on side 2

Operating cycle of swivel and pull-off unit on side 2

Side 1

Side 2

The gripper on the pull-off unit clamps the wire firmly and pulls it back in preparation for stripping.

The pull-off unit moves back to the approach position and the entire unit swivels to the processing station.

After processing, processing, the pull-off unit moves back to the wayback position.

The unit then swivels to the deposit position, where the gripper releases the wire, ending processing on side 2.


The pull-off unit advances to the processing position and the wire is processed on station 2.


6–9

6.1.4.1 Good/bad sorting If the crimp force sensor detects bad processing on wire side 1, the process is stopped, the wire end is cut off and removed by conveyor belt. If bad processing is detected on wire side 2, the bad wire end is cut off at the cutting blade (Pos. 1 / fig. 6.07) and put in a waste container. The wire is rendered unusable by the cut but is put with the batch in the wire tray.

Gamma 333 PC

Gamma 333 PC – B

6.07 Flow diagram for good/bad sorting

6.1.5 Hold-up device The hold-up device ensures that the gripper on side 2 can take over the wire neatly.

fig 6.08 Hold-up device

6 – 10



6.1.6 Wire deposit system and conveyor belt The conveyor belt efficiently removes long wires and disposes of bad wires.

fig 6.09 Machine frame with wire deposit system

6.1.7 Maintenance unit Compressed air supply Stopcock Manometer for operating pressure Pressure control for operating pressure (5–6 bar) 5 Water trap, filter 6 Oiler 7 Outlet for unoiled air 8 Setting screw for drip amount 9 Waste air return 10 Waste air filter 11 Drain plug for waste air filter 12 Main valve 13 Outlet for oiled air after main valve 14 Pressure regulator 15 Outlet for oiled air before main valve 1 2 3 4

12

15

8

7

4

3

13 2 1

14

11 10 9

6

5

fig 6.10 Maintenance unit

The blow-off air connection on the blade block is supplied with unoiled compressed air, so the stripped wire ends are not soiled by oil.



6 – 11

6.2 Control system 6.2.1 Control cabinet Before opening the control cabinet, always switch OFF machine’s main power switch.

Open control cabinet

3

2

1

Basic layout of the control cabinet

Main switch (turn to OFF)

Rear view of the control cabinet

fig 6.11 Overview of control cabinet

S49 1 Main switch G01 2 Switched-mode power supply 24DC G01 ransformer er T01 3 Transform

6 – 12



4

5

6

Piece counter P20 RCS PCB (Redundant Control System) A04 BIO PCB (Basic Input Output) A01 Relay strip K00-K05 Terminal strip X02 Stepping motor controller controller SMC SMC 3003 3003 A10 Output stages for stepping motors A11-A15 Electrolytic capacitor C01

4 5 6 7 8 9 10 11

7

8

11

10

9 fig 6.12 Large mounting plate

14

15

16

17

12

13 14 15

16

17

18 19 20

fig 6.13 Small mounting plate with detailed view

12 13 14 15 16 17 18 19 20

Circuit breaker F01 230 V switch X04 Power supply to MCI 711 X05 Conveyor belt X06 Belt extension X07 Power supply to non-Komax module X08 Fire station X09 Country voltage in-feed X01 Mains filter Z01



6 – 13

21 MRS PCB A65 22 24VDC power feed 23 Fuse, 5AT 24 Connection for PCC card A 25 Connection for PCC card B

21

25 23

22 24

fig 6.14 MRS PCB

6 – 14



6.3 Front control panel

1

2

4

3

5

6

8

7 fig 6.15 Front control panel

1 2 3 4 5 6 7 8

Approval key Start button button for switching on the the connected connected load Stop button button for switching off the connected connected load Start button Stop button Emergency stop key Switch for opening the safety cover Switch for closing the safety cover

The exact functions and uses of the controls are described described in the software instructions for this machine.



6 – 15

6.4 Sensors The movements of the Komax Gamma 333 PC / 333 PC – B are monitored by various sensors.

Hybrid light barriers

BM1 BM2 BM3 BM4 BM5

Inductive sensors (Namur)

Cutting head (blade) Pull-off side 2 Pull-off side 1 Swivel unit side 2 Swivel unit side 1

B10 B11 B12 B13 B14 B16

Lowering gripper side 1 Lowering gripper side 2 Gripper side 2 Hold-up device Gripper side 1 Wire tray

fig 6.16 BM1 sensor cutting head (blade)

6 – 16

fig 6.17 BM2 sensor pull-off side 2

fig 6.18 BM3 sensor pull-off side 1



B11

BM4 B12 fig 6.19 BM4 sensor swiveling side 2 B11 Sensor lowering side 2 B12 Gripper side 2

fig 6.20 BM5 sensor swivel unit side 1

fig 6.21 B10 sensor lowering side 1

fig 6.22 B13 sensor hold-up device

fig 6.23 B14 sensor gripper side 1

fig 6.24 B16 sensor wire tray

Be aware there is a special allocation of pins. Only the RJ45 from Komax can be used as a communication cable; other cables can destroy transmitters and receivers.

NEVER plug in or unplug RJ45 cables when the connected load is on.



6 – 17

6 – 18



7. Machine operation 7.1 Checks prior to startup ......................................................................................................3 7.2 Switching the the machine ON and OFF ................................................................................. 4 7.3 Selecting the operating mode ...................................................................... ....................4 7.4 Safety cover ................................................................................... ...................................5 7.5 Preparing Preparing the machine machine for production production .............................................................................. 5 7.5.1 Knot detection .................................................................................. ...................5 7.5.2 Straightening unit ............................................................................... ...................5 7.5.3 Wire guide parts ................................................................................. ...................6 7.5.4 Wire draw-in ....................................................................................... ...................7 7.5.5 Pull-off unit unit on side 1 and side 2 ..........................................................................7 7.5.6 Crimping module ..................................................................................................8 7.6 Tool Tool drawer ...................................................... ..................................................................9


Machine operation

7–1

7–2

Machine operation


7. Machine operation 7.1 Checks prior to startup To be able to be operated safely and without being damaged, the machine must be in proper running condition. Check your machine before each startup, taking special note of the following points: Electrical connections Connecting cables

All cables must be correctly plugged in and not damaged, otherwise replace them!

Compressed air unit Manometer

Is the correct operating pressure of 5–6 bar set?

Maintenance Maintenanc e unit

Level of pneumatic oil OK? (refer also to Chapter 9; Maintenance)

Compressed air elements Hose

No visible damage; otherwise replace air hoses!

Connections

Check to be sure there are no leaks; repair/adjust if necessary necessary..

Safety devices Emergency stop switches and cover switches

Turn on machine and check to see that these switches are functioning properly properly.. When emergency stop switch is pressed down, the load voltage must switch off and the pneumatic system must be pressureless; the „Stop“ key must remain unlit. Opening the safety covers must trigger a machine stop!

If the safety devices on the Komax Gamma 333 PC / 333 PC – B do not work properly, DO NOT operate the machine. DANGER!

DO NOT commence production until you have successfully carried out all of the above checks. With a properly operating machine, you can avoid production downtime due to machine malfunctions.


Machine operation

7–3

7.2 Switching the machine ON and OFF Once you have carried out all the above checks and determined that the machine is in proper running condition, you can switch it on: Turn the red main switch on the control cabinet to ON . This starts the PC in the control cabinet and loads the user interface. Shortly thereafter, the log-in window appears on the screen so you can enter your password. After successful log-in, the connection is established between the PC and the control unit. This also initiates the motor controllers and the I/O cards.

Switch on the connected voltage with Power with Power On On on on the control panel. The loaded voltage cannot be switched on if the emergency stop switch is pressed and serious machine problems exist. For setup and production, the machine must be reset from the software, i.e. the machine is put in a predefined state by the software and all functions are checked. Any errors are displayed on the monitor screen. After a successful reset, the machine is ready for setup or production.

fig 7.01

power on

fig 7.02

Switching the machine off To switch off the load voltage to the machine, press Power Off and and then turn the red main switch to OFF . No production data is deleted when the machine is switched off. It remains stored in the PC databases.

7.3 Selecting the operating mode The machine distinguishes between two operating modes, automatic mode for producing and setup mode for setup. The two modes differ as follows: Automatic

Production is controlled controlled in this this operating operating mode. mode. The The production production window appears on the screen. All safety covers must be closed before this operating mode can be run.

Setup

Production is set up in this operating mode. The setup window appears on the screen. The safety covers can remain open during setup, but the approval key function must be taken into account.

You should proceed You proceed with special special care in setup setup mode since the machine can execute movements with the safety covers open. Be especially careful that no one else is working on or around the machine.

When the machine is switched on, the moving parts of the wire tray, the wire guide gripper, the grippers on side 1 and side 2, and the hold-up device move into their default positions, posing a PINCHING hazard!! hazard!!

7–4

Machine operation


7.4 Safety cover The safety cover is opened and closed using keys on the front operator’s panel. Opening the safety cover while the machine is in operation always triggers an emergency stop. For further details, read Chapter 2 of these instructions.

2

1

3

Opening the safety cover  Press key 1 Closing the safety cover machine load load voltage 2  Switch on machine  Press close safety cover 3

fig 7.03 Front control panel

7.5 Preparing the machine for production Once you have decided which wire to process, you must make the following adjustments to the machine to adapt it to this specific wire:

7.5.1 Knot detection The perforated disk must be turned to the correct diameter.

fig 7.04 Knot detection

7.5.2 Straightening unit The setting shown is ideal for most types of wires. It is important that the wire is straightened more at the inlet of the straightening station, so that it merely rolls out straight over the last straightening roller (x < y).

4

3

Adjustment: The straightening-roller straightening-roller angle can be set with screws 1 and 2. Use eccentric thumb screw 3 to close the straightening station and scaled dial 4 to set the wire diameter. 1

2 fig 7.05 Straightening unit


Machine operation

7–5

7.5.3 Wire guide parts Gamma 333 PC 

Pull out the the wire wire guide guide 1 and replace it. You have two different diameter diameters s to choose from (Ø 3mm and Ø 6mm).



Detach the two knurled screws 2 and replace the guide tube 3. You have two different diameter diameters s to choose from (Ø 3mm and Ø 6mm).



Pull back the collar and replace replace the guide guide tube 4. Make sure you use the guide tube with the optimum diameter.

1

2

4

3

fig 7.06 Wire guide parts for the Gamma 333 PC

Gamma 333 PC-B 



Replace the clamping screw 1 and clamping lock 2 and replace guide tube 3. You have two different diameter diameters s to choose from (Ø 3mm and Ø 6mm).

1

3

4

Pull back the collar and replace the guide tube 4. Make sure to use the guide tube with the optimum diameter.

2

fig 7.07 Wire guide parts for the Gamma 333 PC-B

7–6

Machine operation


7.5.4 Wire draw-in The Gamma 333 PC has basically the same wire draw-in procedure as the Gamma 333 PC-B.

Proceed as follows: 

Switch on on the machine and and reset it.



Open both straightening stations.



Open the the cover to the wire drive. drive.



Manually insert the wire up to the transport rollers or toothed belt.



1

Reclose the the cover to the wire drive. drive.

Push the wire advance button 1 to advance the wire. To ensure that the beginning of the wire is tidy, you can carry out a zero cut.

fig 7.08 Wire draw-in

7.5.5 Pull-off unit on side 1 and side 2 The gripper pressure on the pull-off units side 1 and side 2 is set using pressure regulating valves 1 and 3. Select a pressure at which the wire is held firmly by the grippers without being squeezed (indented). Manometers 2 and 4 indicate the clamping pressure for each respective gripper. 1 2 3 4

Pressure regulating valve side 1 Manometer side 1 Pressure regulating valve side 2 Manometer side 2

2

4

1

3

fig 7.09 Setting the gripper pressure pressure for the pull-off unit side 2


Machine operation

7–7

7.5.6 Crimping module The crimping modules have a quick-clamping system for holding crimping tools. Before installing the crimping tool, clean the mounting surface, so the tool can rest firmly on it. Use lever 1 to open and close the clamping system. Crimping modules are mounted on continuously height-adjustable crimping module positioning units 2. The height is adjusted by tur ning hexagonal screw 3. The bench top has two dr illing patterns which can be used to adjust the crimping module position rearwards to match the swivel and pull-off units.

1

3

2 fig 7.10 Crimp module on height-adjustable positioning unit

Adjustment range: Height: 20mm Depth:

2 positions

side 1 Side 2

Front position, Rear position,

The scraps of connector paper strips can be disposed of by having them drop down through duct 4 into the waste container. The K 455 connector strip cutter is underneath the crimping module. The duct is attached to the bracket and can be slid in the slotted holes to align it with the crimping tool. To To adapt the duct optimally to the crimping tool, opening 5 must be further adjusted manually.

standard position standard position

5 4

fig 7.11 Duct for disposal of strip scraps

7–8

Machine operation


7.6 The tool drawer The tool drawer contains guide parts, tools, gages and other small parts.

The contents of the drawer for the Gamma 333 PC and the Gamma 333 PC – B are identical except for a few items. The differences are clear from the spare parts catalog.

fig 7.12 Tool drawer for the Gamma 333 PC


Machine operation

7–9

7 – 10

Machine operation


9. Maintenance 9.1 Notes on maintenance .................................................................................... ...................3 9.2. Maintenance plan ........................................................................................... ...................4 9.2.1 Daily maintenance............................................................................................. ....4 9.2.2 Weekly maintenance ......................................................................................... ....4 9.2.3 Monthly maintenance........................................................................................ ....6 9.2.4 Maintenance every six months .............................................................................7 9.3 Explanation of maintenance procedures............................................................................ procedures............................................................................ 9 9.3.1 Maintenance unit ..................................................................................................9 9.3.2 Cutting head .......................................................................................................10 9.3.3 Grippers on side 1 and side 2 ............................................................................. 10


Maintenance

9–1

9–2

Maintenance


9. Maintenance

Before doing any maintenance and repairs, especially in the dangerous areas around moving machine parts and live electrical components, ALWAYS turn off the machine at the main switch and secure it against unauthorized switch-on.

The maintenance tasks must be performed regularly regularly at the stipulated intervals to ensure the operational readiness and long service life of the machine.

The maintenance intervals are geared for single-shift operations. In the event of heavier use, the machine must be serviced more often!

Any shortcomings and and defects arising arising during daily production production must must be remedied remedied immediately to ensure the safety of the machine and the personnel.

9.1 Notes on maintenance Cleaning Use only non-fraying, oil-saturated materials to clean the machine (no cleaning wool or the like).

DO NOT USE compressed air to clean. This will blow minuscule bits of insulation into the guides, increasing wear and impairing accuracy. If you must use compressed air, remove the parts to be cleaned from the machine first.

Any parts cleaned with with solvents must be immediately immediately relubricated or regreased regreased afterwards. afterwards. These maintenance tasks apply to the Komax Gamma 333 PC basic machine only. only. For information on maintaining and cleaning customer-specific customer-specific processing stations and accessories, check the operating instructions for these devices. Lubricants In principle, you can use standard commercial types of bearing grease for all bearings. Use highpressure paste for points of contact subject to pressure. Oils Use a lubricating oil with a viscosity of SAE 25 for all moving parts.

Grease The grease below is recommended for pull-off guides, pinions, lubricating nipples and racks.

The following oil is recommended for the pneumatic maintenance unit: Festo pneumatic oil OFSW-32

Klüber Microlube GL 261

Other possible oils  ARAL Vitam GF 32  BP Energol HLP-HM 32  Esso Nuto H 32  Shell Hydrol DO32  Mobil DTE 24  Hydraulic fluids complying with DIN51 524 Part 2 with a viscosity of 32mm2 /s at 40 40°C °C (HLP 32)


Maintenance

9–3

9.2. Maintenance plan 9.2.1 Daily maintenance Component

View

Activity

Entire machine

Remove insulation and wire remnants. Check pneumatic, mechanical and electrical machine parts for damage.

9.2.2 Weekly maintenance

Weekly maintenance is preceded by daily maintenance.

Component

View

Activity

Maintenance unit

Empty water separator. Check pneumatic liquid. Empty water oil separator. Refer also to Chapter 9.3.

Guide parts

Check for wear and deposits. Remove wire guides and clean with compressed air.

Transport rollers

Check for wear and deposits of insulation materials.

(Gamma 333 PC)

Clean encoder wheel with soft copper brush.

9–4

Maintenance


Wire drive (belt-driven) (Gamma 333 PB – B)

Check for wear and deposits of insulation materials. Check belt tension. Clean encoder wheel with soft copper brush.

Straightening station

Check free movement of straightening rollers. Clean straightening station with cloth lightly soaked in oil.

Scrap container

Empty container.

Conveyor belt

Check lateral running distance. Refer to Chapter 10.

Blade head

Check blade wear. Clean blade with cloth saturated in oil.


Maintenance

9–5

9.2.3 Monthly maintenance

Monthly maintenance is preceded by daily and weekly maintenance.

Component

View

Activity

Maintenance unit

Remove waste-air filter and clean it. Clean sight glass when necessary. Refer also to Chapter 9.3.

Swivel and pull-off unit on side 1 and side 2

Rub down guides with cloth lightly soaked in oil. Lubricate grippers. Also refer to Chapter Chapter 9.3.Also refer refer also to Chapter 9.3.

Cutting head

Clean and oil all guides. Grease rack and pinion. Refer also to Chapter 9.3.

Wire guide grippers

Clean piston road and rub down with cloth lightly soaked in oil. Check free movement.

9–6

Maintenance


9.2.4 Maintenance every six months

Maintenance every six month is precede preceded d by daily and weekly and monthly maintenance.

Component

View

Activity

Wire drive (roller-driven)

Check tension of belt.

Wire drive (belt-driven)

Check tension of toothed belt.

Refer to Chapter 10.


Swivel and


pull-off unit on side 1


Swivel and


pull-off unit on side 2


Cutting head

Check tension of toothed belt. Refer to Chapter 10.


Maintenance

9–7

Control cabinet

Clean the inside of the cabinet.

Conveyor belt

Check belt tension. Refer to Chapter 10

Safety cover

Clean and grease guides.

Guide parts and bearings

Check for damage, wear and corrosion.

Toothed belts

Check for wear and check setting. Refer to Chapter 10.

9–8

Maintenance


9.3 Explanation of maintenance procedures 9.3.1 Maintenance unit Emptying the water trap:  Press up valve 1 and drain the water under pressure.

3

4

Emptying the waste air filter:  Loosen drain plug 2 slightly and let the liquid drain out; then retighten the plug. Cleaning the waste air filter:  Loosen the drain plug 2, detach shell 6 and filter 7; clean filter 7 in gasoline and blow out with compressed air. reassemble, le, reverse the order of the  To reassemb above steps. Setting the number of drops on oiler:  Use screw 3 to set the number of drops. This procedure must be carried out while the machine is running. thumb: 1–2 drops drops over a period of 5  Rule of thumb: minutes.

7 1

6

2

5 fig 9.16 Maintenance unit

The maintenance unit must be completely depressurized depressurized when the following tasks are carried out.

This state is reached when compressed air line 4 is disconnected and the dial on the manometer reads 0 bar. Replenishing the oil in the oiler:  Remove sight glass 5. „Max Oil Level.“  Pour in oil to „Max  Remount sight glass; locking lever must snap into place!

    

Replacing the waste air filter: Unscrew drain plug 2. Pull off plastic cover 6 and remove underlying nut and washer. Replace filter 7. Reposition washer and nut. Mount plastic cover; tighten into place with with drain plug.


Maintenance

9–9

9.3.2 Cutting head To perform the maintenance tasks on the cutting head correctly, you must first remove the covers.



Grease rack and and pinion pinion (arrows). (arrows). Clean and oil linear guides 1.



Check cutting and form form blades blades 2 for wear and replace if necessary.



Use grease gun to inject grease grease into lubricating nipples 3.

1

3 2

fig 9.17 Cutting head

9.3.3 Grippers on side 1 and side 2

To ensure an optimum distribution of grease everywhere, make sure the grippers are completely closed before applying the grease gun.

Grippers on side 1: 1 Lubrication nipple, right 2 Lubrication nipple, left 2

3 Lubrication nipple, front

1 3 fig 9.18 Lubrication nipples on grippers on side 1

9 – 10

Maintenance


Grippers on side 2: 1 Lubrication nipple, right 2 Lubrication nipple, left

2

3 Lubrication nipple, front

You have to remove the plate 4 on left lubrication nipple 2 (2 screws) in order to apply the grease gun to it.

1

4 3

fig 9.19 Lubrication nipples on grippers on side 2


Maintenance

9 – 11

9 – 12

Maintenance


10. Settings and adjustments 10.1 Blade blocks and blades .............................................................................. ....................3 10.1.1 Disassembling the blade blocks .........................................................................3 10.1.2 Assembling the blade blocks .............................................................................. 3 10.1.3 Changing the blades ....................................................................................... ....4 10.2 Mechanical settings and adjustments..............................................................................5 10.2.1 Guide parts and bearings ...................................................................................5 10.2.2 Toothed Toothed belts ................................................................... ...................................6 10.2.2.1 Mounting Mounting a toothed belt ........................................................................ 7 10.2.2.1.1 Toothed Toothed belt for transport unit on Gamma 333 PC ........................ ....7 10.2.2.1.2 Toothed Toothed belt for transport unit on Gamma 333 PC-B......................... 8 10.2.2.1.3 Replacing the drive belt for the swivel head on side 1 and side 2 .....9 10.2.2.1.4 Replacing the drive belt for the cutting head....................................10 10.2.2.2 Operating problems associated with toothed belt drives ....................10 10.2.3 Setting the guide for the pull-off unit on side 2 ................................................11 10.2.3.1 Positioning the toothed rack (user side) ..............................................11 10.2.3.2 Positioning the counter guide (at the back) .........................................12 10.2.3.3 Final Final step and setting-check ..............................................................12 10.2.4 Calibrating the machine ....................................................................................14 10.2.4.1 Calibrating the axes (mechanical) ........................................................14 10.2.4.2 Calibrating the axes under TopWin......................................................14 10.2.4.3 Calibration procedure procedure ......................................................................... 15 10.2.5 Wire feed unit ....................................................................................................17 10.2.5.1 Gamma 333 PC ...................................................................................17 10.2.5.2 Gamma 333 PC-B ...............................................................................18 10.2.6 Lifting device ................................................................................... .................18 10.2.7 Wire guide gripper ............................................................................................19 10.2.8 Conveyor belt ................................................................................... .................20 10.2.9 mci 711 options ................................................................................................21 10.2.10 Safety cover ................................................................................... .................21 10.3 Electrical settings and adjustments ...............................................................................22 10.3.1 Sensors ............................................................................................ .................22 10.3.1.1 Laying sensor cables ...........................................................................22 10.3.1.2 Inductive sensors............................................................................... ..25 10.3.1.3 Hybrid light barriers .............................................................................25 10.3.2 Electric fuses in control control cabinet .......................................................................26 ....... ................................................................26 10.3.3 BIO PCB........................................................................................... .................27 10.3.4 Output stages of the stepping stepping motors .............................................................28


Settings and adjustments

10 – 1

10.4 Pneumatic Pneumatic settings and adjustments .......................................................... ..................30 10.4.1 Operating pressure ........................................................................................ ..30 10.4.2 Throttle non-return valves ............................................................................... ..30 10.5 Setup of processing stations ....................................................................................... ..31 10.5.1 Crimp module setup .........................................................................................31 10.5.2 Setup of mci 761 seal module ..........................................................................32 10.5.3 Setting up non MCI modules ............................................................................33 10.5.4 MRS PCB ......................................................................................... .................34

10 – 2



10. Settings and adjustments

All setting and adjustment adjustment work must be be performed with with the machine turned off and by duly authorized personnel only.

10.1 Blade blocks and blades Before working on the blade blocks or blades, ALWAYS switch off the machine at the main switch.

10.1.1 Disassembling the blade blocks Disassembly procedure 

Remove the waste container from the unit.



Lower the slideable part of the connection piece for channeling scraps into the container by loosening the knurled thumb screw.



Move the two blade blocks completely apart from each other.

Lower blade block 

Unscrew threaded pin 1 to loosen and remove the lower blade block. 2

Upper blade block 

1 fig 10.01 Blade head

Unscrew threaded pin 2 to loosen and remove the upper blade block.. block..

10.1.2 Assembling the blade blocks Assemble the blade blocks blocks by reversing the order of the above steps. Press up on the upper blade block during assembly. Press down on the lower blade block during assembly.

To prevent deformation, it is very important that you tighten the threaded pins only slightly.



10 – 3

10.1.3 Changing the blades You must remove the blade blocks to change the blades. Remove the corresponding screws to take out the old blades.

Prior to inserting the new blades, make sure the blade blocks are completely clean, so the blades will sit firmly in the guides.

When tightening the screws, press the blades in the direction of installation to the stop (arrows).

Blade block, up

The grips on the stripping blades point inward. The grips on the cutting blades point outward when the blade blocks are held together.

Blade block, down

The grips on the stripping blades point outward. The grips on the cutting blades point outward when the blade blocks are held together.

fig 10.02 Blade block, up and down

10 – 4



10.2 Mechanical settings and adjustments Several of the machine parts must be readjusted when newly installed to replace defective or worn parts or if shifted by mechanical loads.

10.2.1 Guide parts and bearings All guide parts must must always have a thin thin oil film on them. The bearings must always always be greased and never be allowed to run dry.

All guide parts and bearings bearings must be checked for for wear at least every six months. months. Damaged guide parts and bearings can cause serious damage to the machine and must be replaced immediately.

Guide parts

Check guide parts for the following types of damage:   

Corrosion Scratches or impact damage Ease of movement

Bearings

Running noise or excessive vibrations or knocks are an indication of bearing problems.

fig 10.03 Example of the guide on the cutting head

Installing and removing the bearings: In the installation of rolling-contact bearings, expertise and cleanliness are the two prerequisites prerequisites for ensuring that the bearings function properly and do not fail prematurely.

Lubrication of the bearings: The bearings are sealed on both sides and already filled with grease. Since the useful life of the lubricant exceeds the expected service life of the bearing, no subsequent lubrication is required or provided for.



10 – 5

10.2.2 Toothed belts With toothed belts, power is transmitted by positive engagement of belt teeth with pulley grooves. For this reason, the tension in the toothed belt must not be too high or too low. Unnecessarily high tension reduces the service life of the drive, increases loading on the bearing and wear on the teeth, and promotes running noise. Too little tension causes vibrations and increases abrasion. The belt teeth could also jump if the load fluctuates.

After adjusting the toothed toothed belts, check check each to make sure sure it is running parallel. parallel.

To tighten the toothed belts, you must remove the sheet metal covers and loosen the tensioning device. Refer to the next chapter for details (10.2.2.1).

Frequency measurement

The frequency is measured to determine the exact tension of the toothed belt. This procedure involves striking the toothed belt to set it vibrating and then measuring the frequency of the vibration. The measuring head must be centered between the grooved pulleys and aligned perpendicular to the belt surface.

1 3

1 Measuring head 2 Indicator 3 Striking the belt 2

fig 10.04 Frequency measurement

The rule of thumb is: The center of the toothed belt must be able to be rotated by 45°. If it cannot be, the toothed belt is too tight.

10 – 6



10.2.2.1 Mounting a toothed belt

Toothed belts have relatively rigid tension members in them. Do not force the belt over the grooved pulley and never force it over a pulley flange.

Check that the pulleys are aligned (flush) and that the axes are absolutely parallel. Avoid any bending, twisting, angling, or buckling of the belt. Make sure the belt does not r un out over the faces of the pulleys. Remember also that once the axis distance is set, it cannot be changed again as long as the machine is running.

10.2.2.1.1 Toothed belt for transport unit on Gamma 333 PC Replacing the large toothed belt on the roller drive:  







 

Remove the entire straightening unit. Remove the sheet metal cover underneath the unit. Loosen the three socket-head cap screws 6 on the motor unit. Loosen the toothed belt by loosening the socket-head cap screw 3. Remove motor unit 4 and set aside in a suitable place. Replace the toothed belt 1. To remount, reverse the order of the above steps.. steps

1

6

3

4 6

2

5

Initial tension of the toothed belt:

Frequency: 110 +/-10Hz

Replacing the small toothed belt 2 on the feed unit:   

fig 10.05 Feed unit, viewed from below

Loosen belt tensioning device 5. Replace toothed belt 2. To remount, reverse the order of the above steps.



10 – 7

10.2.2.1.2 Toothed belt for transport unit on Gamma 333 PC-B Replacing the drive belt in the wire drive: 

Detach screws 1.



Use the eccentric 3 to slacken the toothed belt 2.



Replace the toothed belt 2. When replacing the toothed belt, it might be useful to remove the rollers 4.



To reassemble, reverse the order of the above steps.

Measurementt point 1 Measuremen 2 3

1

Pretensioning Pretensioni ng the drive belt in the wire drive

Measurement point 1: Measurement point 2:

4 2 3

Measurementt point 2 Measuremen

Frequency 170 ± 10Hz Frequency 240 ± 10Hz

1 fig 10.06 Belt drive

The toothed belts must be in fully open position during tensioning.

Replacing the drive belt: 

Remove the entire entire transport unit.



Detach screws 1 (4 screws).



Turn the screw 3 to slacken the toothed belt 2.



Remove the motor 4.



Replace the toothed belt 2.



To reassemble, reverse the order of the above steps.

2

3

Pretensioning Pretensioni ng the drive belt

Frequency 130 ± 5Hz

10 – 8

1

Measurementt point 1 Measuremen

4 fig 10.07 Transport unit



10.2.2.1.3 Replacing Replacing the drive belt for the swivel head on side 1 and side 2 Side 1 Remove the sheet metal cover from the swivel unit. Loosen screwed connections 1 (setting screws); then loosen socket-head cap screws 2 and move the motor unit to underneath the cover 3. Loosen the two socket-head cap screws 4 on thrust bearing 5 and remove the thrust bearing. Disconnect the pneumatic hoses from the gripper. Remove clamp; lower sensor cables 6 and take out the pull-off. Loosen the four socket-head cap screws 7 on the terminal panel and remove the panel. Change the belt. To reassemble, reverse the order of the above steps.

6

4

5 7 2

3 1

Initial stress of the drive belt, side 1 Frequency: 250 +/-10Hz

fig 10.08 Toothed belt for swivel unit, side 1

Exercise great care when laying the sensor cable and the pneumatic hoses.

Side 2 Remove sheet metal cover 1 from the swivel unit on side 2. Loosen screwed connections 2 (setting screws); then loosen the socket-head cap screws 3 and shift the motor unit. Loosen the two socket-head cap screws 4 on thrust bearing 5 and remove the thrust bearing. Disconnect pneumatic hose 6 from the gripper. Remove clamps 7; lower the sensor cable 8 and take out the pull-off. Loosen the four socket-head cap screws 3 on the terminal panel and remove the panel. Change the belt. To reassemble, reverse the order of the above steps. Initial stress of the drive belt, side 2 Frequency: 250 +/-10Hz


1

3

2

6 5 8

7

4

fig 10.09 Toothed belt for swivel unit, side 2


10 – 9

10.2.2.1.4 Replacing the drive belt for the cutting head 

  



 





 

Remove the sheet metal cover from from the cutting head. Detach the pneumatic hose from from the valve. valve. Pull out sensor cables and remove remove clamp. Turn socket-hea socket-head d cap screw 1 to loosen stepping-motor connecting plate. Release belt tension by detaching detaching sockethead cap screw 2. Remove thrust bearing 3. Remove stepping motor unit 4 and set aside in safe place. Remove the entire cutting cutting head by detaching socket-head cap screw 5. Remove both side panels (four socket-head socket-head cap screws on one, eight on the other) 6. Change belt. To reassemble, reverse the order of the above steps.

2

4

1 5

3

6 fig 10.10 Drive belt for cutting head

Initial tension of the drive belt for the cutting head Frequency: 295 +/-10Hz

Be careful of the SM cable when installing the stepping motor.

10.2.2.2 Operating problems associated with toothed belt drives Type of error

Cause

Remedy

Excessive running noises

Excessive Excessiv e belt tautness

Reduce initial stress

Gear wheels are not aligned

Align gear wheels

Abnormal wear wear on the loaded tooth flank of the belt

Incorrect belt tension

Correct tension

Excessively rough surface on toothed Excessively pulleys

Polish or replace the toothed pulleys

Abnormal wear in the gullet of the the belt teeth

Excessively taut belt

Reduce tension

Defective toothed pulleys

Replace the toothed pulleys

Abnormal wear an the lateral flanks flanks of the belt

Sha haft fts s ar are in inco corrrec ectl tly y ali align gne ed

Res esto torre th the pa paral alle leli lity ty and ali lign gnm men entt of the shafts

Flanged wheels ben and / or have rough surface

Replace the flanged wheels

Shaft bearings give

Replace bearing

Belt is broken or belt teeth are sheared off

Air contains acids or corrosives corrosives

Use a suitable suitable belt grade

Apparent elongation elongation of belt belt

Reduce the distance between shafts by loosening the shaft bearings or toothed pulley fixture

Reset the distance between shafts and check the fixture

Excessive heating of the toothed belt, Excessive the toothed pulley or the bearings

Check the heat being transferred from the motor

Init In itia iall str stres ess s is to too o hi high gh or to too o lo low w

Adju Ad just st th the e ini initi tial al st stre ress ss

Excessive destruction from outside particles

Use a toothed belt cover

Subject to heavy oil sprays

Shield the belt from oil spray

Premature Prematur e wear of belt

Bulge in back of belt

10 – 10



10.2.3 Setting the guide for the pull-off unit on side 2 The pull-off unit is set and checked at the factory factory.. There is no maintenance cycle for adjusting the guide. A collision between the gripper arm and a tool, for for example, could cause an undesirable amount amount of play between the two guides.

If there is any play in the guides, they must be readjusted immediately!

10.2.3.1 Positioning the toothed rack (user side)  

Loosen clamp 1 so that wire 2 is exposed. Detach the the flag (small bracing angle) from from the pull-off sensor.

2

1 fig. 10.11



Loosen the the three socket-head cap screws 3 on each side.

3

3 fig. 10.12 

 

The pull-off unit 4 must be mounted level with the two guides 5. Center the roller cages 6. Positioning the rack: - Press the rack against the pull-off unit and rack applying steady pressure (see fig. 10.10). - Distribute any play equally on both sides. - Apply more pressure to the two ends of the rack than to the middle.

5

6

4

fig. 10.13



10 – 11



Slightly tighten tighten screws screws in the the order shown 7, 8 and 9.

8

7

9

fig. 10.14

10.2.3.2 Positioning the counter guide (at the back) 

 



The pull-off unit 4 must be positioned level with the two guides 5. (See Chapter 10.2.3.1 for more information.) Center the roller cages 6. Positioning the guide: Press the guide against the pull-off unit, apply uniform pressure to it. Make sure there is no play. Apply more pressure to the two ends of the guide than to the middle. Slightly tighten the screws in the order shown 10, 11 and 12.

11

10

12

fig. 10.15

10.2.3.3 Final step and setting-check 

Tighten all six screws to 8Nm using a torque wrench 13.

13

fig. 10.16

10 – 12





Check the pull-off unit for flank play, i.e. make sure there is no play in the rack when it is moved backwards and forwards.. forwards..

fig. 10.17



Check the pull-off unit for lateral play, i.e. make sure there is no play in the rack when it is moved from one side to the other.

fig. 10.18

At this point all play play should be eliminated. eliminated.

After adjusting the guides, guides, you must recalibrate recalibrate the the machine! For information on the procedure, see the next chapter.



10 – 13

10.2.4 Calibrating the machine 10.2.4.1 Calibrating the axes (mechanical) If you notice after a reset, for example, that a swivel unit is no longer perfectly flush with the cutting head or a sensor or hybrid light barrier is out of position, you must recalibrate the machine.

2

1

1 Calibration bolt for side 1 2 Calibration bolt for side 2

fig. 10.19 Calibration gauge

To calibrate the machine, you must remove the upper and lower blade blocks and install the calibration gauges in their stead.

fig 10.20 Inserted calibration gauge

During the calibration procedure, each motor axis is approached individually and at a reduced speed; make sure no one can reach into the hazardous area.

10.2.4.2 Calibrating the axes under TopWin Procedure:     

Open cover. Switch off load voltage. voltage. Switch on load voltage. Go to Settings/Configurati Settings/ Configurations ons in TopWin and activate Adjust Machine. With guidance from from the software software assistant, carry out the calibration and save all values. values.

10 – 14



10.2.4.3 Calibration procedure

Start calibration Position pull-off unit 1

Remove blades Position swivel unit 2

Insert calibration gage Position pull-off unit 2

Position blade axis (Clamped up to gage)

Draw back pull-off unit 1+2 (Stop)

Save new calibration data

Remove calibration gage

Position swivel unit 1 Insert blade block

End of calibration



10 – 15

Check to see if the hybrid light barrier on the cutting head is operating properly: The light barrier switches on (diode goes out) when the basic position (calibration position) is reached. To To see the switching of the diode, you must look underneath the covering. The basic position should be reached when the calibration gauge is clamped in by the upper and lower guide rods (fig 10.20). If this is not the case, it means the sensor on the large pinion is out of position.

Check to see if the inductive sensors are operating properly: Make sure the sensor is not acting as a stop.

The sensor gap is as follows: Aluminum: 0.5–0.7mm or 30% of nominal switching distance (sn=2mm) Steel: 0.5–1.5mm In general, the sensor must be damped (diode not lit up) before it reaches its end position. This means there is no contact with the calibration gauge. If there is, the sensor or sensing element (cutting head) can be shifted accordingly.

The following sensors must be checked in the order listed:

Sensors for the stepping motor axes: hybrid light barrier BM1 blade axis BM2 pull-off axis side 2 BM3 pull-off axis side 1 BM4 swivel axis side 2 BM5 swivel axis side 1

10 – 16


Other sensors: inductive sensors (Namur) B10 lowering side 1 B11 lowering side 2 B12 gripper side 2 B13 lifting device B14 gripper side 1 B16 wire trough


10.2.5 Wire feed unit 10.2.5.1 Gamma 333 PC The distance between the wire tr ansport rollers should be 0.2mm. You can adjust this distance by turning screw 1. After making the adjustment, make sure that you retighten counterscrew 2.

0.2mm 3

1

2

1

2

fig 10.21 Distance between rollers in drive

Roller pressure

Adjust the roller roller 3 (fig 10.21) pressure by turning screw 4. Lock screw 4 using the lock screw 5.

4 5

16.5mm

4 5

fig 10.22 Adjusting the roller pressure



10 – 17

10.2.5.2 Gamma 333 PC-B Encoder You must adjust the applied pressure and the end stop if the encoder makes measurement errors or if you are processing special wires.

3

4

Adjust the applied pressure pressure by turning screw screw 1 (tightening = increases pressure, loosening = lowers pressure). Adjust the end stop of of the encoder by turning screw 2 so that a gap of 0.2-0.5mm exists between wheel 3 and 4.

1

2

fig 10.23 Adjusting the encoder

Always have the belt-driven belt-driven wire wire drive closed when making adjustments. adjustments.

10.2.6 Lifting device The height of the unit can be adjusted by turning the two screws 1. The distance between the gripper jaws, when closed, and surface 2 must be 1mm.

1

1

Final position damping of cylinder Up 3 Valve Val ve open

2

Down 4 Valve Val ve open approx. 1/2 turn

3

4 fig 10.24 Lifting device

10 – 18



10.2.7 Wire guide gripper  







1

Reset side 1 of machine. Remove the waste container container and detach the screws on the wire guide gripper. Adjust the lateral play, making sure the play on both sides of the wire guide gripper is the same. Set the wire guide guide gripper (gripper (gripper jaws 1 ) at the same height as the guide tube. Tighten screws and re-install the waste container.

fig 10.25 Wire guide gripper

The jaws of the wire guide gripper can cause injury. Be extremely careful when handling them.

Closing the wire guide gripper You close the wire guide gripper from the software. To do so, go to the Tools menu and select ‘BIO-Debug.’ BIO output no. 2 (arrow) closes the wire guide gripper.

fig 10.26 Inputs/outputs on the BIO card



10 – 19

10.2.8 Conveyor belt To prolong the service life of the conveyor belt, make sure the belt tension is correct and that the belt has minimum contact with the flanges of the deflection rollers, the end shields, and covers. 

Replacing the conveyor conveyor belt

Remove lifting device 1.

1

6

4

6 7

Remove cylinder fork head 2 from tipping tray 3. Remove hand guard 4. Remove tipping tray 3 along with skirt 5 by unscrewing the three screws 6. 3

Remove ramp 7. Remove sheet-metal guard 8.

5

2

Loosen the conveyor belt by turning threaded rods 9. Remove conveyor belt 10 by pulling it out the front of the device. Make sure the axes of the drive and deflection rollers are parallel in terms of alignment and in the horizontal plane.

fig 10.27 Changing the conveyor belt

To reinstall, reverse the order of the above steps. Pull new conveyor belt onto the rollers. 

Adjusting the belt tension

8

Adjust the tension tension of conveyor belt 10 with the two threaded rods 9. 9

The belt should be touching the section at the top and virtually touching it at the bottom. ca. 27mm 

Adjusting lateral running distance

fig 10.28 Threaded rod on the conveyor belt

Align rollers by turning turning each threaded threaded rod individually (the belt is started in the single-step menu). Make sure you always retighten the lock nuts. Switch the machine back on and check the settings and adjustments while the belt is in motion.

10

Then turn off the machine and attach the covers. fig 10.29 Conveyor Conveyor belt touching section

10 – 20



10.2.9 mci 711 options Please refer here to the operating instructions for the mci 711.

10.2.10 Safety cover

fig 10.30 mci 711 crimping module

You must adjust the pressure-operated switch to prevent machine damage from occurring when the safety cover is opened and closed. 

Unscrew the setting screw on the pressurepressureoperated switch; the pressure-operated switch does not respond.



Set the cover switches switches S01, S01, S02 2 with cover closed; the starting roller (switch) is at the very top of the column hole.

2

3

Adjusting end position position dampening 3 in the cylinder: Opened 1/2 turn at top Opened 3/4 turn at bottom 

Adjust pressure-operate pressure-operated d switch 1 while cover is closing; repeat this procedure as often as necessary until the pressure-ope pressure-operated rated switch triggers the reverse function itself when the limit value is reached.



Unscrew setting setting screw for the pressure-operated switch by 1/4 turn.



Then check whether the safety cover is functioning properly.



Default setting for the limit switch 4 The basic setting of limit switch four must be 4mm. Adjust whenever a new switch is installed.

m m 4

4

1

10.31 Pneumatic unit on safety cover

When closing the safety cover, make sure no one can reach into the machinery, otherwise he or she might get pinched!



10 – 21

10.3 Electrical settings and adjustments BEFORE working on any electrical parts throughout the system, ALWAYS turn off the main switch on the machine and secure it against unauthorized switch-on. It is hazardous to touch live parts!!

All settings and adjustments adjustments must be carried carried out by persons persons trained and authoriauthorized to do so.

For current country voltages, please refer to annex in the attached I/O list (Article Number 0025246).

10.3.1 Sensors Be very careful when wiring the sensors; incorrect handling is a frequent cause of sensor cable failure. Observe the following points to avoid problems: 

 

Lay the wires carefully carefully along along the hose, hose, i.e. make sure cables are not squeezed by sharp objects; when changing the direction of cable, do so using a U-shaped loop. Do not pull or strike the the cable and protect it from being pulled pulled or struck. Make sure nothing is rubbing against any part of the cable.

10.3.1.1 Laying sensor cables Side 1 



1

The sensor cable for the lowering sensor 1 must have a strain-relief device on it. The sensor-cabl sensor-cable e and air tubes 2 must run parallel to each other at the base. Do not allow them to cross each other.

2

10.32 Overview of side 1

10 – 22



Side 1 in pull-off position 



The sensor sensor cable for for the pull-off pull-off sensor 3 must not be allowed to touch the safety cover in any position. Check the the angle of the fastening clip 4. The sensor cable should only touch the stationary sheet-metal part.

3

4

10.33 Side 1 in pull-off position

Side 1 in 90° position 



The sensor sensor cables for for the sensor sensor lowering/ sensor gripper and air hoses form a uniform arc 5 and are laid parallel to each other. Make sure the sensor sensor cable cable 6 touches nothing when lowered.

6 5

10.34 Side 1 in 90° position



10 – 23

Side 2 

7 8

Make sure the sensor sensor cables cables 7 do not touch the air hoses 8.

9 fig 10.35 Side 2 from above



The side sensor cable 9 for the pull-off sensor must be strain-relieved. Make sure it is strain-relieved in all positions. 9

fig 10.36 Side 2, side view 1



Make sure the sensor sensor cables cables 10 do not touch each other when they are being lowered.

10

fig 10.37 Side 2, side view 2

Side 2 lower sensor 

The position of the sensor sensor cable shown here 10 is an optimum one for relieving strain on the connector plug.

11

10.37 Side 2 in 90° position

10 – 24



10.3.1.2 Inductive sensors 1

Inductive sensors are sensitive, non-contact electronic switches. To ensure that sensor 1 works properly, the distance to switching plate 2 must be exactly right. If it is too small, i.e. if it touches the switching plate, the sensor will be destroyed. If it is too large, switching errors will occur. x Setting

2

Detach the sensor and replace if necessary. necessary. Use a screw-pitch gauge to set switching distance x. Then retighten the sensor. The sensor distance is as follows: Aluminum: 0.5 -0.7mm or 30% of nominal switching distance ( sn=2mm ) Steel: 0.5 - 1.5mm

fig 10.38 Inductive sensor

10.3.1.3 Hybrid light barriers The Komax Gamma 333PC / 333 PC – B has several photoelectric, or light, barriers (see pages 6 12) and an encoder. encoder. Do not allow dust or foreign objects to cover the slits for the transmitting and receiving diodes. The photoelectric barriers are factory set.



10 – 25

10.3.2 Electric fuses in control cabinet If the current in an electrical circuit exceeds the admissible value, the power supply is cut off by a fuse to ensure the safety of humans and the machine. The Komax Gamma 333 PC / 333 PC – B has the following fusing: Circuit breaker (fig 6.40, Item 12)

The circuit breaker can be reused after being tripped. It has two trip devices, a magnetic tripper which responds to a short circuit and a bimetal tripper which responds to an overload. If the circuit breaker is tripped by a power overload, it cannot be reactivated until the bimetal trip device has cooled off. To To reactivate, push the lever up. This is the main fusing device for the machine. 1 Fine-wire fuses (fig 10.39) These fuses melt in the event of an overload and must be replaced. Remove the fuse from its holder, check to see if the wire is melted and replace with a fuse of exactly the same type and rating.

1

fig 10.39 Miniature circuit breakers and fine-wire fuses

Be very careful never to install a stronger fuse or to switch around „slow“ and „fast“ fuses. Otherwise, the safety of the machine and its operators can no longer be guaranteed!

Fuses must never be repaired or bridged.

Fuse list Designation Fuse for

F01 F02

F03 F06 F07 F08 F09 F18 A65/F1 A01/F1 A01/F2 A04/F1

10 – 26

Type

Installation Installat ion site

Circuit breaker breaker 3×16A Delta drive 3×210 VAC (333 PC) 3×3.15AT Delta drive 3×210 VAC (333 PC – B) 3×5AT Stepping motors 3×92 VAC 3×5AT Power supply 230 VAC 6.3AT SM power supply cards 130 VDC 5AT 5AT Control circuit contactors 120VAC contactors 120VAC 0.5AT (220V) Power supply 24V 8AT Conveyor-belt Conveyor -belt motor protectingprotecting- 1.6-2.5A switches 2.5-4.0A MRS card 5AT 5AT Input BIO card 2AT 2AT Output BIO card 6.3AT RCS card 1.6AT Settings and adjustments

Small mounting plate Large mounting plate (X02) plate (X02) Large mounting plate (X02) plate (X02) Large mounting plate (X02) plate (X02) Large mounting plate (X02) plate (X02) Large mounting plate (X02) plate (X02) Large mounting plate (X02) plate (X02) Large mounting plate (X03) plate (X03) Large mounting plate (X02) plate (X02) MRS BIO BIO RCS

(A03) (A01) (A01) (A04)


10.3.3 BIO PCB The BIO card has dynamic inputs/outputs for use in various applications and options. During input/output configuration, configuration, either the MRS PCB window or the BIO PCB window will appear appear,, depending on whether an MCI module or some other processing station was selected. 2

3

4 7

5

6

8

1

9

10

12 11

17

16

15

14

13

fig 10.40 Layout of the BIO PCB

1 2 3 4 5 6 7 8 9 10

Inputs Connection to RCS PCB Connection to MRS PCB Never plug in Analog inputs Pressure regulator output Splice detection 2 Connection pneumatic valves Outputs Relay outputs


11 12 13 14 15 16 17

Fuse F1 IN Fuse F2 OUT Power feed to BIO PCB (X25) Power feed to RCS PCB (X27) Power feed to expanded BIO PCB Connection for expanded BIO PCB Jumper for optional splice detection unit (Depicted: splice detection not activated)


10 – 27

18

fig 10.41

Select the menu item marked with an arrow in fig 10.38 and window opens with an illustration of the BIO PCB (fig 10.41). If an input/output is functionin functioning g correctly, correctly, a dot lights up at terminal panel 18. This can occur manually or by entering a prescribed repetition interval. You can activate the pneumatic valves at their connector 19 by clicking on the corresponding output.

19

fig 10.42 BIO PCB as depicted in TopWin software

10.3.4 Output stages of the stepping motors

LED 1 LED 2 LED 3 LED 4 LED 5

green red red red red

indicates correct operation indicates short-circuit between two motor phases indicates excess temperature on heat sink (>75°C) indicates excess voltage in braking mode (>140V) indicates undervoltage (<80V)

DIP switches The DIP switches must be OFF! Selection dial for motor phase current (refer also to I/O list) M01 M02 M03 M04 M05

blade axis pull-off axis side 2 pull-off axis side 1 swivel drive side 2 swivel drive side 1

position D position D position D position D position D

fig 10.43 Components of output stage

10 – 28



The output stages are all interchangeable.

Installation location location of the output stages: 1 2 3 4 5 6

blade axis pull-off axis side 2 pull-off axis side 1 swivel drive side 2 swivel drive side 1 stepping motor controller

1

2

3

4

5

6

fig 10.44 Output stages in the control cabinet



10 – 29

10.4 Pneumatic settings and adjustments

1

10.4.1 Operating pressure The operating pressure of the machine is set with the pressure regulating valve 1 to p=6 bar bar..

fig 10.45 Maintenance unit with pressure regulating valve

10.4.2 Throttle non-return valves These valves are utilized to regulate the flow of exit air with double-action cylinders. Changing the amount of air changes the piston speed. Throttle screw 1 regulates the air quantity.

2

2 Lock nut 1

fig 10.46 Throttle non-return valve

Please note that both throttle non-return valves 1 must be closed on side 2. 1

Direction of installation

fig 10.47 Direction of installation for throttle non-return valve

The throttle non-return valves integrated in the pressure regulating valve for the wire grippers on side 1 and side 2 must be closed.

10 – 30



10.5 Setup of processing stations You can position the processing stations from the TopWin user interface using setup gages.

10.5.1 Crimp module setup To align the wire with the station, go to the configuration menu and click there on the station you wish to set up. Then follow the wizard’s instructions.

fig 10.48 Selecting a module

The gage 1 is put directly on the tool mount 2. After the setting is correct and the gripper gripper is pressed down, the wire must sit neatly in the notch and lie at the gage stop.

1

2 fig 10.49 Crimping press



10 – 31

10.5.2 Setup of mci 761 seal module To align the wire with the station, go to the configuration menu and click there on the station you wish to set up. Then follow the wizard’s instructions.

fig 10.50 Selecting a module

Move the loading head forward and remove the lower expanding sleeve. Mount the setup gage for the seal module in its place and move the loading head back.

fig 10.51 Mounting the setup gage

The seal module is correctly positioned if the wire is neatly in the notch and lies at the rear gage stop.

fig 10.52 Aligning a module

10 – 32



10.5.3 Setting up non MCI modules Non-MCI modules can be set up from the software, just like MCI modules. Go once again to the configuration menu menu and select the desired station. Align the wire to the applicator in the positioning window, just as you would for an MCI module. When you click inputs/outputs, however, the BIO card appears instead of the MRS PCB. You must now activate the corresponding connections on the BIO card based on whether or not you want the processing stations wired in the control cabinet (for module wiring, see electrical diagrams). Non available connections are crossed out.

fig 10.59 Example: installing a Komax 106 wire feed system



10 – 33

10.5.4 MRS PCB

Due to the special pin assignment, you must use RJ45 cables with yellow caps from Komax. Incorrect cables will destroy the transmitter and receiver!

NEVER plug RJ45 cables in or out while the load voltage is on. If you do so, the software will crash immediately and you will have to restart the PCC card in the PC by pressing the reset button.

The MRS PCB offers an easy means of connecting the various MCI modules. Standard assignment of channels: CH0 Motor controller Delta drive CH1 SMC CH2 Seals module mci 761 side 1 CH3 Crimping module mci 711 side 1.1 CH4 Reserved CH5 Crimping module mci 711 side 1.2 CH6 Reserved CH7 Crimping module mci 711 side 2 CH8 Reserved CH9 mci 781 side 1 CH10 mci 781 side 2 CH11 Double gripper module CH12 Reserved CH13 BIO PCB CH14 RCS connection

The channels 0, 1, 12, 13 and 14 have preassigned uses and may not be used for MCI modules. 1 2 3 4

Power feed 24VDC Fuse 5AT Connection PCC card A Connection PCC card B

Standard mci 711 side 2

4

2 Standard mci 711 side 1

1 Standard mci 761 side 1

3

fig 10.60 MRS PCB

10 – 34



15. Putting the machine out of operation, storage and disposal 15.1 Putting the machine out of operation Proceed as follows to put the machine out of operation:     

Switch off off the main power switch to the machine. Close the safety covers. Disconnect the machine from the power supply. Disconnect the machine from the compressed air supply. Make sure that that no liquids can escape escape from the machine machine (e.g. flux).

15.2 Storage When putting the machine into storage for an extended length of time, keep the following points in mind:  

 

Put the machine machine out of operation as as described in Chapter Chapter 15.1. The criteria for the storage storage location are the the same as those for the installation installation site (floor (floor properproperties, space requirements, ambient conditions, see Chapter 5.1). Protect the machine machine from from dirt. Protect the machine machine from corrosion corrosion (dry rooms, no no direct sunlight). sunlight).

15.3 Disposal Most materials from which the machine is made (metals, plastics) can be recycled. To dispose of

15. Putting the machine out of operation, storage and disposal 15.1 Putting the machine out of operation Proceed as follows to put the machine out of operation:     

Switch off off the main power switch to the machine. Close the safety covers. Disconnect the machine from the power supply. Disconnect the machine from the compressed air supply. Make sure that that no liquids can escape escape from the machine machine (e.g. flux).

15.2 Storage When putting the machine into storage for an extended length of time, keep the following points in mind:  

 

Put the machine machine out of operation as as described in Chapter Chapter 15.1. The criteria for the storage storage location are the the same as those for the installation installation site (floor (floor properproperties, space requirements, ambient conditions, see Chapter 5.1). Protect the machine machine from from dirt. Protect the machine machine from corrosion corrosion (dry rooms, no no direct sunlight). sunlight).

15.3 Disposal Most materials from which the machine is made (metals, plastics) can be recycled. To dispose of the machine, proceed as follows:  





Put the machine machine out of operation as as described in Chapter Chapter 15.1. Disassemble the machine, machine, sorting the parts by material; material; have these materials transported transported to the appropriate recycling centers. Electrical and electronic electronic components, components, particularly PCBs, monitors, monitors, etc. must be properly disposed of. It is recommended that that you involve companies companies specializing in this type of waste in the the disposal process.

The machine operator is responsible for ensuring that the machine and the materials used in its operations are disposed of in a proper and environmentally friendly manner. Make sure you comply with with the national and local local legal regulations regulations regarding regarding waste disposal. disposal.


15 – 1

15 – 2


0026215_4_BA_Gamma_333_PC_PCB_EN

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