Boschert CU - PROFI Manuel utilisateur
1
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Operating instructions
Copper bar punching machine
CU - PROFI
These operating instructions:
– contain general and special instructions which must be complied with,
– contain technical instructions which must be observed when handling the machine,
– must be read by the responsible technical personnel or operator before setting up and
taking into use,
– must be continuously available at the installation site of the machine.
Retain for future use!
2
Tel.: + 49 / 07621 / 95 93 0
Fax: + 49 / 07621 / 55 184
www.boschert.de
Mattenstrasse 1
79541 Lörrach-Hauingen
BOSCHERT
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List of contents
List of contents
0 General comments ..................................................................... 7
0.1 Introduction ......................................................................................................7
0.2 Contents of the operating manual ...................................................................8
0.3 Separate documents........................................................................................9
0.3.1 Separate documents........................................................................................9
1 Safety ........................................................................................ 10
1.1 The operating personnel................................................................................10
1.2 Clothing ..........................................................................................................10
1.3 Personal protective equipment ......................................................................11
1.4 Intended use ..................................................................................................11
1.5 Explanation of symbols and notices ..............................................................12
1.5.1 Symbols and notices on your machine .........................................................13
1.5.2 Dangers caused by non-compliance with the safety notices........................16
1.6 Safety-oriented working .................................................................................17
1.7 The safety installations ...................................................................................18
1.7.1 The positions of the safety installations on your machine.............................18
1.7.2 Individual safety installations .........................................................................19
1.7.3 Checking EMERGENCY-OFF button, interlock switch and light barrier........21
1.8 Follow the instructions below when erecting the machine ...........................21
1.9 Behaviour in case of danger ..........................................................................22
1.10 Dangers caused by electrical energy ............................................................22
1.11 Dangers caused by the hydraulic ..................................................................22
1.12 Dangers caused by noise emission...............................................................22
1.13 Dangers after switching off the machine .......................................................23
1.14 Reversal of the working motion in case of emergency! ................................23
1.15 Firefighting .....................................................................................................24
1.16 Other notices concerning dangers ................................................................25
1.17 Unauthorised conversion and manufacture of spare parts ...........................25
1.18 Special features of the machine ....................................................................25
1.19 Product surveillance.......................................................................................26
2 Technical data........................................................................... 27
2.1 Characteristic data .........................................................................................27
2.2 Machine data..................................................................................................28
2.2.1 Dimensions ....................................................................................................28
2.2.2 Weights...........................................................................................................29
2.3 Punching force ...............................................................................................29
2.4 Power rating ...................................................................................................29
2.5 Workplace ......................................................................................................29
2.6 Air supply .......................................................................................................29
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List of contents
2.7 Noise ..............................................................................................................30
2.8 Emissions .......................................................................................................30
3 Description ............................................................................... 31
3.1 Mechanical construction ................................................................................31
3.2 Designated utilisation.....................................................................................31
3.3 Operation possibility ......................................................................................31
3.4 Technical data ................................................................................................32
4 Transport and assembly .......................................................... 33
4.1 General notices ..............................................................................................33
4.2 Erection conditions ........................................................................................33
4.3 Planning the workspace.................................................................................34
4.4 Packaging of the machine .............................................................................34
4.5 Intermediate storage ......................................................................................34
4.6 Transport of the machine ...............................................................................35
4.6.1 Transport using a crane .................................................................................35
4.7 Set up the machine ........................................................................................36
4.7.1 Connection of the hydraulic-unit....................................................................37
4.7.2 Connection to the electrical network .............................................................37
4.7.3 Connection to compressed air ......................................................................38
4.7.4 Testing the machine connection ....................................................................38
5 Survey ....................................................................................... 39
5.1 Subassembly inlet side ..................................................................................39
5.1.1 Subassembly inlet side ..................................................................................40
5.2 Subassembly outlet side................................................................................41
5.2.1 Subassembly back side .................................................................................42
5.3 Subassembly outlet side................................................................................43
5.4 Roller table .....................................................................................................44
5.5 Y-axis ..............................................................................................................45
5.6 Tool box system .............................................................................................46
5.6.1 Tool box ..........................................................................................................47
5.6.2 Station AMADA - A .........................................................................................48
5.6.2.1 Reduction AMADA - B/A.................................................................................49
5.6.3 Station AMADA - B .........................................................................................50
5.6.4 Cutting station ................................................................................................51
5.7 Clamping arrangement work piece ...............................................................52
5.8 Punch head ....................................................................................................53
5.8.1 Position sensor...............................................................................................54
5.9 X-axis ..............................................................................................................55
5.10 Pneumatical tilting table .................................................................................56
5.11 Clamp .............................................................................................................57
5.12 Safety device ..................................................................................................58
5.13 Limit switch axis .............................................................................................59
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5.13.1 Limit switch Y-axis ..........................................................................................59
5.13.2 Limit switch X-axis ...........................................................................................60
5.13.3 Limit switch tilting table ..................................................................................61
5.13.4 Limit switch clamp..........................................................................................61
5.14 Limit stops axes .............................................................................................62
5.15 Sprayer ...........................................................................................................63
5.15.1 Spray assembly ..............................................................................................63
6 Setup of the machine ............................................................... 64
6.1 General information........................................................................................64
6.2 The operator´s control on the machine.........................................................64
6.2.1 The operator´s control on the control cabinet ..............................................64
6.2.2 The operator´s controls on the control desk.................................................65
6.2.3 The foot pedal for the hydraulic material clamping .......................................65
6.3 Preparation of the machine for punching ......................................................66
6.3.1 Providing a punching tool ..............................................................................66
6.3.2 Insert the die ..................................................................................................66
6.3.3 Installation of AMADA - Station ......................................................................67
6.4 Preparation of the machine for cutting ..........................................................68
6.4.1 Providing a cutting tool ..................................................................................68
6.4.2 Insert the die ..................................................................................................68
6.4.3 Insert the cutting punch .................................................................................68
6.5 Insert the CU-flat ............................................................................................69
6.6 Starting the machine ......................................................................................70
6.7 Stopping the machine....................................................................................71
6.8 Restarting the machine ..................................................................................71
7 Maintenance ............................................................................. 72
7.1 Maintenance and inspection..........................................................................72
7.1.1 General information........................................................................................72
7.2 Maintenance and inspection list ....................................................................73
7.3 Cleaning the machine ....................................................................................74
7.3.1 Auxiliary agents and their use ........................................................................74
7.4 Lubrication......................................................................................................75
7.4.1 Lubrication points...........................................................................................76
7.4.1.1 Lubrication points X-axis ................................................................................77
7.4.1.2 Lubrication points Y - axis..............................................................................77
7.4.1.3 Lubrication points punch head ......................................................................78
7.4.1.4 Lubrication point tool box ..............................................................................79
7.4.1.5 Lubrication points clamp ...............................................................................79
7.5 Corrosion prevention .....................................................................................80
7.5.1 Notes on corrosion prevention agents, oils and lubricants...........................80
7.5.2 Disposal of corrosion-preventing agents, oil and lubricants .........................80
8 Hydraulic................................................................................... 81
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List of contents
8.1 The hydraulic aggregate ................................................................................81
8.2 Oil change ......................................................................................................82
8.3 Assembly of the hydraulic unit .......................................................................83
8.3.1 Assembly of the tank cover............................................................................84
8.3.2 Assembly of the machine...............................................................................85
8.4 Hydraulic diagram ..........................................................................................86
8.5 Hydraulic - Parts list 614 04004 ....................................................................87
8.5.1 Spare parts list hydraulic hoses.....................................................................88
9 Pneumatik ................................................................................. 91
9.1 Assembly of the pneumatic unit ....................................................................92
9.2 Pneumatic diagram tilting table and sprayer 614 60013 ..............................93
9.3 Pneumatic diagram sprayer ...........................................................................94
10 Electronic .................................................................................. 95
10.1 Operating elements........................................................................................95
10.2 Control cabinet ...............................................................................................96
10.3 Electronic diagram .......................................................................................100
11 Drawings and lists.................................................................. 101
11.1 Subassemblys..............................................................................................101
11.2 Space required.............................................................................................102
11.2.1 Space required rollter table 3m ...................................................................102
11.2.2 Space required rollter table 6m ...................................................................103
11.3 Subassembly Roller race .............................................................................104
11.3.1 Parts list 614 02001 Roller race...................................................................105
11.3.2 Subassembly Roller race .............................................................................106
11.4 Subassembly Y - axis ...................................................................................107
11.4.1 Subassembly Y - axis - detail .......................................................................108
11.4.2 Parts list 614 05032 Y - axis ........................................................................109
11.5 Tool box ........................................................................................................111
11.5.1 Parts list 614 03021 Tool box ......................................................................112
11.6 Subassembly Tool ........................................................................................113
11.6.1 Parts list 314 03003 AMADA Station B........................................................113
11.6.2 Parts list 319 03001 Cutting station ............................................................113
11.7 Subassembly Clamping arrangement work piece ......................................114
11.7.1 Parts list 614 05035 Clamping arrangement work piece ............................115
11.8 Subassembly Punch head ...........................................................................118
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Tel.: + 49 / 07621 / 95 93 0
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List of contents
Important notes!!
- The machine corresponds to the present state of knowledge
and techniques and meets the recognised regulations for
technical safety,
- nevertheless danger can arise in the event of improper use or
use contrary to the regulations. (Use contrary to the regulations
also includes non-compliance with the operating instructions).
11.8.1 Subassembly Punch head - details .............................................................119
11.8.2 Subassembly Punch head - details .............................................................120
11.8.3 Parts list 614 03025 Punch head ................................................................121
11.9 Subassembly X-axis .....................................................................................124
11.9.1 Subassembly X-axis details..........................................................................125
11.9.2 Parts list 614 05033 X-axis...........................................................................126
11.10 Subassembly Tilting table ............................................................................128
11.10.1 Parts list 614 002002 Tilting table ...............................................................129
11.11 Subassembly Clamp ....................................................................................130
11.11.1 Parts list 614 05036 Clamp .........................................................................131
11.12 Subassembly Waste stripper .......................................................................133
11.12.1 Parts list 614 06007 ......................................................................................133
11.12 Subassembly Safety device .........................................................................134
11.12.1 Parts list 614 06005 Safety device ..............................................................134
11.13 Subassembly Hydraulic unit ........................................................................135
11.13.1 Parts list 614 04004 Hydraulic unit standard ..............................................136
11.13.2 Parts list 614 04003 Hydraulic unit speed ..................................................137
12 Spare parts management and after-sales service ............... 138
12.1 Spar parts management ..............................................................................138
12.2 Spare parts, spare parts graphics ...............................................................138
12.3 Address for spare parts and after-sales service ..........................................138
Notes on our products...................................................................... 139
7
Tel.: + 49 / 07621 / 95 93 0
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General comments
0 General comments
0.1 Introduction
These operating instructions are supposed to facilitate operation, maintenance and
upkeep of the machine for the respective operator. They are supposed to assist in
keeping the machine at a high level of performance during its long working life and to
contribute to accident prevention.
During maintenance and upkeep work on the machine:
- Safety regulations and
- Accident prevention regulations
have to be particularly observed.
The operating instructions constitute an essential part of the delivered item. The operator
of the delivered item ensures that the operating personnel are familiarised with these
guidelines. In case of a possible transfer of the delivered item the operating instructions
have to be passed on, too.
After termination of the assembly and prior to commissioning of the delivered item the
buyer has to arrange for the implementation of a trial run of the delivered item checking all
safety installations in order to make sure that the machine can be operated safely and
that the personnel are able to handle it proberly and securely.
The operator is obliged to adapt the delivered item to the respectively effective safety
regulations.
8
Tel.: + 49 / 07621 / 95 93 0
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Version: 05 / 2011Changes reserved
The L. Boschert GmbH+Co.KG. company reserves the copyright for this operating
manual, which is intended exclusively for use by the installation, operating and
monitoring staff. This operating manual contains technical instructions and drawings
which must not be copied, distributed or otherwise used for competition purposes
neither as a whole nor in parts nor communicated to others.
Violation of these copyright provisions will be prosecuted.
Copyright
0.2 Contents of the operating manual
Explanation
In this operating manual: OM = operating manual
Symbols:
- this stands before listed items,
* here, a sequence of work steps is explained
here, the consequence of a cause is explained.
General information
Orientation of the
machine:
front
left right
rear
9
Tel.: + 49 / 07621 / 95 93 0
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0.3 Separate documents
In the annex you will find documents prepared by third-party manufacturers. They
contain relevant information on supplied parts.
- We provide you with this OM; you will have to work with it.
- We have attempted to prepare this OM as comprehensive as possible. You’ll see
whether our efforts were successful. In your own interest, please inform us about
faults, wishes or proposals so that we may be able to optimise this operating
manual.
Thank you for your co-operation.
L. Boschert GmbH+Co.KG
P.O. Box 7042
D - 79523 Lörrach
Telefon: + 49 (0)7621 - 95 93 0
Telefax: + 49 (0) 7621 - 55 184
www.boschert.de
General information
- User manual for maintenance of AMADA-tools. AMADA
- Operating Instructions HPM MMKS series TC HPM
- High-pressure internal gear pumps Typ IPV Voith-Turbo
- DMA2 + DM1 Mounting + Maintenance Istructions Dutchi Motors
- Fluid Level Gauge FSA HYDAC
- Return Line Filter RFM HYDAC
- Accumulator Charging Unit SLE 02 H+L
- Data sheet Air-oil heat exchanger AP COSTANTE SESINO
- Safety valves direct operated Rexroth
0.3.1 Separate documents
10
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Safety
1.1 The operating personnel
The operator of the machine has to ensure that the
equipment is operated, maintained, inspected and
assembled/disassembled exclusively by authorised,
qualified and skilled personnel.
Authorized and qualified personnel are skilled employees:
- of the operator,
- of the manufacturer,
- of the service partner.
These persons must:
- have received practical training with the machine,
- have read and understood the operating manual,
- be familiar with the safety features of the machine,
- have been instructed about possible dangers,
- be familiar with the responsibilities to avoid unclear
responsibilities with regard to safety,
- be familiar with all relevant regulations (particularly the
accident prevention regulations to ensure that the
operation of the machine will cause no danger).
1.2 Clothing
The most serious injuries may result if clothes or
jewellery are caught by machine parts in motion.
During work, protect yourself by:
- wearing closely fitting working clothes with
waistbands on the sleeves,
- wearing sturdy, closed shoes,
- wearing a hairnet if you have long hair,
- taking off jewellery (rings, watches).
Danger
1 Safety
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