User & Maintenance Manual (original) Type: IMPORTANT Carefully read this User Manual and follow the instructions and warnings before operating the machine. Any modification or change may cause the loss of warranty and manufacturer liability. This Manual should always be stored ti the machine and visible for operators and maintenance technicians for any future reference. The Manual is part of the machine. 1
Index: -.EC Declaration of Conformity:... 3 -.Transport and unloading of the machine:... 4 -.Dimensions and weight:... 5 -.Set-up and connection:... 6 -.Description:... 7 -.Technical features:... 7 -.Instructions for Use:... 8 -.Safety systems and messages:... 10 -.Functions of the main MENU:... 11 -.JOB:... 12 -.MANUAL:... 14 -.NEW:... 15 -.MEMORIES:... 20 -.CONFIGURATION:... 21 -.Preparation:... 22 -.Die change:... 24 2
-.EC Declaration of Conformity: We declare under our responsibility that this machine: - Type: - Brand: ERM Engineering -Model: PAF-200 - Serial number: 810034 - Manufactured in: 2016 Complies with all essential safety and health requirement of the European Directive: 2006/42/CE Complies with the technical and design and construction specifications of the following European Norms: EN ISO 12100-1 EN ISO 12100-2 EN 60204-1 EN ISO 13250 EN ISO 13857 EN ISO 14121-1 Technician: Eduardo Ramos Martínez Arenys de Munt (Barcelona) July, 2016 3
-.Transport and unloading of the machine: Given the fragility of some components of the machine, it needs a wooden crate with reinforced platform for attachment to the base by bolts in the holes of the rubber feet. With the aim of keeping the weight well balanced, we recommend moving the die head halfway before packing the machine up. In case of maritime transport, the linear guides and the driving spindle located in the lower section of the cutting head need to be lubricated and totally covered with a plastic sheet. We will place the four rubber feet and level the machine. 4
-.Dimensions and weight: Total weight: 485 kg Dimensions: 2738x725x1495 mm 5
-.Set-up and connection: Compressed air supply with a pipe, inner diameter 8 mm minimum, connected to the input jack. REMARK: Please take into account that the air consumption of this punching machine is 180 litres/minute Connect the power cord of the control panel to 230 v single phase. REMARK: We recommend that the two air and power supplies are hung from the top, to prevent operators tripping or falling. We will connect the power cord of the vacuum cleaner to the socket of the power panel. 6
-.Description: Pneumatic punching machine with powered head to cut holes in conveyor belts, with step-bystep powered balls spindle and positioning control Pressure and punching time control Interchangeable cutting heads for different cut diameters, with the possibility to program diverse movement steps Motorized rollers for the belt s movement This punching machine has been specially designed for cutting thermoplastic materials with interior tissue. -.Technical features: Dimensions 2738x725x1495 mm (l x w x h) Weight 485 kg Max. thickness 8 mm Voltage 1 x 230 Power 3.7 kw Max. pressure 6 bar Conveyor width 2000 mm Feed speed 1 meter/minute 7
-.Instructions for Use: WARNING: THIS DEVICE INVOLVES THE RISK OF HANDS AND ARMS BEING TRAPPED DUR TO THE MOVEMENT OF THE CUTTING HEAD. CAUTION SHOULD ALSO BE EXERCISED BETWEEN THE CUTTING HEAD AND THE SUPPORT PLATE TO AVOID THE RISK OF CUTS. - Once the machine has been connected to the power network and provided with air, we can start the machine with the general switch of the control panel. Then, press the blue SYSTEM RESET button. If not reset, we will see that the emergency stops are unlocked and we will read the alarm messages shown on the screen to deactivate them. 8
We shall verify that the regulator pressure is between 2 and 4 Bar, depending on the cut diameter TÍTULO set-up DEL and DOCUMENTO the belt thickness. 9
-.Safety systems and messages: This punching machine is equipped with the following safety systems: 1- EMERGENCY STOP This system allows performing a stop at any moment with the two buttons located on the upper and frontal panel of the power panel. We have to unlock the button and then press RESET to reposition the cutting head to its initial position. 2- SPINDLE DRIVE NOT POSITIONED This device prevents the cutting head from cutting if it is not positioned in its 0 starting point. Press on RESET on the screen in Operation Mode to reposition the cutting head to its starting point. 3- DOOR OPEN This device detects that one or two doors are not closed. To deactivate the device, close the door. 4- CYLINDER DETECTOR This device does prevent the movement of the cutting head, because it detects that the cutting cylinder is not raised. This can be due to lack of air or a detector error. To deactivate the device, supply the machine with air or replace the detector. 10
-.Functions of the main MENU: To program the punching machine, we need to know the different functions of the screen MENU: - JOB: Pressing on Job, the machine will show us the latest job loaded of the main memory used. This Job Menu will be always used to operate the machine in automated mode. - MANUAL: Pressing on Manual, the screen will show us the scheme of the machines with the elements that can be activated with the buttons shown. - NEW: Pressing on New, the screen will show us three possible geometries for punching. To select any of these three shapes, we can enter to pinpoint the dimensions and later save them in the memory or load them for a job. - CONFIGURATION: Pressing on Configuration, the screen will show us the time and measurement parameters of some commands which we can change. - SYSTEM: Pressing on System, the machine will require an user and a password to get access to other protected configurations. - MEMORIES: Pressing on Memories, the Memory Administrator will appear, allowing us to search, load, save or eliminate. 11
-.JOB: Once a memory or a NEW file has been loaded, the Job Screen will appear. - The Reference field will show us the name of the loaded memory; the field will be blank if it is a new file not saved in the memory. Should any ALARM appear, we shall read the alarm message clicking on the warning icon above this red alarm sign and act upon the incidence to deactivate it. 12
REMARK: IT IS ALWAYS RECOMMENDABLE TO PRESS THE RESET KEY BEFORE STARTING ANY JOB TO PUT THE GAUGES TO 0 AND POSITION THE MECHANISMS. Once the machine has been reset, press START/ON to start the job. We can stop the cycle at any moment pressing on STOP/OFF and re-initiating again with START/ON. This allows us stopping or pausing the cycle without losing the positioning memory of the drives,. WARNING: IF A PROTECTION DOOR IS OPENED OR THE EMERGENCY BUTTON IS PRESSED DURING OPERATIONS IN AUTOMATED MODE, THE POSITIONING VALUES WILL BE LOST AND WE HAVE TO RESTART THE JOB PRESSING ON RESET. On the screen we can see how far the belt has progressed, the position of the cutting head and the number of rows punched. 13
-.MANUAL: In the Manual Mode, we can execute a punching test to adjust the pressure or the cutting time. To this purpose, we will feed the machine with a sample of the same material and, with the door closed, press on the cylinder key. The cylinder will operate with the gauge pressure and the time set in the configuration. In this Manual Mode, we can also position the belt at a precise measure with the pushbuttons of the feed drive. 14
When we move the belt, we can see the measurement, putting it at 0 and pressing on RESET ENCODER. We can also activate or deactivate the suction motor and the table displacement motor. -.NEW: When we select a new file, the three possible geometries will appear: 15
A TYPE: Punched holes aligned in one singe area B TYPE: Staggered or interspersed punched holes with one single area C TYPE: Staggered or interspersed punched holes with the possibility to program up to 5 different areas in the conveyor belt width A TYPE Enter the values in millimetres, pressing on each of them A1 distance from the belt border to the first hole B1 distance between holes NA number of holes in each row C1 distance between rows NC number of rows Once all values have been set, with can LOAD to start punching. The Job Screen will appear. We can SAVE the job, adding a name to the memory. We can ELIMINATE the job, if we want to erase the saved file. 16
B TYPE Enter the values in millimetres, pressing on each of them A1 distance from the belt border to the first hole B1 distance between holes D1 distance from the belt border to the first hole of the second row F1 distance between holes of the second row NA number of holes in the first row ND number of holes in the second row C1 distance between rows NC number of rows Once all values have been set, with can LOAD to start punching. The Job Screen will appear. We can SAVE the job, adding a name to the memory. We can ELIMINATE the job, if we want to erase the saved file. 17
C TYPE AREA 1 Enter the values in millimetres, pressing on each of them A1 distance from the belt border to the first hole B1 distance between holes D1 distance from the belt border to the first hole of the second row F1 distance between holes of the second row NA number of holes in the first row ND number of holes in the second row C1 distance between rows NC number of rows RENARK: IF THE PUNCHING HOLES ARE TO BE ALIGNED INSTEAD OF BEING STAGGERED OR INTERSPERSED, WE WILL ENTER THE SAME VALUES: A1 = D1 B1 = F1 NA = ND Once the AREA 1 has been programmed, press on the image on the right to accede to AREA 2 Introduce the values of AREA 2, taking into account that the values for A-1 and D-1have always to be considered as distance from the border of the belt. 18
EXAMPLE AREA 1 AREA 2 AREA 3 AREA 4 AREA 5 A-1 30 180 300 565 665 B-1 40 30 35 30 40 D-1 50 180 317.5 565 685 F-1 40 30 35 30 40 N-A 3 2 6 2 3 N-D 3 2 5 2 2 C-1 25 N-C? 19
-.MEMORIES: We can store in the Memory Administrator of the machine up to 25 memories. We can search these memories with the cursor located in the upper right of the quadrant. To work with any of these memories, simply click on LOAD once you see the memory on the screen; you can also modify the memory and save it with a different name. To erase an existing memory, click on ERASE. REMARK: TO SAVE A MEMORY, WE NEED TO ASSIGN A NAME TO IT. 20
-.CONFIGURATION: In the Configuration Menu, we can see and modify some parameters, depending on the job we want to execute. - Switch on interval of the suck drive Time in seconds during which the suck drive will stop - Time during which the suck drive will be switched in REMARK: THESE SUCK TIMES SHALL BE ADJUSTED DEPENDING ON THE PUNCHING HOLE DIAMETER AND ITS FREQUENCY. - Switch on time of the table displacement After completing each row, the nylon table will move some millimetres depending on this time set. This table movement makes cutting easier and ensures a homogenous wear of the table. This time will usually last 0.3 to 0.5 seconds. - Punching time This is the time during which the solenoid of the die is activated. It shall be adjusted depending on the thickness of the material and the punching pressure. - Batch end belt progress The progress in millimetres of the belt when a program or a sequence has been completed. 21
-.Preparation: To start a job, introduce the end of the belt to be punched on the right side of the machine, passing the belt below the hold-down bar. Ensure that the belt is properly placed on the wheel of the measurement encoder, completely tangential to the left guide of the table up to the drive rollers. Once the initial end has been introduced, adjust the two right guides to prevent the material from suffering any displacement. 22
Lower the pressure role with the manual lever valve to get it fixed, allowing belt progress in automated mode. If we have a starting reference, we will operate in MANUAL mode to advance or rewind the belt to the desired extent; then execute a ENCODER RESET to put the gauge to 0. REMARK: TO PASS THE BELT BELOW THE HOLD-DOWN BAR, THE MACHINE NEEDS TO BE RESET WITH THE BLUE BUTTON OF THE CONTROL PANEL. 23
-.Die change: To change the diameter for another with a different diameter, open the protection door and unwind the screw fixing the die (as shown in the picture below). Once the screw has been extracted, move the die to the right to remove it and place the new die. REMARK: AFTER DIE CHANGES, WE NEED TO ADJUST THE PUNCHING PRESSURE. 24