Chapter 2. TC 2020 R FMC compact installation conditions. Drawing number: EN Part number:

Transcription

1 Chapter 2 TC 2020 R FMC compact installation conditions Drawing number: EN Part number: B435EN02.DOC TC 2020 R FMC compact installation conditions - Version 2 2-1

2 Table of Contents 1. Installation site Space requirements Floor requirements Weight distribution Ambient conditions Electrical power supply Power supply network Notes on isolating transformers Connected loads, fuse protection Teleservice Network connection Pneumatic connection Operating utilities Hydraulic oil Filling the machine with hydraulic oil Filling the automation unit with hydraulic oil Lubricants for spray tool Modifying existing tool cartridges Using new multitools and tapping tools Machine transport Work to be performed by the customer TRUMPF service work Planning aid TC 2020 R FMC compact installation conditions - Version 2 B435EN02.DOC

3 Installation site 1.1 Space requirements The layout of the individual system components and the space required for standard installation are specified in the respective installation layout. Also indicated in the layout is the space required for opening the doors of the control cabinet. A custom installation layout is needed for non-standard system configurations. 1.2 Floor requirements Evenness The floor on which the system is installed must be as flat and level as possible. The variation in height across the area of the machine and the SheetMaster compact must not exceed 10 mm. Installation surface The entire installation surface for the machine and the SheetMaster compact must consist of one continuous plate beneath the load-bearing points and must have a smooth surface. This is particularly the case beneath the wedge mounts. Elastic base plate Minimum thickness 200 mm. Crosswise reinforcement 3.7 cm²/m, double-layered. Concrete quality (corresponding to tensile strength C 25/30): Cylinder compressive strength 20 N/mm². Ceiling plate/ free span base plate Effective load 15 kn/m². Minimum thickness 200 mm (with an effective load of 15 kn/m²). Concrete quality (corresponding to tensile strength C 25/30): Cylinder compressive strength 30 N/mm². Multiple span girder. If these specifications are not met, it is essential that a structural analyst carry out an evaluation. B435EN02.DOC Installation Site - Version 2 2-3

4 1.3 Weight distribution Structural stress analysis The load bearing capacity of the floor must be reviewed by a structural engineer prior to installation. The weights of the individual system components and the load at the support points are specified in the table below. Component Weight Distribution of weight Machine 1 Automation unit P1: 2850 kg (6282 lbs) P2: 2850 kg (6282 lbs) P3: 2850 kg (6282 lbs) P4: 2850 kg (6282 lbs) Empty: P5: 1500 kg (3250 lbs) P6: 1500 kg (3250 lbs) Loading: P5: 2725 kg (6000 lbs) P6: 2725 kg (6000 lbs) Weight support with 4 wedge mounts Weight support on 2 surfaces Control cabinet 500 kg (1100 lbs) Fringe area supports main load. Control panel 100 kg (220 lbs) Fringe area supports main load P1 P2 P5 P6 P3 P Fig In punching mode, the support points P3 and P4 bear an additional dynamic load of max kg (3300 lbs). 2-4 Installation Site - Version 2 B435EN02.DOC

5 1.4 Ambient conditions Ambient temperature An ambient temperature between +10 C and +40 C must be maintained for machine operation. For temperatures up to +45 C, a tropical cooling unit must be installed for the hydraulics. The temperature must not be allowed to drop below +4 C when the machine is off. Direct sunlight and drafts from one side should be avoided (uneven heat distribution) (e.g. use Venetian blinds if the system is installed near a window). Control cooling The control is cooled by means of internal ventilation in the housing. The components are thus well protected against dust and dirt. The heat from the control housings is normally dissipated by means of external heat exchangers with fans drawing in the air and blowing it along the cooling fins. Care must be taken to avoid excessive air contamination in the intake range of the fans behind the control cabinet since dust on the cooling fins reduces the cooling effect. Control panel cooling The control panel is cooled by means of two fans. Filter mats ensure that no dirt can enter the panel. B435EN02.DOC Installation Site - Version 2 2-5

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7 2. Electrical power supply The machine is designed for operation at the following nominal voltages: Nominal voltage Frequency 400 V ±10 % 50 Hz ±1 % 460 V +10 % / -5 % 60 Hz ±1 % An isolating transformer must be installed if the nominal voltage deviates from 400 V or 460 V, respectively. 1 A four-wire connection with copper cables is required for power supply to the system (L1, L2, L3, in clockwise phase sequence; PE (ground)). Mains connection at the machine switch cabinet must be made in accordance with the layout. Electrical power supply Regulation: Execution according to DIN EN /4.3.1 Power cable Cable Cross-section Ground conductor Regulation: 4-wire copper cable (L1, L2, L3, PE (ground)) According to VDE 0100 Part 430 (IEC ) According to VDE 0100 Part 540 (IEC ) 2.1 Power supply network Residual-current operated device Network configurations If a residual-current operated device is used on the supply side for protection against direct or indirect contact, only Type B devices are allowed. See EN Pt (VDE 0160, edition April 1998). If a residual-current operated circuit-breaker is used where the leakage current is greater than the fault current setting, an isolating transformer must be installed to separate the machine from the mains supply. See EN Pt (VDE 0160) In the case of IT and TT systems and asymmetrical networks (one phase grounded), the machine must be connected via an isolating transformer. 1 The line voltage tolerance must be determined if the nominal voltage is 380 V or 415 V at 50 Hz. No isolating transfomer is needed if the tolereance is between 360 V 440 V. B435EN02.DOC Electrical Power Supply - Version 2 2-7

8 Notes on isolating transformers The following must be observed if the machine is equipped with an isolating transformer: The power cables to the isolating transformer and from the transformer to the control cabinet of the machine can be routed into the transformer from the sides and from the rear (top and bottom) through PG 48 fittings. The power cables must be supplied and installed by the customer. The location of the transformer must be determined by the customer. Transformer dimensions: Length: 800 mm Width: 600 mm Height: 1200 mm When installing the transformer, assure that access through the door at the front (door with nameplate) remains clear. A safety clearance of 800 mm must be maintained. A minimum distance of 100 mm is required at the sides and at the rear. 800 mm 600 mm mm 2 1 Isolating transformer 2 Safety clearance Space requirements for the transformer Fig For information, please refer to the manufacturer s documentation for the transformer: Series transformer MD 30000, from Roller and Fischer, Mat. no.: This documentation is available in German, English and French. 2-8 Electrical Power Supply - Version 2 B435EN02.DOC

9 2.2 Connected loads, fuse protection TC 2020 R TC 2020 R TC 2020 R FMC compact with tropical cooling unit - hydraulic system (optional) Total connected load 22 kva 28 kva 32 kva 38 kva Max. fuse protection at 400 V / 50 Hz 35 A 50 A 50 A 63 A TC 2020 R FMC compact with tropical cooling unit - hydraulic system (optional) Max. fuse protection at 460 V / 60 Hz 35 A 45 A 50 A 60 A Max. permitted interruption of the nominal voltage See EN 60204, Part 1, Point 4.3.2, Alternating current supply. See EN 60204, Part 1, Point 4.3.2, Alternating current supply. See EN 60204, Part 1, Point 4.3.2, Alternating current supply. See EN 60204, Part 1, Point 4.3.2, Alternating current supply. 2.3 Teleservice The control cabinet of the machine is fitted ex works with the following interface: Interface for telephone connection (Telediagnostics) via an analog modem: RJ11 connector with telephone adapter for country-specific telephone outlet boxes (e.g. in Germany: TAE6-N adapter). The user must arrange for the following work to be performed: Installation of a telephone outlet box for an analog modem at the control cabinet of the machine by his telephone company. A digital connection must be converted into an analog connection by means of a converter. It must be possible to access the modem through a direct-dial extension number. If not, a separate line to outside will be needed. 2.4 Network connection The control cabinet of the machine is fitted ex works with the following interfaces for the network (programming system): BNC connector for customers with RG58 network cabling and RJ45 connector for customers with Shielded-Twisted Pair network cables. A Personal Hub (network distributor) is needed if several machines are linked to the network. This hub is located in the machine control cabinet and must be supplied with AC voltage by the user as the distributor function must be maintained even when the machine is OFF. Power must be supplied as described below: B435EN02.DOC Electrical Power Supply - Version 2 2-9

10 Power supply (except USA and Canada): 230 V with grounding outlet or in compliance with local regulations. Grounded coupling is supplied with the machine. Power supply in USA and Canada: 115 V with outlets in accordance with US standards. If a Personal Hub (network distributor) is installed, the tolerances for nominal voltage and frequency as stated under 2. Electrical Power Supply must also be observed in both power supply alternatives Electrical Power Supply - Version 2 B435EN02.DOC

11 3. Pneumatic connection Either flexible hoses or rigid pipes can be used for the pneumatic connection. Connections Connected pressure Minimum nominal diameter of lines 6-14 bar DN9 (3/8") Compressed air consumption approx Nm 3 /h The user must provide a filter-lubricator unit which ensures that the compressed air at the tapping point meets the following requirements: Characteristic Requirement Quality class ISO Free of condensate cooled to +7 C (press. dew point) Free of dust Max. particle size: 15 µm Action (recommendation) 4 Use a cold dryer 7 Use an air filter at the intake side Free of oil Max. particle density: 8 mg/nm 3 Max. oil content: 4 Oil-free compacting screw-type 5 mg/nm 3 compressor Compressor A suitable compressor must be installed if the compressed air supply is not adequate. Due to the risk of condensate build-up, the maximum distance between the compressor and the machine should not exceed 50 m. B435EN02.DOC Pneumatic connection - Version

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13 4. Operating utilities The customer must make arrangements to have the following utilities ready before the machine arrives: 4.1 Hydraulic oil The hydraulic oil should be initially examined by a lubricant laboratory after 5000 operating hours or after 2 years whichever applies first. After that, the hydraulic oil should be analyzed every 2000 operating hours or annually. Depending on the results of the test, an oil change may be necessary. If these intervals are observed, the oil should attain a life of up to 5 years. Recommended hydraulic oil Specification (as per DIN 51524) Quantity (liters) Filler port SHELL Tellus Oil DO 46 HLPD / ISO VG 46 max. 130 Hydraulic unit MOBIL DTE 25 B435EN02.DOC Operating Utilities - Version

14 Filling the machine with hydraulic oil The machine accessories include an oil pump with hoses and fittings for pumping the hydraulic oil from the oil drum into the tank of the hydraulic unit. A drilling machine is used to drive this pump. Caution Unfiltered oil in the hydraulic circuit will damage the hydraulic system! A filter of at least 10 µm fineness must be used when adding oil to the tank. When adding the oil and during operation, the oil-air filter element and the blue plastic fitting must remain in the return filter without fail! Failure to observe this will void all warranty coverage! To oil drum 5 Oil tank of hydraulic unit 2 Oil tank of hydraulic unit 6 Return filter 3 Oil pump with hoses and fittings 7 Blue plastic fitting 4 Cleaning port 8 Adapter with first coupling half Adding hydraulic oil Fig Operating Utilities - Version 2 B435EN02.DOC

15 Procedure 1. Main switch OFF 2. Attach oil pump (included in the accessories) to mounting plate with 2 screws 3. Attach the mounting plate with oil pump to the hydraulic container 4. Remove the black cap on return filter (do not remove the blue cap!) 5. Screw the adapter with first coupling half onto the return filter and tighten it 6. Mount the second coupling half, letting it snap in 7. Hang oil hose with intake fitting into the oil barrel 8. Mount drilling machine on the oil pump 9. Pump the oil in (make sure there are no bubbles) until about 1 cm beneath top of level indicator (drilling machine must turn clockwise) 10. Unscrew the adapter from return filter and remove the fittings 11. Replace oil/air filter element in return filter (included in the accessories) 12. Replace the black cap on the return filter If the machine was shipped with the oil tank already filled, the transport protection must be removed and the return filter (supplied) mounted before starting the machine up! Filling the automation unit with hydraulic oil Filling nozzle 2 Drain cock Filling with hydraulic oil Fig B435EN02.DOC Operating Utilities - Version

16 1 1 Level indicator Fig Procedure 1. Main switch OFF 2. Remove the cover from the automation unit. 3. Open the seal cap. 4. Refill with oil to up to ¾ of the level indicator. 5. Close the seal cap. 6. Switch on the machine and move the automation unit times up and down. 7. Main switch off 8. Refill with oil to up to ¾ of the level indicator. 9. Close the seal cap and install the casing Operating Utilities - Version 2 B435EN02.DOC

17 4.2 Lubricants for spray tool Application Recommended lubricant Quantity (liters) Mild steels Stainless and acid-proof steels TRUMPF nibbling oil SRH/5 in the following container sizes: Spray can (Mat. No ) 1 kg tin (Mat. No ) 10 kg tin (Mat. No ) 2.5 Aluminium and aluminium alloys Akamin (from Wisura, Order No ) In addition to the afore-mentioned oils, non-corrosive synthetic lubricants or coolants of a viscosity ranging from ISO VG 5 to ISO VG 150 can also be used for spray lubrication. Lubricants and coolants containing solvents or agents which corrode rubbers seals or PVC hoses are not suitable. B435EN02.DOC Operating Utilities - Version

18 4.3 Modifying existing tool cartridges Stripper monitoring The TC 2020 R FMC compact features sensor-based stripper monitoring. A light sensor on the punching head checks whether the stripper is present. If older cartridges are used, the light beam is interrupted by a cartridge stripper arm. With the aid of the template provided, the cartridge must be ground on a floor stand grinder or, better yet, on a belt grinder to the template dimension. Please contact TRUMPF if you do not have any facilities for modifying the cartridges. New cartridges, recognizable by the writeable magnetic plates, are supplied for the TC 2020 R FMC compact and do not need to modified. Template Fig Marking with the template Fig Grinding the right cartridge side on the wheel stand Fig Operating Utilities - Version 2 B435EN02.DOC

19 4.4 Using new multitools and tapping tools Apart from the new multitools, the new tapping tools are also used for the TC 2020 R FMC compact (as previously for the TC 2000 R). Neither of these tools are compatible with the existing tools like those used on the TC 200 R, TC 500 R and TC 600 L. Caution Tool collision results in damage to the stripper adapter! Do not use the existing multitools and tapping tools on the TC 2020 R FMC compact! Do not use the new multitools and tapping tools on older machines! See chapter Description for details! B435EN02.DOC Operating Utilities - Version

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21 5. Machine transport All machine components must be examined upon receipt for damage incurred during transit. Visible transport damages must be recorded on the bill of lading and counter-signed by the truck driver. Hidden transport damages must be reported to the insurance company and to TRUMPF within 6 days, at the latest. The customer must make the necessary arrangements and convey the machinery from the truck to its final installation site. Such matters as the transport path to the final installation site should be clarified well in advance of the machine s arrival. In particular, checks must be carried out on gateway dimensions, potholes, cable racks, whether the ground is suitable for supporting armored rollers etc. Remember to take the machine dimensions (as per the installation layout) into account in your planning! Dimensions of machine components incl. transport gear Component Machine with control cabinet Automation unit Length [mm] Width [mm] Height [mm] Accessories and handling aids Crane truck. A hydraulic crane truck with a load capacity of at least 50 t is recommended. If on-site conditions necessitate a greater lever arm, use a crane truck of higher load capacity. with Form C shackle, nominal size 20 (DIN 82101) with the customary chains and transport straps Hall crane (min. carrying capacity 20 t) or Armored (heavy-duty) rollers (1 steerable and 2 rigid rollers, min. 10 t carrying power each) At least 2 hydraulic jacks of min. 10 t lifting capacity (min. clearance height: 30 mm) Crow bar (1 m) and extension B435EN02.DOC Transport - Version

22 5.1 Work to be performed by the customer Off-loading the machine from the truck Conveying the machine from the yard to the installation site Erecting the machine at the installation site Unload the machine or the automation unit from the truck with a crane truck of adequate respective hoisting power. C-shape crane shackle, nominal size 20 (DIN 82101) required for the machine transport eyebolt. Use slings of adequate loading capacity for the automation unit. Remove the wooden beams from the machine legs while the machine is suspended from the crane. Transport the machine on armored rollers from the yard into the factory hall. To continue to the installation site, use either a gantry crane of sufficient carrying capacity or armored rollers. If armored rollers are being used, hydraulic jacks will be needed to set the machine down and to align it at its final duty station. Lift the machine with the hydraulic hoisting jacks: Apply the hydraulic hoisting jacks to the frame web or the legs on the right side and to the machine frame on the left side. Push the wedge mounts underneath. The leveling screws of the wedge mounts must point outward. The quality of the floor at the installation site must meet the requirements stipulated in section 1.2 Floor Requirements. Installation of the automation unit The automation unit is doweled to the floor by TRUMPF service technicians, using 4 screws per leg Transport - Version 2 B435EN02.DOC

23 5.2 TRUMPF service work Leveling the machine Machine leveling is undertaken by the TRUMPF service engineer. Machine start-up The machine is started up by a TRUMPF engineer. This includes installation of the system components in conformity with the installation layout, connecting the machine to the power supply, instructing the personnel and testing machine functions. B435EN02.DOC Transport - Version

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25 Planning aid The checklist below provides an overview of the work and preparations to be undertaken by the customer. For details, refer to the corresponding sub-sections in the installation conditions. Time before machine delivery Planning criterion Work to be done 15 weeks Personnel and training Appoint a member of the staff to coordinate the preparations for receiving the machine Appoint the operating and maintenance staff, the programmers and enroll them in the necessary training courses. 14 weeks, but not later than week weeks, but not later than week... Installation site Decide on the final machine site. Allow for space requirements as specified in the installation layout. Check the floor requirements (floor quality, levelness, oil-proof floor without expansion joints). Keep in mind the machine dimensions and weight. Do the ambient conditions meet specifications (room temperature, exposure to sunlight)? Examine the transport route (door openings, potholes, cable racks, room to maneuver around corners etc.) Electrical power supply Install the electrical connections at the installation site. Conductor cross-section and fuses must conform to local regulations. Have the necessary Teleservice connections made. 12 weeks, but not later than week... Compressed air supply Install the compressed air supply at the installation site (connection, purity, air consumption) B435EN02.DOC Planning Aid - Version

26 Time before machine delivery Planning criterion Work to be done 4 weeks, but not later than week... Utilities Stock up on: Hydraulic oil Oil for the spray tool lubrication 4 weeks, but not later than week... Transport gear Have the necessary transport gear ready in time. 4 weeks, but not later than week... Acceptance workpiece Have the material ready for the machine acceptance: 1000 x 1000 mm USt (DIN EN 10131) Thickness = 2.5 mm 2-26 Planning Aid - Version 2 B435EN02.DOC