Operating instructions

Transcription

1 Operating instructions Sample Machine number: Page 1 of 18 Translation of the Original Operating instruction

2 Contents 1 GENERAL SPECIAL SAFETY INSTRUCTIONS Safety rules Requirements for operative staff Icons used on the machine Safety equipment Position of safety equipment on your machine The main switch on the switch cabinet: EMERGENCY-STOP button (use only with danger!) Safety switches Protective covering GENERAL INFORMATION ON THE MACHINE Overview of the machine Machine description (brief desciption) REGULATING THE SYSTEM Overview of control system Main Screen Manual operation Type selection Quick selection System functions Error messages Start the machine (automatic) MALFUNCTIONS, TROUBLESHOOTING General MAINTENANCE General Safety rules for maintenance work Requirements for operative staff Storage of lubricants Maintenance table Customer service information Page 2 of 18

3 1 General These operating instructions are part of the user information for operating the machine and should thus be kept in a location where they are accessible to the owner and operator. In all phases of the machine s lifecycle, observe the instructions in the operating instructions and or user manuals (also from OEM suppliers). Read the relevant chapters in the operating instructions and user manuals carefully before starting work. We do not accept any liability occurring due to failure to observe these operating instructions. Internal responsibilities must be unequivocally assigned with respect to responsibility for the machine (owner) and persons authorised to work with it (operators). Clear responsibilities must be assigned to staff for transporting, installing, tooling, setting up, operating, servicing, maintaining and repairing the machine. The original operating instructions and user manual in the German language are definitive with respect to the accuracy of content. Page 3 of 18

4 2 Special safety instructions 2.1 Safety rules Check safety devices daily before switching on! In case of irregularity / malfunctions, stop working, switch off the machine, wait until the machine is idle. If you do not have a line of sight to the main switch, padlock the main switch against re-enabling. Additionally display signs to indicate that work is in progress on the machine. Remedy the malfunction. If necessary, inform your superior / customer service. Perform all measurements/checks and retooling only while the machine is stationary. Do not clean yourself, your clothing and the machine with compressed air. Regular and careful cleaning of the machine will extend its service life and functional safety, reduce malfunctions and improve accuracy. 2.2 Requirements for operative staff (See chapter 6 of the operating instructions) 2.3 Icons used on the machine Observe the following, which are displayed on the machine Safety instructions Rotation direction arrows Labels for connections Other instructions Keep all of these in completely legible state. 2.4 Safety equipment Never manipulate the EMERGENCY STOP device any other safety equipment Keep the EMERGENCY STOP buttons accessible and visible at all times. Page 4 of 18

5 2.4.1 Position of safety equipment on your machine The emergency stop switches are located on the control panel. The main switch is located on the machine s switch cabinet. Safety sensors will monitor the closed state of the protective enclosures. Protective enclosure complete with Safety trip switches Main Switch Emergency Stop Switches The main switch on the switch cabinet: interrupts the power supply to all units is lockable in 0 position protects you against the danger of accidental or unauthorised switching on of the machine. Always lock the main switch: for all maintenance and repair work whenever switching on the machine can be dangerous Page 5 of 18

6 2.4.3 EMERGENCY-STOP button (use only with danger!) The EMERGENCY STOP button switches the machine to a safe state. Press the button in case of danger => the machine is stopped immediately Reset by pulling or turning the red button and Acknowledge by pressing the " EMERGENCY STOP Acknowledge" Warning! Danger of injury! If the emergency stop is activated, the protective doors are subsequently opened and the pneumatic cylinder is then moved/pushed deliberately, then the pneumatic cylinder will then move back to its original position upon acknowledgement of the emergency stop circuit, even if the protective doors are opened! Therefore, the emergency stop circuit must only be acknowledged when the maintenance and protective doors are closed Safety switches Safety switches are attached to covers which can be opened without tools must be opened for setup or maintenance work. Opening monitored covers while the machine is running will stop the machine! Protective covering The protective covering protects the interior of the machine against external influences, and the operator against machine movements and internal media. If the machine is running in automatic mode, no persons are permitted within the perimeter of the protective covering. The protective covering must be closed in automatic mode. The door positions are monitored by safety switches. Opening the doors on the protective covering immediately leads to an stop the machine! In the automatic enterprise the protection lining doors are closed by bolting devices and could be opened only by deliberate impact. Check for safe operational state before commencing operations.. Page 6 of 18

7 3 General information on the machine 3.1 Overview of the machine Camera test i.o. belt Touch Panel Pneumatic unit discharge unit n.i.o. belt Workpiece carrier electric control cabinet 3.2 Machine description (brief desciption) The operator can then push the workpiece carrier on to a conveyor belt, which will then transport the workpiece carrier forwards and convey it underneath a camera. During the movement, the presence of the object and the correct mounting position of the surface element will be checked. Subsequently, the tested workpiece carriers will travel into a discharge unit, in which they will be discharged, according to their test results, either onto the I.O. belt or onto the N.I.O. belt. N.I.O. tested workpiece carriers can be reworked manually and can then be placed on the feed conveyor belt again by the worker. Page 7 of 18

8 4 Regulating the system 4.1 Overview of control system Main Screen AUTO = start automatic operation HAND = start manual functions GS = Plant starts in basic position ERROR = switches to error menu Type selection = switches to data entry System = switches to system overview Quick Select = Select the three main types of brakes Page 8 of 18

9 N.I.O. on the N.I.O. belt = N.I.O. tested components will be discharged by the N.I.O. belt. N.I.O. to the worker = N.I.O. tested components will be transported back to the worker by the conveyor belt travelling backwards The discharge type can only be changed if: - system is in manual mode - system is in normal position - no test in the system Page 9 of 18

10 4.1.2 Manual operation -here the cylinders can be displaced individually in work position (AS) and basic position (GS), the conveyor belt will be switched on and off - switches to main screen Page 10 of 18

11 4.1.3 Type selection - here new data sets can be applied, saved and uploaded -can just be selected, if not Quick select is active - Auto starts automatic operation - switches to main screen Using the password-protected "EDIT" button, the menu is used to change existing and create new records. Page 11 of 18

12 4.1.4 Quick selection - is for the three main programs (17mm; 17mm backside and 17mm flatness) - if Quick select is avtive then type selection is disabled Page 12 of 18

13 4.1.5 System functions - changing the user language - adjusting contrast settings - setting the Time - Change password - Change return time of the work piece carrier using setting 'NIO to workers' -password protected system control of panel - switches to main screen Page 13 of 18

14 4.1.6 Error messages - Display of error messages - Acknowledgement of error messages - switches to main screen 4.2 Start the machine (automatic) 1. turn main switch on 2. acknowledge (release) emergency stop 3. press Button Control on 4. activate Automatic Page 14 of 18

15 5 Malfunctions, troubleshooting 5.1 General You can avoid errors in operating the machine by observing the following: Read the operating instructions in full before starting work. Keep to the order specified in the chapter Operating the machine. Observe the instructions in case of EMERGENCY STOP. Always switch the machine on and off correctly. If a machine malfunction occurs, the process is interrupted at this point and an error message is displayed on screen. In addition to this, some malfunctions that can occur are not identified by the control unit. If a malfunction of this type occurs and you are unable to ascertain the cause or remedy the malfunction, please contact our customer service. WARNING In setup mode, the machine can be operated with the safety devices overridden. The safety devices may only be disabled by staff with appropriate training and authorisation from the owner/operator; they must be reenabled after completing the setup work. All setup work must be performed by staff with appropriate training. During setup work, make sure that no persons are in the hazardous area of moving axes, carriages etc. The owner/operator is responsible for observing these safety rules. Page 15 of 18

16 6 Maintenance 6.1 General For maintenance and repair work always observe chapter 2 Special safety instructions and all the safety instructions it lists. Malfunctions caused by insufficient or inappropriate maintenance can cause expensive repairs and machine downtime. Regular maintenance is vital. The operational safety and life expectancy of the machine depend on appropriate maintenance among other factors. All work on the machine must be performed by experienced and qualified staff. These persons should receive special training to avoid damage due to lack of specialist knowledge. The manufacturer accepts on liability for damage caused by inappropriate maintenance or failure to maintain the machine. 6.2 Safety rules for maintenance work - Observe safety at work rules! - Switch off the power supply - Wait for the machine to come to a standstill - Safe dissipation of residual energy (e.g. pressure accumulator, electrical system, pneumatic system) - Do not clean yourself, your clothing and the machine with compressed air. - Do not overestimate your own strength; if needed call a helper, or use lifting gear, e.g.: fork lifts. - Do not clean the machine with pressure cleaning equipment. - Maintain OEM parts in line with OEM part manufacturers instructions. - During all repair work, keep the workplace tidy and clean. - Keep access routes clear. - After completing repair work, return the machine to a safe state for operations, i.e. check the following: - that all screw connections are screwed tight - fully refit all safety equipment and check for functionality check that all connections / lines are leak tight Page 16 of 18

17 6.3 Requirements for operative staff (See chapter 6 of the operating instructions) 6.4 Storage of lubricants Lubricants must always be stored in clean, closed and suitable containers. Lubricant containers must be stored in catchment sumps capable of holding the total content of the lubricant container in case of a leak. In case of accidents, inform the authorities and/or rescue services immediately. Lubricant containers must be labelled, including labelling with an appropriate warning symbol as necessary. Different oils must not be mixed. Lubricants must never be kept in food containers (e.g. drinking bottles). Contaminated lubricants must not be used; dispose of them in a responsible way. If necessary, contact a qualified waste disposal service provider. 6.5 Maintenance table Interval Location Task Daily Whole machine Visual check for loose objects andv visible damage Monthly EMERGENCY-STOP button Check functionality Monthly Protective housing e.g. automatic operations must not be possible when open Monthly Tooling sets Check for functionality and damage Monthly Stops, initiators Check for tight seating, readjust and tighten as needed. Monthly Fastening screws on cyinders, coupling elements Check for secure seating and tighten if necessary Monthly limit switch Check for functionality, readjust or replace as needed. Monthly Electrical lines, connectors and Check, replace if necessary. energy chains Every six months or after 100 Km of travel Linear guides Check lubrication film and lubricate as necessary Monthly Fans and air conditioning devices Check for function Every 6 months Filter pads in fans and air conditioning devices Replace. Do this at shorter intervals in case of severe air pollution annual Pneumatic hoses Check, replace if necessary. Other maintenance intervals of purchased parts, see the maintenance plans purchased part documentation. Recommended grease: generaly: DIN-label: DIN-number: content KP 2 - K 51502/51825 Lithium soap grease ball bearing guide: KP2K Lithium soap grease roller bearing guide: KP2N Lithium complex Page 17 of 18

18 6.6 Customer service information Schuster Sondermaschinenbau GmbH Moosweg 1 D Böbing Tel. Service Mechanical / Tel. Service Electrical / Fax. Service / Service m.lautenbacher@schuster-sondermaschinenbau.de Page 18 of 18