Manual Peddinghaus
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Operating Instructions for the Peddimat tandem Saw/Drill Line
Table of contents
Drilling Line BDL 1000/9 FUNDAMENTAL NOTES
1
FUNDAMENTAL NOTES ON SAFETY
2
TRANSPORTATION, STORAGE AND DELIVERY
3
TECHNICAL SPECIFICATIONS
4
INSTALLATION, ASSEMBLY AND INITIAL START-UP
5
OPERATING THE MACHINES
6
TOOLS
7
THE SIGNOSCRIPT MARKING UNIT (OPTION)
8
MAINTENANCE AND SERVICING
9
CHANGING THE SAW BLADE
10
THE SIGNOMAT MARKING UNIT (OPTION)
11
Peddimat – BDL 1000/9
Operating Instructions for the Peddimat tandem Saw/Drill Line
MEBA BAND SAW (OPTION)
12
CONFORMITY AND MANUFACTURER’S DECLARATIONS
13
PART 2 OPERATING MANUAL; CIRCUIT DIAGRAMS; BILLS OF MATERIAL
B
Peddimat – BDL 1000/9
Operating Instructions for the Peddimat tandem saw/drill line
Table of contents Chapter 1
Fundamental notes 1.1 Foreword 1.1.1 Customer service 1.2 Intended use 1.3 Warranty and liability 1.4 Brief description and machine function 1.4.1 The drilling machine 1.4.2.1 Options 1.4.2 Mechanical assemblies 1.4.3 Electrical components 1.4.3.1 The CNC control 1.4.3.2 The power section 1.4.3.3 The axis drives 1.4.3.4 The axis feedback section 1.4.4 Hydraulic components 1.4.5 Safety equipment 1.5 Special installation instructions for the user 1.6 Publication, date of issue of the manual 1.7 Copyright 1.8 Manufacturer’s address
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Operating Instructions for the Peddimat tandem saw/drill line
1 FUNDAMENTAL NOTES 1.1 Foreword This operating manual contains information and details necessary for the operation and maintenance of your Peddimat tandem saw/drill line. The Peddimat saw/drill line represents equipment incorporated in the Peddinghaus range of products. Series design, years of experience in machine tool building coupled with modern production and testing methods guarantee a high standard of quality together with reliable operation and long service life. Always observe all notes on safety, and the pertinent operating and maintenance instructions. This instruction manual contains all the information required for operating the machines. The handbook for the Siemens control ( Sinumerik 840D ) is part and parcel of this manual.. This manual is intended for technically qualified, specially trained operators or for operators with in-depth knowledge in the field of NC technology. Full knowledge and technically competent implementation of the safety instructions and warnings are a pre-requisite for non-hazardous installation and commissioning as well as for safe operation and maintenance. Only qualified personnel have the necessary specialist knowledge to interpret and implement the safety instructions and warnings in case of an emergency.
1.1.1 Customer service The Peddinghaus Service Department is at your disposal to assist in remedying technical problems. Tel.
+ 49 (0) 2332 – 72 – 0
Fax.
+ 49 (0) 2332 – 72 – 208
Peddimat – BDL 1000/9
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Operating Instructions for the Peddimat tandem saw/drill line
1.2 Intended use The Peddimat saw/drill line is to be used solely for processing of structural sections and flat bar by sawing, drilling, pop marking and marking in accordance with previously compiled parts programmes. Only operate the machine when it is in technically perfect condition and only for performing the work for which it is designed. Always observe all safety, operating and maintenance instructions set forth in this manual and be aware of potential dangers. Faults affecting safety, in particular, are to be remedied immediately. The Peddimat saw/drill line is only to be used in: ♦ automatic cycle ♦ manual in-feed ♦ manual part removal mode! The machine can only be started by using the : ♦ starting facilities on the controls (control consoles) The machine may be operated by several operators . Proviso:
♦ authorisation must be given for several operators to operate the line (refer to Chapter 2.7.)
The following norms ( standards ) were taken into consideration in the design of the saw/drill line, the individual machines and their safety equipment: ♦ DIN EN 292 – 1/ 2 / 953 / 954-1 / 1088 / 50100 / 60204-1 Any use other than that described above is considered not to be in accordance with the intended use! Messrs. Paul Ferd. Peddinghaus GmbH are not liable for any damage that may result from such improper use. Intended use also encompasses: ♦ observance of all instructions in the manual and ♦ adherence to all inspection and maintenance instructions
1.3 Warranty and liability Our “Conditions of sale and supply” apply. Warranty and liability claims in case of injury to persons or damage to property are excluded when they are to be traced back to one or several of the following causes: ♦ not using the machine for its intended purpose; ♦ improper installation, start-up, operation and maintenance of the machine; ♦ operation of the machine when safety equipment is faulty, not fitted properly or does not function correctly. ♦ non-compliance with the instructions in the manual in respect of transportation, storage, installation, start-up, operation, maintenance and machine set-up; non-authorised modification of the machine parameters and / or of the drive parameters set at the factory; ♦ inadequate monitoring of machine components subject to wear; ♦ improper repairs; ♦ cases of disaster caused by the effects of foreign bodies and Act of God;
Peddimat – BDL 1000/9
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Operating Instructions for the Peddimat tandem saw/drill line
1.4 Brief description and machine function The Peddimat saw/drill line is a modern , CNC controlled machining centre designed for the automatic sawing, drilling, pop marking and marking of structural steel sections and flat bar. The system consists of the following assemblies: ♦ Drilling machine υ Band saw ( option ) υ Circular cold saw LC 1250 (option) υ Signomat (option) or Signoscript (option ) υ CNC control ♦ Hydraulic power-pack ♦ Out-feed conveyor ( option ) ♦ In-feed conveyor ( option ) υ Cross transfer table ( option )
1.4.1 The drilling machine The drilling machine consists of: ♦ ♦ ♦ ♦ ♦ ♦
3 drill assemblies roller feed, clamping and disc measuring system hydraulic power-pack hydraulic drive for the working and pressure cylinders and for the drill feed units CNC control Power section for the drilling and positioning drives with machine interface
1.4.1.1 Options The following optional equipment is available for link-up to the drilling machine: υ Band saw MEBA υ Circular cold saw LC 1250 υ Signomat υ Signoscript υ In-feed conveyor υ Out-feed conveyor υ Cross transfer table Options and additional equipment in accordance with the order acknowledgement.
1.4.2
Mechanical drilling machine assemblies
The Peddimat BDL 1000/9 is of robust steel plate design with a welded base frame and a superstructure of welded and bolted plate design. The machine is equipped with 3 drill assemblies each with 3 spindles and an air cooling system through the spindles for the drills. The material is traversed in the X-axis by a high-precision, high-speed disc measuring system with roller feed.
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Operating Instructions for the Peddimat tandem saw/drill line
1.4.3 Electrical components
1. 2. 3. 4. 5.
CNC control and console Power cabinet Axis drives Axis feed-backs System wiring and electrical components
1.4.3.1 The CNC control The CNC control serves to take over and store the required data in the form of parts programmes. The positioning drives are controlled and all commands for drilling operations issued by the CNC control in accordance with the programme organisation. The control console contains all function and signalling components ( switches and signal lamps ).
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Operating Instructions for the Peddimat tandem saw/drill line
1.4.3.2 The power section The power section is located in the switch cabinet (depending on model ) and contains all switchgear and protective equipment for controlling the drive units such as drill motors, adjuster motors and the hydraulic pump motor. All hydraulic valves contained in the system are controlled by power amplifiers. Several control transformers generate the required control and auxiliary voltages. All master fuses are located on an appropriate board.
1.4.3.3 The axis drives The power amplifiers for the digital positioning drives of the material feed X-axis and the (W,Y and Z ) drill axes, the power sections for the main spindle drives, the saw axis, the Signo axis and the hydraulics ( proportional valve, hole tapping and drill feed ) are located in the CNC cabinet. 1.4.3.4 The axis feed-back section The axis feed-back section is arranged in the CNC cabinet. and is responsible for processing and switching the positioning feed-back signals.
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Operating Instructions for the Peddimat tandem saw/drill line
1.4.4 Hydraulic components The saw/drill line is equipped with a separate hydraulic power-pack complete with valve manifolds for the following control functions:
Clamping and measuring rolls Z – side 15 – 80 bar
Internal clamp Z – side 50 bar
Peddimat – BDL 1000/9
Internal clamp W – side 50 bar
Hold-downs 20 – 50 bar
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Operating Instructions for the Peddimat tandem saw/drill line
1.4.5 Safety equipment The safety equipment must protect all persons or objects against the hazards emanating from the machine. They are co-ordinated and installed in conjunction with the user and site conditions. The following safety appliances can be installed: ♦ ♦ ♦ ♦ ♦ ♦
Protective barriers (fixed, partition fencing ); Safety gates (movable, partition gates with or without locks); Guards; Non-contact safety appliances (BWS); Colour floor marking; Warning signs and warnings;
1.5 Special installation instructions for the user The machine is to be installed and assembled by personnel well acquainted with electromagnetic compatibility. The installation and assembly drawings provided by the suppliers of the appliances, systems and components are to be observed, thus guaranteeing perfect operation of the overall system
Warning!
It is a Class A machine. Special arrangements are to be made for installation of the machine in residential, business or factory areas as well as for small businesses. The user is responsible for any electro-magnetic disturbances which can emanate from the machine when the instructions in respect of installation are ignored.
1.6 Publication, date manual issued First edition 01 / 2003
1.7 Copyright The copyright on this instructions manual remains with Messrs. Paul Ferd. Peddinghaus GmbH. The manual is only intended for the user and his staff. It contains instructions and notes which are neither to be ♦ reproduced ♦ distributed nor passed onto third parties either in part or in full. Violation of these regulations can result in prosecution.
1.8 Manufacturer’s address Company:
Paul Ferd. Peddinghaus GmbH
Address:
D-58285 Gevelsberg, Hasslinghauser Str. 156
Tel.
+ 49 (0) 2332 – 72 – 0
Fax.
+ 49 (0) 2332 – 72 – 208
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Drilling Line BDL 1000/9
Operating Instructions
Table of contents Chapter 10
Changing saw blades (LC 1250) 10.1 Preparations 10.2 Changing the blade 10.3 Chip remover 10.3.1 Changing the chip remover 10.3.2 Adjusting the chip remover
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10.1 Preparations The following steps must be taken to change the saw blade: Pre-conditions: Key 12 >
Main switch is on Control voltage is on • the LED display is on
Action:
− press key „ Control Off „ on control console • the control and hydraulics are turned off • the LED lamp above the key lights up • the safety gate is unlocked and released − open safety gate − change blade − change chip remover, if necessary − close safety gate − press key „ Control ON „ on control console • the control and the hydraulics are turned on • the LED lamp above the key lights up − press key „ Delete error „ on control console − press key „ Secure system „ on control console • the safety gate is locked • the LED lamp above the key lights up
The gearbox must be manually traversed to be able to change the blade; the blade is now easily accessible.
Carry out the following operations: •
press "JOG" , LED lights up.
•
press key "V" axis, LED lights up.
•
press directional keys "Plus" or "Minus"
•
Move the gearbox such that the complete cover is out of the area of the vertical head support.
•
press key "Enter danger zone".
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Caution!
Operating Instructions
♦ Observe the safety regulations and general instructions on safety. ♦ Wear your personal safety apparel (ear muffs, safety shoes, gloves). ♦ Never place your hands in the work and moving parts zones when the machine is running. − danger of injury to the operator The operator must wear suitable safety equipment!
Peddimat – BDL 1000/9
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10.2
Operating Instructions
Changing the blade
•
Completely remove the locking screw – 2-, raise the guard -3- .
•
loosen the screws -4- .
•
Turn and push the chip remover -5- in the direction of the arrow away from the blade.
• •
loosen the hex. bolt -6- and screw out.
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•
Operating Instructions
extract the thrust flange -7- .
•
attach the special hook -8- to the blade as depicted,
•
carefully remove the blade from the gearbox journal and lift away with a crane.
Peddimat – BDL 1000/9
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Operating Instructions
The rear stabilisers – 11 - must be checked for wear and replaced, if necessary. •
Fit blade and chip remover in reverse sequence. When fitting a blade with a different tooth pitch, you must also exchange the chip remover. Refer to Chapter 9.3.1.
•
loosen the locking screws -12-.
•
gently adjust the front stabilisers -9- and the rear stabilisers -11- by hand with the aid of the pressure screws (guard- front side).
Caution! The stabilisers must only make slight contact with the blade and not exert pressure. Make sure that the blade does not become misaligned or jammed by the stabilisers. Correct adjustment ensures square, clean cuts and increases the service life of the blade.. •
Retighten the locking screws -12- .
Peddimat – BDL 1000/9
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•
Operating Instructions
press key "Secure system".
Lock safety gates. When the key "Secure system" has been operated, the message „ Press key Tool Off „ appears. By operating the key „Tool Off „, the spindles will return to their home positions. Sawing operations are continued.
Measure the diameter of the blade after completion of the blade change and enter the actual diameter and thickness in the programming software under # 2 machine data # 5 saw data ( FD software only ).
Make sure, under all circumstances, that the blade is moistened with cooling emulsion before the first cut is made.
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Operating Instructions
10.3 Chip remover The chip removing wheels are tuned to the tooth pitch of the individual blades used. The standard scope of supply includes a chip remover for Z5 tooth pitch. Suitable chip removers are available for blades of other tooth pitches.
10.3.1 Changing the chip remover •
Prepare the system for changing the chip remover as described in Chapter 10.2 “Changing the blade „.
•
remove the holder -2- after releasing the screws -1-
•
loosen screws -3-
•
pull out chip remover complete with axle -4-
•
Fit new chip remover in reverse sequence.
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Operating Instructions
10.3.2 Adjusting the chip remover. •
Prepare the system for adjusting the chip remover as described in chapter 10.0 „Changing the blade“.
•
loosen screws -3-
•
Push the remover together with the axle towards the gearbox to the point where the remover pins locate in the base of the teeth.
Turn the remover together with the axle to the point where the pins dip into the blade over its full width.
• tighten screws -3-
The remover must not jam in the blade after it has been adjusted. It must be easily movable by hand.
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Operating Instructions
Table of contents Chapter 11
The Signomat (OPTION) 11.1 Notes on safety 11.2 Adjustment of the Signomat
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Drilling Line BDL 1000/9
Operating Instructions
11.1 Notes on safety Please pay specific attention to the notes on safety when operating and working on the marking system.
Warning!
♦
Always turn the main disconnect switch off before carrying out any repair, servicing or maintenance work.
♦
If the system is hooked up to factory supply lines, the system is only to be put into operation when the point of sourcing is made safe and the prescribed safety equipment is in place.
♦
The operator must make sure that the system is ready for operation prior to beginning work ( change of shifts ).
♦ The operator should be equipped with safety gloves, safety shoes, leather apron and safety glasses. Ear protectors are also recommended. ♦ No mechanical modifications or additions are to be made to the system.
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11.2
Operating Instructions
Adjusting the Signomat The Signomat is controlled by the program and automatically adjusted to the particular section to be marked. The Signomat must, however, be manually adjusted to the flange or leg thickness of the work-piece.
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Drilling Line BDL 1000/9
Operating Instructions
The pass-through aperture of the Signomat is to be adapted to the work-piece by adjusting the counter-holder -2- . Examples: Position of the counter-holder on an I beam
-
Position of the counter-holder on I beams and channels up to 120mm
-
Position of the counter-holder on angle iron.
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Drilling Line BDL 1000/9
Operating Instructions
The stamping pressure is set on the pressure reducing valve -15-. Maximum pressure = 150 bars. The required stamping pressure ( inscription depth ) is adjusted by the pressure switch -14- . It must be lower than that set on the pressure reducing valve -15- .
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Operating Instructions
Table of contents Chapter 12
MEBA Band Saw (OPTION) 12.0 MEBA Band Saw 560 DG 1000
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Operating Instructions
12.0 MEBA Band Saw 560 DG 1000
You will find the operating instructions for the MEBA band saw 560 DG 1000 in Part 2 of this manual.
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Operating Instructions
Table of contents Chapter 13
EC Conformity and Manufacturer’s Declarations 13.1 Manufacturer’s declaration of conformity Peddinghaus.
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Operating Instructions
13 EC CONFORMITY AND MANUFACTURER‘S DECLARATIONS 13.1 EC Declaration of conformity by the manufacturer
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Drilling Line BDL 1000/9
Operating Instructions
13.1 EC Declaration of Conformity as specified by the EC guidelines
Ξ Ξ
Machines 98/37 EC, Annex II A
Electro-magnetic compatibility 89/336/EEC Ξ Low voltage guidelines 73/23 EG The machine Make: Model:
Flat Bar Drilling and Flame Cutting Machine Peddimat – FDB 600 / 3
is developed, designed and manufactured in accordance with the EC Guidelines 89/37 EC under sole responsibility. Firm:
Paul Ferd. Peddinghaus GmbH, D-58285 Gevelsberg, Hasslinghauser Str. 156
The following harmonised standards are applied: Ξ Ξ
DIN EN 292-1/2 DIN EN 294
Ξ Ξ Ξ
DIN EN 349 DIN EN 418 DIN EN 953
Ξ Ξ
DIN EN 954-1 DIN EN 982
Ξ
DIN EN 983
Ξ Ξ
DIN EN 1037 DIN EN 1050
Machine Safety – Appliances and systems Safe distances to prevent the upper limbs from reaching pinots of danger. Minimum safe distances to prevent crushing of parts of the body E-stop facilities, functional aspects, design guidelines General requirements in respect of design and assembly of separating safety equipment. Safety related parts of controls; general design guidelines Safety requirements in respect of fluid operated systems and hydraulic components Safety requirements in respect of fluid operated systems and pneumatic components Machine Safety – prevention of unintentional start-up Machine Safety – risk assessment
Ξ Ξ Ξ Ξ Ξ Ξ Ξ
DIN EN 1088 DIN EN 50100-1 DIN EN 50100-2 pr EN 50081-2 pr EN 50082-2 DIN EN 60204-1 prEN 31202
Locking devices with and with follower Non-contact safety appliances Non-contact safety appliances with active optical–electrical principle EMC Standard Interference Transmission Industrial Field EMC Standard Interference Resistance Industrial Field Electrical equipment of machines; general requirements Acoustics, noise radiation by machines
Complete technical documentation is available. Ξ ϒ
The appropriate operating instructions manual for the machine is available in the original version. The appropriate operating instructions manual for the machine is available in the language of the country in which it is in use.
______________________ Place, Date
______________________ Signature Peddimat – BDL 1000/9
_______________________ Details of person signing Chapter 13 / 3
Operating Instructions for the Peddimat tandem Saw/Drill line
Table of contents Chapter 2
Fundamental notes on safety 2.1 2.2 2.3 2.4 2.5 2.6 2.7
Observance of safety instructions in the manual 2–2 Informal safety measures 2–2 Duties of the user and the operator 2–2 Training of operating personnel 2–2 Explanation of hazard symbols, notes and signs 2–3 Personal safety apparel 2–3 Places of work for the operating personnel/ particular danger 2 – 4 zones 2.8 Hazards involved in the operation of the saw/drill line 2–4 2.9 Safety measures under normal operation 2–4 2.10 Hazards caused by electrical energy 2–4 2.11 2.12 2.13 2.14
Hazards caused by hydraulic and pneumatic energy Maintenance and servicing , remedying faults Mechanical modifications to the system Noise levels emitted by the system
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Operating Instructions for the Peddimat tandem Saw/Drill line
2 FUNDAMENTAL NOTES ON SAFETY 2.1 Observance of safety instructions in the manual The basic requirement for the safe use and trouble-free operation of this machine is full knowledge of the fundamental safety notes and instructions contained in this manual. This manual sets forth the most important instructions for operating the machines in a safe manner. The instructions manual, in particular the safety instructions, must be observed by all persons working on or operating the machines! In addition, the accident prevention regulations and instructions applicable to the site at which the machine is located must also be observed.
2.2 Informal safety measures The operating instructions manual is always to be kept on site. In addition to the manual, both the generally applicable and the local accident prevention regulations and environment protection regulations must also be on site and be observed. All safety and hazard signs on the machine must be kept in a clearly legible condition.
2.3 Duties of the user and the operator Only persons are allowed to operate the machine who ♦ are fully acquainted with the fundamental safety and accident prevention regulations ♦ have been fully trained in the operation of the machine ♦ have read and fully understood the chapter on safety and the warning signs ♦ and have confirmed the above by applying their signature. The user will check the safety conscious operation of the machine by the operating personnel at regular intervals.
2.4 Training of operating personnel Only fully trained personnel are allowed to work with the machine. The responsibilities of the operators is to be clearly stipulated by the user in respect of assembly, start-up, set-up, checks, operation, maintenance and servicing. It is the operator’s job to: − set up the machine for the desired purpose − set the machine to the desired mode of operation and to secure against unauthorised readjustment − set up the required tools − adjust and check all safety equipment − check the machines upon completion of set-up − to operate the machines when they have been set up
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Operating Instructions for the Peddimat tandem Saw/Drill line
2.5 Explanation of hazard symbols, notes and signs The following symbols and descriptions are used in the manual to denote hazards:
Danger!
Warning!
Caution!
This symbol indicates immediate danger to the life and health of persons. Non-observance will result in severe damage to health and even cause life threatening injuries. This symbol, indicates a possible threat of danger to the life and health of persons. Non-observance will result in severe damage to health and even cause life threatening injuries. This symbol indicates a possible dangerous situation. Non-observance can lead to slight injury or cause damage to property. This symbol provides important information on the proper operation of the machines. Non-observance can lead to faults on the machines or disturbances in the surrounding area.
♦
This sign indicates a value determined and fixed by the manufacturer.
•
This sign indicates a machine reaction subsequent to an actuation.
–
This sign indicates that the operator must perform an action.
2.6 Personal safety apparel When working with the machines, the operating personnel must wear suitable safety apparel: The operator must pay particular attention when working with the machines and handling the work-pieces and the tools to: − − − − −
Warning!
head protection (hard hat) finger protection (long gloves) protection of the upper limbs (arms) protection of the body (leather apron) protection of the feet (safety shoes)
• sharp edged work-pieces − can cut the upper limbs Wear suitable safety apparel!
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Operating Instructions for the Peddimat tandem Saw/Drill line
2.7 Places of work for the operating personnel / particular danger zones The operator workplaces are always located outside the machine’s safety equipment (barriers etc.) in the vicinity of : ♦ the controls The area in the machine, up to 1m from the tool location, must be considered as being a particular danger zone. The operator is only allowed to walk in the area inside the safety fencing to remedy faults under very special conditions.
2.8 Hazards involved in the operation of the saw/drill line The Peddimat tandem saw/drill line is built in accordance with state-of-the-art technology and the recognised safety regulations and standards contained in the EG guidelines. Nevertheless, hazards to life and limb of the user or third parties or influences affecting the machines and property can occur during its use. The machines are only to be used: ♦ for their intended purpose ♦ in perfectly safe condition ♦ faults affecting the safe use must be reported to the responsible people and remedied immediately.
2.9 Safety measures under normal operation Only operate the machines when all safety equipment is fully functional. Care must be taken to ensure that, prior to turning on the machines, nobody can be endangered when they start up. Check the machines at least once every shift for externally recognisable damage and full functionality of all safety equipment ( refer to Chapter 6.8 Operation).
2.10 Hazards caused by electrical energy Work on electrical and electronic supply facilities is only to be performed by a qualified electrician: − the electrical equipment must be regularly checked. − the switch cabinet must be kept closed at all times.
−
access is only granted to authorised personnel with key or tool.
2.11 Hazards caused by hydraulic and pneumatic energy Work on the hydraulic / pneumatic equipment is only to be performed by qualified personnel with special experience in the field of hydraulic/pneumatic and press technology: − depressurise the sections of the system to be opened and pressures lines prior to − commencing maintenance work and secure against dropping ( refer to Chapter 9 ). − replace hydraulic hoses at the prescribed intervals, even when no faults or damage that could affect safety are apparent (refer to Chapter 9).
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Operating Instructions for the Peddimat tandem Saw/Drill line
2.12 Maintenance and servicing, remedying faults The prescribed adjustment, maintenance and inspection work must be carried out at the times stipulated: (refer to Chapter 7) − operating personnel are to be informed prior to the commencement of maintenance and service work. − de-energise the system, lock the main switch and remove the key when all maintenance, inspection and repair work is to be performed − attach a warning sign to prevent restarting of the machine − larger assemblies are to be attached to lifting gear and secured when being replaced − check screw connections that have become loose for tightness − check the safety equipment and its function after maintenance work has been completed
2.13 Mechanical modifications to the system No modifications, conversions or additions to the machines may be made without the express consent of the manufacturer. This also applies to welding work on components subject to load and stress. All modification or conversion work must be confirmed in writing by Messrs. Paul Ferd. Peddinghaus GmbH. Components not in perfect condition must be replaced immediately. Only Original spare parts and consumables may be used. It is not guaranteed that parts purchased from other sources are properly designed to cope with stresses and provide the required degree of safety.
2.14 Noise levels emitted by the system The permanent noise level emitted by the system is ≤ 70 dB (A) A noise level of 85 dB (A) at the place of work can be exceeded as a result of such influences as material transport through the machine, sawing and drilling; in this case, noise protection measures for the operator are compulsory.
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Table of contents Chapter 3
Transportation, storage and delivery 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8
Information and protective measures for transportation Delivery of the machines Dimensions and weights Unloading, loading of the machines and assemblies Storage location, duration, protective measures Checking scope of supply for damage, missing parts Scope of supply Notification of defects, damage and/or missing parts upon receipt of delivery
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Operating Instructions for the Peddimat tandem Saw/Drill Line
3 TRANSPORTATION AND DELIVERY 3.1 Information and protective measures in connection with the transportation of the machine The various machine assemblies must be safely loaded onto the carrying vehicle ( truck, wagon ) by means of a crane or forklift truck and secured. Securing can be effected by means of: ♦ tying chains ♦ tying straps The dismantled assemblies / machine must be protected against environmental influences. The following steps should be taken: − use a suitable cover to protect assemblies/ machine against dust or dirt. To avoid damage to the paint, don’t allow straps or chains to rub against movable parts of the assemblies / machines. Insert rubber shims between the chains or straps.
3.2 Delivery of the machine The assemblies/ machine are delivered from the factory in the following manner: Description
Manufacturer
Qty.
Packed
Dismantled
Drilling machine incl. control
Peddinghaus
1
no
yes
Band saw incl. control console (option) Circular cold saw LC 1250 (option) Hydralic power-pack
MEBA
1
no
yes
Peddinghaus
1
no
yes
BW - Hydraulik
1
no
yes
Control
Peddinghaus
1
yes
yes
Signomat (option)
Peddinghaus
1
no
yes
In-feed and out-feed conveyors
Peddinghaus
1/1
no
yes
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Operating Instructions for the Peddimat tandem Saw/Drill Line
3.3 Dimensions and weights Description Drilling machine incl. control Band saw incl. control console (option) Circular cold saw LC 1250 (option) Hydraulic power pack Signomat (option) Control In-feed and out-feed conveyors
Dimensions L x W x H (mm) 2100 x 6100 x 3000 2600 x 3250 x 2300 1450 x 3350 x 2400 1100 x 700 x 1150 1400 x 900 x 1700 850 x 800 x 1500 12140-24020 x 1590 x 660
Weight (kg)
Method of loading 10.000 Crane 3.300 Crane 9.000
Crane
550 Crane / forklift 1100 Crane/forklift 300 Crane/forklift depending Crane/forklift on weight
3.4 Unloading, loading of the machine and assemblies The assemblies / machine must be conveyed by a suitable means of unloading (crane / forklift). Use suitable cables, chains or straps in accordance with the weights for loading or unloading. (see 3.2). The arrangement of the cables (chains) and the points of attachment to the machine and assemblies can be taken from the drawings.
Warning!
♦ machine or assembly suddenly falls down − crushing of persons or parts of the body It is prohibited for persons to walk or dwell in the danger zone of the machines or assemblies.
The following points must be observed upon delivery of the machine and assemblies:
Warning!
♦ only lift the machines or assemblies off the carrying vehicle by means of crane or forklift truck ♦ unloading and transportation of the machine and assemblies to the erection site must be carried out by a qualified person with the aid of a crane or forklift truck and, at the same time, observing all safety requirements. ♦ attachment of the cables or chains to the machine components must only be carried out with shackles or straps ( in accordance with the load ).
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Operating Instructions for the Peddimat tandem Saw/Drill Line
3.5 Storage location, duration, protective measures
If the machines and assemblies are put into storage, attention must be paid to the following points! Max. period of storage
♦
Longer storage
♦ if a period of 1 month is exceeded, a new coating of preservative must be applied to the assemblies
Protective measures
♦ ensure adequate protection against dust and dirt ♦ the base preservative must not be removed ♦ protect all electrical and electronic parts against condensation of water.
Ambient temperature
♦
3.6
1 month
storage not below + 5 C ° to max. 70 % humidity
Checking the consignment for damage and missing parts:
The system is to be immediately checked upon delivery for: ♦ visible damage (transportation damage) to the assemblies incl. accessories ♦ completeness of the consignment. If damage ( defects ) to the machine are established, or the consignment is incomplete, direct your claim in writing ( see attached form ) within 1 week to the manufacturer or supplier.
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Operating Instructions for the Peddimat tandem Saw/Drill Line
3.7 Scope of supply Description
Manufacturer
Qty.
Drilling machine incl. control
Peddinghaus
Band saw incl. control console (option)
MEBA
Circular cold saw LC 1250 (option)
Peddinghaus
Hydraulic power-pack
BW Hydraulik
1
Out-feed conveyor (option)
Peddinghaus
1
In-feed conveyor (option)
Peddinghaus
1
In-feed cross transfer table (option)
Peddinghaus
1
Out-feed cross transfer table (option)
Peddinghaus
1
1
Operating materials Accessories Technical documentation Control
Peddinghaus
1
Special accessories: Description
Manufacturer
Peddimat – BDL 1000/9
Qty.
Chapter 3 / 5
Operating Instructions for the Peddimat tandem Saw/Drill Line
3.8 Notification of defects, damage and / or missing parts Name of machine
:
Machine type
:
Year built
:
The following
q damage, q defects, q
missing parts were established on the assem-
blies upon receipt of delivery on....................................................... Transport damage:
q yes
q
no
if yes, indicate nature:
Was the truck driver informed of the damage incurred during transportation? q yes q no Who established that damage had been incurred? Name:
Which parts and equipment are missing ?
When was the consignment checked for completeness? Who did the checking? Name:
Date:
Telephone:
Name and address of the user: Company :
Contact:
Street: Postal code/town: Telephone:
Facsimile:
Complete the questionnaire and post or fax it to:
Company:
Firma Paul Ferd. Peddinghaus GmbH
Address:
D-58285 Gevelsberg, Hasslinghauser Str. 156
Fax.
+ 49 (0) 2332 – 72 208
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Table of contents Chapter 4
Technical specifications 4.1 4.2
Description, model, serial number Technical specifications 4.2.1 Assemblies and machines comprising the system 4.2.2 Overall dimensions 4.2.3 Weights of auxiliary components 4.3 Machine specifications 4.3.1 Overall dimensions 4.3.2 Machine specification 4.3.2 Technical specifications – drilling machine 4.3.2 Technical specification – circular cold saw (option) 4.3.2 Technical specifications - Signomat 4.3.2 Technical specifications – bought-in components 4.3.3 Electrical specifications 4.4 Electrical equipment in accordance with VDE 4.5 Climatic conditions on site 4.6. Foundations
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–2 –2 –2 –2 –2 –2 –2 –3 --3 --4 --5 --5 –6 –6 –7 –7
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Operating Instructions for the Peddimat tandem Saw/Drill Line
4 TECHNICAL SPECIFICATIONS 4.1 Description, model, serial number Description: Model: Serial – No. / Inventory – No. Year built
Drilling machine BDL 1000/9 Peddimat BDL 1000/9
4.2 Technical specifications 4.2.1 Assemblies and machines comprising the system Description Drilling machine Hydraulic power-pack Band saw MEBA ( option ) Circular cold saw LC 1250 ( option ) Signomat (option) Control Out-feed conveyor (option) In-feed conveyor (option)
Manufacturer
Qty 1 1 1
Peddinghaus BW - Hydraulik MEBA Peddinghaus Peddinghaus Peddinghaus Peddinghaus Peddinghaus
1 1 1
4.2.2 Overall dimensions Unit mm mm mm
Overall width Overall length Overall height of the system
Dimensions Com. 6500 2720 2900
4.2.3 Weights of the auxiliary components Unit kg kg
Signomat Hydraulic power-pack Out-feed conveyor (option)
kg
In-feed conveyor (option)
kg
Dimensions Com. 1100 550 Depends on length
4.3 Machine specifications 4.3.1 Overall dimensions Overall Overall Overall Weight
Unit mm mm mm kg
width of machine length of machine height of machine of machine Peddimat – BDL 1000/9
Dimensions Com. 2720 6500 2900 10000 Chapter 4 / 2
Operating Instructions for the Peddimat tandem Saw/Drill Line
4.3.2 Machine specifications 4.3.2.1
Drilling machine technical specifications
BDL 1000/9 G
Metric
Max. working width Max. working height Max. traversing speed in the X-axis Traversing speed web (Y-axis) Traversing speed flanges ( Z and W axes) Work-piece weight Measuring range Total connected load Air consumption / per hour Air pressure Control Machine height)
dimensions
(depth
x
width
1000 mm 420 mm 40 m/min 20 m/min 17 m/min Max. 8000 Kg 99,999 m 50 kW approx. 80 m³/h 6 bars CNC 840 D x
2720 x 6500 x 2900 mm
Weight Number of drill spindles Number of drill spindles per axis
approx. 10.000 kg 9 3
Feed rates, program controlled
25 – 300 mm/min
Drill speeds Spindle 1 from – to min-1 Program Spindle 2 from – to min-1 Program Spindle 3 from – to min-1 Program Drill diameter from – to Work-piece dimensions I beams (INP) I beams (IPE) Standard channels (UNP) I beams (HEB) I beams (HEA) I beams (HEM) Angle iron, equal legs
Angle iron, unequal legs
10 – 580 10 – 395 10 – 580 8 – 40 mm 80 – 600 mm 80 – 600 mm 50 x 25 mm - 400 mm 100 – 1000 mm 100 – 1000 mm 100 – 1000 mm 80 x 8 mm 200 x 28 mm 80 x 65 x 8 mm 250 x 90 x 16 mm
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4.3.2.2 Circular cold saw technical specifications (option)
LC 1250
Metric
Max. beam width at 90° Max. beam width at 45° Max. beam depth Connected load Air consumption/ per hour Air pressure
1000 (1250) mm 700 (800) mm 440 mm 20 kW 50m³/h 6 bars
Machine dimensions depth x width x height Weight (loading and shipping weight incl. base plate Weight not incl. base plate Blade Blade diameter diameter Kerf Kerf Cutting speed standard design Cutting speed ( option ) Blade feed Blade return speed Work-piece dimensions I beams (INP) I beams (IPE Standard channels (UNP) I beams (HEB) I beams (HEA) I beams (HEM) Angle iron, equal legs
Angle iron, unequal legs
1450 x 3105 x 2375 mm 10.000 kg 8.300 kg 1250 mm 9 mm max. 40 m/min 20 / 40 m/min max. 4 m/min 6 m/min
80 – 600 mm 80 – 600 mm 50 x 25 mm - 400 mm 100 – 1000 mm 100 – 1000 mm 100 – 1000 mm 80 x 8 mm 200 x 28 mm 80 x 65 x 8 mm 250 x 90 x 16 mm
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Technical specifications – Signomat (option) Type
Signomat 05
Marking speed
Seconds per stroke
1.5
Marking pressure
kN
0 – 75
Height adjustment – cylinder stroke
mm
0 – 650
Marking stroke
mm
100
Pass through dimension
mm
8 – 165
Machine dimensions
approx. Mm
1400 x 900 x 1700
Weight
approx. Kg
1200
Workpiece sizes
All standard section sizes processed on the saw/drill line (angles, channels and I beams) can be marked.
4.3.2.4 Technical specifications of bought-in components (Options) Description Hydraulic power-pack CNC control Processing software Band saw ( option Chip conveyor
•
Manufacturer BW - Hydraulik Siemens Farm Design ) MEBA IFT
Supplier manual refer refer refer refer refer
to to to to to
manual manual manual manual manual
* * * * *
Please refer to the separate instructions manuals included in the scope of supply for the technical specifications of bought-in components.
Peddimat – BDL 1000/9
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Operating Instructions for the Peddimat tandem Saw/Drill Line
4.3.3 Electrical specifications Unit kW 3 PE V A
Connected load Type of mains Control voltage AC/DC Fusing max.
Value
Com.
55 400 V 220 / 24 50
4.4 Electrical equipment in accordance with VDE Enclosed, air conditioned control console with control and power outputs for: ♦ axis drives, ♦ hydraulic pump, ♦ tank heater, ♦ main spindle drive ♦ drill hydraulics ♦ coolant, ♦ clamping hydraulics ♦ E-stop system. ♦ built-in CNC – control using micro-processor technology, Model Sinumerik 840 D from Siemens ♦ compact unit for logics and operating panel, ♦ control panel with TFT monitor, machine control panel, ♦ RS232 C interface, V 24 or 20 MA, buffered parts programme memory. ♦ system diagnostics and integrated PLC control. The system is installed by Peddinghaus engineers. It is only to be powered up by a qualified electrician. Electrical hook-up is to be effected in accordance with the circuit diagrams whereby the VDE 0100 regulations and the special regulations of the local electricity supply company are to be observed. Compare the operating voltage with the available mains supply. The operating voltage of the machine is stated on a card attached to the switch cabinet. The voltage stated is the phase-to-phase voltage ( voltage between the phases L1-L2-L3). The phase-to-phase voltage must not exceed a maximum of VAC + 0%! Primary fusing and the power supply cable are to be sized and made available by the user and installed by a qualified electrician in accordance with the layout. In doing so, the VDE 0100 regulations and the special regulations of the local power supplier must be observed. The power supply cable for a connected load of 55 KW (not including optional equipment) must be installed at the point depicted in the layout and be of sufficient length above the ground.
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4.6 Climatic conditions on site The following climatic conditions must be maintained in order to guarantee trouble-free operation of the system: Ambient temperature:
♦ ♦
Humidity:
♦ ♦
Height:
♦ 1000 m above sea level
+ 5 C° / + 40 C° the average air temperature must not exceed over a period of 24 hours.
+ 35° C
30 % to 95 % (non-condensing) Standard 70
4.6 Foundations The machines and their appropriate material handling system must be placed on a level foundation and bolted to the floor! ♦ Level concrete flooring with a thickness of at least 200 mm is required. The floor load is approx. 5 kg / cm2. ♦ The depth of the foundations depends on the existing site conditions. The user is responsible for the installation of the correct foundations. (refer to the foundation drawing in Part 2 of this manual).
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Table of contents Chapter 5
Installation, assembly, initial start-up 5.1 Factory site / place of use 5.2 Machine and foundation dimensions 5.3 Erecting the system 5.3.1 Installation and assembly of the machine (A) 5.3.2 Installation and assembly of the hydraulics (B) 5.3.3 Installation and assembly of the conveyors (C) 5.3.4 Installation of the control console (D) 5.3.5 Fitting the safety equipment (E) 5.3.6 Mounting the air supply lines (F) 5.3.7 Fitting the electrical connection cables (G) 5.3.8 Hook-up of the power supply (H) 5.3.9 Cleaning machine components (I) 5.4 Conditions for initial start-up / trial run 5.5 Initial start-up / trial run 5.6 Acceptance protocol
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5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
– – – – – – – – – – – – – – –
2 2 2 3 3 4 4 4 4 4 5 5 6 7 9
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Operating Instructions for the Peddimat tandem Saw/Drill Line
5 INSTALLATION, ASSEMBLY, INITIAL START-UP 5.1 Factory site / place of use To ensure guaranteed accuracy in conjunction with maximum machine and component stability, the following conditions must prevail on site: ♦ a level concrete floor, at least 200 mm thick ♦ the floor load capacity must be at least approx. 5 kg/cm 2 (machine weight approx. 10.000 kg) ♦ foundations prepared in accordance with Peddinghaus specifications ♦ power supply point (connected loads Chapter 4.)
5.2 Machine and foundation dimensions The machines must be placed on a smooth, level foundation and securely welded (refer to foundation drawing). The machine and foundation dimensions are to be taken from the enclosed drawing
5.3 Installing the system The installation of the system in conjunction with the initial start-up must be carried out by the manufacturer’s service engineers. ( Chapters 1.3 and 1.5 Fundamental notes ). Please take all installation dimensions from Chapter 5. The following installation work must be performed in the sequence indicated: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Installation and assembly of the system Band saw from Meba Drilling machine Signomat (option) Hydraulic power-pack Control console Hoop-up of the power supply Assembly of the pneumatic and hydraulic connections Fitting the safety equipment Cleaning the drilling machine and auxiliary components
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Operating Instructions for the Peddimat tandem Saw/Drill Line
5.3.1 Installation and assembly of the machine (A) I. The following action is required for installing the machine: 1. Attach the lifting cables to the machine’s lifting lugs with shackles (appropriate to the loads). 2. Lift the machine by crane and place on the foundation. 3. Place machine on foundation.
Warning!
• machine suddenly sways or drops − crushing of persons or parts of the body Do not dwell or walk in the danger zone or under the suspended load!
II. Fixing the machine to the foundations: ♦ in accordance with the manufacturer’s specifications, a solid connection must be created between the foundations and the machine.
5.3.2 Installation and assembly of the hydraulics (B) − place the hydraulic power-pack, using suitable lifting gear ( crane/forklift truck ) on its location and install − install the hydraulic piping
Warning!
• components suddenly drop down − crushing of persons and parts of the body Do not dwell or walk in the danger zone or under the suspended load!
The hydraulic power-pack is supplied without fluid! The following points must be observed when filling the machine with hydraulic fluid: Chapter. 9.7.2 >
− only use the prescribed hydraulic fluid (Chapter.9.7.2) − use a filter when filling − close the filler cap tightly when filling completed
The following work is required for this purpose: Chapter. 9.7.4 >
− Remove the filler cap − Pour in hydraulic fluid up to 1 cm below the max. level (observation glass) − Replace filler cap − Absorb and dispose of spilt fluid immediately (danger of slippery floor surface)!
The oil level is to be checked after a test run and replenished, if necessary! Caution!
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Operating Instructions for the Peddimat tandem Saw/Drill Line
5.3.3
Installation and assembly of the conveyors (C) − place the conveyors on the in-feed and out-feed sides in position with the aid of suitable lifting gear ( crane/forklift truck ) and assemble
Warning!
• components suddenly drop down − crushing of persons and parts of the body Do not dwell or walk in the danger zone or under the suspended load!
5.3.4 Installation of the control console (D) Assembly work:
Warning!
− Place the console in position with the aid of suitable lifting gear (crane/forklift truck) and fix in position − install the electric cables to the machine and the components
• components suddenly drop down − crushing of persons and parts of the body Do not dwell or walk in the danger zone or under the suspended load!
5.3.5 Fitting the safety equipment (E) Position the guards and safety equipment and assemble.
5.3.6 Mounting the air supply lines (F) − − − −
Fitting:
assemble the air supply lines on site the supply pressure must be 6 bars only use dry compressed air check lines and connections for leakage
5.3.7 Fitting the electrical connection cables (G) • electrical energy This work is only to be carried out by a qualified electrician ( refer to Chapter 2.10) Caution!
Installation work:
− install all electrical connection cables from the console to he machine, components and operating controls.
Peddimat – BDL 1000/9
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Operating Instructions for the Peddimat tandem Saw/Drill Line
5.3.8 Hook-up of the power supply (H) • Electric power Hook-up is only to be carried Chapter 2.10)
out by a qualified electrician
(refer to
Caution!
− Connect the terminals L1, L2, L3, PE in the switch cabinets to the power point 3 PE 400V 50 Hz. (refer to Chapter 4 for connected loads) When the machine has been connected up to the power supply, the direction of rotation of the drive motors must be checked and corrected, if necessary.
5.3.9 Cleaning machine components (I) All components of the machine protected by anti-corrosive : − guides − tool chucks − etc. must be cleaned with a suitable solvent or cleaning agent (refer to manufacturer’s instructions in respect of the solvent/cleaning agent to be used). Pay attention to the applicable regulations when disposing of the solvent (waste disposal act)!
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Operating Instructions for the Peddimat tandem Saw/Drill Line
5.4 Conditions for initial start-up / trial run Conditions:
− the service personnel must be fully acquainted with the machines and know how to handle them.
The following instructions on safety must be observed under all circumstances prior to turning the machine on! On site prior to powering up: Checks must be made to ensure that: Warning!
♦ all documentation i.e. operating instructions manuals, electrical, hydraulic, pneumatic circuit diagrams, technical drawings or testing equipment etc. are available. ♦ all guards and safety equipment are in place and no unprotected danger zones exist in the areas of access. Start-up: The checks must also verify that the following points coincide with the plicable sections of the safety standards:
Warning!
ap-
♦ that separation/connection of the power supply and the normal stopping and starting of the machine function properly. ♦ that acoustic and visible warning facilities function properly. ♦ that speeds and areas of movement of all movable components are in line with specifications and that all limit switches and E-stops operate properly when actuated. Faults incurred during installation/assembly:
Warning!
♦ It can happen, as a result of incomplete assembly of various components, that during the installation process and at start-up, hazards of varying nature occur. ♦ The person responsible for installation and start-up must carefully study the requirements set forth in the instructions on machine installation and ensure that such requirements are met and all safety instructions fully applied.. Overview of the control and display elements as well as the fault indicators; refer to Chapter 6.2
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Operating Instructions for the Peddimat tandem Saw/Drill Line
5.5 Initial start-up / trial run The installation and start-up personnel must carry out the following work: Procedures 1 - 21
1. Turn main switch to position ON • the CNC control will be turned on.
Chapter. 6.3.2.1 >
2. Perform visual check of all safety equipment 3. Press key „ Control ON „ on the control console • the hydraulics are turned on • wait for approx. 10 seconds until the display “Pressure build-up please wait” extinguishes. The LED lamp above the key lights up 4. Press key „ Secure system”
Chapter. 6.3.3.2 >
Warning!
5. Check E-stop by: − pressing E-stop • the hydraulic system will be turned off • The message „ E-stop pressed“ will appear on the control display.
• E-stop malfunction − danger of injury to the operator If the functional test cannot be performed as described, immediately turn off the machine and notify the manufacturer’s customer service department!
6. Unlock E-stop 7. Press key „ Control ON „ • the LED lamp above the key lights up hydraulics are turned on 8. Press key “ secure system „ • control voltage, the error message on the control display extinguishes Chapter. 6.3.2.2 > Chapter. 6.3.2.3 >
9. Make functional check of safety switches on the safety gates or − conduct a visual and functional check of the safety light barrier (optional)
Chapter. 6.5 >
10. Carry out adjustments and checks
Chapter. 6.6 >
11. Turn on the peripheral components ( conveyors ) 12. Press key „ Spindle start „ • the main spindle drives are activated 13. Press key „ Tool automatic „ • the tool call-ups are activated automatically in line with the programme Peddimat – BDL 1000/9
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Operating Instructions for the Peddimat tandem Saw/Drill Line 14. Press key „ Coolant ON „ • the coolant feed is enabled The system is ready for operation. 15. Conduct a test run of the system. The following action is to be taken when the prescribed system quality has been achieved and no faults detected: 16. Check function of all safety equipment and record in the acceptance protocol. 17. Train and instruct all operators on the system ( hand-over ) Chapter. 6.8 >
18. Turn the system off
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Operating Instructions for the Peddimat tandem Saw/Drill Line
5.6 Acceptance Protocol Name and address of user: Company: ______________________________ Street:________________________ Postal code/Town: _______________________________________________________________ Name of system:__________________________________ Serial No.:
______________________________
Model: __________
Year built: _________
Name of the service and training engineer:_____________________________________ Name of the tester/user: ________________________________________________ System started up on : _ _________________________________ Check of operating and safety equipment performed as per Chapter. 5.5 / 19 on: ________________________________________ Training on the machine carried out on: ______________ Duration: _______________ Machine handed over on:__________________________________________________ Names of operators trained: ____________________________________________ _______________________________________________________________________ The operators trained on the machine confirm the requirements set forth in Chapter 2, section 2.3 by the manufacturer by applying their signature. _______________________________________________________________________ _______________________________________________________________________ Signature(s) The machine was handed over in proper operational condition.
__________ Date
__________________ Signature
The machine was handed over in proper operational condition.
_____________ Date
___________________ Stamp / Signature Peddimat – BDL 1000/9
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Operating Instructions for the Peddimat tandem Saw/drill Line
Table of contents Chapter 6
Operating the machine 6.1 6.2 6.3
6.4 6.5
6.6 6.7 6.8 6.9
Introduction Operating and display controls, fault messages 6.2.1 The Siemens control 840 D 6.2.2 Controls on the control console The safety equipment 6.3.1 Guards, safety fence with safety gates, light barrier 6.3.1.1 The guards on the machines 6.3.1.2 Safety fence with gates 6.3.1.3 The safety light barrier 6.3.2 Checking the guards, the safety fence with gates and light barrier 6.3.2.1 Visual check 6.3.2.2 Functional check of the safety switches on the safety gates 6.3.2.3 Visual and functional check of the safety light barrier ( option ) 6.3.3 E-stop facilities 6.3.3.1 Operating the E-stop on the system 6.3.3.2 Functional check of the E-stop facility 6.3.3.3 Restarting the system after E-stop Mode of operation and work-cycle 6.4.1 Automatic operation Adjustments and checks prior to commencing work operations 6.5.1 Checking the pressure of the clamping and measuring rolls 6.5.2 Checking the hold-down / adjustment 6.5.3 Checking the drill assemblies 6.5.3.1 All tools in place 6.5.3.2 Drill rates of feed 6.5.3.3 Changing the drill bits Instructions for checking, adjusting and switching on the system Turning off the system on normal operation Restarting the machine after a power failure Instructions for switching individual modules on/off
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3 4 4 5 8 8 8 9 9 9
6–9 6 – 10 6 - 10 6 6 6 6 6 6 6
– – – – – – –
11 11 11 11 12 12 13
6 – 13 6 – 13 6 – 14 6 - 14 6– 14 6 - 15 6 – 16 6 – 17 6 – 17 6 – 18
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.10 6.11 6.12 6.13 6.14 6.15
6.16
6.9.1 Switching the band saw on/off (option) 6.9.2 Switching the circular cold saw on/off (option) Loading / unloading the machines Disposal of swarf/chips Checking the coolant system Replenishing lubricating coolant Regulating the amount of coolant Maintenance instructions for the operator 6.15.1 Maintenance instructions for the drilling machine 6.15.2 Maintenance instructions for the band saw ( option ) 6.15.3 Maintenance instructions for the circular cold saw ( option ) List of addresses 6.16.1 Addresses for manual data input
6 – 18 6– 18 6– 6– 6– 6– 6– 6– 6– 6-
19 19 20 21 21 22 22 22
6 – 23 6 – 23
6.17 Error messages 6 – 26 6.17.1 BDL error messages 6 – 26 6.18 Trouble shooting 6 – 27 6.18.1 No drill call-up 6 – 27 6.18.2 No axis movement ( Y,Z,W and Q on the drill, U and 6 – 28 V on Signomat and saw ) 6.18.3 No X-axis movement 6 – 28 6.19 Summarised operating instructions 6 – 29 6.19.1 Turning the system on 6 – 29 6.19.2 Jog mode 6 – 30 MDA mode 6 – 31 6.19.4 Loading programmes 6 – 32 6.19.5 Deleting programmes 6 – 33 6.19.6 Deleting a programme 6 – 33 6.19.7 Deleting several programmes 6 – 33 6.19.8 Processing parts programmes 6 – 34 6.19.9 Single part output( FD software only ) 6 – 35 6.19.10 Manual entry of a programme 6 - 36
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Operating Instructions for the Peddimat tandem Saw/drill Line
6 OPERATING THE MACHINE 6.1 Introduction This instructions manual is thought for technically, specially trained and qualified nel or personnel with expert knowledge in the field of NC technology.
person-
Full knowledge and technically perfect implementation of the safety instructions and warnings are prerequisites for non-hazardous operation. Only qualified personnel have the necessary expert knowledge to correctly interpret and implement the safety instructions and warnings provided in the generally accepted manner.
Peddimat –BDL 1000/9
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.2 Operating and display controls, fault messages 6.2.1 The Siemens control 840 D
Funktionstasten
Achsanwahltasten
Drill Hold Down 1 On
Drill Hold Down 2 Off
X
Y
Tool Off
Drill Coolant On
Y-Z-W Automatic On
W
Q
Tool Mark
Saw Trim Cut On
Saw Inital Setting
V
A
Tool Test
Inspect Plant
Protect Plant
Sprayer
Laserpointer
Control Off
Control On
-
Tool Automatic
Peddimat –BDL 1000/9
Z
U
WCS MCS
Rapid
+
Chapter 6 / 4
Operating Instructions for the Peddimat tandem Saw/drill Line
6.2.2 Controls on the control console No
Description
Function
1
E-stop
♦ Turns off the machine in case of hazard or fault • The key locks automatically − Unlock by turning in the direction of the arrow
2
Automatic tool control
• Tool call-ups effected as per programme
3
Hold-down 1
• Hold-down 1 active
4 5
Hold-down 2
• Hold-down 2 active
Tool OFF
• Tool call-ups not executed. Drilling, marking , sawing operations not executed. • Tool command interrupted
6
Coolant ON/OFF
• Internal coolant supply turned ON/OFF
7 8 9
YZW automatic mode ON Tool mark
• Stand-off automatic mode ON/OFF • The drills pop mark
Trim cut
• Trim cut active/inactive
10 Saw home position
• Saw frame traverses to topmost position.
11 Tool test
Drill spindles briefly extend from the home position
12 Enter danger zone
The system functions are turned off in a controlled manner. * The safety gates unlocked • The safety gates are locked
13 Secure system 14 Laser pointer 15 Control ON 16 Control OFF
• Turn laser pointer for manual saw cut on ( only applies to the MEBA band saw ) • Hydraulic system turned on • Hydraulic system turned off * CNC control remains on
For description of keys 14 – 20, refer to the SIEMENS operating manual. • X-axis activated 17 Select X-axis
18 Select Y-axis
• Y-axis activated
19 Select Z-axis 20 Select W-axis
• Z-axis activated • W-axis activated
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Operating Instructions for the Peddimat tandem Saw/drill Line
21 Select Q-axis
• Q-axis activated
22 Select U-axis
• U-axis activated
23
* A-axis activated * Cooling lubricant for band saw ON
24
Select A-axis Saw spray oil
25 Clamp saw
* Horizontal vice is opened in sawing cycle
26 WCS/MCS 27 - key
* Switch-over key „drill axis/linear axis“ * The axis selected is traversed in the minus direction
28 Rapid
• Rapid key. The axes are traversed at rapid speed when the “RAPID” key is pressed in conjunction with the plus or minus key
29 + key
• The axis selected is traversed in the + direction
30 Main switch ON/OFF
♦ Switch position ON • system is supplied with current • the CNC control is switched on υ Switch position OFF • the system is de-energised the hydraulic tank heater remains on can only be turned off using the DO-Q 22 switch ( in the power section ) Attention! Press the “EXIT” key on the computer keyboard before tuning off the main switch. The computer is run down. Only turn off the main switch when the message “Computer is now safe. Restart” appears on the screen.
31 E-Stop
32 Jog 33 Teach-in 34 MDA 35 Auto
36 Reset (red) 37 Single block
• Turns off the complete system in case of hazard or a fault. • The key is self-locking * Turn in direction of arrow to unlock ♦ Manual traversing of the axes
♦ This key is not used • Manual data input • Automatic run-off on parts programmes Attention: Parts programmes can only be managed with the control turned on and in automatic mode! Reset key: delete errors, reset control, interrupt parts programmes Single block key: running off a parts programme block for block Peddimat –BDL 1000/9
Chapter 6 / 6
Operating Instructions for the Peddimat tandem Saw/drill Line
38 Cycle stop ( red )
Programme stop key
39 Cycle start
Programme start key
40 Potentiometer spindle speed 41 Potentiometer spindle feed
υ Potentiometer spindle speed override Speed change of 50% - 120% of the value specified in the part programme Potentiometer % of axis feed
42 Spindle stop ( red )
υ Main spindle drive stop
43 Spindle start (green)
υ Main spindle drive start
44 Feed stop ( red )
υ Axis feed stop
45 Feed start ( green )
υ Axis feed start
46 Key switch
Green key: The green key is only for service purposes Orange key: the orange key is only to be used by authorised personnel Attention! Improper use can lead to all data being erased. COMPLETE MACHINE STANDSTILL Black key: The black key should always be in the “1” position. Key position “0” = data only displayed. Key position “1” = load or delete data:
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.3 The safety equipment The machine is guarded at the particular points of hazard by safety equipment. The equipment is as follows:
♦ Guards, safety barrier ( fence ) with safety gates ♦ Safety light barrier (Option) ♦ E-stops ( buttons)
6.3.1 Guards, safety fence with gates, light barrier 6.3.1.1 The guards on each machine Hazard caused by:
− unintentional/intentional operation
Prevention:
♦ by rigidly bolted guards at the points of danger
contact with movable parts during
6.3.1.2 Safety fence with gates Hazard caused by:
− unintentional / intentional intervention in the work-cycle of the machine during operation − unintentional / intentional entry into the inner danger zone ( inside the safety fence ) when the machine is in operation
Prevention:
♦ a solid, fully closed off protective area around the whole of the system including safety gates secured by protective switches
Function:
♦ all safety gates must be closed when operating in “automatic” mode ♦ The safety gates must be locked by pressing key„ Secure system„
I the event that a safety gate is to be opened during „Automatic“ mode , the following action is to be taken: Function:
− Press key „ Enter danger zone „ on the control console • the system functions are turned off in a controlled manner • the LED lamp above the key lights up • the safety gate is unlocked and released − the operator is able to enter the inner area of the machine
The system remains turned off when the safety gate is closed until the following action is taken: Action:
− Press key „ Secure system „ on the control console • the safety gate will be locked • the LED lamp above the key lights up − the machine can now be restarted
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.3.1.3 The safety light barrier The system can be equipped with a non-contact safety appliance in the form of a light barrier (AOS), which protects the whole area surrounding the tools. Hazard caused by:
− unintentional / intentional intervention in the work-cycle of the machine during operation − unintentional / intentional entry into the inner danger zone (inside the safety fence) when the machine is in operation
Prevention:
♦ by installing a non-contact safety device in the form of a light barrier which protects the whole area surrounding the tools
Components:
♦ transmitter
Significance of the signal lamps on the light barrier Function Effect
Signal lamps green yellow green red Function:
♦ receiver
• • • •
lights up flashes flashes flashes
♦ ♦ ♦ ♦
The protected area is active Fault in system Contaminated or misadjusted The protected is interrupted
♦ the light barrier is constantly active
If the protected area is interrupted during operation: Function:
• all movements of the system are turned off in a controlled manner • the red signal lamp lights up (protected area interripted)
Restarting the machine after an interruption: Function:
− Press acknowledge key „ Light barrier active „ • the LED lamp above the key lights up • the green signal lamp light up (protected area active) − the system can now be restarted
6.3.2 Checking the guards, the safety fence with gates and the light barrier A check of the guards, the safety fence, the safety gates and the light barrier must be carried out prior to turning on the machine.
6.3.2.1 Visual check Action:
− check for tightness − check for damage − the safety gates must be closed
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.3.2.2 Functional check of the safety switches on the safety gates Conditions: Control ON>
♦ Main switch turned on ♦ Control voltage turned on • The LED lamp is on
Action:
− check all safety gates (open and close) and make sure that nobody is in the inner danger zone ( inside the fence ) − press key „ Secure system „ • the LED lamp above the key lights up ♦ the safety switches operate properly!
Warning!
• malfunction of a safety switch − danger of injury to the operator If the functional test cannot be carried out as described, immediately turn the machine off and notify the manufacturer’s service personnel!
Chapter 6.7 >
6.3.2.3
− for further action refer to Chapter 6.7
Visual and functional check of the safety light barrier (op-
tional) I. Visual check Action: 1 - 4
1. Check transmitter and receiver for tightness 2. Check transmitter and receiver for cleanliness and damage 3. Check whether access to the hazardous machine movements is possible from an area that is not protected by the light barrier 4. Check whether the minimum distance between the area of hazardous machine movements to the light barrier has been maintained (compare with info on the nameplate)
II. Functional check − Placing of the test object of suitable diameter in the protected area. − The test object should be moved down very slowly at three different points; in the vicinity of the transmitter/ receiver and at the centre of the protective area. • The indicator lamp that indicates the interruption of the protected area should change when the test object enters the protected area or leaves it. • When the test object is in the protected area, its status should not alter in any way during the whole period.
Warning!
• malfunction of the components − danger of injury to the operator If the functional test cannot be carried out as described, immediately turn off the machine and notify the manufacturer’s service personnel!
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.3.3 E-stop facilities The system is equipped with several E-stops: ♦ Button 1 on the control console ♦ Button 2 at the most dangerous points of the system If an immediate threat of danger to the operator, the machine or to the material occurs, all machine functions can be immediately stopped by pressing the E-stop.
6.3.3.1 Operating the E-stop on the system If an E-stop on the system is operated, the turned off:
following machine functions are immediately
• Control voltage and hydraulics • The message „ E-stop operated“ appears on the control display • The work-cycle is immediately interrupted
Caution!
The impending danger or the fault in the system must be investigated and cleared after an E-stop has been operated.
6.3.3.2 Functional check of the E-stop facilities A check of all E-stop facilities must be made in accordance with Chapter 6.3.3.1 prior to the machine being turned on!
Warning!
• malfunction of an E-stop − danger of injury to the operator’s upper and lower limbs If the functional test cannot be carried out as described, immediately turn off the machine and notify the manufacturer’s service personnel!
6.3.3.3 Restarting the machine after an E-stop The following steps must be taken to restart the machine: Action:
− unlock the E-stop − press key „ Control ON „ • the hydraulics are turned on • the LED lamp above the key lights up - press key “Secure system” - * the control voltage is enabled − the machine can now be restarted - restart the work-cycle ( programme ) Refer to the separate instructions manual issued by Siemens for restarting the programme!
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.4 Mode of operation and work-cycle Virtually all structural steel sections can be drilled, pop marked, sawn and marked on the Peddimat tandem saw drill line. The machine only operates in „Automatic“ mode. Work operations: − place the work-piece on the in-feed conveyor and start the programme by pressing the cycle start key. Start the system • the work-piece is now drilled and sawn in accordance with the programme called up and then discharged automatically onto the out-feed conveyor. − the finished work-piece can now be removed from the out-feed conveyor
6.4.1 Automatic operation The following conditions mode: − − −
must be fulfilled before the machine can be started in „automatic“ all adjustments and checks must have been performed. the machine itself must have been checked. the work-piece must be resting on the in-feed conveyor.
When all conditions for automatic operation have been created, the machine can be started: Starting automatic − press key „ Cycle Start „ operation: • the LED lamp above the key lights up • the work-cycle is initiated Attention: Take note of the display on the screen (e.g. trim cut yes/no) Automatic hold:
−
press key „ Cycle stop „ • the LED lamp above the key lights up • the work-cycle is interrupted Attention: Drilling operations are not interrupted, the axes do not stop immediately but complete the value specified in the data block first.
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.5 Adjustments and checks prior to commencing work operations The following adjustments and checks must be made prior to the machine going into production: Chapter. 6.5.1 > Chapter. 6.5.2 > Chapter. 6.5.3 >
− check pressure of the clamping and measuring rolls. − check and position the hold-down. − check the drill assemblies.
6.5.1 Checking the pressure of the clamping and measuring rolls ♦ Check the pressure of the clamping and measuring rolls. The required clamping pressure depends on the weight and thickness of the material and is between 25 and 70 bars. The pressure can always be measured!
6.5.2 Checking the hold-down / adjustment Check to make sure that the hold-down is at the correct height in relation to the work-piece. Conditions: Control ON
♦ Main switch turned on ♦ Control voltage on • the LED lamp lights up
Action:
− press key „ Enter danger zone „ on the control console • the system functions are turned off in a controlled manner • the LED lamp above the key lights up • the safety gate is unlocked and released − open the safety gate − loosen the lever –1- and set the roller to the appropriate section width - close the safety gate − press key „ Secure system „ on the control console • the safety gate is locked • the LED lamp above the key lights up
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.5.3 Checking the drill assemblies The following checks must be made on the drill assemblies: Chapter 6.5.3..1 > Chapter 7.6>
− All tools (drill bits) in place − Check for correct grinding of the drill bits
The drill speeds are specified by the programme and can be adjusted by the operator on the rotary potentiometer Spindle Override”
6.5.3.1 All tools in place The data pertinent to the drill bits fitted must coincide with those shown on the control display. Change the drills, if necessary (refer to Chapter 6.5.3.3)
6.5.3.2 Adjusting the drill rates of feed The drill feed rates are set by the parts program.
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.5.3.3 Changing the drill bits Change the drill bits in the following manner: Conditions: Control ON Action
♦ Main switch on ♦ Control voltage on • the LED lamp lights up - Press key „Enter danger zone“ on the control console * the safety gate is unlocked and released - open safety gate - knock the drill out of the spindle with a drift - clean the taper - fit new drill and knock gently using an aluminium hammer - close the safety gate - press the key „Secure system“ on the control console * the safety gate is locked * the LED above the key lights up To prevent a newly ground drill from breaking, the cutting edges must be sharpened (whet) by hand with grinding stone.
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.6 Instructions for checking, adjusting and switching on the system Checking and switching on of the system is only to be carried out by an experienced, trained and authorised operator! Conditions:
♦ all E-stops are unlocked ♦ the pneumatics are operating
Work operations 1. Carry out maintenance work prior to operation
1 - 15 Chapter 6.15
2. Set main switch to ON • the CNC control is turned on Chapter 6.3.2.1 >
3. Carry out a visual check of the safety equipment 4. Press key „ Control ON „ on control console • the hydraulics are turned on • the LED lamp above the key lights up
Chapter 6.3.3.2 >
Warning!
5 Check E-stop by pressing it • control and hydraulics will be switched off • the message „ E-stop operated“ appears on the control display.
• E-stop malfunction − danger of injury to the operator If the functional test cannot be carried out as described, immediately turn off the system and notify the manufacturer’s service personnel! 6. Unlock E-stop 7. Press key „ Control ON „ • the LED lamp above the key lights up • the hydraulics are turned on • the error message on the control display extinguishes.
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Operating Instructions for the Peddimat tandem Saw/drill Line
Chapter 6.3.2.2 > Chapter 6.3.2.3 > Chapter 6.5 > Chapter 6.9 >
9. Carry out check of switches on the safety gates or − carry out a check of the light barrier (option) 10. Perform adjustment work and checks 11. Switch on the handling system 12. Press key „ Tool automatic „ * the tools are called up automatically by the programme 13. Press key “Coolant ON” *
the coolant supply is turned on
14. Press key „ Hold-down ON“ „ • the higher ranking selection of the hold-down is active 15. Press key “Y,Z, W Auto ON” The system is ready for operation
6.7 Switching off the system in normal operating mode Switch off the system at the end of a shift in the following manner. Work operations:1- 6 when the programme has been completed: 1. Press key „Enter danger zone„ 2. Press key „Control OFF“ • the LED lamp above the key lights up • the LED lamp above the key 16 extinguishes • the hydraulics are turned off 3. Press the softkey “EXIT” on the screen • the MMC runs down * The message „ Computer is safe, now restart?“ 4. Turn off main switch and lock 5. 6.
Shut off the compressed air supply Switch off the material handling system
6.8 Restarting the system after a power failure When the system is turned off as a result of a power failure • all system movements are turned off The following work operations are necessary to restart the system when the power is restored: Work operations: Chapter 6.9 >
1. Carry out work operations 4 – 10 / 12 – 15.
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.9 Instructions for switching individual modules on/off Modules can be optionally attached to the system, or operate in conjunction with the system, which must, however, be switched on and off separately.
6.9.1 Switching the band saw on/off (option) The band saw must be checked and switched on/off in accordance with the instructions contained in manufacturer’s manual.
6.9.2 Switching the circular cold saw on/off The circular cold saw must be checked and switched on/off in accordance with the instructions contained in the manufacturer's manual.
6.10 Loading / unloading The system is manually loaded and unloaded. Loading:
− place the section to be processed on the in-feed conveyor and feed it, using the joystick, into hat system.
Unloading:
− the section can be removed from the out-feed conveyor upon completion of processing.
Caution!
Caution!
• sharp edged, coolant residues − danger of injury to the operator The operator must wear suitable safety apparel! • work-piece falls downs during loading or unloading operations • danger of injury to the operator In the case of heavy work-pieces, loading or unloading must be carried out with the aid of suitable lifting gear!
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.11 Disposal of swarf/chips The interior of the machine must be regularly cleaned with a brush.
Caution!
Action:
• chips/swarf, coolant residues − danger of injury to the operator The operator must wear suitable safety apparel! − Press key „ Enter danger zone „ on control console • the machine functions are turned off in a controlled manner • the LED lamp above the key lights up • the safety gate is unlocked and released − use hand brush to remove swarf and chips from the interior − press key „ Secure system „ on control console • the safety gate is locked • the LED lamp above the key lights up − the system can now be restarted
Observe the pertinent regulations when disposing of swarf/chips (waste disposal act).
6.12 Checking the coolant system The coolant system must be regularly checked for leaks, damage and coolant level.
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.13 Replenishing cooling lubricant The machine is equipped with a cooling lubricant reservoir which must always be full. The reservoir has a capacity of 1 litre spray oil. We recommend bio spray oil HP 42.
The reservoir is filled as follows: Action:
− Press key „ Enter danger zone „ on control console • the machine functions are turned off in a controlled manner • the LED lamp above the key lights up • the safety gate is unlocked and released − open safety gate - pour in spray oil (refer to instructions manual HP Microspray II) − close safety gate − press key „ Secure system „ on control console • the safety gate is locked • the LED lamp above the key lights up − the machine can now be restarted Check coolant level several times daily and replenish, if necessary.
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.14 Regulating the coolant flow The coolant unit delivers drips of coolant automatically, which are atomised by the flow of air.
The mixture of air and coolant is set at the factory and normally needs not to be changed. Action:
− Press key „ Enter danger zone „ on control console • the machine functions are turned off in a controlled manner • the LED lamp above the key lights up • the safety gate is unlocked and released − open the safety gate − adjust micro dosing unit (refer to instructions manual HP Micro spray II) − close safety gate − Press key „ Secure system „ on control console • the safety gate is locked • the LED lamp above the key lights up − the system can now be restarted
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.15 Maintenance instructions for the operator 6.15.1 Maintenance instructions for the drilling machine Working hours Points to be checked/ maintenance instruc(h) or intervals tions 8 / daily − Check the pneumatic pressure on the cooling system (max. 6 bars) − Check for cleanliness, clean if necessary Chap. 9.7.3 / 9.7.4 − Check fluid level in the hydraulics and replenish, if > necessary Chap. 6.12 / 6.13 > Chap. 7.7 > 40 / weekly Chap. 9.5.1 > Chap. 9.6 >
Materials
Hydraulic fluid
− Check coolant level − Check condition of drill bits and regrind, or replace, if necessary
Spray oil
− Check oil level in drill assembly and replenish, if
BP GR-XP gearbox oil Roller bearing grease.
necessary. Grease machine components
6.15.2 Maintenance instructions for the band saw (option ) Maintenance instructions for the saw are to be found in the MEBA handbook.
6.15.3 Maintenance instructions for the circular cold saw (option) Maintenance instructions for the circular cold saw are to be found in this manual in sections 10.1 – 10.3.2
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.16 List of addresses 6.16.1 Addresses for manual data input By entering addresses, the clamping, sawing, Signoscript, Signomat and drilling functions can be called up one by one. M address
Function
Clamping functions:
M M M M M M M M
22 23 24 25 26 27 28 29
clamp in-feed side/hold-down down in-feed side release in-feed side/hold-down up in-feed side clamp/hold-down down out-feed side release out-feed side/hold-down up out-feed side activate clamps 1 and 3 deactivate clamps 1 and 3 activate clamps 2 and 4 deactivate clamps 2 and 4
Circular cold saw functions
M M M M M
40 41 42 43 44
Band saw functions (option)
M 40 trim cut ON M 41 saw cut M 44/M30 saw blade home position
Signoscript functions (option)
M 45 turn Signoscript on M 46 turn Signoscript off
saw saw saw saw saw
slow speed on trim cut ON fast speed on trim cut ON slow speed fast speed OFF
Signomat functions M 145 Signomat: marking operation (option) M 146 Signomat: traverse Signomat up
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Operating Instructions for the Peddimat tandem Saw/drill Line
M address Drilling
functions
M 51 M 52 M 53 M54 M55 M56 M57 M58 M59 M61 M62 M63 M64 M65 M66 M67 M68 M69 M71 M72 M73 M74 M75 M76 M77 M78 M79
Function
Spindle Y1 drilling Spindle Y2 drilling Spindle Y3 drilling Spindle Y1 pop marking Spindle Y2 pop marking Spindle Y3 pop marking Deselect valves for drilling function Y/activate valves for Y tapping function Activate valves for Y drilling function / deselect valves for Y tapping function Spindle Y1 advance with no rotation Spindle Z1 drilling Spindle Z2 drilling Spindle Z3 drilling Spindle Z1 pop marking Spindle Z2 pop marking Spindle Z3 pop marking Deselect valves for drilling function Z/activate valves for tapping function Z Activate valves for drilling function Z/ deselect valves for tapping function Z Spindle Z1 advance with no rotation Spindle W1 drilling Spindle W2 drilling Spindle W3 drilling Spindle W1 pop marking Spindle W2 pop marking Spindle W3 pop marking Deselect valves for drilling function W/activate valves for tapping function W Activate valves for drilling function W/deselect valves for tapping function W Spindle W1 advance with no rotation
The spindle speed and the direction of rotation as well as the individual rapid feed/feed rates must be entered for the drill addresses.
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Operating Instructions for the Peddimat tandem Saw/drill Line Example of a complete drill call-up: Drilling with spindle Y3 at a speed of 250 r.p.m.: ♦ ♦ ♦ ♦
M1 = 3 S1 = 250 M53 M1 = 100 M1 = 195 M5
* * * *
enable spindle with clockwise rotation and a speed of 250 r.p.m. drilling with spindle 3 at rapid feed feed turn spindle off
M address Diverse functions
Function
M 81 Adjust height of clamping rolls to the dimension set in the R41 parameter ( in mm ). M 88 Web sensing activation M 90 Activate X-axis zero reference lever M 91 Activate X-axis zero reference bar M 95 Measuring system switch-over completed M 96 Switch over measuring system M 97 Activate measuring system on in-feed side M 98 Activate measuring system on out-feed side M 300 Chip conveyor TDK permanently ON M 301 Chip conveyor TDK permanently OFF M 302 Chip conveyor saw permanently ON M 303 Chip conveyor saw permanently OFF M 94 Activate in-feed encoder M 999 Reduce piece counter by one
Address Function Sub-programme function
L 24 Activate encoder on out-feed side L 25 Activate encoder on in-feed side L 74 Travel to X-axis zero reference point S_Measuring Web probes PH_Measuring Measure section depth
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Operating Instructions for the Peddimat tandem Saw/drill Line 6.17 Error messages
6.17.1 BDL – Error messages Error number
Description
700032 700033 700034 700035 700036 700037 700038 700039 700040 700041 700042 700043 700044 700045 700046 700047 700048 700049 700050 700051 700052
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
700053 700054 700055 700056 700057 700058 700059 700060 700061 700062 700063 700140 700141 700142 700143 700144 700145 700146 700148 700149 700150 700151 700152 700153 700154 700155 700156 700157 700158 700239
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
NC fault Fault E/R module (=G1-A11) Watchdog module (=G1-A21)“ Fault on chip conveyor saw Fault on saw motor No oil on drill hydraulics Oil filter contaminated on drill hydraulics Piece counter in excess of 999 Saw option LC 1000 missing“ Saw option LC 1250 missing No air Pressure build-up time for hydraulics, please wait Secure system Quantity reached, select new programme Clamp roll height adjustment on in-feed side in end limit Clamp roll height adjustment on out-feed side in end limit Fault on extraneous ventilator spindle Y (=H1-Q12) Fault on extraneous ventilator spindle Z (=H2-Q12) Fault on extraneous ventilator spindle W (=H3-Q12) Fault hydraulic motor drilling machine (=E1-Q12) Drilling function call up with no programmed speed or spindle. Hold on the machine control panel is active. No coolant Web probing active Saw horizontal vice reached Option Signoscript/Signomat missing Option tapping/countersinking on Y-axis drill assembly missing Option tapping/countersinking on Z-axis drill assembly missing Option tapping/countersinking on W-axis drill assembly missing V saw axis not in home position Fault clamping roll height adjustment (=E2-Q12, = E3-Q12)” Fault on air conditioners (=D0-Q31,=D0-Q32)” Plus end limit X-axis on Signomat reached Minus end limit Signomat reached” Fault chip conveyor drilling machine (=E8-Q12) Fault tank heater drilling machine (=DO-Q22) Fault tank heater band saw (=D0-Q23) Fault control voltage 230V (=D0-Q33)” Encoder switch-over activated with clamps open X-axis encoder not switched over to clamp Saw blockage monitor has responded Over-current saw hydraulic motor ( =E5-Q12) Fault saw motor (=E4-U11) Over-current saw – chip conveyor (=E7-Q12) Over-current saw – coolant pump (=E6-Q12) Saw home position not reached Measuring system clamping block inactive Reserve for saw module FC 141 Saw clamping vice inactive Saw clamping vice not closed Saw clamping vice not open Wrong supply to FB 126 password
Error messages must be acknowledged by pressing the “Reset delete” key.
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Operating Instructions for the Peddimat tandem Saw/drill Line
6. 18.
Trouble shooting
6.18.1 No drill call-up Cause
Remedy
♦ Tool mode “OFF“ active.
− Turn on „Automatic“ mode.
♦ Spindle only extends for a short time. − Turn on „Automatic“ mode. Tool „test“ mode active. ♦ Drill only makes a mark and immedi- − Turn on „Automatic“ mode. ately returns to its home position. Tool mode „ Pop marking“ active. ♦ Message hydraulic fluid level too low. − Check fluid level and replenish ♦ Message clean hydraulic fluid filter.
− Clean fluid filter
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.18.2 No Y,Z,W and Q-axis movement on the drill and no U and Y movement on the Signomat and saw Cause
Remedy
♦ Home position of spindles 1,2 or 3 not − Check limit switch indicated. ♦ Message + Y software limit switch, plus end limit Y-axis reached. ♦ Message -Y software end limit switch, minus end limit of an axis reached. Message – software limit switch of an axis ♦ Feed at 0 percent.
− JOG mode minus key of the appropriate axis, release axis. − JOG mode plus key of the appropriate axis, release axis − Press RESET key
♦ „Feed hold“ on.
− Press „Feed start“ key
− Increase feed
6.18.3 No X-axis movement Cause
Remedy
♦ Home position of spindles 1, 2 or 3 not − Check limit switch. All spindles must be in indicated the topmost position. ♦ Feed at 0 percent.
− Increase feed.
♦ „Feed hold“ on.
− Press „Feed start“ key.
♦ Clamp stations not closed
− Close clamp stations
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.19 Summarised operating instructions
6.19.1 Turning the system on
1. Check compressed air and coolant reservoir 2. Set main switch to ON 3. Wait till the basic screen appears (enter the password in the case of a mains power board or press INPUT key) 4. Press key Control ON and wait till the hydraulic system has started up 5. Press the keys Secure system and Spindle start in succession 6. Press key Stand-off* if necessary 7. Switch on the material handling system 8. The machine is now ready and is in JOG mode * When the stand-off automatic mode is enabled, the drills stop at a distance of approx. 20 mm from the work-piece on the return movement after the holes have been drilled.
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.19.2 Jog mode
X= Y= Z= W=
work-piece axis web drill assembly axis flange drill assembly axis clamping side flange drill assembly axis on the material feed side with Signoscript Q = Z tower V = saw gearbox U = slewing the saw* 1.
Select the axis to be traversed
2.
Press the key Secure system
3.
Press key + or – (also press RAPID for the raid feed key) 4.The axis can only be traversed with the material clamped in position * + Saw slews in clockwise direction – saw slews in anti-clockwise direction
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Operating Instructions for the Peddimat tandem Saw/drill Line
6.19.3 MDA mode
1.
Press key MDA
2.
Enter data if MDA memory empty
3.
4.
5.
6.
If the MDA memory is full, either press key MDA buffer delete or select data using the blue arrow keys and press key DEL and then enter new value Press key Cycle Start If M30 is not indicated in the MDA buffer as the last line (programme end), the programme must be interrupted by pressing the Reset key To skip a block ( fade out ), a semi-colon can be entered in front of the block
For example: M22¶;M23¶M30¶”eof” eof means “end of file” = end of programme
Peddimat –BDL 1000/9
Chapter 6 / 31
Operating Instructions for the Peddimat tandem Saw/drill Line
6.19.4
Loading programmes
The Control ON must have programme should be in process
been
pressed
and
no
Keep the ALT key pressed, press the F key and then load the programmes with the FD software ( refer to page „ single part output FD software )
and move to AUTO mode 1.
Press key Menu select
2.
Press softkey Programme
3.
Press softkey Parts Programme
4.
Use cursor to select MPF programme
5.
Press key Select
6.
Go back to basic screen by pressing key M Machine
Concerning points 4 and 5: when the parts programme has been selected, you only need to press Menu Select twice and you will be back in the parts programme
Peddimat –BDL 1000/9
Chapter 6 / 32
Operating Instructions for the Peddimat tandem Saw/drill Line
6.19.5 Deleting programmes 7.
Press key Menu Select
8.
Press softkey Programme
9.
Press key Parts Programme
10.
Select programme to be deleted by pressing the arrow key
6.19.4 Deleting a programme
1.
Press key Manage Programmes
2.
Press softkey Delete
3.
Question: Delete the marked files with the softkey No, Reply: Yes all of them, Yes or Stop Press the softkey
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