Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Gamma 333 PC
Gamma 333 PC B
Publisher
Komax AG
Industriestrasse 6
CH-6036 Dierikon-Lucerne, Switzerland
Phone
Fax
E-mail
Internet
Date issued
Version number
1998
June 2003
June 2004
January 2007
March 2009
Version 1
Version 2
Version 2.1
Version 3
Version 4
Reproduction of these instructions or parts of them in whatever form is not permitted without express written permission from the publisher.
Komax reserves the right to make technical changes necessary to improve the machine that
could diverge from gures and information in these instructions.
lu
Table of contents
Part A
Information for every machine user
Part B
Information for the machine operator
Part C
Information for the service technician
Part A
1. Product description..................................................................................................................13
1.1 The operating instructions .............................................................................................14
1.1.1 Layout of the instructions ................................................................................14
1.1.2 Size of the instructions......................................................................................14
1.1.3 Updating of the instructions .............................................................................15
1.2 Other types of documentation ......................................................................................15
1.3 Personnel qualications and training ............................................................................16
1.3.1 Personnel qualications ....................................................................................16
1.3.2 Training .............................................................................................................16
1.4 Machine identication ....................................................................................................17
1.5 Technical data / scope of performance .........................................................................18
1.6 Conformity......................................................................................................................19
1.7 Accessories ..................................................................................................................110
2. Safety .........................................................................................................................................23
2.1 Explanation of notes ......................................................................................................23
2.2 Safety notes ...................................................................................................................23
2.2.1 Personal protection ...........................................................................................23
2.2.2 Machine protection ...........................................................................................25
2.2.3 General safety notes ........................................................................................25
2.3 Safety features ...............................................................................................................26
2.4 The RCS safety system ..................................................................................................28
3. Transport ...................................................................................................................................31
Table of contents
03
5. Installation.................................................................................................................................53
5.1 Installation site ...............................................................................................................53
5.2 Installation ......................................................................................................................54
Part B
6. Machine overview and functions ............................................................................................63
6.1 Basic machine ................................................................................................................63
6.1.1 Straightening unit ..............................................................................................65
6.1.2 Transport unit ....................................................................................................65
6.1.2.1 Gamma 333 PC ...................................................................................65
6.1.2.2 Gamma 333 PC-B ...............................................................................65
6.1.2.3 Encoder ...............................................................................................66
6.1.2 Swivel and pull-off unit on side 1 ......................................................................66
6.1.3 Cutting head .....................................................................................................68
6.1.4 Swivel and pull-off unit on side 2 ......................................................................69
6.1.4.1 Good/bad sorting...............................................................................610
6.1.5 Hold-up device ...............................................................................................610
6.1.6 Wire deposit system and conveyor belt .........................................................611
6.1.7 Maintenance unit ............................................................................................611
6.2 Control system .............................................................................................................612
6.2.1 Control cabinet ...............................................................................................612
6.3 Front control panel ......................................................................................................615
6.4 Sensors ........................................................................................................................616
04
Table of contents
Part C
9. Maintenance .............................................................................................................................93
9.1 Notes on maintenance ...................................................................................................93
9.2. Maintenance plan ..........................................................................................................94
9.2.1 Daily maintenance.............................................................................................94
9.2.2 Weekly maintenance .........................................................................................94
9.2.3 Monthly maintenance........................................................................................96
9.2.4 Maintenance every six months .........................................................................97
9.3 Explanation of maintenance procedures........................................................................99
9.3.1 Maintenance unit ..............................................................................................99
9.3.2 Cutting head ...................................................................................................910
9.3.3 Grippers on side 1 and side 2 .........................................................................910
Table of contents
05
06
Table of contents
_____________________________________________________________________
13.2
_____________________________________________________________________
13.3
_____________________________________________________________________
13.4
_____________________________________________________________________
_____________________________________________________________________
14.2
_____________________________________________________________________
14.3
_____________________________________________________________________
14.4
_____________________________________________________________________
15. Putting the machine out of operation, storage and disposal ..........................................151
15.1 Putting the machine out of operation.........................................................................151
15.2 Storage .......................................................................................................................151
15.3 Disposal .....................................................................................................................151
Table of contents
07
08
Table of contents
1. Produktebeschreibung
1.1 The operating instructions .................................................................................................4
1.1.1 Layout of the instructions ....................................................................................4
1.1.2 Size of the instructions..........................................................................................4
1.1.3 Updating of the instructions .................................................................................5
1.2 Other types of documentation ..........................................................................................5
1.3 Personnel qualications and training ................................................................................6
1.3.1 Personnel qualications ........................................................................................6
1.3.2 Training .................................................................................................................6
1.4 Machine identication ........................................................................................................7
1.5 Technical data / scope of performance .............................................................................8
1.6 Conformity..........................................................................................................................9
1.7 Accessories ......................................................................................................................10
Product description
11
12
Product description
1. Product description
The Komax Gamma 333 PC / 333 PC B is an expandable, fully automatic crimping machine with
up to three individual processing stations.
The Komax Gamma 333 PC / 333 PC B is intended for the following wire processing applications if operated according to the technical specications (see Chapter 1.5):
Application
Cutting wire to size / Stripping
Marking
Crimping
Seal application, one end
Tinning
Length measurement
Seal monitoring (on/off)
Crimp force analysis
Splice monitoring
Conveyor-belt deposition of wire
Good/bad sorting
Sequences
Batch sorting
Split cycle
Double crimping
Sleeves
g 1.1 Scope of application for the Gamma 333 PC
This list assumes that the machine is used to process only the materials (conductors, contacts, etc.) specied in the technical data.
Please take a moment now and read through the operating instructions carefully. They will guide
you step by step through Komax Gamma 333 PC / 333 PC B operations, enabling you to be
running it successfully in no time at all.
Product description
13
14
Product description
under Chapter 8
under Chapter 11
under Chapter 12
under Chapter 14
The operating instructions for the accessories are enclosed with each device.
Make sure not to mislay these instructions when unpacking and setting up the device; keep them in the main machine documentation.
Training materials
All training materials, personal notes, and customer-specic documents can also be led in these
operating instructions (under Chapter 13).
Spare parts catalog
The spare parts catalog lists all spare and wearing parts for the basic machine. All spare parts lists
for accessories can also be led here.
If you need additional copies of the sets of documentation, just contact your Komax dealer.
Product description
15
1.3.2 Training
Komax offers individually adapted courses for all, from operators and setup engineers to maintenance and service technicians. You become more familiar with your product, the accessories and
the peripherals and learn how to use them to optimum effect in the production process. Greater
knowledge about maintenance and repairs helps you to increase the availability and service life of
the machine. After successfully completing the training, each participant receives a certicate.
Courses and their contents
The training program is divided into machine-specic and module-specic units. Basically
speaking a training course consists of the following topics:
Tour of Komax
Machine layout
Machine maintenance
Mechanical system
Electrical system
Pneumatic system
Software
Practical exercises
Trouble-shooting
Wrap-up discussion
General information on the way courses are set up
Duration of training: Depends on machine, 1 to 5 days, or as agreed
Venue:
Training center at Komax in Dierikon or at customers premises
Accommodations:
We are happy to make hotel reservations (in downtown Lucerne)
for you.
Training organizer:
Customer Service at Komax in Dierikon
Languages:
German or English
Class size:
The class size is limited to at most three persons.
Training materials:
All materials are distributed on the rst day of training.
16
Product description
Machine type
Voltage version
Power input
1
g 1.01 Machine overview of Gamma 333 PC / 333 PC B
Product description
17
Length accuracy
Length measurement
Stripping lengths
0.125 5.0mm2
AWG26 AWG10
Piece output
see g 1.02
Feed speed
Electrical connection
Air consumption
Weight
mci 721 at 60
mci 721 at 35
4000
3500
mci 721 at 60
3000
2500
mci 721 at 35
2000
mci 721 at 60
1500
mci 761 at 35
1000
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
mci 721 at 90
10000
Conductor
Pneumatic pressure
Speed
Acceleration
Quality monitoring
Press optimization
Crimping modules
FLRY 0.75mm2
6bar (87psi)
10m/s (32.8ft/s)
50m/s (164ft/s2)
active
yes
mci 721
18
Product description
1.6 Conformity
If used in accordance with the operating documents and specications (operated exclusively with
the stipulated protective, safety, and operating devices), this machine is in conformity with
Directive 89/392/EEC as amended by Directives 91/368/EEC, 93/44/EEC and 93/68/EEC (Machinery Directive).
Directive 89/336/EEC as amended by Directives 91/263/EEC and 92/31/EEC (EMC Directive).
Directive 73/23/EEC as amended by Directive 93/68/EEC (Low Voltage Directive).
In addition, we conrm that the machine complies with the following standards:
EN 50 081-2
EN 50 082-2
Product description
19
1.7 Accessories
With the many accessories, the Komax Gamma 333 PC / 333 PC B can be tailored perfectly to
your specic application yet remains open to accommodating future requirements. The following
list gives a quick overview of the possibilities provided by the individual devices.
Blades
Cutting head
Set for stripping lengths up to 30mm on side 1
1
V form stripping blade R 0.1
1
V form stripping blade R 0.5
1
V form stripping blade R 0.75
1
V form stripping blade R 1.0
1
V form stripping blade R 1.5
1
V form stripping blade R 2.0
2
Cutting blade
3 Bad wire cutting blade
1
3
2
g 1.03 Blade head
Wire guides
Various wire guides (arrows) can be used to
ensure optimum wire guidance. Special guides
are available on request.
1 Wire guide
2 Guide hose
3 Wire guide tube, short/long
short
long
1.3
1.5
1.7
2
2.5
3
3.5
4
5
5.5
1
2
Grease: Standard
1 10
Product description
Processing stations
Press accessories
Fixed press positioning
Lever-operated quick clamping system for
mini applicators
Contact feed plates for side 1 and side 2,
side-feed and back-feed
Contact strip cutter, K 455
Paper strip take-up device, K 496
g 1.06
Monitoring
The wire end check is done in the wire drive
with an encoder.
(g 1.07 shows the encoder in the roller
drive for the Gamma 333 PC.)
Product description
1 11
Wire deposition
Standard: 1.5m conveyor belt
Optional: 2m extension for conveyor belt, K 419
4m extension for conveyor belt, K 420
1 12
Product description
Hinweiserklrung
GEFAHR
Bezeichnet eine Gefahr mit hohem Risiko.
Wenn sie nicht gemieden wird, sind Tod oder schwerste Verletzungen die Folge.
WARNUNG
Bezeichnet eine Gefahr mit mittlerem Risiko.
Wenn sie nicht gemieden wird, knnen Verletzungen die Folge sein.
VORSICHT
Bezeichnet eine Gefahr mit geringem Risiko.
Wenn sie nicht gemieden wird, knnen Sachschden die Folge sein.
HINWEIS
Bezeichnet Anwendertipps und andere ntzliche Informationen.
Es ist kein Signalwort fr Gefahren.
Verbrennungsgefahr durch
heisse Oberchen
Verletzungsgefahr fr Augen
durch Kabel und Litzen
Deutsch
Sicherheit
Deutsch
Allgemeine Sicherheitshinweise
Betriebsanleitung
Die Betriebsanleitung ist ein Bestandteil der Maschine. Bevor Sie mit der Maschine arbeiten, muss die Betriebsanleitung gelesen und verstanden werden. Beachten Sie insbesondere die Sicherheits- und Warnhinweise.
Anleitungen Zubehr
Beachten Sie neben den Sicherheitshinweisen in dieser Betriebsanleitung auch die Sicherheitshinweise in den Anleitungen des Zubehrs.
Personensicherheit
Die Personensicherheit ist nur fr einen einzigen Bediener gewhrleistet. Personen die
an der Maschine arbeiten, mssen sich stets vergewissern, dass durch ihr Handeln keine
Personen gefhrdet werden.
Personalqualikation
Die Maschine darf nur von Personen welche die entsprechenden Qualikationen mitbringen
bedient, eingestellt und gewartet werden.
English
Safety
Explanation of notes
DANGER
Indicates a danger involving a high risk.
Not avoiding it results in death or serious injury.
WARNING
Indicates a danger involving a medium risk.
Not avoiding it could result in injuries.
CAUTION
Indicates a danger involving a low risk.
Not avoiding it could result in property damage.
NOTE
Indicates user tips and other useful information.
It is not a word that signals dangers.
The following symbols are used hereafter to indicate the specic dangers posed by the
machine:
English
AVERTISSEMENT
Dsigne un danger risque moyen.
Si on ne lvite pas, il peut entraner des blessures.
PRECAUTION
Dsigne un danger faible risque.
Si on ne lvite pas, il peut entraner des dommages matriels.
REMARQUE
Dsigne des conseils pour utilisateurs et autres informations utiles.
Ce nest pas un mot-cl signalant des dangers.
Par ailleurs, les symboles suiants sont utiliss pour dsigner des dangers spciques la
machine:
Danger: laser
Danger: dcharges
lectrostatiques (ESD)
Danger: explosion
Franais
Scurit
Franais
AVVISO
Contrassegna un pericolo di medio rischio.
Se non viene evitato, come conseguenza si possono subire delle lesioni.
CAUTELA
Contrassegna un pericolo di basso rischio.
Se non viene evitato, possono vericarsi danni materiali.
NOTA
Indica suggerimenti per lutente ed altre utili informazioni.
Non una parola che segnala dei rischi.
Inoltre, vengono impiegati i seguenti simboli per rischi specici della macchina:
Rischio da laser
Rischio di scariche
elettrostatiche
Rischio di esplosioni
Italiano
Sicurezza
Italiano
Espaol
Seguridad
Explicacin de las indicaciones
PELIGRO
Designa un peligro de elevado riesgo.
Si no se evita, provoca la muerte o heridas graves.
ADVERTENCIA
Designa un peligro de riesgo mediano.
Si no se evita, puede provocar heridas.
CUIDADO
Designa un peligro de riesgo reducido.
Si no se evita, puede provocar daos materiales.
AVISO
Designa avisos para el usuario y otras informaciones provechosas.
No es ningn aviso sobre un peligro.
Por lo dems, se emplean los siguientes smbolos para peligros especcos de la mquina:
Peligro de atrapamiento de
dedos o manos
Peligro de aplastamiento de
dedos o manos
Espaol
ADVERTNCIA
Indica um perigo mdio.
Se no for evitado, pode provocar ferimentos.
CUIDADO
Indica um perigo baixo.
Se no for evitado, pode provocar danos materiais.
NOTA
Indica dicas de aplicao e outras informaes teis.
No um sinal de perigo.
Para alm disso, sero utilizados os seguintes smbolos para perigos especcos da
mquina:
Perigo causado por corrente
elctrica
Portugus
Segurana
Portugus
Symbolforklaring
FARE
Angiver fare med hj risiko.
Hvis ikke den undgs, er flgen dd eller alvorlige kvstelser.
ADVARSEL
Angiver fare med mellemhj risiko.
Hvis ikke den undgs, kan flgen vre kvstelser.
FORSIGTIGHED PBUDT
Angiver fare med lav risiko.
Hvis ikke den undgs, kan flgen vre skader p ting.
OBS!
Angiver brugerinformationer og andre nyttige oplysninger.
Er ikke en faresignalbetegnelse.
Forbrndingsfare p grund af
varme overader
Eksplosionsfare
Dansk
Sikkerhed
Dansk
Generelle sikkerhedsanvisninger
Driftsvejledning
Driftsvejledningen er en del af maskinen. Fr der arbejdes med maskinen, skal driftsvejledningen gennemlses og indholdet forsts. Opmrksomheden henledes srligt p
sikkerhedsinstruktioner og advarsler.
Vejledninger for tilbehr
Ud over sikkerhedsinstruktionerne i nrvrende driftsvejledning skal ogs sikkerhedsinstruktionerne i dokumentationerne for tilbehret overholdes.
Personlig sikkerhed
Den personlige sikkerhed kan kun garanteres for en enkelt operatr. Personer, der arbejder
ved maskinen, skal altid overbevise sig om, at deres handlinger ikke indebrer risiko for
andre personer.
Uddannelse
Maskinen m kun betjenes, indstilles og vedligeholdes af personer med den relevante
uddannelse.
Toelichting op de aanwijzingen
GEVAAR
Betekent een gevaar met groot risico.
Indien dit niet gemeden wordt, zijn de dood of ernstige verwondingen het gevolg.
WAARSCHUWING
Betekent een gevaar met middelgroot risico.
Indien dit niet gemeden wordt, kunnen verwondingen het gevolg zijn.
PAS OP
Betekent een gevaar met gering risico.
Indien dit niet gemeden wordt, kan materile schade het gevolg zijn.
AANWIJZING
Betekent gebruikerstips en andere nuttige informatie.
Het is geen waarschuwing voor gevaar.
Hieronder worden de volgende symbolen voor een speciek gevaarlijke machine gebruikt:
Nederlands
Veiligheid
Nederlands
Algemene veiligheidsinstructies
Handleiding
De handleiding vormt een bestanddeel van de machine. Voordat u met de machine werkt,
moet de handleiding gelezen en begrepen worden. Let met name op de veiligheidsinstructies en waarschuwingen.
Handleiding accessoires
Let naast de veiligheidsinstructies in deze handleiding ook op de veiligheidsinstructies in
de handleidingen voor de accessoires.
Veiligheid van personen
De veiligheid van personen is uitsluitend gewaarborgd voor n enkele operator. Personen
die aan de machine werken, moeten zich er steeds van vergewissen, dat door hun handelen geen personen in gevaar worden gebracht.
Kwalicatie van het personeel
De machine mag uitsluitend door hiertoe gekwaliceerde personen bediend, ingesteld en
onderhouden worden.
Merkkien selitys
VAARA
Merkitsee suuren riskin vaaraa.
Vaaran seurauksena voi olla kuolema tai vakava tapaturma.
VAROITUS
Merkitsee keskisuuren riskin vaaraa.
Vaaran seurauksena voi olla tapaturma.
HUOMIO
Merkitsee pienen riskin vaaraa.
Vaaran seurauksena voi olla esinevahingot.
OHJE
Merkitsee vinkkej kyttjlle ja muuta hydyllist tietoa.
Ei viittaa mahdolliseen vaaratilanteeseen.
Shkiskun vaara
Sormien ja ksien
puristumisvaarasormien ja
ksien koneeseen vedetyksi
Silmien vahingoittumisvaara
kaapelien ja johdinten vuoksi
Sormien ja ksien
viiltovammojen vaarasormien
ja ksien koneeseen vedetyksi
Shkstaattisen purkauksen
aiheuttama vaara
Rjhdysvaara
Suomi
Turvallisuus
Suomi
Yleisi turvallisuusohjeita
Kyttohje
Kyttohje on osa konetta. Kyttohje on luettava huolellisesti ja sen sislt ymmrrettv
ennen koneen kyttmist. Perehdy erityisesti turvallisuusohjeisiin ja varoituksiin.
Lisvarusteiden ohjeet
Noudata tmn kyttohjeen turvallisuusohjeiden lisksi mys lisvarusteiden turvallisuusohjeita.
Henkilturvallisuus
Henkilturvallisuus on taattu vain yhdelle ainoalle kyttjlle. Koneella tyskentelevien
henkiliden on varmistettava, ett he eivt vaaranna toiminnallaan muiden henkiliden
turvallisuutta.
Henkilkunnan ptevyys
Konetta saavat kytt, st ja huoltaa vain henkilt, joilla on thn soveltuva ptevyys.
Frklaring
FARA
Indikerar fara med hg risk.
Om varningen inte tas p allvar, kan det leda till att livshotande skador uppstr.
VARNING
Indikerar fara med medelrisk.
Om varningen inte tas p allvar, kan det leda till att skador uppstr.
FRSIKTIGHET
Indikerar fara med lg risk.
Om varningen inte tas p allvar, kan det leda till att sakskador uppstr.
INFORMATION
Indikerar anvndartips och annan vrdefull information.
Detta r inte ett varningstecken.
Nedan visas symboler fr specika faror som kan uppst i samband med att maskinen
anvnds:
Risk fr elchock
Risk fr tennstnk
Svenska
Skerhet
Svenska
Allmnna skerhetsanvisningar
Bruksanvisning
Bruksanvisningen hr till maskinen. Innan arbetet med maskinen pbrjas, r det viktigt
att lsa och frst innehllet i bruksanvisningen. Var extra uppmrksam p skerhets- och
varningsanvisningarna.
Tillbehrsanvisningar
Frutom skerhetsanvisningarna i den hr instruktionsboken ska ven tillbehrens skerhetsanvisningar fljas.
Personskerhet
Personskerheten kan endast garanteras fr en anvndare. Personer som arbetar vid
maskinen mste alltid se till att ingen annan person skadas genom arbetet.
Personalkvalikationer
Maskinen fr endast hanteras, stllas in och underhllas av personer med lmpliga kvalikationer.
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Vysvtlen pokyn
NEBEZPE
Oznauje nebezpe s vysokm rizikem.
Pokud se nebezpe nezamez, jsou nsledkem smrt nebo nejt porann.
VSTRAHA
Oznauje nebezpe se stednm rizikem.
Pokud se nebezpe nezamez, me zpsobit zrann.
POZOR
Oznauje nebezpe s nzkm rizikem.
Pokud se nebezpe nezamez, me zpsobit vcn kody.
UPOZORNN
Oznauje rady pro uivatele a jin uiten informace.
Nen to vstran text pro ohroen.
V dal sti budou pouity nsledujc symboly pro specick nebezpe stroje:
Nebezpe vlivem
elektrostatickho vybjen
Ohroen vbuchem
esky
Bezpenost
esky
.
.
.
.
.
.
.
.
Laser
. ,
.
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.
.
,
.
,
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Komax.
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,
Komax.
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Megjegyzsek lersa
VESZLY
Nagy kockzat veszlyt jell.
Amennyiben nem kerli el, hallhoz vagy slyos srlsekhez vezethet.
FIGYELMEZTETS
Kzepes kockzat veszlyt jell.
Ha nem kerli el, srlshez vezethet.
VIGYZAT
Kis kockzat veszlyt jell.
Ha nem kerli el, dologi krhoz vezethet.
MEGJEGYZS
Felhasznli tancsokat s egyb hasznos informcikat jell.
Veszlyt nem jell.
Magyar
Biztonsg
Magyar
A gp mszaki llapota
Veszlytelen mkds
Amennyiben felttelezhet, hogy a gp veszlytelen mkdse tbb nem biztostott, a
gpet ki kell kapcsolni s az akaratlan bekapcsols ellen biztostani kell.
Biztonsgi berendezsek
A gpet kizrlag mkd biztonsgi berendezsekkel szabad zemeltetni.
A biztonsgi berendezseket, klnsen a vdfedelet nem szabad eltvoltani, thidalni
vagy brmilyen egyb formban manipullni.
Karbantarts
A gpet a megadott idintervallumok szerint kell karbantartani.
Ha a gp nem kerl rendszeresen karbantartsra, gy ennek gpkr lehet a kvetkezmnye.
Ptalkatrszek
A hibs alkatrszeket csak eredeti ptalkatrszekkel szabad ptolni. Az eredeti alkatrszek
a Komax cgnl szerezhetk be.
tptsek
A gpet alapveten nem szabad tpteni. Amennyiben mgis szksgesek lennnek
tptsek, gy ezeket csak a Komax vllalattal trtnt egyeztets utn szabad elvgezni.
Szoftvermdostsok
A szoftver mindennem mdostsa tilos.
Mrkuse selgitus
OHT
Thistab krge riskiga ohtu.
Kui seda ra ei hoita, on tagajrjeks surm vi rasked vigastused.
HOIATUS
Thistab keskmise riskiga ohtu.
Kui seda ra ei hoita, vivad tagajrjeks olla vigastused.
HOIATUS
Thistab keskmise riskiga ohtu.
Kui seda ra ei hoita, vib tagajrjeks olla materiaalne kahju.
MRKUS
Thistab npuniteid kasutajale ja muud kasulikku teavet.
Ei mrgista ohte.
Elektrioht
Laserioht
S rmede v i k te m lj misoht
Tinapritsmete oht
Plahvat soht
Eesti
Ohutus
Eesti
ldised oh t sj hised
Kas t sj hend
Tarvik te j hendid
Personali oh t s
Personali kvalikatsioon
Masinat tohivad kasutada, seadistada ja hooldada ainult vastava kvalikatsiooniga isikud.
Kaitseseadised
Hoold s
Var osad
mberehit sed
Tarkvara modikatsioonid
Tarkvara igasugune moditseerimine on keelatud.
Pastab iaikinimas
PAVO US
ymi pavoj, susijus su didele rizika.
Jeigu jos nevengiama, gali itikti mirtis arba sunkus kno sualojimas.
SPJIMAS
ymi pavoj, susijus su vidutine rizika.
Jeigu jos nevengiama, galite susialoti.
ATSARGIAI
ymi pavoj, susijus su nedidele rizika.
Jeigu jos nevengiama, gali bti padaryta materialin ala.
PASTA A
ymi naudojimo patarimus ir kit nauding informacij.
Tai ne spjimas apie pavoj.
Sprogimo pavojus
Lietuvi k.
Lietuvi k.
Technin prieira
Technin mainos prieir reikia atlikti prajus nustatytam laikui.
Jeigu reguliariai neatliekama technin mainos prieira, ji gali sugesti.
Atsargins dalys
Sugedusias dalis galima keisti tik originaliomis atsarginmis dalimis. Atsargines dalis galite
sigyti i Komax.
Modikavimas
Main modikuoti grietai draudiama. Jeigu main reikia modikuoti, tai galima atlikti tik
suderinus su Komax.
Programins rangos modikavimas
Grietai draudiamas bet koks programins rangos modikavimas.
Nordjumu skaidrojums
BSTAMI
Apzm bstambu ar augstu riska pakpi.
Ja no ts neizvairs, iestjas nve vai var gt nopietnas traumas.
BRDINJUMS
Apzm bstambu ar vidju riska pakpi.
Ja no ts neizvairs, var gt traumas.
UZMANBU
Apzm bstambu ar zemu riska pakpi.
Ja no ts neizvairs, var rasties materilie zaudjumi.
NORDE
Apzm padomus lietotjam un citu lietdergu informciju.
Tas nav risku signlvrds.
Latviski
Droba
Latviski
Objanienie wskazwek
NIEBEZPIECZESTWO
Oznacza zagroenie o wysokim stopniu ryzyka.
Jeli si go nie uniknie, konsekwencj moe by mier lub cikie obraenia.
OSTRZEENIE
Oznacza zagroenie o rednim stopniu ryzyka.
Jeli go si nie uniknie, konsekwencj mog by obraenia ciaa.
OSTRONIE
Oznacza zagroenie o niskim stopniu ryzyka.
Jeli go si nie uniknie, konsekwencj mog by szkody rzeczowe.
WSKAZWKA
Oznacza wskazwki dotyczce uytkowania i inne poyteczne informacje.
Nie oznacza zagroenia.
Niebezpieczestwo poparzenia
przez gorce powierzchnie
Niebezpieczestwo wcignicia
palcw lub doni
Niebezpieczestwo wywoane
przez laser
Niebezpieczestwo zmiadenia
palcw lub doni
Niebezpieczestwo skaleczenia
oczu przez kable i druty
Niebezpieczestwo przecicia
palcw lub doni
Niebezpieczestwo wywoane
odpryskami cyny
Niebezpieczestwo
wywoane przez wyadowania
elektrostatyczne
Niebezpieczestwo wywoane
wybuchem
Polski
Bezpieczestwo
Polski
Explicaia indicaiilor
Legend
PERICOL
Indic un pericol cu risc ridicat.
Dac nu poate evitat, implic vtmri grave sau chiar decesul.
AVERTI ARE
Indic un pericol cu risc mediu.
Dac nu poate evitat, poate s cauzeze vtmri grave.
ATENIE
Indic un pericol cu risc redus.
Dac nu poate evitat, poate s cauzeze pagube materiale.
INDICAIE
Indic recomandri pentru utilizator i alte informaii utile.
Nu reprezint o formul de semnalizare a pericolelor.
Romn
Sigurana
Romn
UPOZORNENIE
Oznauje nebezpeenstvo so strednm rizikom.
Ak mu nepreddete, me ma za nsledok raz.
POZOR
Oznauje nebezpeenstvo s nzkym rizikom.
Ak mu nepreddete, me ma za nsledok raz.
INFORMCIA
Oznauje tipy na pouvanie a in uiton informcie.
Nie je to slovo signalizujce nebezpeenstv.
alej v texte sa bud pouva nasledujce symboly pre pecick nebezpeenstv stroja:
Nebezpeenstvo spsoben
elektrickm prdom
Nebezpeenstvo poplenia na
horcich povrchoch
Nebezpeenstvo spsoben
laserom
Nebezpeenstvo pomliadenia
prstov alebo rk
Nebezpeenstvo poranenia o
kblom a holm vodiom
Nebezpeenstvo od
odstrekujceho cnu
Nebezpeenstvo ESD
(elektrostatickho vboja)
Nebezpeenstvo vbuchu
Slovensk
Bezpenos
Slovensk
TEHLKE
Yksek risk tayan bir tehlikeye iaret eder.
nlenmedikleri takdirde sonucunda lm ve ar yaralanma meydana gelir.
UYARI
Orta derecede risk tayan bir tehlikeye iaret eder.
nlenmedikleri takdirde sonucunda ar yaralanma meydana gelir.
DKKAT
Dk derecede risk tayan bir tehlikeye iaret eder.
nlenmedikleri takdirde sonucunda maddi hasarlar meydana gelebilir.
UYARI
Kullanc nerilerine ve dier yararl bilgilere iaret eder.
Tehlike sinyali iin kullanlan bir kelime deildir.
Trk e
Trk e
Razlaga simbolov
EVAR OST
Oznauje nevarnost z visoko stopnjo tveganja.
e se je ne izognete, so njena posledica smrt ali teke pokodbe.
OPO ORILO
Oznauje nevarnost s srednjo stopnjo tveganja.
e se je ne izognete, so njena posledica lahko pokodbe.
PO OR
Oznauje nevarnost z nizko stopnjo tveganja.
e se je ne izognete, so njena posledica lahko pokodbe predmetov.
APOTEK
Oznauje napotke za uporabnika in druge uporabne informacije.
Ni signalna beseda za nevarnost.
Nevarnost toka
Nevarnost elektrostatine
razelektritve
Nevarnost eksplozije
Slovenina
Varnost
Slovenina
Varnost oseb
bljajo, se morajo vedno prepriati, da s svojim ravnanjem ne ogroajo drugih oseb.
Kvalikacija oseb
Stroj lahko upravljajo, nastavljajo in vzdrujejo samo osebe, ki imajo ustrezno kvalikacijo.
Varnostna oprema
Stroj lahko obratuje le z delujoimi varnostnimi napravami.
Varnostnih naprav, e posebej zaitnega pokrova, ne smete odstranjevati, premostiti ali na
kakren koli nain z njimi manipulirati.
Vzdrevanje
Stroj morate vzdrevati glede na navedene asovne intervale.
e stroja ne vzdrujete redno, so posledica nevzdrevanja lahko okvare stroja.
Nadomestni deli
-
Predelave
Stroja v osnovi ne smete predelati. e je predelava nujna, se jo lahko izvede le po posvetu
Spjega
T ISSIJA
Jindika periklu li jinvolvi riskju medju.
Jekk ma tevitax jirriulta riei.
KA TELA
Jindika periklu li jinvolvi riskju baxx.
Jekk ma tevitax jista jirriulta sara lil proprjet.
N TA
Jindika gajnuniet u informazzjoni utli ora.
Mhux kelma li turi li hemm xi sarat.
Malti
rt
Malti
.
.
.
.
.
.
.
.
.
.
.
.
. ,
.
,
, .
. .
.
- - .
.
.
. Komax.
. Komax.
.
2. Safety
2.1 Explanation of notes ..........................................................................................................3
2.2 Safety notes .......................................................................................................................3
2.2.1 Personal protection ...............................................................................................3
2.2.2 Machine protection ...............................................................................................5
2.2.3 General safety notes ............................................................................................5
2.3 Safety features ...................................................................................................................6
2.4 The RCS safety system ......................................................................................................8
Safety
21
22
Safety
2. Safety
2.1 Explanation of notes
The note boxes in these instructions are marked with three symbols you must understand and
obey. The symbols have the following meanings:
This symbol marks a safety note regarding all work procedures posing a hazard to
you or other persons. Heed these warnings and exercise particular caution in these
situations. Also pass these warnings on to other users.
This symbol is next to all work procedures where special care must be taken to
prevent machine damage. Pass these safety notes on to other machine users.
This symbol signals useful tips and draws your attention to correct procedures and
behavior. Heed these remarks and you will save yourself a lot of time and unnecessary headaches.
Komax AG accepts no liability whatsoever in the event of non-compliance with instructions
marked on the machine or in these notes.
Safety
23
Danger of injury !
The blades can cause cuts even when not in operation. Prior to working
on the cutting head or blades, ALWAYS turn the main power switch on
the machine to OFF.
Cutting head
Wire draw-in
Control cabinet
Wire drive
Feed belt
and wire deposit tray
Swivel and
pull-off units
g 2.01 Potential sources of danger
24
Safety
Safety devices
Before starting the machine, ALWAYS check to see that all safety devices, especially covers, are properly attached and functioning.
Safety requirements
The safety requirements are not met unless the safety devices are functioning properly. Moreover, the machine must be operated according to the scope of application described in Chapter 1 and to the technical specications. Make sure it is not
used for any purpose other than the one stipulated.
Safety
25
Approval switch
When entering a command in setup mode that triggers a machine movement, you
must press the approval switch at the same time or the command will not be executed.
26
Safety
When closing the machine cover, make sure no one can reach into the machine
chamber; otherwise, he or she could get pinched.
Safety
27
Power
switch-on A
Approval A
Feedback B
Approval B
Hazardous components
The RCS safety system (Redundant Control System) operates with two separate channels. Each
safety cover is tted with two switches. Both channels have to give their approval before certain
actions are carried out, e.g. before a crimp module is triggered.
This machine must NEVER be used with the safety covers bridged.
28
Safety
3. Transport
When transporting the machine, please follow the instructions below and heed
general rules of safety and accident prevention.
The Komax Gamma 333 PC / 333 PC B is prepared for shipping as a single unit.
Dimensions of the packaging (WxHxD): 274 x 184 x 201cm
Weight incl. packaging:
approx. 1130kg (machine alone: approx. 840kg)
Up
Keep dry
Keep cool
Delicate
electronic
appliance
Do not load
cover
Delicate
electronic
appliance
Fragile
Weight is not
in balance
Weight is not
in balance
Weight is not
in balance
Corrosion protection
To protect the machine from corrosion, a special mat containing inhibitors is placed in the pakkaging. When the inhibitors vaporize, they protect the metal surfaces. Please note:
Prevent this protective atmosphere from escaping.
Reseal any tears or damage to packaging immediately.
Do not open the package until you use the machine.
For control purposes, the outer covering can be opened briey, but it should be resealed
immediately thereafter. The protective atmosphere is replenished automatically after the pakkaging is sealed.
Transport
31
32
Transport
Check the items delivered against the delivery documents to be sure everything
was sent that was supposed to have been.
Please report any missing or defective parts immediately to Komax AG or the nearest Komax dealer.
41
42
5. Installation
5.1 Installation site ...................................................................................................................3
5.2 Installation ..........................................................................................................................4
Installation
51
52
Installation
5. Installation
5.1 Installation site
Prior to installing your Komax Gamma 333 PC / 333 PC B, check the following points:
Floor:
Even, solid surface free of vibration
Does the oor have sufcient loading capacity?
Machine weighs approx. 840 kg; with two mci 711 crimp presses, approx. 1030kg
Avoid rooms with high humidity!
Ambient temperature should be neither too high nor too low
Power connection
3x208480V, N, PE; 50 60Hz 6kVA
54mm; 25A fuse
Figure in extra space to accommodate wire feed systems, wire deposit system,
pre-processing stations, etc.
Installation
53
5.2 Installation
The machine must be installed and put into operation by an experienced technician.
The weight must be distributed equally among each of the ve feet. The less you
unscrew the feet, the more stable the machine will be.
Make sure to tighten the lock nuts on the threaded rods of the feet.
This will ensure that the additional vibrations of the machine do not cause the stepping motors to
malfunction, e.g., to fall out of step.
54
Installation
When laying the compressed air hoses, be careful not to create any kinks in them.
In hazardous areas around moving parts, the hoses must be secured to keep them
from being abraded and pinched. Select hose lengths that do not impair the movements of the components involved.
Power to the machine must be supplied via a power cable with a cross section of at least
54mm2 (25 A fuse on supply side).
Be careful never to switch around the phase and PEN conductors when connecting
the power!
Installation
55
The PC connections and the terminal assignments are covered in two separate
documents (document Komax PC connection diagram, doc Komax PC hardware
overview). The documents are included in the delivery in a separate package. The
documentations contain the connection diagrams and indicate the assignments of
the PC ports.
56
Installation
Lower the rollers on the extension frame to the position they were in before and move the conveyor belt extension up to the basic module. Align the extension module with the basic module, making sure it is ush in the vertical and the horizontal.
Make sure the ramp does not touch any part of the belt.
Screw the conveyor belts with the two connectors provided and attach the tipping trays as well
as the sections of the deposit trays for the basic and extension modules.
3
4
Installation
57
Power is supplied to the rst extension directly from the control cabinet (connection X07).
Power is supplied to the second extension and any further extensions via the electrical box of
the previous extension.
This completes the installation of the Komax Gamma 333 PC / 333 PC B itself. The installation of the processing stations and the accessories is described in the set of instructions for
each respective device.
The operating and software instructions and the spare parts catalog must be stored in a suitable spot. This also applies to the electrical and mechanical accessories. File away the diagrams
for the compressed air system and the electrical system as well as the I/O list in the operating
instructions under Chapter 11 and Chapter 12.
Dispose of the packaging and pallet in an ecological manner when you nish.
58
Installation
Machine overview
and functions
61
62
Machine overview
and functions
14 15
16
17
18
6
19
10
11 12
1
13
23
22
21
20
5
g 6.01 Machine overview of Gamma 333 PC / 333 PC B basic machine
Straightening unit
Straightens the wire
11
Wire drive
Wire feed, length measurement and wire-end monitoring
12
13
14
Power connection
15
Control cabinet
Contains the power supply and the control
system (PC)
Cutting head
Cuts the wire to the desired length or makes a cut
in the insulation in preparation for stripping; cuts off
bad wire
16
Monitor
17
Operators station
Machine controls and station for the machine
operator
Machine side 1
Processing of the lead end of the wire
18
Keyboard
19
Mouse
20
21
22
10
Machine side 2
Processing of the trailing end of the wire
23 Safety cover
Machine overview
and functions
63
10 11 12 13 14 15 16 17 18
19
20
A
21
22
23
Detail A
Gamma 333 PC B
24
Gamma 333 PC
25
3 5 6
1
2
3
4
5
6
7
8
9
10
11
12
64
Machine overview
and functions
13 Stop button
(to switch off load voltage)
14 Monitor
15 Keyboard
16 Start button
17 Stop button
18 Emergency off switch
19 Opening the safety cover
20 Closing the safety cover
21 Mouse
22 Main switch
23 Control cabinet
24 Contact rollers
25 Waste container (at back)
1 Protection pane
2 Perforated disk
3 Straightening device with quick-action release
4 Installation site for splice detection
(optional)
5 Toolbox
Please consult Chapter 7.5.2 for an explanation
on how to set the straightening units correctly.
5
g 6.03 Straightening unit
5
g 6.04 Roller drive
10
11
12
Machine overview
and functions
65
6.1.2.3 Encoder
The transport unit has a brushless AC servomotor with length measurement and slip
control.
The ASS automatic slip control compares the
two values of the motor encoder and the length
measurement encoder. The roller drive stops if
the maximum value that can be set in the parameters is exceeded.
The swivel and pull-off unit pulls off the insulation after it has been cut into and then approaches the processing stations.
The gripper on the swivel and pull-off unit on
side 1 is pressed down to the crimp tool during
crimping.
66
Machine overview
and functions
Side 2
Side 1
Machine overview
and functions
67
2
3
g 6.05 Cutting head with top and bottom blade block
68
Machine overview
and functions
Wire gripper
Pull-off unit
Swivel unit
Drive belt for the swivel unit
Side 1
Side 2
Machine overview
and functions
69
Gamma 333 PC
Gamma 333 PC B
6 10
Machine overview
and functions
12
15
13
2
1
14
11 10 9 6
The blow-off air connection on the blade block is supplied with unoiled compressed air, so the stripped wire ends are not soiled by oil.
Machine overview
and functions
6 11
1
Basic layout of the control cabinet
1 Main switch
S49
2 Switched-mode power supply 24DC G01
3 Transformer
T01
6 12
Machine overview
and functions
4
5
6
7
8
9
10
11
Piece counter
P20
RCS PCB (Redundant Control System) A04
BIO PCB (Basic Input Output)
A01
Relay strip
K00-K05
Terminal strip
X02
Stepping motor controller SMC 3003 A10
Output stages for stepping motors A11-A15
Electrolytic capacitor
C01
11
10
9
g 6.12 Large mounting plate
14
15
16
17
12 13 14 15 16 17 18 19 20
g 6.13 Small mounting plate with detailed view
12
13
14
15
16
17
18
19
20
Circuit breaker
F01
230 V switch
X04
Power supply to MCI 711
X05
Conveyor belt
X06
Belt extension
X07
Power supply to non-Komax module X08
Fire station
X09
Country voltage in-feed
X01
Mains lter
Z01
Machine overview
and functions
6 13
21
22
23
24
25
21
25
23
22
24
6 14
Machine overview
and functions
7
g 6.15 Front control panel
1
2
3
4
5
6
7
8
Approval key
Start button for switching on the connected load
Stop button for switching off the connected load
Start button
Stop button
Emergency stop key
Switch for opening the safety cover
Switch for closing the safety cover
The exact functions and uses of the controls are described in the software instructions for this machine.
Machine overview
and functions
6 15
6.4 Sensors
The movements of the Komax Gamma 333 PC / 333 PC B are monitored by various sensors.
B10
B11
B12
B13
B14
B16
6 16
Machine overview
and functions
B11
BM4
B12
g 6.19 BM4 sensor swiveling side 2
B11 Sensor lowering side 2
B12 Gripper side 2
Be aware there is a special allocation of pins. Only the RJ45 from Komax can be
used as a communication cable; other cables can destroy transmitters and receivers.
NEVER plug in or unplug RJ45 cables when the connected load is on.
Machine overview
and functions
6 17
6 18
Machine overview
and functions
7. Machine operation
7.1 Checks prior to startup ......................................................................................................3
7.2 Switching the machine ON and OFF .................................................................................4
7.3 Selecting the operating mode ..........................................................................................4
7.4 Safety cover ......................................................................................................................5
7.5 Preparing the machine for production ..............................................................................5
7.5.1 Knot detection .....................................................................................................5
7.5.2 Straightening unit ..................................................................................................5
7.5.3 Wire guide parts ....................................................................................................6
7.5.4 Wire draw-in ..........................................................................................................7
7.5.5 Pull-off unit on side 1 and side 2 ..........................................................................7
7.5.6 Crimping module ..................................................................................................8
7.6 Tool drawer ........................................................................................................................9
Machine operation
71
72
Machine operation
7. Machine operation
7.1 Checks prior to startup
To be able to be operated safely and without being damaged, the machine must
be in proper running condition. Check your machine before each startup, taking
special note of the following points:
Electrical connections
Connecting cables
Maintenance unit
Connections
Safety devices
Emergency stop switches
and cover switches
Turn on machine and check to see that these switches are functioning properly. When emergency stop switch is pressed down, the
load voltage must switch off and the pneumatic system must be
pressureless; the Stop key must remain unlit.
Opening the safety covers must trigger a machine stop!
If the safety devices on the Komax Gamma 333 PC / 333 PC B do not work properly, DO NOT operate the machine. DANGER!
DO NOT commence production until you have successfully carried out all of the
above checks. With a properly operating machine, you can avoid production downtime due to machine malfunctions.
Machine operation
73
g 7.01
power
on
g 7.02
Setup
Production is set up in this operating mode. The setup window appears on the
screen.
The safety covers can remain open during setup, but the approval key function must
be taken into account.
You should proceed with special care in setup mode since the machine can execute movements with the safety covers open. Be especially careful that no one else is
working on or around the machine.
When the machine is switched on, the moving parts of the wire tray, the wire guide
gripper, the grippers on side 1 and side 2, and the hold-up device move into their
default positions, posing a PINCHING hazard!!
74
Machine operation
4
3
Adjustment:
The straightening-roller angle can be set with
screws 1 and 2.
Use eccentric thumb screw 3 to close the
straightening station and scaled dial 4 to set
the wire diameter.
2
g 7.05 Straightening unit
Machine operation
75
Detach the two knurled screws 2 and replace the guide tube 3.
You have two different diameters to choose
from ( 3mm and 6mm).
3
g 7.06 Wire guide parts for the Gamma 333 PC
76
Machine operation
Proceed as follows:
Switch on the machine and reset it.
Open both straightening stations.
Open the cover to the wire drive.
Manually insert the wire up to the transport
rollers or toothed belt.
Machine operation
77
2
g 7.10 Crimp module on height-adjustable positioning unit
Adjustment range:
Height:
20mm
Depth:
2 positions
side 1
Side 2
Front position,
Rear position,
standard position
standard position
5
4
78
Machine operation
The contents of the drawer for the Gamma 333 PC and the Gamma 333 PC B are
identical except for a few items.
The differences are clear from the spare parts catalog.
Machine operation
79
7 10
Machine operation
9. Maintenance
9.1 Notes on maintenance .......................................................................................................3
9.2. Maintenance plan ..............................................................................................................4
9.2.1 Daily maintenance.................................................................................................4
9.2.2 Weekly maintenance .............................................................................................4
9.2.3 Monthly maintenance............................................................................................6
9.2.4 Maintenance every six months .............................................................................7
9.3 Explanation of maintenance procedures............................................................................9
9.3.1 Maintenance unit ..................................................................................................9
9.3.2 Cutting head .......................................................................................................10
9.3.3 Grippers on side 1 and side 2 .............................................................................10
Maintenance
91
92
Maintenance
9. Maintenance
Before doing any maintenance and repairs, especially in the dangerous areas
around moving machine parts and live electrical components, ALWAYS turn off the
machine at the main switch and secure it against unauthorized switch-on.
The maintenance intervals are geared for single-shift operations. In the event of
heavier use, the machine must be serviced more often!
Any shortcomings and defects arising during daily production must be remedied
immediately to ensure the safety of the machine and the personnel.
DO NOT USE compressed air to clean. This will blow minuscule bits of insulation
into the guides, increasing wear and impairing accuracy. If you must use compressed air, remove the parts to be cleaned from the machine rst.
Any parts cleaned with solvents must be immediately relubricated or regreased afterwards.
These maintenance tasks apply to the Komax Gamma 333 PC basic machine only. For information on maintaining and cleaning customer-specic processing stations and accessories, check the
operating instructions for these devices.
Lubricants
In principle, you can use standard commercial types of bearing grease for all bearings. Use highpressure paste for points of contact subject to pressure.
Oils
Use a lubricating oil with a viscosity of SAE 25
for all moving parts.
Grease
The grease below is recommended for pull-off
guides, pinions, lubricating nipples and racks.
Maintenance
93
View
Activity
Entire machine
Component
View
Activity
Maintenance unit
Guide parts
Transport rollers
94
Maintenance
Straightening station
Scrap container
Empty container.
Conveyor belt
Blade head
Maintenance
95
Component
View
Activity
Maintenance unit
Cutting head
96
Maintenance
Component
View
Activity
Wire drive
(roller-driven)
Swivel and
Swivel and
Cutting head
Maintenance
97
Control cabinet
Conveyor belt
Safety cover
Toothed belts
98
Maintenance
7
1
6
2
5
g 9.16 Maintenance unit
The maintenance unit must be completely depressurized when the following tasks
are carried out.
This state is reached when compressed air line 4 is disconnected and the dial on the manometer
reads 0 bar.
Replenishing the oil in the oiler:
Remove sight glass 5.
Pour in oil to Max Oil Level.
Remount sight glass; locking lever must snap into place!
Replacing the waste air lter:
Unscrew drain plug 2.
Pull off plastic cover 6 and remove underlying nut and washer.
Replace lter 7.
Reposition washer and nut.
Mount plastic cover; tighten into place with drain plug.
Maintenance
99
1
3
2
Grippers on side 1:
1 Lubrication nipple, right
2 Lubrication nipple, left
1
3
g 9.18 Lubrication nipples on grippers on side 1
9 10
Maintenance
Grippers on side 2:
1 Lubrication nipple, right
2 Lubrication nipple, left
4
3
Maintenance
9 11
9 12
Maintenance
10 1
10 2
1
g 10.01 Blade head
Unscrew threaded pin 2 to loosen and remove the upper blade block..
To prevent deformation, it is very important that you tighten the threaded pins only
slightly.
10 3
Prior to inserting the new blades, make sure the blade blocks are completely clean,
so the blades will sit rmly in the guides.
When tightening the screws, press the blades in the direction of installation to the stop (arrows).
Blade block, up
The grips on the stripping blades point inward.
The grips on the cutting blades point outward
when the blade blocks are held together.
10 4
Guide parts
Check guide parts for the following types of
damage:
Corrosion
Scratches or impact damage
Ease of movement
Bearings
Running noise or excessive vibrations or
knocks are an indication of bearing problems.
10 5
After adjusting the toothed belts, check each to make sure it is running parallel.
To tighten the toothed belts, you must remove the sheet metal covers and loosen the tensioning
device. Refer to the next chapter for details (10.2.2.1).
Frequency measurement
The frequency is measured to determine the
exact tension of the toothed belt.
This procedure involves striking the toothed
belt to set it vibrating and then measuring the
frequency of the vibration. The measuring head
must be centered between the grooved pulleys
and aligned perpendicular to the belt surface.
1
3
1 Measuring head
2 Indicator
3 Striking the belt
10 6
Toothed belts have relatively rigid tension members in them. Do not force the belt
over the grooved pulley and never force it over a pulley ange.
Check that the pulleys are aligned (ush) and that the axes are absolutely parallel. Avoid any bending, twisting, angling, or buckling of the belt. Make sure the belt does not run out over the faces
of the pulleys. Remember also that once the axis distance is set, it cannot be changed again as
long as the machine is running.
1 6 3
4
6
2
5
10 7
4
2
3
Measurement point 2
1
g 10.06 Belt drive
10 8
1
Measurement point 1
4
g 10.07 Transport unit
10.2.2.1.3 Replacing the drive belt for the swivel head on side 1 and side 2
Side 1
Remove the sheet metal cover from the swivel
unit.
Loosen screwed connections 1 (setting
screws); then loosen socket-head cap screws
2 and move the motor unit to underneath the
cover 3.
Loosen the two socket-head cap screws 4 on
thrust bearing 5 and remove the thrust bearing.
Disconnect the pneumatic hoses from the
gripper.
Remove clamp; lower sensor cables 6 and take
out the pull-off.
Loosen the four socket-head cap screws 7 on
the terminal panel and remove the panel.
Change the belt.
To reassemble, reverse the order of the above
steps.
5
7
2
3
1
Exercise great care when laying the sensor cable and the pneumatic hoses.
Side 2
Remove sheet metal cover 1 from the swivel
unit on side 2.
Loosen screwed connections 2 (setting
screws); then loosen the socket-head cap
screws 3 and shift the motor unit.
Loosen the two socket-head cap screws 4 on
thrust bearing 5 and remove the thrust bearing.
Disconnect pneumatic hose 6 from the gripper.
Remove clamps 7; lower the sensor cable 8
and take out the pull-off.
Loosen the four socket-head cap screws 3 on
the terminal panel and remove the panel.
Change the belt.
To reassemble, reverse the order of the above
steps.
Initial stress of the drive belt, side 2
Frequency: 250 +/-10Hz
3
2
5
8
10 9
1
5
6
g 10.10 Drive belt for cutting head
Cause
Remedy
Correct tension
Reduce tension
Replace bearing
10 10
1
g. 10.11
3
g. 10.12
g. 10.13
10 11
g. 10.14
11
10
12
g. 10.15
13
g. 10.16
10 12
g. 10.17
g. 10.18
10 13
During the calibration procedure, each motor axis is approached individually and at
a reduced speed; make sure no one can reach into the hazardous area.
10 14
Start calibration
Position pull-off
unit 1
Remove blades
Position swivel unit 2
Insert calibration
gage
Position pull-off
unit 2
Position blade
axis
(Clamped up to
gage)
Position swivel
unit 1
Insert blade
block
End of calibration
10 15
Check to see if the hybrid light barrier on the cutting head is operating properly:
The light barrier switches on (diode goes out) when the basic position (calibration position) is reached. To see the switching of the diode, you must look underneath the covering. The basic position should be reached when the calibration gauge is clamped in by the upper and lower guide rods
(g 10.20). If this is not the case, it means the sensor on the large pinion is out of position.
10 16
Other sensors:
inductive sensors (Namur)
B10 lowering side 1
B11 lowering side 2
B12 gripper side 2
B13 lifting device
B14 gripper side 1
B16 wire trough
0.2mm
Roller pressure
Adjust the roller 3 (g 10.21) pressure by
turning screw 4. Lock screw 4 using the lock
screw 5.
4
5
16.5mm
4
5
10 17
3
4
2
g 10.23 Adjusting the encoder
Always have the belt-driven wire drive closed when making adjustments.
The height of the unit can be adjusted by turning the two screws 1.
The distance between the gripper jaws, when
closed, and surface 2 must be 1mm.
Down 4
Valve open approx. 1/2 turn
3
4
g 10.24 Lifting device
10 18
The jaws of the wire guide gripper can cause injury. Be extremely careful when
handling them.
10 19
6
7
Remove ramp 7.
Remove sheet-metal guard 8.
10
10 20
Unscrew the setting screw on the pressureoperated switch; the pressure-operated switch
does not respond.
Set the cover switches S01, S02 2 with cover
closed; the starting roller (switch) is at the very
top of the column hole.
4mm
When closing the safety cover, make sure no one can reach into the machinery,
otherwise he or she might get pinched!
10 21
All settings and adjustments must be carried out by persons trained and authorized to do so.
For current country voltages, please refer to annex in the attached I/O list (Article
Number 0025246).
10.3.1 Sensors
Be very careful when wiring the sensors; incorrect handling is a frequent cause of sensor cable
failure. Observe the following points to avoid problems:
Lay the wires carefully along the hose, i.e.
make sure cables are not squeezed by sharp objects;
when changing the direction of cable, do so using a U-shaped loop.
Do not pull or strike the cable and protect it from being pulled or struck.
Make sure nothing is rubbing against any part of the cable.
10 22
Side 1 in 90 position
The sensor cables for the sensor lowering/
sensor gripper and air hoses form a uniform
arc 5 and are laid parallel to each other.
Make sure the sensor cable 6 touches
nothing when lowered.
6
5
10 23
Side 2
7
8
9
g 10.35 Side 2 from above
The side sensor cable 9 for the pull-off sensor must be strain-relieved. Make sure it is
strain-relieved in all positions.
10
11
10.37 Side 2 in 90 position
10 24
10 25
Be very careful never to install a stronger fuse or to switch around slow and
fast fuses. Otherwise, the safety of the machine and its operators can no longer
be guaranteed!
Fuse list
Designation Fuse for
F01
F02
F03
F06
F07
F08
F09
F18
A65/F1
A01/F1
A01/F2
A04/F1
10 26
Type
Installation site
Circuit breaker
316A
Delta drive 3210 VAC (333 PC)
33.15AT
Delta drive 3210 VAC (333 PC B) 35AT
Stepping motors 392 VAC
35AT
Power supply 230 VAC
6.3AT
SM power supply cards 130 VDC 5AT
Control circuit contactors 120VAC 0.5AT (220V)
Power supply 24V
8AT
Conveyor-belt motor protecting- 1.6-2.5A
switches
2.5-4.0A
MRS card
5AT
Input BIO card
2AT
Output BIO card
6.3AT
RCS card
1.6AT
Settings and adjustments
(A03)
(A01)
(A01)
(A04)
1
9
10
12
11
17
16
15 14
13
1
2
3
4
5
6
7
8
9
10
Inputs
Connection to RCS PCB
Connection to MRS PCB
Never plug in
Analog inputs
Pressure regulator output
Splice detection 2
Connection pneumatic valves
Outputs
Relay outputs
11
12
13
14
15
16
17
Fuse F1 IN
Fuse F2 OUT
Power feed to BIO PCB (X25)
Power feed to RCS PCB (X27)
Power feed to expanded BIO PCB
Connection for expanded BIO PCB
Jumper for optional splice detection
unit (Depicted: splice detection not
activated)
10 27
18
g 10.41
19
LED 1
LED 2
LED 3
LED 4
LED 5
green
red
red
red
red
DIP switches
The DIP switches must be OFF!
Selection dial for motor phase current (refer also to I/O list)
M01
M02
M03
M04
M05
blade axis
pull-off axis side 2
pull-off axis side 1
swivel drive side 2
swivel drive side 1
position D
position D
position D
position D
position D
10 28
blade axis
pull-off axis side 2
pull-off axis side 1
swivel drive side 2
swivel drive side 1
stepping motor controller
10 29
2 Lock nut
Direction of
installation
The throttle non-return valves integrated in the pressure regulating valve for the
wire grippers on side 1 and side 2 must be closed.
10 30
2
g 10.49 Crimping press
10 31
10 32
10 33
Due to the special pin assignment, you must use RJ45 cables with yellow caps
from Komax. Incorrect cables will destroy the transmitter and receiver!
NEVER plug RJ45 cables in or out while the load voltage is on. If you do so, the
software will crash immediately and you will have to restart the PCC card in the PC
by pressing the reset button.
The MRS PCB offers an easy means of connecting the various MCI modules.
Standard assignment of channels:
CH0
Motor controller Delta drive
CH1
SMC
CH2
Seals module mci 761 side 1
CH3
Crimping module mci 711 side 1.1
CH4
Reserved
CH5
Crimping module mci 711 side 1.2
CH6
Reserved
CH7
Crimping module mci 711 side 2
CH8
Reserved
CH9
mci 781 side 1
CH10 mci 781 side 2
CH11 Double gripper module
CH12 Reserved
CH13 BIO PCB
CH14 RCS connection
The channels 0, 1, 12, 13 and 14 have preassigned uses and may not be used for MCI
modules.
1
2
3
4
2
Standard mci
711 side 1
1
Standard mci
761 side 1
10 34
15.2 Storage
When putting the machine into storage for an extended length of time, keep the following points in
mind:
Put the machine out of operation as described in Chapter 15.1.
The criteria for the storage location are the same as those for the installation site (oor properties, space requirements, ambient conditions, see Chapter 5.1).
Protect the machine from dirt.
Protect the machine from corrosion (dry rooms, no direct sunlight).
15.3 Disposal
Most materials from which the machine is made (metals, plastics) can be recycled. To dispose of
the machine, proceed as follows:
Put the machine out of operation as described in Chapter 15.1.
Disassemble the machine, sorting the parts by material; have these materials transported to
the appropriate recycling centers.
Electrical and electronic components, particularly PCBs, monitors, etc. must be properly disposed of.
It is recommended that you involve companies specializing in this type of waste in the disposal
process.
The machine operator is responsible for ensuring that the machine and the materials used
in its operations are disposed of in a proper and environmentally friendly manner. Make sure
you comply with the national and local legal regulations regarding waste disposal.
15 1
15 2