Blue Max Mini Modular Plus User manual

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Operating manual
BlueMax Mini Modular Plus

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en
86
1. Foreword
1. Introduction 89
2. Important notes 89
Revision service 89
Updating 89
3. Validity of this operating manual 89
Application 89
Copyright reserved 89
4. Owner‘s personal responsibility 89
5. Service 89
2. EC declaration and protocols
1. EC Declaration of Conformity 90
2. Important note 91
3. Verification of instruction 91
3. General safety rules
1. Information on signs, symbols and markings 92
2. General 93
3. Safety advice for the user company 94
4. Noise 94
5. Oils, greases and other chemical substances 94
6. Residual risk 94
7. Safety advice for operating personnel 95
8. Safety advice for operating the machine 95
9. Safety advice for carrying out maintenance work 95
10. Training / instruction 95
11. Personal protective equipment 96
4. Purpose / operating principle
1. General information 98
2. Intended use 98
3. Foreseeable incorrect use 98
4. Operating principle and description of the machine 99
5. Rating plate 99
6. Limit values 99
7. Liability 99
5. Technical information
1. Safety precautions 100
2. Attachment points 100
3. Technical Specifications 101
4. Equipment 102
Programming digital display 104
Setting 106
5. Guards 106
6. Noise mission 107
7. Aligning / fastening 107
General information 107
8. Connections required 107
Main power connection 107
Compressed air connection 108
9. Transportation 108
Transportation on fork lift truck or pallet jack 108
10. Internal handling 108
11. Checking delivery for missing items 108
12. Dealing with shipping damage 108
13. Measures on temporary storage 108
14. Site of installation 109
15. Safety guards to be provided by the owner 109
16. Permissible ambient conditions 109
17. Removing preservatives 109
18. Electrics 109
19. Compressed air connection 109
20. Suction extractor 109
6. Start up / trial run
1. General 111
2. Safety check 111
3. Malfunctions on start-up 111
4. Starting up for the first time 111
5. Machine versions supplied 112
6. Interchangeable drilling units 113
Interchangeable drilling unit, 3 spindles Selekta 113
Interchangeable drilling unit, System 32 hole line 113
Interchangeable drilling unit, System 32 hole line 90° 113
7. Other accessories 113
8. Assemblies 114
Press-in frame for the interchangeable drilling unit,
6 spindles 114
Centre stop 115
Continuation stops 115
Drilling depth settings 118
Drum stop 118
Hold-down clamp 118
Converting from manual operation to foot pedal 119
Connecting foot switch for a machine
with horizontal drilling unit 119
Connecting foot switch for a machine
without horizontal drilling unit 120
9. Carrying out trial run 121
10. Concluding start-up 121
7. Setting up
1. Preparing machine 122
Readiness for use 122
Connecting to extractor system 122
Connecting to compressed air supply 123
Connecting to power supply 123
Switching on 124
Operating 124
Drilling hole line, interchangeable drilling unit,
9 spindles 125
Inserting hinges 126
2. Setting up (preparing for work) 126
Tools used (drill bits) 126
Interchangeable drilling unit, 6 spindles,
Interchangeable drilling unit, 3 spindles (Selekta 22/9) 127
Interchangeable drilling unit, 9 spindles 127
Interchangeable drilling unit, 90°, 9 spindles 128
Changing interchangeable drilling units 128
Cleaning 128
Fitting drilling units 129
Checking switch for proper working order 129
Setting drilling depth, vertical drilling unit 130
Drilling with horizontal drilling unit 130
Settings on the back of the machine 131
Limiting drilling stroke for drilling hole lines 132
3. Hold-down clamp and centre stop 132
Hold-down clamp 132
Centre stop 133
Setting the drum stops 133
Pendulum stops 133
8. Operation
1. Safety check 134
General information 134
Readiness for use 134
Control panel 135
2. Switching on 136
Preparatory work 136
3. Operating 136
Hold-down clamp 137
Fitting Hettich hinges 137
Drilling 138
Pressing in 138
Contents
109

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4. Malfunctions during operation 139
Troubleshooting 139
5. Checks during operations 139
Checks for proper working order 139
9. Servicing / care
1. General information 140
Working on electrical components 140
2. Instructing maintenance personnel 140
3. Making the machine safe on shutdown 141
4. Cleaning the machine 141
Electric motors 141
5. Servicing work 141
Servicing and maintenance 141
Servicing unit 142
6. Instructions on inspections 142
General 142
10. Malfunctions / troubleshooting
1. General information 143
2. Malfunctions caused by the owner 143
3. Troubleshooting 143
General causes of malfunction 143
Malfunctions while machine is operating 143
4. Reporting malfunctions 143
11. Dismantling / disposal
1. General information 144
Before dismantling 144
2. Taking out of service 144
3. Dismantling 145
General information 145
Dismantling the machine / system 145
4. Hazardous substances / disposal 145
Protecting the environment 145
Scrapping 145
Oil and oily wastes 145
12. Replacement parts lists
1. Base frame 147
2. Work surface 147
3. Eccentric tensioner 148
4. Guide frame 148
5. Foot extension 149
6. Suction extractor 149
7. Cable drag chain 150
8. Console 150
9. Lifting cylinder 151
10. Drill depth stop 152
11. Adjustable stop 152
12. Clamping element 153
13. Motor with support 154
14. Centre stop 154
15. Press-in frame 155
16. Hold-down clamp, rear 155
17. Hold-down clamp, front 155
18. Drum stop 156
19. Horizontal drilling unit 157
20. Interchangeable drilling unit, 90°, 9 spindles 158
21. Interchangeable drilling unit, 9 spindles 159
22. Interchangeable drilling unit, 6 spindles 159
23. Interchangeable drilling unit, 3 spindles,
Selekta (22/9) 159
24. Pneumatics diagram 160
25. Circuit diagram 161
13. Replacement part numbers
1. List of replacement part numbers with designation 162
14. Instructions for installing accessories
1. Press-in frame 164
2. Converting from pushbutton to foot switch 164
Connecting foot switch for a machine
with horizontal drilling unit 165
3. Installing laser 166
4. Installing support block 167

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1. Foreword
1. Introduction 89
2. Important notes 89
Revision service 89
Updating 89
3. Validity of this operating manual 89
Application 89
Copyright reserved 89
4. Owner‘s personal responsibility 89
5. Service 89
Foreword
WARNING
Read these operating instructions carefully in order
to obtain a thorough understanding of the machine
and how to handle and maintain it. Operate the
machine in the proper manner as described in these
instructions so as to avoid injury and damage to the
system. Do not operate the machine on the basis of
suppositions. Keep these operating instructions to
hand and consult them if you are in any doubt as
to carrying out any particular procedure.
If any questions remain unanswered after reading
through the instructions, you must not put the
machine into operation.
Settle any unanswered questions first by consulting
Paul Hettich GmbH & Co. KG.
These operating instructions are intended to make it easier
for you to become familiarised with the machine and use its
capabilities in the proper manner.
The operating instructions contain important information on
operating the machine in a safe, proper and cost effective
manner. Following them will help to avoid hazards, repair
costs and down times, enhance reliability and prolong service
life.
Existing national regulations on preventing accidents and on
protecting the environment are also applicable.
The machine will only be assembled and
installed by persons instructed to do so by
Paul Hettich GmbH & Co. KG. This also applies in
particular to starting it up for the first time.
The operating instructions must be available at the machine
all the time. The operating instructions must be read and
applied by any person entrusted with working with / on the
machine, e.g.:
• Operation
• Including setting up, troubleshooting while working,
disposal of production waste, care, disposing of
consumables and auxiliary substances,
• Maintenance
• Servicing, inspection, repair
• Transportation
given the task.

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1. Introduction
The main objective of this operating manual is to protect
“man and machine“ in accordance with the EC Machinery
Directives. It is intended for all persons involved in working
with and on this machine or system, in particular the
operating personnel.
• As operating / servicing personnel, first read this operating
manual and familiarise yourself with using the machine
and operating it safely as well as with how to perform
the necessary set-up, servicing and / or repair work in the
proper way while meeting the safety requirements.
• Your personal safety and that of your surroundings as
well as safe machine operation without risk to other
property or the environment will only be ensured if you
are familiar with and follow all of the information in this
operating manual as well as in pertinent health and safety
regulations.
• As customer and / or owner, make sure that this operating
manual is given to your operating / servicing personnel
before putting the machine / system into service for the
first time, that it remains available directly at the machine
at all times and that all persons concerned observe the
information and warnings provided in this operating
manual, the code of practice applicable to the site of
installation as well as the regulations on occupational
health and safety etc.
In other words, this operating manual does not release the
owner from the duty to devise his or her own health and
safety rules as well as safe work procedures tailored to his
or her production requirements / needs, to any specific
system / machine combination, to specific installation
conditions, to specific modes of connection and/or tool and
component properties etc., and to apply these, have them
applied and monitor their observance.
2. Important notes
Revision service
This operating manual is not subject to any revision service.
If changes / additions are made after the machine has been
delivered, it is the responsibility of the owner to update
this operating manual using his or her own addenda or any
addenda provided by Paul Hettich GmbH & Co. KG.
The right is at all times reserved to amend and improve
all technical specifications, details and illustrations in the
interest of technical progress.
Updating
The laws, provisions, regulations, directives, codes of practice
etc. specified in this operating manual as well as statements
derived from them were up to date at the time this manual
was compiled.
They must be heeded in their latest, applicable wording,
updated at the responsibility of the owner and always applied
in their more restrictive (stringent) wording.
We also point out that the content of this operating manual
is not part of any earlier agreement, assurance or legal
relationship or intended to amend such. All obligations on the
part of Paul Hettich GmbH & Co. KG arise from the pertinent
supply contract that also contains the complete and solely
applicable warranty arrangements or draws attention to
these. Statements made in this operating manual neither
extend nor restrict these warranty provisions.
3. Validity of this operating manual
• This operating manual only applies to this machine.
• Please always quote the machine no. in all queries and
orders for replacement parts.
Statements made in this operating manual in relation to
items of equipment not included with the machine are for
information only. They do not give rise to any legal claim to
the machine being equipped with these items.
Application
This operating manual has been produced in compliance
with EC directives, European (harmonised) standards etc.
References to occupational health and safety, environmental
protection and safety provisions may not yet conform
to harmonised accident prevention regulations (UVV) /
statutory accident insurance regulations (GUV) applicable
in Germany or to the DIN standards or technical regulations
stated in the appendix to the German Equipment Safety Act
(Gerätesicherheitsgesetz (GSG)).
The customer / owner is personally responsible for:
• regarding specified laws, regulations, directives etc., as the
basis for safe handling and maintenance practice,
• implementing and observing them in line with national /
regional / company-internal regulations,
• providing supplementary safety or protective equipment
prescribed by the responsible local, regional or national
authorities and for fitting them before using the machine /
system for the first time.
Operating instructions:
Paul Hettich GmbH & Co. KG
© 2017 by Paul Hettich GmbH & Co. KG
Copyright to the operating instructions
The copyright to this operating manual remains with
Paul Hettich GmbH & Co. KG.
These operating instructions are intended for the operating
personnel. They contain regulations and drawings of a
technical nature that must not be duplicated either in whole
or in part, distributed, used without permission for advertising
purposes or communicated to others.
Reproduction either in whole or in part is not permitted.
4. Owner‘s personal responsibility
The customer or owner is personally responsible for ensuring
that:
• provisions on occupational health and safety, environmental
protection and disposal are observed in relation to the
machine, handling it as well as in the course of inspections,
servicing and repair measures,
• no improper changes or modifications are made to the
machine and safety guards,
• the machine is not used in any inappropriate, improper or
non-intended manner.
5. Service
Customer Service
Paul Hettich GmbH & Co. KG
Vahrenkampstrasse 12 - 16
D-32278 Kirchlengern

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2. EC declaration and protocols
1. EC Declaration of Conformity 90
2. Important note 91
3. Verification of instruction 91 1. EC Declaration of Conformity
EC declaration and protocols
EC Declaration of Conformity is enclosed loose.

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2. Important note
Information for the owner
In addition to these operating instructions and the accident
prevention regulations in force in the country of use or at
the place of application, it is also necessary to follow the
recognised code of safe and proper working practice.
Without the consent of Paul Hettich GmbH & Co. KG, the
machine owner must not make any additions, alterations or
modifications to the machine that may affect safety.
Replacement parts used must meet the technical
requirements defined by Paul Hettich GmbH & Co. KG. This is
always ensured when using genuine replacement parts from
the applicable replacement parts list.
Only ever deploy trained or instructed personnel and clearly
define personnel responsibilities with regard to operating,
servicing and repair.
Use for other purposes and modifications
We expressly point out that the EC declaration shall become
null and void if modifications / changes etc. are made to the
machines listed above.
The company making the modification must amend the EC
declaration and extend or make out new documentation to
reflect the latest modification
(Art. 8 (6) of the EC Machinery Directive).
Name Date
from / to
Type of instruction received Signature of
the person
instructed
Instructor Person instructed Operation Safety rules Servicing
3. Verification of instruction
By signing this protocol the undersigned confirm that the
following details and specifications are correct.
Confirmation
I hereby confirm that I have read and understood the
operating manual for the machine:
Designation BlueMax Mini Modular Plus
Type Automatic drilling and insertion machine
Machine no.
have read and understood.
I furthermore undertake to observe and follow the general
safety precautions, the servicing and care instructions
as well as power-up and operating instructions and the
provisions relating to malfunctions. I am aware that any
failure to observe these instructions and provisions may lead
to accidents, put persons at risk and result in damage to
property and the machine.

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General safety rules
3. General safety rules
1. Information on signs, symbols and markings 92
2. General 93
3. Safety advice for the user company 94
4. Noise 94
5. Oils, greases and other chemical substances 94
6. Residual risk 94
7. Safety advice for operating personnel 95
8. Safety advice for operating the machine 95
9. Safety advice for carrying out maintenance work 95
10. Training / instruction 95
11. Personal protective equipment 96
1. Information on signs, symbols and markings
The safety advice in the operating instructions is structured as
follows:
DANGER
This danger advice draws attention to an immediately
dangerous situation that will lead to death or serious
injuries if the safety measures are not followed.
WARNING
This danger note draws attention to a potentially
dangerous situation that may lead to death or serious
injuries if the safety measures are not followed.
CAUTION
This danger note draws attention to a potentially
dangerous situation that may lead to minor or slight
injuries if the safety measures are not followed.
NOTE
This advice draws attention to potential damage
to property or to a process of particular interest /
importance that may occur if the safety measures are not
followed.
In the operating instructions, hazard points are identified as
follows:
DANGER
Danger from electric shock!
Working on live components in the improper manner
presents a danger to life!
Work on electrical equipment must only be carried out
by authorised electricians!
WARNING
Hearing damage warning!
Some areas of the facility can reach noise levels of
over 80 dB (A).
Wear ear protectors when working in noisy areas!
WARNING
Danger from wood dust!
Wood dust can affect the respiratory tract. For this
reason, wear a dust protection mask.

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WARNING
Fire risk!
Grinding and welding work must never be performed
on this machine.
Follow welding regulations and accident prevention
regulations.
WARNING
Explosion protection
Machine is not explosion-protected. Do not install
near paint shops.
WARNING
Warning - Hand injuries!
Hands could be crushed, drawn in or otherwise injured.
Never reach into the system‘s moving parts!
Wear hand protection!
WARNING
Warning - Hot surfaces / objects!
There is a risk of injury from touching hot surfaces
(e.g. electric motors).
Do not touch!
2. General
The machine described in the operating instructions is built to
the state of the art and safe to operate.
It complies with DIN EN 12100.
Hazard zones are made safe in compliance with the
regulations. However, the machine may present hazards if
it is used by untrained personnel improperly or not for the
intended purpose.
This may then result in risks to life and limb, jeopardise the
machine and prevent it from working efficiently.
Any person given the task of installing, starting, operating,
servicing or repairing the machine at the user‘s premises must
have read and understood these instructions, in particular the
section on “Safety precautions“.
In his or her own interest, the safety officer at the user
company should obtain written conformation from operating
personnel that they have received instruction and training
and are familiar with all safety precautions before they use
the machine for the first time.
The safety guards must never be removed or taken out of
operation.
If safety guards need removing for maintenance and repair
work, they must be refitted as soon as such work has been
completed.
The machine must only be used if it is in proper working order
and operated by trained, authorised personnel.
Work requiring specialised knowledge (e.g. electrical,
pneumatic system) must only be carried out by persons
specifically trained and suitable to do so.
Before attempting any work on the machine, turn the main
switch to the “0“ position (OFF), make the machine safe and
disconnect from the compressed air supply.
Switch off energy sources before carrying out repair, servicing,
installation or cleaning work.
Energy sources:
• Electrical energy
• Pneumatic energy
CAUTION
Danger from residual energy!
Stored energy will not be dissipated even after switching
the system off at the main switch.
Dissipate residual or stored energy!
Switch off / dissipate energy sources:
For safety regulations applicable to third party devices, refer
to the documentation from the third party manufacturers
(operating instructions for bought in units).
Electrical energy via the motor switch / machine‘s main
switch. Additionally attach a notice when servicing or other
work is being carried out on the machine.
Fig. 3: Main switch
(viewed by the operator, on the right hand side of the
machine frame)
Fig. 4: Motor protection circuit breaker

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CAUTION
Warning - Hand injuries!
The main switch only shuts down the drive system, not
the pneumatic system!
The machine has no emergency stop button or
emergency stop facility. This means it is necessary to
take particular care when handling and working on
this machine.
Pneumatic energy through the supply connection on the
machine frame. Make sure that all machine components are
depressurised and any stored energy is dissipated. As part of
the installation process, the owner will provide a mechanical
main cock at which the machine can be disconnected from
the compressed air supply.
Fig. 5: Pneumatic system servicing unit
(viewed by the operator, on the left hand rear side of the
machine frame)
3. Safety advice for the user company
All persons entrusted with operating the machine (including
line managers) must familiarise themselves with the section
on “Safety advice“.
The safety advice must be followed.
The machine must only be operated if it is in proper working
order. The user company will issue clear responsibilities, e.g.
for servicing, cleaning or repair, and ensure that the persons
carrying out this type of work have received the training
necessary for it.
The safety regulations applicable in the owner‘s country must
also be observed. Refrain from any work that adversely affects
operating safety.
The operating personnel will check the machine for changes
or malfunctions, report such to the safety officer responsible
and, if necessary, take the machine out of operation.
Only appropriate tools must be used for the work that needs
to be done; remove tools after completing work. The place at
which staff work must be selected in such a way as to ensure
that work operations can be viewed at all times, the machine
can always be stopped immediately and safety is never at risk.
General safety rules
WARNING
Never:
• reach into the machine when it is operating,
• remove covers and take safety guards out of operation,
• hinder unobstructed access to the controls,
• continue operating the machine if changes occur that
adversely affect safety and
• manipulate or circumvent safety guards.
4. Noise
The weighted equivalent continuous sound level
is > 80 dB (A).
WARNING
Hearing damage warning!
Local conditions may produce elevated sound pressure
and cause noise induced hearing loss!
Operating personnel must be provided with appropriate
protective equipment or be protected by other measures!
Wear ear protectors when working with the machine!
5. Oils, greases and other chemical substances
When handling oils, greases and other chemical substances,
you must observe and follow the applicable regulations and
safety data sheets of the manufacturers of these substances
with regard to storing, handling, using and disposing of them.
When working with caustic substances, you must wear
protective equipment of suitable material (safety goggles,
rubber gloves, rubber boots, protective clothing).
In the event of contact with the eyes or skin, immediately
rinse the area affected with copious quantities of water.
Appropriate facilities (eye wash bottle, wash basin, shower)
must be provided near the work area.
6. Residual risk
CAUTION
Residual hazards!
Handling the machine involves residual hazards that could
not be eliminated by design measures.
Pay attention to the residual risks in the Technical
Documentation!
The machine reflects the state of the art and is built in
accordance with recognised safety regulations. All the same,
the user or third parties may still be exposed to hazards.
The machine must be used
• for the intended purpose
• in an absolutely safe state.

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WARNING
Risk of injury!
Never remove safety devices or render them ineffective by
making changes to the machine!
Malfunctions presenting a safety risk must be rectified
without delay!
Before attempting servicing and cleaning work, switch off
the entire machine and disconnect from the compressed
air supply!
7. Safety advice for operating personnel
• Work on the machine must only be carried out by
instructed, skilled personnel.
• Only skilled personnel who have received training or
instruction must be deployed.
• The generally recognised code of occupational health and
safety as well as accident prevention regulations must be
observed.
• Please keep first aid equipment (first aid kit etc.) in easy
reach.
• The owner must stipulate that operating personnel are
to wear personal protective equipment (safety shoes and
sturdy work clothing).
Work which may be done by the operating personnel
Work which may be done by the operating personnel:
• Activate, deactivate the machine
• Change drill bits
• Set the machine to component dimension
• Feed in individual parts (flat panels made of engineered
wood, hinges and connecting fittings)
• Start the drilling and inserting process
• Remove finished components
• Clean the machine
Requirements on operators
The operator must organise the work environment so as to
permit optimum, continuous production.
The operator must be receive instruction before commencing
work for the first time and every year thereafter.
Prior to commencing work, all persons working on or at the
system shall undertake to
• follow the basic regulations on health and safety at work
and on accident prevention
• wear personal / workplace related protective clothing and
equipment for the purpose of ensuring work safety and use
such while working if they are necessary for safety reasons
Work must only be performed for which authorisation has
been given.
For example:
• work on pneumatic equipment must only be carried out
by a specialist specifically trained to do so or by instructed
persons under the direction and supervision of such a
specialist in accordance with the applicable technical
regulations.
8. Safety advice for operating the machine
• The machine must only be put into operation in a fully
installed and operational state.
• The machine must only be operated if all protective guards
and safety related equipment, e.g. protective claddings or
enclosures, are in working order and undamaged.
• On putting the system into operation, the operator must
make sure that all safety equipment and protective guards
as well as the controls are in correct working order and free
of damage.
• The workplace environment must be kept clean and tidy at
all times. This must be ensured by internal checks.
• Immediately report any irregularities or malfunctions to the
department / person responsible. If necessary, the machine
must be shut down immediately and made safe.
9. Safety advice for carrying out maintenance work
• Maintenance work must only be performed by
the manufacturer‘s skilled personnel or under the
manufacturer‘s supervision.
• If the machine is completely shut down for servicing and
repair work, it must be prevented from switching back on
unexpectedly.
• If necessary, please cordon off the maintenance zone,
providing a wide safety margin!
• Attach a warning sign
•
For maintenance measures, use tools that are appropriate for
the work involved.
• Servicing and repair work must only be carried out by the
owner‘s qualified personnel.
• If safety devices need removing for servicing and repair
work, they must be refitted and checked as soon as the
work has been completed.
• Always tighten screw connections that have been loosened
during servicing and repair work.
• At the start of work, connections and screw connectors must
be cleaned of oil, operating consumables and dirt.
•
Make sure operating consumables and auxiliary substances
as well as replaced parts are disposed of safely and in an
environment friendly manner.
10. Training / instruction
• As owner, you are obliged to inform and instruct the
operating personnel in respect of applicable legal and
accident prevention regulations as well as the safety guards
fitted. In this context, bear in mind the varying specialised
qualifications of your staff.
• The operating personnel must understand the instruction
they are given, follow it as well as sign the documentation.
• This is the only way you can be sure that operating
personnel work in awareness of safety and of the hazards
that are involved. As owner, you should therefore obtain
written confirmation from all members of staff that they
have received training/instruction.
• Applying these safety measures will minimise potential
hazards to such an extent that the machine can be operated
safely.

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NOTE
All of the safety guards in place must be checked at
least once before the start of each shift to make
sure that they are in place and undamaged (visual
inspection).
11. Personal protective equipment
The owner must provide the following personal protective
equipment:
• Safety shoes
• Ear protection
• Safety goggles
• Dust protection mask
• Safety gloves (as necessary)
General safety rules

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Purpose / operating principle
4. Purpose / operating principle
1. General information 98
2. Intended use 98
3. Foreseeable incorrect use 98
4. Operating principle and description of the machine 99
5. Rating plate 99
6. Limit values 99
7. Liability 99
1. General information
This operating manual must be kept at the machine all
the time and be constantly available there. To ensure safe
operation and proper machine handling, it is important for
you to have read and understood the operating manual
and, in particular, the safety rules. The safety provisions and
operating instructions described in this operating manual
must be followed exactly.
Regularly check this machine‘s safety guards and work
sequences.
Danger!
Any person given the task of installing, servicing,
starting, operating or repairing the machine must have
read and, in particular, understood these instructions.
2. Intended use
WARNING
The machine must only be used for its intended
purpose and be in a perfectly safe condition!
Operating safety is only guaranteed if the machine is
used for its intended purpose!
The BlueMax Mini Modular Plus is a semi automatic drilling
and insertion machine for panel type workpieces and the
furniture fittings intended for them. This machine must only be
used for working on flat panels made of wood-based materials,
such as chipboard, blockboard panels, MDF, solid wood or
similar materials.
Any other use beyond this is deemed to be improper and non
intended use.
Intended use also includes following the operating, servicing
and maintenance conditions prescribed by the manufacturer.
Unauthorised changes to the machine will result in the loss of
product liability and liability on the part of the manufacturer
for resultant damage.
Any other use beyond this is deemed to be non intended use.
The manufacturer shall not be liable for any damage this
causes, with the risk involved being borne solely by the user.
3. Foreseeable incorrect use
WARNING
Hazards may occur if the system is used incorrectly!
The following situations in particular are deemed to be
foreseeable hazardous situations:
•
If the machine is used for any non-intended purpose,
treated improperly or operated by untrained or
unauthorised persons, it may present a risk of injury to
personnel and a risk of damage to the machine itself.
For this reason, only trained, instructed and authorised
persons must be allowed to operate this machine.
•
Improperly assembling, starting, operating and servicing
this machine
• Operating the machine with faulty safety guards
• Operating the machine with improperly fitted safety
guards
• Operating the machine with non-functioning safety
guards and protective equipment

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• Failing to observe the information and instructions given
in the operating manual in relation to transporting,
storing, assembling, starting, operating, servicing and
setting up this machine
• Unauthorised structural changes
• Unauthorised changes to this machine‘s drive system
(power output, speed)
• Inadequate monitoring of machine parts subject to
particular wear
• Improperly performed repairs
• Disasters caused by the impact of foreign objects
or Acts of God
The situations above describe some of the residual hazards
which, despite being impermissible, may occur and harm the
health of staff.
The owner must observe the safety requirements defined
in the German Ordinance on Industrial Safety and Health
(Betriebssicherheitsverordnung).
4. Operating principle and description of the machine
The BlueMax Mini Modular Plus is a semi automatic drilling
and insertion machine for panel type workpieces. This
machine must only be used for working on flat panels made
of wood-based materials, such as chipboard, blockboard
panels, MDF, solid wood or similar materials.
All parts being worked on are fed into the machine by hand.
Flat panels made of wood-based materials, such as chipboard,
blockboard panels, MDF and solid wood are laid on the work
table and fixed into place with the clamping equipment. The
drilling process is initiated by pressing the start button / foot
switch (optional). The start button / foot switch (optional)
must remain pressed until the drilling process has been
completed. Using the integrated insertion facility (optional),
the furniture fittings are pressed into place by means of a
manually operated press-in frame (optional). This concludes
the machining process.
BlueMax Mini Modular Plus with accessories
5. Rating plate
Note!
The rating plate is located on the machine.
The rating plate shows the following information:
Manufacturer
Address
Type designation,
machine numbers
Year of manufacture
Technical specifications
(e.g. nominal pressure)
All country specific information, such as the depiction of the
CE or UKCA mark, can be found on the type plate attached to
the machine.
State all of the above details when requesting technical
information and ordering replacement parts.
6. Limit values
The following limit values apply to items of equipment
and accessories, such as drive motors, electric / electronic
operating equipment etc.:
• ambient temperature: 35 °C max.
• rel. air humidity: approx. 65 %
Space required by the machine
The space required for the BlueMax Mini Modular Plus is largely
determined by the dimensions of the machine base frame.
Machine life
The machine‘s life will depend on whether or not it is used
for its intended purpose, on adherence to regular servicing
intervals and on the regular replacement of expendable parts.
7. Liability
Defects must only be rectified by competent personnel.
Our liability is restricted to damage caused while using
the system in the intended manner. We shall not be liable
for safety defects not yet identifiable on the basis of the
current state of the art.
Failure to observe:
• safety advice for operating personnel
• advice on particular hazards
• the ban on unauthorised modifications and changes
• use replacement and expendable parts or auxiliary materials
approved by the manufacturer will rule out any liability on
our part for the consequences

100
en
100
Technical information
1. Safety advice
Observe the regulations, warnings and provisions on health,
safety and environmental protection for all of the work
described in this section.
2. Attachment points
Only use suitable and approved lifting gear (crane) for
unloading the machine, assemblies and components as well
as for lifting heavy loads; only use appropriate means of
transport for handling the machine internally.
Any unloading or internal transportation must not be done by
hand if such involves weights in excess of 25 kg.
When using industrial trucks to unload the machine and move
it internally, always take into account the machine‘s total
permissible weight (see Technical specifications).
Danger!
Never stand or work under loads suspended on lifting
gear. This presents the risk of fatal injury!
Observe the following when using lifting gear:
•
Only attach lifting gear at the points marked (lifting
eyebolts etc.) on the machine / assemblies / components.
•
Only use appropriate and tested load suspension devices
(lifting belts, ropes, chains, shackles etc.) with a sufficient
load carrying capacity.
•
Only give experienced, skilled personnel the task of
attaching the machine / assemblies / components.
•
Always ensure level standing for machine / assemblies, lift
vertically, never drag at an angle.
Protect projecting machine parts and equipment from
damage when using lifting gear and moving the machine
internally.
Set down loads gently with the usual care and take
immediate action to prevent them from falling over /
tipping, rolling away, suffering damage from external force,
e.g. colliding with industrial trucks and objects falling from
above.
5. Technical information
1. Safety precautions 100
2. Attachment points 100
3. Technical Specifications 101
4. Equipment 102
Programming digital display 104
Setting 106
5. Guards 106
6. Noise mission 107
7. Aligning / fastening 107
General information 107
8. Connections required 107
Main power connection 107
Compressed air connection 108
9. Transportation 108
Transportation on fork lift truck or pallet jack 108
10. Internal handling 108
11. Checking delivery for missing items 108
12. Dealing with shipping damage 108
13. Measures on temporary storage 108
14. Site of installation 109
15. Safety guards to be provided by the owner 109
16. Permissible ambient conditions 109
17. Removing preservatives 109
18. Electrics 109
19. Compressed air connection 109
20. Suction extractor 109

101
en
101
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16 
-L
A1
862141
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15
16 
-L
A1
862141
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15
16 
-L
A1
862141
3. Technical specifications
Bezeichnung: Bohr- und Einpressautomat für plattenförmige Werkstücke
BlueMax Mini Modular Plus
H x W x D (mm) 862 x 800 x 1856
Weight approx. 145 kg
Power output data
Cycle time manual
Electrics
Operating voltage 400 V
Motor power 1.1 kW
HB unit power 0.55 kW
Rated current 2.65 A
Mains power fuse protection 6 A
Pneumatic system
Air pressure min. 6 bar, max. 7 bar
Noise Max. noise level: > 80 dB (A)
Temperature < 35°C
Working dimensions, vertical drilling unit
Max. workpiece thickness: 38 mm
Max. drill bit diameter: 35 mm
Max. drilling size: 30 mm
Max. pull out distance of drilling unit: 600 mm
Working dimensions, horizontal drilling unit
Max. workpiece thickness: 38 mm
Max. drill bit diameter: 8 mm
Max. drilling height: 5 – 20 mm
Max. drilling depth: 40 mm
Space required for machine

102
en
102102
1bis 5
1
2
3
4
5
61bis 5
4. Equipment
Switches and other controls for operating
and monitoring the machine are described
below.
Fig. 2: Controls on the automatic drilling and insertion machines
Technical information
Item Designation Explanation
1Pushbutton For activating work process
2Change-over switch Drilling vertically / horizontally
3Change-over switch For automatically unclamping the hold-down clamps
4Pushbutton For manually releasing the front hold-down clamps
5Pushbutton For manually releasing the rear hold-down clamps
6Main switch Machine power supply ON / OFF

103
en
103103
1
2
Fig. 5: Compressed air connection
Fig. 4: Foot switch (optional)
NOTE
The hand switch is not operational when using the foot
switch.
Item Designation Explanation
1Foot switch (optional) For activating work process
Item Designation Explanation
1Pressure regulator For setting operating pressure (6-7 bar)
2Plug in coupler Compressed air connection

104
en
104104
Programming digital display
• To enter the parameter programming, press the button for
a few seconds and the display will show PASS.
• Now press RESET/ ENTER, three zeroes will appear and the
first digit on the right will flash.
• Using the and buttons, now enter 273 as the password
and confirm by pressing RESET/ENTER.
Entering the incorrect password will close the menu. Otherwise,
the following menu options can be selected with the button:
To change the selected parameters:
• Press RESET/ ENTER twice (pressing once shows the value).
• Enter the chosen value with the and buttons.
• Press RESET/ ENTER to confirm your setting.
• To quit the programming mode, press the button.
The following parameters can now be programmed.
Value to be displayed after moving a 10 mm linear
shift.
Factory setting: 10.0 (given in millimetres with one decimal
place)
• First enter the chosen value and close by pressing .
• The decimal place can be moved to the chosen position with
the button.
• Then confirm by pressing RESET/ ENTER.
Number of decimal places
• Using the button, select a number between 1 and 5 to
denote the number of places after the decimal point.
• Then confirm by pressing RESET/ ENTER.
Defining button assignment
In the form of a 3-digit number, this parameter defines a wide
range of function that can be assigned to the buttons. This
is done by selecting the relevant values at the correct digit
position. (see table)
• Example: in parameter tASt I, enter the value 1 at the 3rd digit
of the code to assign the RESET function to the RESET/ENTER
button.
Technical information
111 means:
Digit 1. 2. 3.
Button   RESET/ENTER
Value
0 - - -
1 mm/inch ABS/REL function RESET
2 - - PRESET
3 - - FAST PRESET
4. - - Zero oset
0; 1; 2
5 - - OFFSET
6 - - FAST OFFSET
7 - - Delayed RESET*
8 - - Delayed PRESET*
* Delayed means that the button must be pressed for 3 seconds
to activate the function.
mm / inch:
Lets you switch between inch mode and mm mode
• The mode is changed by pressing button. The inch modus has
an additional decimal place. Means that parameter nDEC=4 is
not available.
ABS / REL function
Lets you switch between the absolute and relative
position
• Pressing displays the REL symbol and the current value
is temporarily zeroed.
• It is now possible to measure a relative movement of the
sensors in relation to the current reference point.
• Pressing again displays the ABS symbol and the absolute
value reappears.
RESET
After pressing RESET/ ENTER, the value displayed is
set to zero
• Position the sensor at a known measuring point with measured
value, e.g. at the stop of the measurement path with measured
value = 0.
• In parameter tASt I, enter the value 1 at the 3rd digit of the
code (RESET) and press RESET/ENTER to confirm.
• From now on, the display will be reset to zero after pressing
the RESET/ENTER button once.
