Boschert CU - PROFI User manual
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Operating instructions
Copper bar punching machine
CU - PROFI
These operating instructions:
– contain general and special instructions which must be complied with,
– contain technical instructions which must be observed when handling the machine,
– must be read by the responsible technical personnel or operator before setting up and
taking into use,
– must be continuously available at the installation site of the machine.
Retain for future use!
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List of contents
List of contents
0 General comments ..................................................................... 7
0.1 Introduction ......................................................................................................7
0.2 Contents of the operating manual ...................................................................8
0.3 Separate documents........................................................................................9
0.3.1 Separate documents........................................................................................9
1 Safety ........................................................................................ 10
1.1 The operating personnel................................................................................10
1.2 Clothing ..........................................................................................................10
1.3 Personal protective equipment ......................................................................11
1.4 Intended use ..................................................................................................11
1.5 Explanation of symbols and notices ..............................................................12
1.5.1 Symbols and notices on your machine .........................................................13
1.5.2 Dangers caused by non-compliance with the safety notices........................16
1.6 Safety-oriented working .................................................................................17
1.7 The safety installations ...................................................................................18
1.7.1 The positions of the safety installations on your machine.............................18
1.7.2 Individual safety installations .........................................................................19
1.7.3 Checking EMERGENCY-OFF button, interlock switch and light barrier........21
1.8 Follow the instructions below when erecting the machine ...........................21
1.9 Behaviour in case of danger ..........................................................................22
1.10 Dangers caused by electrical energy ............................................................22
1.11 Dangers caused by the hydraulic ..................................................................22
1.12 Dangers caused by noise emission...............................................................22
1.13 Dangers after switching off the machine .......................................................23
1.14 Reversal of the working motion in case of emergency! ................................23
1.15 Firefighting .....................................................................................................24
1.16 Other notices concerning dangers ................................................................25
1.17 Unauthorised conversion and manufacture of spare parts ...........................25
1.18 Special features of the machine ....................................................................25
1.19 Product surveillance.......................................................................................26
2 Technical data........................................................................... 27
2.1 Characteristic data .........................................................................................27
2.2 Machine data..................................................................................................28
2.2.1 Dimensions ....................................................................................................28
2.2.2 Weights...........................................................................................................29
2.3 Punching force ...............................................................................................29
2.4 Power rating ...................................................................................................29
2.5 Workplace ......................................................................................................29
2.6 Air supply .......................................................................................................29
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2.7 Noise ..............................................................................................................30
2.8 Emissions .......................................................................................................30
3 Description ............................................................................... 31
3.1 Mechanical construction ................................................................................31
3.2 Designated utilisation.....................................................................................31
3.3 Operation possibility ......................................................................................31
3.4 Technical data ................................................................................................32
4 Transport and assembly .......................................................... 33
4.1 General notices ..............................................................................................33
4.2 Erection conditions ........................................................................................33
4.3 Planning the workspace.................................................................................34
4.4 Packaging of the machine .............................................................................34
4.5 Intermediate storage ......................................................................................34
4.6 Transport of the machine ...............................................................................35
4.6.1 Transport using a crane .................................................................................35
4.7 Set up the machine ........................................................................................36
4.7.1 Connection of the hydraulic-unit....................................................................37
4.7.2 Connection to the electrical network .............................................................37
4.7.3 Connection to compressed air ......................................................................38
4.7.4 Testing the machine connection ....................................................................38
5 Survey ....................................................................................... 39
5.1 Subassembly inlet side ..................................................................................39
5.1.1 Subassembly inlet side ..................................................................................40
5.2 Subassembly outlet side................................................................................41
5.2.1 Subassembly back side .................................................................................42
5.3 Subassembly outlet side................................................................................43
5.4 Roller table .....................................................................................................44
5.5 Y-axis ..............................................................................................................45
5.6 Tool box system .............................................................................................46
5.6.1 Tool box ..........................................................................................................47
5.6.2 Station AMADA - A .........................................................................................48
5.6.2.1 Reduction AMADA - B/A.................................................................................49
5.6.3 Station AMADA - B .........................................................................................50
5.6.4 Cutting station ................................................................................................51
5.7 Clamping arrangement work piece ...............................................................52
5.8 Punch head ....................................................................................................53
5.8.1 Position sensor...............................................................................................54
5.9 X-axis ..............................................................................................................55
5.10 Pneumatical tilting table .................................................................................56
5.11 Clamp .............................................................................................................57
5.12 Safety device ..................................................................................................58
5.13 Limit switch axis .............................................................................................59
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5.13.1 Limit switch Y-axis ..........................................................................................59
5.13.2 Limit switch X-axis ...........................................................................................60
5.13.3 Limit switch tilting table ..................................................................................61
5.13.4 Limit switch clamp..........................................................................................61
5.14 Limit stops axes .............................................................................................62
5.15 Sprayer ...........................................................................................................63
5.15.1 Spray assembly ..............................................................................................63
6 Setup of the machine ............................................................... 64
6.1 General information........................................................................................64
6.2 The operator´s control on the machine.........................................................64
6.2.1 The operator´s control on the control cabinet ..............................................64
6.2.2 The operator´s controls on the control desk.................................................65
6.2.3 The foot pedal for the hydraulic material clamping .......................................65
6.3 Preparation of the machine for punching ......................................................66
6.3.1 Providing a punching tool ..............................................................................66
6.3.2 Insert the die ..................................................................................................66
6.3.3 Installation of AMADA - Station ......................................................................67
6.4 Preparation of the machine for cutting ..........................................................68
6.4.1 Providing a cutting tool ..................................................................................68
6.4.2 Insert the die ..................................................................................................68
6.4.3 Insert the cutting punch .................................................................................68
6.5 Insert the CU-flat ............................................................................................69
6.6 Starting the machine ......................................................................................70
6.7 Stopping the machine....................................................................................71
6.8 Restarting the machine ..................................................................................71
7 Maintenance ............................................................................. 72
7.1 Maintenance and inspection..........................................................................72
7.1.1 General information........................................................................................72
7.2 Maintenance and inspection list ....................................................................73
7.3 Cleaning the machine ....................................................................................74
7.3.1 Auxiliary agents and their use ........................................................................74
7.4 Lubrication......................................................................................................75
7.4.1 Lubrication points...........................................................................................76
7.4.1.1 Lubrication points X-axis ................................................................................77
7.4.1.2 Lubrication points Y - axis..............................................................................77
7.4.1.3 Lubrication points punch head ......................................................................78
7.4.1.4 Lubrication point tool box ..............................................................................79
7.4.1.5 Lubrication points clamp ...............................................................................79
7.5 Corrosion prevention .....................................................................................80
7.5.1 Notes on corrosion prevention agents, oils and lubricants...........................80
7.5.2 Disposal of corrosion-preventing agents, oil and lubricants .........................80
8 Hydraulic................................................................................... 81
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8.1 The hydraulic aggregate ................................................................................81
8.2 Oil change ......................................................................................................82
8.3 Assembly of the hydraulic unit .......................................................................83
8.3.1 Assembly of the tank cover............................................................................84
8.3.2 Assembly of the machine...............................................................................85
8.4 Hydraulic diagram ..........................................................................................86
8.5 Hydraulic - Parts list 614 04004 ....................................................................87
8.5.1 Spare parts list hydraulic hoses.....................................................................88
9 Pneumatik ................................................................................. 91
9.1 Assembly of the pneumatic unit ....................................................................92
9.2 Pneumatic diagram tilting table and sprayer 614 60013 ..............................93
9.3 Pneumatic diagram sprayer ...........................................................................94
10 Electronic .................................................................................. 95
10.1 Operating elements........................................................................................95
10.2 Control cabinet ...............................................................................................96
10.3 Electronic diagram .......................................................................................100
11 Drawings and lists.................................................................. 101
11.1 Subassemblys..............................................................................................101
11.2 Space required.............................................................................................102
11.2.1 Space required rollter table 3m ...................................................................102
11.2.2 Space required rollter table 6m ...................................................................103
11.3 Subassembly Roller race .............................................................................104
11.3.1 Parts list 614 02001 Roller race...................................................................105
11.3.2 Subassembly Roller race .............................................................................106
11.4 Subassembly Y - axis ...................................................................................107
11.4.1 Subassembly Y - axis - detail .......................................................................108
11.4.2 Parts list 614 05032 Y - axis ........................................................................109
11.5 Tool box ........................................................................................................111
11.5.1 Parts list 614 03021 Tool box ......................................................................112
11.6 Subassembly Tool ........................................................................................113
11.6.1 Parts list 314 03003 AMADA Station B........................................................113
11.6.2 Parts list 319 03001 Cutting station ............................................................113
11.7 Subassembly Clamping arrangement work piece ......................................114
11.7.1 Parts list 614 05035 Clamping arrangement work piece ............................115
11.8 Subassembly Punch head ...........................................................................118
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List of contents
Important notes!!
- The machine corresponds to the present state of knowledge
and techniques and meets the recognised regulations for
technical safety,
- nevertheless danger can arise in the event of improper use or
use contrary to the regulations. (Use contrary to the regulations
also includes non-compliance with the operating instructions).
11.8.1 Subassembly Punch head - details .............................................................119
11.8.2 Subassembly Punch head - details .............................................................120
11.8.3 Parts list 614 03025 Punch head ................................................................121
11.9 Subassembly X-axis .....................................................................................124
11.9.1 Subassembly X-axis details..........................................................................125
11.9.2 Parts list 614 05033 X-axis...........................................................................126
11.10 Subassembly Tilting table ............................................................................128
11.10.1 Parts list 614 002002 Tilting table ...............................................................129
11.11 Subassembly Clamp ....................................................................................130
11.11.1 Parts list 614 05036 Clamp .........................................................................131
11.12 Subassembly Waste stripper .......................................................................133
11.12.1 Parts list 614 06007 ......................................................................................133
11.12 Subassembly Safety device .........................................................................134
11.12.1 Parts list 614 06005 Safety device ..............................................................134
11.13 Subassembly Hydraulic unit ........................................................................135
11.13.1 Parts list 614 04004 Hydraulic unit standard ..............................................136
11.13.2 Parts list 614 04003 Hydraulic unit speed ..................................................137
12 Spare parts management and after-sales service ............... 138
12.1 Spar parts management ..............................................................................138
12.2 Spare parts, spare parts graphics ...............................................................138
12.3 Address for spare parts and after-sales service ..........................................138
Notes on our products...................................................................... 139
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General comments
0 General comments
0.1 Introduction
These operating instructions are supposed to facilitate operation, maintenance and
upkeep of the machine for the respective operator. They are supposed to assist in
keeping the machine at a high level of performance during its long working life and to
contribute to accident prevention.
During maintenance and upkeep work on the machine:
- Safety regulations and
- Accident prevention regulations
have to be particularly observed.
The operating instructions constitute an essential part of the delivered item. The operator
of the delivered item ensures that the operating personnel are familiarised with these
guidelines. In case of a possible transfer of the delivered item the operating instructions
have to be passed on, too.
After termination of the assembly and prior to commissioning of the delivered item the
buyer has to arrange for the implementation of a trial run of the delivered item checking all
safety installations in order to make sure that the machine can be operated safely and
that the personnel are able to handle it proberly and securely.
The operator is obliged to adapt the delivered item to the respectively effective safety
regulations.
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The L. Boschert GmbH+Co.KG. company reserves the copyright for this operating
manual, which is intended exclusively for use by the installation, operating and
monitoring staff. This operating manual contains technical instructions and drawings
which must not be copied, distributed or otherwise used for competition purposes
neither as a whole nor in parts nor communicated to others.
Violation of these copyright provisions will be prosecuted.
Copyright
0.2 Contents of the operating manual
Explanation
In this operating manual: OM = operating manual
Symbols:
- this stands before listed items,
* here, a sequence of work steps is explained
here, the consequence of a cause is explained.
General information
Orientation of the
machine:
front
left right
rear
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0.3 Separate documents
In the annex you will find documents prepared by third-party manufacturers. They
contain relevant information on supplied parts.
- We provide you with this OM; you will have to work with it.
- We have attempted to prepare this OM as comprehensive as possible. You’ll see
whether our efforts were successful. In your own interest, please inform us about
faults, wishes or proposals so that we may be able to optimise this operating
manual.
Thank you for your co-operation.
L. Boschert GmbH+Co.KG
P.O. Box 7042
D - 79523 Lörrach
Telefon: + 49 (0)7621 - 95 93 0
Telefax: + 49 (0) 7621 - 55 184
www.boschert.de
General information
- User manual for maintenance of AMADA-tools. AMADA
- Operating Instructions HPM MMKS series TC HPM
- High-pressure internal gear pumps Typ IPV Voith-Turbo
- DMA2 + DM1 Mounting + Maintenance Istructions Dutchi Motors
- Fluid Level Gauge FSA HYDAC
- Return Line Filter RFM HYDAC
- Accumulator Charging Unit SLE 02 H+L
- Data sheet Air-oil heat exchanger AP COSTANTE SESINO
- Safety valves direct operated Rexroth
0.3.1 Separate documents
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Safety
1.1 The operating personnel
The operator of the machine has to ensure that the
equipment is operated, maintained, inspected and
assembled/disassembled exclusively by authorised,
qualified and skilled personnel.
Authorized and qualified personnel are skilled employees:
- of the operator,
- of the manufacturer,
- of the service partner.
These persons must:
- have received practical training with the machine,
- have read and understood the operating manual,
- be familiar with the safety features of the machine,
- have been instructed about possible dangers,
- be familiar with the responsibilities to avoid unclear
responsibilities with regard to safety,
- be familiar with all relevant regulations (particularly the
accident prevention regulations to ensure that the
operation of the machine will cause no danger).
1.2 Clothing
The most serious injuries may result if clothes or
jewellery are caught by machine parts in motion.
During work, protect yourself by:
- wearing closely fitting working clothes with
waistbands on the sleeves,
- wearing sturdy, closed shoes,
- wearing a hairnet if you have long hair,
- taking off jewellery (rings, watches).
Danger
1 Safety
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Safety
1.3 Personal protective equipment
The symbols below indicate when you have to wear which type of protective
equipment.
Wear safety boots
Wear ear protectors
Wear gloves
Wear safety glasses
Wear safety helmet
1.4 Intended use
The operational safety of the delivered machine is only guaranteed if it is
operated according to its intended use.
Intended use means that:
- the machine is used for punching or nibbling metal sheets.
Furthermore, the following should be observed:
- the conditions specified in the order confirmation,
- the values specified in the „Technical data“ chapter,
- the conditions regarding safety, operation, maintenance and service as specified in
the operating manual.
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Safety
If the machine is used for other purposes, then this is „Improper use“.
Improper use can result in material damage or health hazard.
The manufacturer/supplier assumes no responsibility for damages resulting from
improper use. The user exclusively takes the risk for such uses.
Misappropriated use of the machine is not known to the manufacturer.
1.5 Explanation of symbols and notices
Notices that are marked with the following symbols should be taken very seriously.
These notices serve to avoid danger to life and health of persons.
Inform the other users about these notices.
This symbol replaces the symbol in case of danger due to electrical
current!
Furthermore, observe the applicable general safety and accident prevention
regulations of your legislation.
Symbol Explanation of the Signal word Possible consequences
symbol if notices are not observed
Danger Death or very severe injuries
General Danger Warning Very severe or severe
Symbol injuries
Caution Minor injuries
Here you receive
notices for easier
handling of the
product and for Information Material damage
avoiding damage
to the product.
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Safety
1.5.1 Symbols and notices on your machine
Directly attached to the machine:
- Safety notices,
- Arrows that indicate the sense of rotation,
- Marks for fluid connections.
Keep them in a completely readable condition.
ATTENTION! Tool in motion
Keep toolholder clean
Keep toolholder clean
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Safety
Switch cabinet
ATTENTION Danger due to electrical current
Pneumatic
Pressure setting: max. 4 bar
Switch-box
ATTENTION Danger due to electrical current
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TP1
Safety
arrow for sense of
rotation
Hydraulic unit
temperature
oil
Tank connection
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Safety
The following symbols can also be found in this operating manual.
Falling load
Danger of bruising
Danger of cut injuries
Danger of slipping
Observe these notices to avoid the dangers described above.
1.5.2 Dangers caused by non-compliance with the safety notices
Non-compliance with the safety notices
may result in the following dangers:
- Failure of critical machine functions.
- Failure of specified service and maintenance methods.
- Danger to persons through electrical, mechanical, or chemical influences.
- Danger to the environment due to leakage of dangerous substances.
Furthermore, you may lose all claims for damages.
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Safety
1.6 Safety-oriented working
The operating staff* must:
- observe the safety notices contained in this OM,
- know where the EMERGENCY-OFF buttons are located,
- observe the factory´s instructions regarding work, operation and safety.
It must be ensured:
- that the machine is switched off before any maintenance and repair work is started
and that it is safeguarded against accidental switching on (main switch on the
control cabinet is locked),
- up to 3 locks can be present,
- each work group (electricians, fitters) should attach its own lock; thus, each group
can prove that all safety and protective equipment are mounted and checked after
maintenance and repair and before commissioning,
- that only lifts with appropriate load-bearing capacity are used,
- that the machine is lifted only with the specified tools,
- that the manufacturer´s notices are observed when using chemicals (solvents,
cleaning agents, etc.),
It is forbidden:
- to conduct any work on the machine during operation,
- to perform alterations to the machine without the manufacturer´s permission,
- to use working methods, which affect the safety of the machine,
- to open doors, flaps or protective equipment during operation or to operate the
machine without these parts.
Removing, bridging or overriding
safety installations is absolutely
forbidden!
Never operate the machine when you
have taken alcohol or illegal drugs.
* Operating stuff in the sense of the EU Official Journal 183, annex I, clause 1.1.1 section 3 are the person(s), who is/are responsible for
installation, operation, setting up, maintenance including cleaning, fault correction and transport of a machine.
Never use gasoline or nitro-dilutions for cleaning. These substances develop
readily flammable vapours.
One spark (cigarette) is enough to cause
ignition.
This can result in most serious burns.
Danger
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Safety
1.7 The safety installations
1.7.1 The positions of the safety installations on your machine
= work positions to be taken by the operating staff
= EMERGENCY-OFF
= Protection without safety switch
= Protection with special key
= Light barrier
Never bride an EMERGENCY-OFF installation!
You would expose yourself and others to the most
serious hazards.
Most serious injuries caused by parts in motion, death caused by high
voltage may be the consequences. Always ensure free access and sight
to the EMERGENCY-OFF buttons. Always use the light barrier.
The machine must also be safeguarded on sides B, C and D so that no person
will be injured. The Boschert company assumes no liability if these instructions
are not observed.
Operator controls must not be located within the safety area or be operable from
the safety area.
Danger
Main switch
foot pedal
Reset - light barrier Two-handed operation
EMERGENCY-OFF button
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1
2
Safety
1.7.2 Individual safety installations
The main switch on the control cabinet
The main switch on the control cabinet:
- interrupts power supply to all aggregates,
- can be locked in the „0“ position by 3 means of
padlocks,
- protects you from accidental or unauthorised switching
on (after locking by means of a padlock).
Every person working on the machine should attach his
own lock. This provides protection.
The following assemblies are still live in the control
cabinet even after switching off the main switch:
- the main switch at the entrance side
When working on these parts it is
imperative to remove the main fuse of
the mains lead. Make sure that
unauthorised insertion of the main
fuse will be impossible.
How to lock the main switch:
* Move the lever to the „0“ position,
* pull out the red interlock (1),
* hang lock into the opening (2) and lock up,
* take out the key and keep it in a safe place to prevent
unauthorised use.
The EMERGENCY-OFF button
EMERGENCY-OFF buttons are the red pushbuttons.
Mode of operation:
- hit the button in case of danger.
The machine will stop immediately.
Resetting:
- Pull out the red button.
Danger
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1
2
Safety
Danger
Danger
The following assemblies are live in spite of
EMERGENCY-OFF:
In the control cabinet:
- the motor circuit protectors,
- the fuses,
- the contactors at the entrance side,
- the power supply,
- the control voltage is present,
- the programmable logic control.
On the machine:
- the control voltage is present.
When working on these parts, it is imperative to set
the main switch to „0“ and to secure it against
switching on.
The light barrier (1)
The light barrier protects you from dangers:
- caused by the ram,
- due to the motion of the workpiece.
Always work with an active light barrier (1).
Always stay outside the light barrier.
The area between light barrier and machine is
dangerous due to workpiece motion!
You can only start the machine when the light barrier
is active.
Activate light barrier
* go out of the area between light barrier and
machine,
* press button (2) at the light barrier. (The light barrier
is activ).
The interlock switch
The die punch motion cannot be started unless the inter-
lock switch has been pressed.
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