ERKO SH400PLC User manual

ISO 9001 ISO 14001
Producent / Producer / Производитель
Zakłady Metalowe ERKO R. Pętlak spółka jawna
Bracia Pętlak
ul. Ks. Jana Hanowskiego 7, 11-042 JONKOWO k/OLSZTYNA
tel./fax [phone] NIP: 739-020-46-93
e-mail: [e-mail], exp[email protected] serwis informacyjny: www.erko.pl.
OPERATION MANUAL
BUSBAR PROCESSING SITE
SH400PLC TYPE
SWW 0792 #VSH400PLC090909 PKWiU 29.56.25-90.00

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Thank you for buying our product.
Before using this equipment, please carefully read the user and the maintenance
manuals.
* ERKO has the right to introduce construction modifications due to equipment
modernization.

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TABLE OF CONTENTS
1 APPLICATION…………………………………………………………… 3
2 TECHNICAL DATA.....………………………………………………….. 3
3 ACCESSORIES…………………………………………………………. 4
4 MACHINE INSTALLATION…………………………………………….. 5
5 CONTROL PANEL……………………………………………………… 5
6 SOFTWARE……………………………………………………………… 6
7 ZERO ADJUTING OF THE MEASUREMENT SYSTEM…………… 11
8 TECHNOLOGY………………………………………………………….. 17
9 MAINTENANCE AND OPERATION RECOMMENDATIONS……… 23
10 HYDRAULIC GENERATOR……………………………………………. 24
11 WORK SEFETY AND HYGIENE MANUAL………………………….. 27
12 SERVICING……………………………………………………………… 27
13 DISPOSAL……………………………………………………………….. 27

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Before using this equipment, please read the user and the
safety manuals.
The equipment can be used only with Al and Cu rails
1. APPLICATION
The SH 400PLC machine can be used for cutting, die blanking and bending copper
and aluminum rails with electronic measurement of the angle and the distance
between the hole and the front of the rail, equipped with a touch display.
The basic features which ensure the efficient and precise operation of the equipment
include:
Programmable sensor of the bending angle (accuracy 0.1°)
Built-in measurement bar for positioning within an accuracy of 0.1 mm.
Precise regulation of the height of the hole cutting head (accuracy 0.1 mm).
Making round and oval holes without burrs
Rail cutting without distortion or burr
Pedal control
Built-in reliable hydraulic drive
2. TECHNICAL DATA
Station weight 782.64lb
Max dimensions L x W x H 1400 x 850 x 1420 mm
Max table dimensions 2030 x 715
Working pressure 630 bar
Working pressure on the head outlet 630 bar
Power supply 3x400/230 V 50 Hz, 1.4kW
Control 24V DC
Supply plug
16A 400V 3P N+E IP44
(PCE 015-6v)
Protection degree IP40
Busway machining (Cu, Al) (thickness X width) 12 x 125 mm
Bending range 0÷90°

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3. ACCESSORIES
The station is equipped with the following accessories:
1. Complete table (1 item)
2. Control system (1 item)
3. Hydraulic power system (1 item)
4. A high pressure 630 bar hydraulic conduit with a PM connection for feeding
external heads. (1 item)
5. The body of the cutting and hole cutting segment. (1 item)
6. Software (1 item)
7. Technical documentation (1 item)
Standard versions of the SH400PLC station
Accessories Code
SH400PLC-SILVER
SH_400PLC1-3F
SH400PLC-GOLD
SH_400PLC2-3F
SH400PLC-PLATINUM
SH_400PLC3-3F
A precision bending insert (built-in encoder) SH 401PLC-E + + +
Rail cutter SH 405 + + +
Cut rail length gauge SH 415PLC o o +
Rail offsetting insert SH 406PLC o + +
Additional side tabletop SH 408PLC o o +
Extended length measurement (range from 0 to 1020) SH 418PLC o o +
Round hole cutter (dimensions as per the catalogue) SH 403 o o o
Oval hole blanking die (dimensions as per the
catalogue)
SH 404 o o o
Rectangular hole blanking die (dimensions chosen by
the customer)
SH 409 o o o
Insert for forcing in nuts SH 407 o o o
Additional rbusbar support SH 408 o o o
+ standard accessories
o additional accessories ordered individually by a customer
Additional equipment (optional):
External equipment as per ERKO catalogue:
GU 120 Head for clamping dies on cables 10 – 120 mm2, reforming sector
conductors
GU 300 Head for clamping dies on cables 10 – 300 mm2, reforming sector
conductors
GO 300 Head for clamping dies on cables 6 – 300 mm2, reforming sector

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conductors
GU 625 Head for clamping terminals on cables 300 – 625 mm2
GW Head for punching holes in switching cabinets
GC 50N Head for cutting cable conductors
GC 100 Head for cutting cable conductors
GL 6 Assembly rail cutter
GLP Assembly rail cutter
4. MACHINE INSTALLATION
 The station should be positioned on hard and even foundation, so that it will
securely lean on all four wheels.
Operation of the station on an unadapted foundation may result in
accelerated wear and in some cases it can be a cause of a defect or
destruction of the station.
Block the brakes of the station wheels.
Connect the equipment to the electrical power supply.
In order to work properly, station type SH400PLC requires five-line electrical
network - L1, L2, L3, N, PE in any sequence of phases. For four-line network it is
necessary to bridge PE and N lines in the supply socket.
5. CONTROL PANEL
The control panel consists of the following elements:
The main switch Q1 – used for starting the station.
A white signalling lamp L1 – used for signalling correct power supply.
LCD panel with a touch screen – contains technological software.
Emergency stop switch Q2.
Foot switch Q3 – acts as an operational switch-key.
Body height regulating crank S1.
Limiter stop S2.
Fig. 1.
crank

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6. SOFTWARE
6.1 PREPARATION FOR WORK
NOTE:
In specific cases the software may deviate from that presented below.
Connecting and disconnecting the communication cord of the bending insert
(SH401PLC-E) is allowed only with the station power supply disconnected.
If it is necessary to remove the measuring insert frequently, place it in the immediate
storage area (Fig. 24) without disconnecting the communication cord.
In order to start the station, switch on the main switch Q1 to position I. Then a
screen (Fig. 2) will appear on the panel screen, where you will be asked to
choose the user interface language by clicking the appropriate flag.
After the appropriate language has been selected, the message “Communication
OK. on CAN” (Fig. 3) will appear, followed by the screen from which you will
select the type of operation (Fig. 4).
Fig. 2. Fig. 3
Fig. 4.
It is possible to change the menu language at any time by clicking the appropriate flag
on the bar at the top of the screen (Fig. 4)
If other messages or no messages appear, restart the station or, if this does not give
the desired result, contact the service.

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Work type selection:
Body: enables bending conductor rails, offsetting, die blanking and forcing in nuts.
Cutting: starts the SH 405 module for rail cutting.
Head: starts the external conduit for powering auxiliary devices with hydraulic oil.
After pressing the Body menu it is necessary to define the reference points on the
measurement bars. The programmer signals it with red areas H, L, A or H, L,
depending on the operation that is being performed.
In order to find them:
H-REF – turn the knob S1 upwards and/or downwards. As a result the red area should
disappear.
L-REF – Move the stop slide S2 from the body to the table end. As a result the red
area should disappear.
A-REF – Bend the angle measurement insert level, the insert must be connected with
the assembly socket. As a result the red area should disappear.
After all these actions have been performed, the station is ready to work.
If only the HEAD (GŁOWICA) or CUTTING (CIĘCIE) menu is used, looking for
reference points is not necessary.
6.2 DIE BLANKING
Die blanking is the default option when you go to the BODY (KORPUS) menu is there
is no equipment in the body.
After starting the BODY (KORPUS) menu, a window will appear where you will have to
define the reference points of the measurement bars (Fig. 5.
Fig. 5. Fig. 6
For the die blanking operation to be performed correctly, it is necessary:
To determine the distance between the hole centre and the lower rail
edge.
Turn the knob S1 so that the desired offsetting value will be displayed in
area H Fig. 6
To determine the distance between the hole centre and the right rail
edge.

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Move and block the stop slide S2 to the desired distance. The value of
offsetting is displayed in area L Fig. 7.
Fig. 7.
6.3 BENDING
In order to start the bending operation, go the BODY menu and equip the body with a
punch and the measuring insert SH 401PLC - E.After a mandrel is installed, a window
will appear where you will have to define the reference points of the measurement bars
(Fig. 8).
Fig.8 Fig.9
Fig.10 Fig.11

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Fig.12 Fig.13
For the bending operation to be performed correctly, it is necessary:
To enter the rail width.
Press the button situated below the heading “HEIGHT H OF THE RAIL”
(The default value displayed on the button – “0” Fig. 8). The numerical
keyboard will be displayed with which you will enter the width of the rail
being bent. Confirm the value by pressing RET Fig. 9.
To enter the desired bending angle.
Press the button situated below the schematic drawing (the default value:
45, Fig. 8). The numerical keyboard will be displayed with which you will
enter the angle value. Confirm the value by pressing RET Fig. 10.
To adjust the body height in relation to the rail.
Turn the knob S1 so that the centre of the rail width will coincide with the
centre of the bending mandrel. The arrow in area H in Fig. 11 and Fig.
12, showing whether the body should be lifted or lowered, will help.
When the value has been achieved, the OK message will appear in area
H, Fig. 13.
To adjust the distance between the hole centre and the rail edge.
Move and block the stop slide S2 to the desired distance. The value of
offsetting is displayed in area L, Fig. 13.
6.4 OVERBENDING
In order to start the bending operation, go the BODY (KORPUS) menu and equip the
body with a mandrel and the measuring insert SH 401PLC - E.
After a mandrel is installed, a window will appear where you will have to define the
reference points of the measurement bars (Fig. 8).
There is a button “BENDING WITHOUT OVERBENDING” in the centre of the screen
which should be pressed in order to start the overbending operation. Fig. 8.
The follow the procedure from 6.2 (die blanking).
Note: When the overbending option is on, the bending angle must be higher than 5°.
Bending of up to 5°without overbending.
Overbending is a standard option in the stations SH400PLC – GOLD and SH400PLC
– PLATINUM.

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6.5 OFFSETTING
In order to start the offsetting operation, go to the BODY menu and equip the body with
offsetting inserts SH 406PLC. After the inserts are installed, the screen as in Fig. 14
should be displayed on the screen.
Fig.14 Fig.15
Fig.16 Fig.17
For the offsetting operation to be performed correctly, it is necessary:
To introduce the rail width.
Press the button situated below the heading “HEIGHT OF THE RAIL H”
(The default value displayed on the button – “0” Fig. 14). The numerical
keyboard will be displayed with which you will enter the width of the rail
being bent. Confirm the value by pressing RET Fig. 15.
To adjust the body height in relation to the rail.
Turn the knob S1 so that the centre of the rail width coincide with the
centre of the bending insert. The arrow in area H in Fig. 16, showing
whether the body should be lifted or lowered, will help. If the value has
been achieved, the OK message will appear in area H, Fig. 17
To adjust the distance between the offsetting and the rail edge.
Move and block the bumper slide S2 to the desired distance. The value
of offsetting is displayed in area L Fig. 17.

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6.6 CUTTING:
In order to start the cutting operation, go to menu CUTTING, Fig. 18. The program
starts and controls module SH405 and SH415PLC.
Fig.18 Fig.19
Working with SH415PLC. In order to find a reference point, press pedal Q3, move the
rail being cut to the cutter; after the pedal is released, the system sets to zero and
gives the negative offset, equal to the cutter thickness, Fig. 19, Fig. 20.
Fig.20 Fig.21
In order to adjust the length of the rail element which is being cut, move it under the
cutter for the desired length. The value is displayed in area G, Fig. 21. After the
desired length has been cut off, the counter sets to zero and gives the offset equal to
the thickness of the cutter.
NOTE: Electronic measurement of the length of cut rail is available as an option or as
part of the standard in the models of the SH400PLC PLATINUM series.

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6.7 POWER SUPPLY TO THE EXTERNAL EQUIPMENT
In order to supply power to the external equipment connected to the hydraulic head, go
to the HEAD menu, Fig. 22. The program starts the module controlling the power
supply to the hydraulic high pressure pipe ending with a quick coupler.
Fig.22
6.8 FOLDING AND UNFOLDING THE TABLETOP
To unfold the tabletop:
• fold up the extended measurement bar to its basic position (if any),
• press the button TABLETOP FOLDING (SKŁADANIE BLATU) on the control
panel (the button releases for 5 seconds the blockade of the tabletop blocking
bolts)
• release the bolts and lift the tabletop to the working position
• bolt the tabletop
• The “TABLETOP FOLDING” button is available at any time of the station
operation, but it is only active when the “extended measurement bar” is in its
basic position.
To fold the tabletop:
• fold up the extended measurement bar to its basic position (if any),
• press the button TABLETOP FOLDING on the control panel (the button
releases for 5 seconds the blockade of the tabletop blocking bolts)
• release the bolts and lower the tabletop to the resting position
• bolt the tabletop
Note:
The station is equipped with safety devices, but you must not try to fold up
the tabletop is the “extended measurement bar” is not in its basic position.
This may result in damaging the measurement bar.
An additional tabletop is available as an option or as part of the standard in the models
of the SH400PLC PLATINUM series.
An extended measurement bar available only with an additional tabletop is available
as an option or as part of the standard in the models of the SH400PLC PLATINUM
series.

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7. ZERO ADJUSTING OF THE MEASUREMENT SYSTEM
Only for the software version SH400 PLC3-V2
Length scaling of the cut bus (counter G)
1. Switch on the power supply of the stand
Fig.23
2. After selecting the language version on the control panel [Fig. 24] select the
option KORPUS (body) [Fig. 25]
Fig.24 Fig.25
3. Put the locating insert SH410PLC (2) and the offset insert (3) [Fig.4] into the
body (1); the screen will display a message about the instrumentation error
[Fig.27])
Fig.26 Fig.27
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4. On the instrumentation error screen in its bottom part, click TRYB
SERWISOWY (service mode)
5. The device switches into service mode
6. Press the pedal and wait till the mobile knife shifts to the low position [Fig.28]
Fig.28
7. Shift the bus of minimal length 1.5 m under the measurement roll (1) pushing
it up to the knife (2). The bus should have the length of 1 m marked, counting
from the side of the knife (2).[Fig.29]
Fig.29
8. Release the pedal and wait till the knife withdraws completely to its top
position
9. Slowly but firmly shift the bus by 1 m (the marked value on the bus should
match the left edge of the cutting die)
10. Hold the bus so as to not allow it to be moved and press the pushbutton
G >0< on the panel at the height of the counter G [Fig.30]
Fig.30
1
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11. Return to the basic screen of the panel by taking out the locating insert (2) or
offset insert (3) [Fig.26]
12. Check correctness of cutting
13. If necessary, scale the system of the counter G again
Zero adjusting of the insert for measurement of the bending angle (counter A)
1. Perform the steps 1-5 from the point ”Scaling of the cut bus length”
2. Make a move with the levers (1) of the measurement insert [Fig.31] till the
moment the inscription REF on the counter A [Fig.32] vanishes.
Fig.31 Fig.32
3. Using, for example, a straight piece of bus, position the levers (1) in a position
parallel to the body of the measurement insert.
4. Holding the immobilized levers (1) [Fig.31] on the panel [Fig.32] press the
pushbutton A >0< at the height of the counter A
5. Return to the basic screen of the panel by taking out the locating insert (2) or
the offset insert (3) [Fig.26]
6. Check the correctness of bending
7. If necessary, scale the system of the counter A again
Zero adjusting of the length measurement system (counter L1)
1. Perform the steps 1-5 from the point ”Scaling of the cut bus length”
2. Make a move with the measurement system L (4) [Fig.26] till the moment the
inscription REF on the counter L [Fig.34] vanishes.
Fig.33 Fig.34
3. Move the measurement lever (1) till the vertical axis of the locating insert (2)
[Fig.33]
4. Holding the immobilized lever on the panel press the pushbutton L1 >0< at
the height of the counter L
1
2
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5. Return to the basic screen of the panel by taking out the locating insert (2) or
the offset insert (3) [Fig.26]
6. Check whether the hole is correctly made with the proper distance from the
edge of the bus
7. If necessary, scale the system of the counter L again
Zero adjusting of the length measurement system (counter L2)
1. Perform the steps 1-5 from the point ”Scaling of the cut bus length”
Make a move with the measurement system L (4) [Fig.26] till the moment the
inscription REF on the counter L [Fig.34a] vanishes
Fig.33a Fig.34a
2. Move the lever measurement system to the second measurement range
3. Put the standard section of 1 m length (3) [Fig.33a] between the basing insert
(2) and the measurement lever (1)
4. Holding the immobilized lever on the panel press the pushbutton L2 >0< at
the height of the counter L
5. Return to the basic screen of the panel by taking out the locating insert (2) or
the offset insert (3) [Fig.26]
6. Check whether the hole is correctly made with the proper distance from the
edge of the bus
7. If necessary, scale the system of the counter L again
Zero adjusting of the height measurement system (counter H)
1. Perform the steps 1-5 from the point ”Scaling of the cut bus length”
2. Make a move with the body (2) of the measurement system H using the crank
(1) [Fig.35] till the moment the inscription REF on the counter H [Fig.36]
vanishes
Fig.35 Fig.36
2
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3. Move the body (1) so as the horizontal axis of the locating insert (2) covers
with the table top surface (5) [Fig.26]. For levelling, it is recommended to use
the straight piece of bus of length approximately 1.5 m.
4. Holding the immobilized body on the panel press the pushbutton H >0< at the
height of the counter H
5. Return to the basic screen of the panel by taking out the locating insert (2) or
the offset insert (3) [Fig.26]
6. Check whether the hole is correctly made with the proper distance from the
edge of the bus
7. If necessary, scale the system of the counter H again
8. TECHNOLOGY
8.1 DIE BLANKING
NOTES:
When punching holes in aluminium rails, lubricate the punch with oil or
kerosene each time. Recommended agent: HHS 2000 manufactured by
WÜRTH.
Fig.23
8.1.1 ROUND HOLES
Prepare the station as described in 6.1
busbar
setting mandrel
stamp + spring

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Equip the station with a blanking die and enter the settings as described in
item 6.2
Move the rail in the space between the die block and the punch and move the
rail to the bumper S2
Press the pedal Q3 to start the die blanking procedure; after the operation is
complete, the piston rod will return to its starting position.
To repeat the operation, release the pedal and press it again.
8.1.2 OVAL AND SQUARE HOLES
Prepare the station as described in 6.1
Equip the station with a blanking die and enter the settings as described in
item 6.2
Insert the setting mandrel [16].
Install the appropriate punch and blanking die.
Move the rail into the space between the die block and the punch and move
the rail to the bumper S2
Press the pedal Q3 to start the die blanking procedure; after the operation is
complete, the piston rod will return to its starting position.
To repeat the operation, release the pedal and press it again.
Accessories as per order
Punches, type SH403 – hole for M6-M20 screws (a set of punch and blanking die)
Standard dimensions
Designation
Hole diameter
[mm]
For a screw
M
SH403 6,6
ν6,6 6
SH403 8,5
ν8,5 8
SH403 11
ν11 10
SH403 13
ν13 12
SH403 17
ν17 16
SH403 21
ν21 20
Punches, type SH403 with any diameter are available in the range from ν6,6 to ν21
mm are available on request.
Oval punches, SH404, with dimensions A and B (see the
table)
Standard dimensions
Designation
Dimension A
[mm]
Dimension B
[mm]
For a screw
M
SH404 8,5-12 8,5 12 8
SH404 11-16 11 16 10
SH404 13-18 13 18 12
SH404 17-21 17 21 16
Other dimensions of oval punches, type SH404, are available on request; the
condition of B/A<2 should be met

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8.2 BENDING
Prepare the station as described in 6.1
Equip the station with a mandrel [1b] and a measuring insert [1a] and enter
the settings as described in item 6.3
Move the rail into the bending space and move the rail to the bumper S2
Press the pedal Q3 to start the bending procedure; after the operation is
complete, the piston rod will return to its starting position.
To repeat the operation, release the pedal and press it again.
NOTES:
The mechanical properties of rails made of copper or aluminum may vary -
different cross sections have different moment of inertia; this may result in different
bending angles. The property is particularly linked to the moment of inertia of a cross
section. In order to perform precise bending, bend a rail by an angle which is smaller
by 5-10°from the target value and measure the angle with a measuring insert.
Calculate the difference between the desired and the obtained angle. Then bend the
rail again, adding the calculated adjustment value to the target angle.
There is a risk of damaging the piston rod if the bending procedure is started
before the station is properly equipped.