Gesipa 8000 eco User manual

Automatic blind riveting
system GAV-electronic
Model 8000
Model 8000 eco
fully automatic blind riveting system
Year of manufacture . . . . . . . .
Device no. . . . . . . . . . . . . . . . . .
Operating Manual
including spare parts list and extras

Table of Contents
Table of Contents
Table of Contents
Chapter Page
1. Dimension sheet, specifications and working area.…………………. 4
2. Intended use and safety instructions.………………………………….. 5 - 6
3. Notes on environment, recycling, declaration of conformity.……… 7
4. Transport and installation.………………………………………………... 8
5. Commissioning and handling .…………………………………………... 9 - 10
6. Operational characteristics .……………………………………………… 11
7. Description of functions .…………………………………………………. 12 - 16
8. Operation .…………………………………………………………………… 17
8.1 Operational controls .…………………………………………………. 18
8.2 Graphic display .………………………………………………………. 19
8.3 Structure of menu .……………………………………………………. 20
8.4 Main menu .……………………………………………………………. 21 - 22
8.5 Error message .……………………………………………………….. 23 - 25
8.6 Access management .………………………………………………… 26
8.7 Manual operation .…………………………………………………….. 27
8.8 Setting parameters …………………………………………………… 28
8.9 Selecting data…………………………………………………………. 29
8.10 Text input ……………………………………………………………… 30
9. Settings GAV .………………………………………………………………. 31
9.1 Oscillating conveyor .…………………………………………………. 32
9.2 Pressure sensors .…………………………………………………….. 33 - 35
9.3 Large pressure transmitter .………………………………………….. 36 - 39
9.4 Small pressure transmitter .………………………………………….. 40 - 41
9.5 Singulator .……………………………………………………………... 42
9.6 Blast air .……………………………………………………………….. 43 - 44
9.7 Mandrel extractor .……………………………………………………. 45 - 46
9.8 Cycle……………………………………………………………………. 47
9.9 Additional functions .………………………………………………….. 48
9.10 Drive PLC .…………………………………………………………….. 49
9.11 Permanent test .……………………………………………………….. 50
9.12 I/O-test .………………………………………………………………… 51
9.13 PLC interface test .……………………………………………………. 52
10. Maintenance .………………………………………………………………... 53
10.1 Notes on maintenance .………………………………………………. 54 - 55
10.2 Maintenance messages .…………………………………………….. 56 - 57
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Table of Contents
Table of Contents
Table of Contents
Chapter Page
11. Process control .…………………………………………………………. 58
11.1 Functional characteristics .………………………………………… 59
11.2 Settings ……………………………………………………………… 60 - 61
11.3 Creating a profile .………………………………………………….. 62 - 66
11.4 Loading a profile .…………………………………………………… 67
11.5 Storing a profile .……………………………………………………. 68 - 69
11.6 Creating a profile list .………………………………………………. 70 - 73
11.7 Loading a profile list .………………………………………………. 74
11.8 Profile lists PLC .……………………………………………………. 75
11.9 Process Control Calibration .…………………….………………… 76
11.9.1 Force Calibration ……………………………………… 77
11.9.2 Stroke Calibration .…..…………………………………… 78
12. Process data .…………………………………………………………….. 79
13. Process counter .………………………………………………………… 80
14. Operating data collection .……………………………………………... -
15. Access codes .…………………………………………………………… 81
16. Time and Language …………………………………………………... 82
17. System info .……………………………………………………………… 83
18. GRivCheck ..……………………………………………………………… 84
19. Faults feeding unit ..……………………………………………….…… 85
20. Faults blind rivetting gun .…………………………………………….. 86 - 89
21. Repair instructions blind rivetting gun .………………………..…... 90 - 93
22. Disassembly and assembly of pressure transmitter .……………. 94 - 95
23. Repair instructions pressure transmitter ………………………….. 96 - 97
24. Filling hydraulic systems ……………………………………………... 98 - 99
25. Replacing control components ………………………………………. 100
26. Pneumatic connection diagram ……………………………………… 101
27. Electric connection diagram .……………………………..………….. 102 - 103
28. PLC interface .……………………………………………………………. 104
28.1 Technical description .……………………………………………… 105 - 107
28.2 PLC interface test .…………………………………………………. 108
28.3 Drive PLC .………………………………………………………….. 109 - 110
28.4 Process counter .…………………………………………………… 111
28.5 Selecting a profile list ………………………………………..…….. 112
28.6 Selecting a profile directly .………………………………………… 113
28.7 Selecting a profile step by step .………………………………….. 114
28.8 Evaluation process .………………………………………………... 115
28.9 Evaluation component .……………………………………………. 116
28.10 Other functions .…………………………………………….. 117
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not included in GAV-8000 eco

Table of Contents
Table of Contents
Table of Contents
Spare parts list
Overview subassemblies Spare parts list
page
Assembly 1: Pneumatic assembly .……………………………………….. 2 - 3
Assembly 2: Blind riveting gun……………………………………………. 4 - 10
Assembly 3: Hydraulic amplifier unit .……………………………………. 11 - 12
Assembly 4: Singulator ……………………………………………………... 13
Assembly 5: Case unit ………………………………………………………. 14
Assembly 6: Oscillating conveyor unit .………………………………….. 15
Assembly 7: Feed bundle …………………………………………………... 16
Assembly 8: Controls………………………………………………………… 17
Assembly 9: Accessories …………………………………………………... 18 - 19
Assembly 10: Front plate ……………………………………………………. 20
Assembly 11: Cable tree ……………………………………………………. 21 - 23
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1 Dimension sheet,
specifications and working area
Dimension sheet, specifications
and working area
Feed unit
Weight: 100 kg
Volume remaining mandrel collecting basin: approx. 1800 – 5500 pieces (3.5 l) depending on size
Electrics
- Rated voltage: 230 Volt ~ 50 Hz
- Rated current: < 2,5 A
- System of protection: IP 54
Pneumatic equipment
- Network pressure < 10 bar
- Working pressure: 6 -7 bar
- Air consumption / blind riveting process: 15 NL
- Air consumption / vacuum extractor for remaining mandrels (VE): 340 NL/min.
- Connecting line: ½ " (12.5 mm) max. length 5m
- Outlet hose remaining mandrel: 3.75 m length / exterior-8 mm / interior-5 mm
- Pressure transmitter: pneumatic / hydraulic
Hydraulic
- Hydraulic oil ISO-VG 46 (e.g. Shell Hydrol HV 46 or comparable HVLP-D products): 1.2 l
- Viscosity, kinematic at 40°C (DIN 51562) without silicone parts: 47 mm² / s
Ambient temperature: 10 -40°C
Blind riveting gun
- Weight: approx. 2.5 kg
- Setting motion: 16 -20 mm
- Setting force: 11770 N
- Hose assembly length (standard): 3.75 m
- Working cycle (theoretical setting performance) intended use: 1.25 sec.
Working environment
- Blind rivet up to Ø 5,0 mm stainless steel
- Blind rivet up to Ø 6,0 mm steel
- Blind rivet up to Ø 6,4 mm aluminium
- Maximal setting head diameter: 11.4 mm
- Maximal blind rivet shaft length:
(additional size on request) 25.0 mm
According to the supply agreement the device is designed for a specific blind rivet model suitable
for automatic systems.
1
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Standard tubing
length: 3,5 meter
(12,3ft)

Dimension sheet, specifications
and working area
Feed unit
Weight: 100 kg
Volume remaining mandrel collecting basin: approx. 1800 – 5500 pieces (3.5 l) depending on size
Electrics
- Rated voltage: 230 Volt ~ 50 Hz
- Rated current: < 2,5 A
- System of protection: IP 54
Pneumatic equipment
- Network pressure < 10 bar
- Working pressure: 6 -7 bar
- Air consumption / blind riveting process: 15 NL
- Air consumption / vacuum extractor for remaining mandrels (VE): 340 NL/min.
- Connecting line: ½ " (12.5 mm) max. length 5m
- Outlet hose remaining mandrel: 3.75 m length / exterior-8 mm / interior-5 mm
- Pressure transmitter: pneumatic / hydraulic
Hydraulic
- Hydraulic oil ISO-VG 46 (e.g. Shell Hydrol HV 46 or comparable HVLP-D products): 1.2 l
- Viscosity, kinematic at 40°C (DIN 51562) without silicone parts: 47 mm² / s
Ambient temperature: 10 -40°C
Blind riveting gun
- Weight: approx. 2.5 kg
- Setting motion: 16 -20 mm
- Setting force: 11770 N
- Hose assembly length (standard): 3.75 m
- Working cycle (theoretical setting performance) intended use: 1.25 sec.
Working environment
- Blind rivet up to Ø 5,0 mm stainless steel
- Blind rivet up to Ø 6,0 mm steel
- Blind rivet up to Ø 6,4 mm aluminium
- Maximal setting head diameter: 11.4 mm
- Maximal blind rivet shaft length:
(additional size on request) 25.0 mm
According to the supply agreement the device is designed for a specific blind rivet model suitable
for automatic systems.
-4-R-
1-R Dimension sheet,
specifications and working area
1-R
A
dapter -
fastening -
thread M10
Standard tubing
length: 3,75 meter
(12,3ft)

Dimension sheet, specifications
and working area
Feed unit
Weight: 100 kg
Volume remaining mandrel collecting basin: approx. 1800 – 5500 pieces (3.5 l) depending on size
Electrics
- Rated voltage: 230 Volt ~ 50 Hz
- Rated current: < 2,5 A
- System of protection: IP 54
Pneumatic equipment
- Network pressure < 10 bar
- Working pressure: 6 -7 bar
- Air consumption / blind riveting process: 15 NL
- Air consumption / vacuum extractor for remaining mandrels (VE): 340 NL/min.
- Connecting line: ½ " (12.5 mm) max. length 5m
- Outlet hose remaining mandrel: 3.75 m length / exterior-8 mm / interior-5 mm
- Pressure transmitter: pneumatic / hydraulic
Hydraulic
- Hydraulic oil ISO-VG 46 (e.g. Shell Hydrol HV 46 or comparable HVLP-D products): 1.2 l
- Viscosity, kinematic at 40°C (DIN 51562) without silicone parts: 47 mm² / s
Ambient temperature: 10 -40°C
Blind riveting gun
- Weight: approx. 2.5 kg
- Setting motion: 16 -20 mm
- Setting force: 11770 N
- Hose assembly length (standard): 3.75 m
- Working cycle (theoretical setting performance) intended use: 1.25 sec.
Working environment
- Blind rivet up to Ø 5,0 mm stainless steel
- Blind rivet up to Ø 6,0 mm steel
- Blind rivet up to Ø 6,4 mm aluminium
- Maximal setting head diameter: 11.4 mm
- Maximal blind rivet shaft length:
(additional size on request) 25.0 mm
According to the supply agreement the device is designed for a specific blind rivet model suitable
for automatic systems.
-4-U-
1-U Dimension sheet,
specifications and working area
1-U

Dimension sheet, specifications
and working area
Feed unit
Weight: 100 kg
Volume remaining mandrel collecting basin: approx. 1800 – 5500 pieces (3.5 l) depending on size
Electrics
- Rated voltage: 230 Volt ~ 50 Hz
- Rated current: < 2,5 A
- System of protection: IP 54
Pneumatic equipment
- Network pressure < 10 bar
- Working pressure: 6 -7 bar
- Air consumption / blind riveting process: 15 NL
- Air consumption / vacuum extractor for remaining mandrels (VE): 340 NL/min.
- Connecting line: ½ " (12.5 mm) max. length 5m
- Outlet hose remaining mandrel: 3.75 m length / exterior-8 mm / interior-5 mm
- Pressure transmitter: pneumatic / hydraulic
Hydraulic
- Hydraulic oil ISO-VG 46 (e.g. Shell Hydrol HV 46 or comparable HVLP-D products): 1.2 l
- Viscosity, kinematic at 40°C (DIN 51562) without silicone parts: 47 mm² / s
Ambient temperature: 10 -40°C
Blind riveting gun
- Weight: approx. 2.5 kg
- Setting motion: 16 -20 mm
- Setting force: 11770 N
- Hose assembly length (standard): 3.75 m
- Working cycle (theoretical setting performance) intended use: 1.25 sec.
Working environment
- Blind rivet up to Ø 5,0 mm stainless steel
- Blind rivet up to Ø 6,0 mm steel
- Blind rivet up to Ø 6,4 mm aluminium
- Maximal setting head diameter: 11.4 mm
- Maximal blind rivet shaft length:
(additional size on request) 25.0 mm
According to the supply agreement the device is designed for a specific blind rivet model suitable
for automatic systems.
-4-UA- 1-U
1-UA Dimension sheet,
specifications and working area
1-UA
Standard tubing length:
3,75 meter (12,3ft)

2 Intended
use and safety instructions
Intended use
and safety instructions
Intended use
The blind riveting tool is intended exclusively for the processing of blind rivets suitable for
use in automatic systems. Any other use or use beyond those limits will not be considered as
intended.
 Operators must receive instruction and follow safety instructions.
Safety instructions
The machine is designed in accordance with the latest state-of-the-art technology and
accepted safety regulations.
 When put to the use intended, a safe work environment will be ensured.
 The device is intended exclusively for the processing of blind rivets.
 Read the operating instructions before commissioning.
 Any work on the electrical equipment of the device must be carried out by an electrical
specialist in accordance with the rules of electro technology.
 Any work on the mechanical, hydraulic or pneumatic system must be carried out by instructed
persons with a special knowledge of the device.
 To protect against electrocution, injury and danger of fire during all setting,
maintenance and repair work, or the elimination of device disturbances there is a
duty to ensure that
- protective goggles are worn
- the electric mains plug has been pulled
- the pneumatic air supply was separated from the device
- no blind rivet is present on the chute or singulator
- the gun is at no time aimed at persons or other creatures.
 The blind rivet is conveyed at high speed from the feed unit through the convey-
ing hose to the blind riveting gun!
 It is absolutely essential that the measures described above are followed when
the feed hose or the expanding mouth piece have to be removed during repair or
maintenance work ; in addition to this attach a warning sign to the device.
 Non-compliance with intended use or inexpert handling may result in injury.
2
Attention!
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2 Intended
use and safety instructions
Intended use
and safety instructions
Prevention of accidents
Working with the GAV-8000 is only permitted for persons who
- have read and understood the operating and safety instructions (training!)
- have checked the device and the working area for hazards to life and limb before starting to
work
- comply with accident prevention regulations
- do not wear their hair loose or loose fitting clothes or jewellery including rings (hazard of in-
jury!)
- wear personal safety gear, such as: protective clothing, protective goggles, ear protection, pro-
tective shoes and gloves.
Work place
 This blind riveting tool is only intended as a place of work for an instructed operator possess-
ing the special knowledge required for this tool.
 Keep your work place tidy.
 Do not expose the blind riveting tool to rain, wetness or dampness.
 Do not use the blind riveting tool near flammable gasses or liquids. Risk of explosion!
 Ensure sufficient lighting at the work place.
 Ensure the provision of a safe floor for operators and the riveting tool as uneven floors pose a
danger of injury.
 Comply with the regulations for hazardous materials when handling hydraulic oil.
Blind riveting tool
The expanding mouth piece and the rivet mandrel conveying appliance with outlet hose or a
mandrel collecting basin must be mounted before the blind riveting tool is commissioned.
 Do not rivet without joint material! The blind rivet may shoot off the device! Do
not point the device towards yourself or other persons!
 Do not overload the blind riveting tool.
 Always check blind rivet system for perfect working order before use.
 If a conveying frame is mounted, lock the guide rolls first.
 Maintenance and repair is to be carried out by a suitable expert. If in doubt,
send the device to the manufacturer.
 Spare parts and fittings must meet the requirements determined by the
manufacturer. This is guaranteed when genuine parts are used.
 When putting the blind riveting gun onto a surface secure it against falling.
 Proper care of blind riveting tool (Keep handle dry and free of oil and grease)
 Check plugs and cables on a regular basis. When damaged, have them re-
paired by an electrical specialist.
 Check compressed air and hydraulic connections and hoses regularly. When
damaged, have them replaced by an instructed person.
2
Attention!
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