KabaTec KTS SpeedTec mini Operational manual
Translation of the original operating manual for the KTS SpeedTec mini
B|HM0SM|00001|V0006|EN
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Taping • Insulation • Bundling • Marking • Fixing • Wrapping
KTS
Translation of the original
operating manual
Machine number
Quality control
Customer
Date
SpeedTec
mini
Translation of the original operating manual for the KTS SpeedTec mini
B|HM0SM|00001|V0006|EN
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EC Declaration of Conformity
We hereby confirm that the following product
KTS SpeedTec mini
satisfies the regulations specified in Machinery Directive 2006/42/EC,
Annex II A, in particular the protection requirements.
Likewise, it satisfies the regulations that are specified in the European Community directive for
harmonization of statutory regulations concerning electromagnetic compatibility (2004/108/EC), in
the directive for changing the
CE mark (93/68/EEC), in the Low-Voltage Directive (2006/95/EC), as well as those regulations
specified in the Device Product Safety Law (Ninth Ordinance to the Equipment and Product
Safety Act (9th GPSGV)).
This declaration applies to all identical models of the product, which are manufactured in
accordance with the development, design and manufacturing drawings and descriptions included
herein (these being components of this declaration).
The following applicable harmonized European standards, the sources of which have been
published in the Official Journal of the European Union, have been applied:
EN ISO 13857
EN 349
EN 1037
EN ISO 14121-1
EN 547-2
EN 60204-1
EN ISO 12100-1
EN 614-1
EN 61000-4-2
EN ISO 12100-2
EN 983
EN 61000-4-4
EN ISO 13850
EN 999
EN 13849
This declaration is made on behalf of the following manufacturer:
Company name: KABATEC GmbH & Co. KG
Address: Bahnhofstr. 28
D-36151 Burghaun, Germany
Tel.: +49 (0) 6652 79362 –0
Name of person authorized to compile the documentation: Heinz Billing (in-house)
Name of signatory: Heinz Billing
Position in the company: Managing director
____________________________________________________________________________
Place Date Legally-binding signature
Burghaun
14/6/2016
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Legal notice
General information
This operating manual was prepared by KABATEC GmbH & Co. KG
in June 2016.
Directives
This operating manual has been prepared having regard
to Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006
concerning machinery and amending Directive 95/16/EC.
Contact
Please feel free to contact us if you have any questions or suggestions.
KABATEC GmbH & Co. KG
Bahnhofstraße 28
D-36151 Burghaun, Germany
Telephone: +49 (0) 6652 / 7 93 62 - 0
Telefax: +49 (0) 6652 / 7 93 62 - 10
Copyright
All texts, photos and graphics in this documentation are protected by copyright. No portion of this
documentation may be duplicated or made available to third parties without the express written
consent of KABATEC GmbH & Co. KG.
Liability
We have compiled all the information in this operating manual with the utmost care and have
checked it for consistency with the described hardware and software. Nevertheless we cannot
entirely exclude the possibility of deviations. We assume no legal responsibility or liability for
damage that may possibly occur due to such deviations.
Note
We reserve the right to make technical changes and add supplementary information.
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Table of contents
EC Declaration of Conformity ................................................................................................................................... 2
Legal notice .............................................................................................................................................................. 3
Guarantee declaration ..................................................................................................................................... 71.
For your safety................................................................................................................................................. 92.
2.1 General safety information............................................................................................................................. 9
2.2 Types of safety symbols used........................................................................................................................10
2.3 Safety and warning signs.............................................................................................................................. 11
2.4 Intended use .................................................................................................................................................12
2.5 Application....................................................................................................................................................12
2.6 Note on familiarization and operation .........................................................................................................12
2.7 Safety measures at setup site ....................................................................................................................... 12
2.8 Description of the workplace ........................................................................................................................13
2.9 Required personal protective equipment .....................................................................................................13
2.10 Emissions ......................................................................................................................................................13
Description of the machine............................................................................................................................ 143.
3.1 General information .....................................................................................................................................14
3.2 Taping unit....................................................................................................................................................18
3.3 Technical data for the KTS SpeedTec mini ....................................................................................................20
Commissioning .............................................................................................................................................. 214.
4.1 Unpacking.....................................................................................................................................................21
4.2 Transportation..............................................................................................................................................21
4.3 Setup............................................................................................................................................................. 21
4.4 Connection....................................................................................................................................................22
4.5 Possible hazards ...........................................................................................................................................23
Use ................................................................................................................................................................ 255.
5.1 Establishing readiness for operation ............................................................................................................ 25
5.2 Activation/Deactivation................................................................................................................................ 26
5.3 Faults ............................................................................................................................................................26
5.4 Start screen of touch panel........................................................................................................................... 26
5.5 Main menu at touch panel ...........................................................................................................................27
5.6 Start (operation) ...........................................................................................................................................28
5.7 Editing programs ..........................................................................................................................................29
5.8 Loading programs.........................................................................................................................................31
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5.9 Copying programs.........................................................................................................................................31
5.10 Deleting programs ........................................................................................................................................33
5.11 Messages ......................................................................................................................................................33
5.12 Options ......................................................................................................................................................... 34
5.12.1 Touch panel settings ............................................................................................................................34
5.12.2 Language setting .................................................................................................................................. 35
5.12.3 Table of input variables ....................................................................................................................... 35
5.12.4 Table of output variables ..................................................................................................................... 35
5.12.5 Workplace height setting..................................................................................................................... 36
5.12.6 Lamp test ............................................................................................................................................. 36
5.12.7 Archive .................................................................................................................................................36
5.12.8 Functions..............................................................................................................................................37
5.12.9 User management ............................................................................................................................... 38
5.12.10 Processes ............................................................................................................................................. 38
5.12.11 Tensile force calibration.......................................................................................................................39
5.13 Service........................................................................................................................................................... 39
5.13.1 W-axis ..................................................................................................................................................39
5.13.2 X-axis....................................................................................................................................................40
5.13.3 Cable clamping axis..............................................................................................................................40
5.14 Inserting adhesive tape................................................................................................................................41
5.15 Positioning the clamping unit and safety stop ............................................................................................. 43
5.16 Tensile force calibration................................................................................................................................ 46
5.17 Inserting items to be taped........................................................................................................................... 48
5.18 Starting the taping process........................................................................................................................... 49
5.19 Ending the taping process ............................................................................................................................ 49
5.20 What to do in an emergency ........................................................................................................................49
5.21 End of tape....................................................................................................................................................50
Maintenance and servicing ............................................................................................................................ 516.
6.1 Maintenance schedule for three-shift operation ..........................................................................................51
6.2 Checking/Lubricating the guides and carriages............................................................................................52
6.3 Cleaning the cutter and hold-down device ...................................................................................................52
6.4 Replacing and setting the cutter...................................................................................................................53
6.5 Oiling the cutter............................................................................................................................................ 56
6.6 Checking/Cleaning the safety light barriers.................................................................................................. 56
6.7 Cleaning the air filter ....................................................................................................................................57
6.8 Cleaning the Makrolon discs.........................................................................................................................57
6.9 Setting the end-of-tape sensor .....................................................................................................................58
6.10 Cleaning the guide rollers .............................................................................................................................59
6.11 Cleaning the taping-unit carriage guide....................................................................................................... 59
6.12 Greasing the bearings...................................................................................................................................59
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6.13 Cleaning the positioning finger.....................................................................................................................60
6.14 Changing the belts........................................................................................................................................60
6.14.1 Belt for drive unit (part no. 15764) ......................................................................................................60
6.14.2 Belt for clamping device on right (part no. 15764).............................................................................. 63
6.14.3 Belt for linear unit (part no. 12817) .....................................................................................................66
6.15 Fault list ........................................................................................................................................................68
Scope of delivery ........................................................................................................................................... 697.
7.1 Items included in the scope of delivery .........................................................................................................69
7.2 Optionally available items ............................................................................................................................69
7.3 Contact details.............................................................................................................................................. 69
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Guarantee declaration1.
Article 1 Relation to other guarantee rights and national law
1. With this guarantee, the rights of the purchaser against the seller,
arising from the concluded purchase contract, are not affected.
2. The guarantee conditions of
KABATEC GmbH & Co. KG cited above apply, if nothing to the contrary
is specified in national law in this regard.
Article 2 Guarantee coverage
1. KABATEC GmbH & Co. KG grants a guarantee of 12 months, effective from the date the
device was acquired by the purchaser, for mechanical and electrical components of the
device, under the conditions described here. If within this guarantee period defects occur
which is not attributable to one of the causes cited under Article 3, KABATEC GmbH &
Co. KG shall, at its discretion, either replace the device or have the device transported to
its plant in Burghaun and repair it there.
2. No other circumstances shall be covered by guarantee.
Article 3 Guarantee conditions
1. The guarantee does not entitle the holder to free-of-charge inspection or
maintenance/repair
of the machine, particularly if the defects are attributable to improper use.
Likewise defects of wear parts that are attributable to normal wear are not covered by the
guarantee.
2. In addition, no guarantee claims will be accepted
for damage to the machine caused by:
- improper use or use of the machine for a
purpose other than its normal purpose (misuse), in disregard of
the information in the operating and maintenance manuals provided by KABATEC
GmbH & Co. KG;
- connecting or using the machine in a manner
not compliant with the applicable technical or safety-related requirements
of the country in which the machine is used;
- acts of nature, or other causes for which
KABATEC GmbH & Co. KG is not responsible.
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3. The guarantee becomes null and void if the machine is repaired by the customer itself or
by a party other than KABATEC GmbH & Co. KG.
4. If, through an inspection of the device by
KABATEC GmbH & Co. KG, it is determined that the damage does not warrant the
guarantee claims,
the costs of the inspection by
KABATEC GmbH & Co. KG will be borne by the customer.
Article 4 Transfer of the guarantee
1. The guarantee is valid only for the original purchaser, which obtained the machine from
KABATEC GmbH & Co. KG, and is not transferable.
2. Apart from KABATEC GmbH & Co. KG, no party is entitled to honour the guarantee on
behalf of KABATEC GmbH & Co. KG.
Article 5 Claims for damages
1. The purchaser is not entitled to make any claims for damages due to poor performance in
respect of the
guarantee claims, in particular due to consequential damage.
The liability of KABATEC GmbH & Co. KG is limited in all cases
to the merchandise value of the machine.
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For your safety2.
2.1 General safety information
Please read this operating manual thoroughly prior to using the device, and comply with the
information on conduct and safety prior to and following commissioning.
Keep the manual in the vicinity of the device at all times and in a safe and dry location that is
protected from direct sunlight. The manual should always be on hand whenever needed.
All persons responsible for setup, start-up, operation or maintenance of the machine must have
carefully read and understood this operating manual.
Qualified, specialist personnel, within the context of this basic safety information, are those
persons familiar with the setup, assembly, start-up and operation of the winding and taping
system and who are appropriately qualified for the work assigned to them.
The winding and taping system has a protective device and has been subjected to safety and
quality testing.
Unauthorized removal of required covers or protective devices, or improper use or incorrect
operation of the product can result in severe injuries or substantial damage to property.
The specified service and maintenance intervals are to be complied with.
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2.2 Types of safety symbols used
Caution
Indicates a hazard with a low-risk factor, which can result in slight or moderate physical injury or damage
to property if not avoided.
Warning
Indicates a possible hazard with a medium-risk factor, which can result in death or (severe) physical injury
if not avoided.
Never used for damage to property alone.
Danger
Indicates an immediate hazard with a high-risk factor, which can result in death or severe physical injury.
Never used for damage to property.
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2.3 Safety and warning signs
Indicates a hazard zone.
Indicates a risk of hand injury.
Indicates a risk of injury from being cut.
Indicates a risk of electric shock.
Indicates required protective equipment hairnet.
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2.4 Intended use
The KTS SpeedTec mini is a compact taping machine with many useful features. A wide variety
of taping tasks can be performed quickly and reliably.
A combined length-measurement/feed system ensures a compact design and makes the KTS
SpeedTec mini an efficient tool for producing cable sets.
2.5 Application
Taping of cable sets and modules.
Tape lengths and feed distance can be set according to individual winding steps and can be
worked through in succession.
This allows a wide variety of cable harness geometries to be generated.
2.6 Note on familiarization and operation
The owner of the winding and taping system must make the operating manual available to
operating personnel and also ensure that it has been read and understood by such personnel.
It has to be ensured that only instructed and authorized operating personnel work at the winding
and taping system.
Only trained and authorized personnel are to maintain the winding and taping system.
2.7 Safety measures at setup site
The setup surface must be level and suitably stable given the weight of the winding and taping
system.
Ensure that the accident prevention regulations are always complied with at the workplace, by
means of appropriate internal instructions and checks.
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2.8 Description of the workplace
The winding and taping system is operated at the front.
2.9 Required personal protective equipment
Do not work without using the following personal protective equipment:
- Tight-fitting work clothing
- Hair net, to protect long hair
- Closed work shoes or safety boots
2.10Emissions
The daily noise exposure level 𝐿𝐸𝑋,8ℎ does not exceed the upper action value of
85 dB (A).
The peak sound pressure level 𝐿𝑝𝐶,𝑝𝑒𝑎𝑘 does not exceed the upper action value of
137 dB(C).
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Description of the machine3.
3.1 General information
Identification of individual parts:
1. Touch panel
2. USB port
3. On switch
4. Ready indicator
5. Off switch
6. Stop button
7. “Fault reset” button (“Error Reset” in diagram)
8. Emergency stop button
9. “Edit” switch
8
1
2
5
6
7
9
3
4
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Identification of individual parts:
10. Protective hood
11. Line clamp on left side
12. Taping unit
13. Line clamp on right side
14. Signal lamp tower
15. Compressed-air maintenance unit
16. Lifting column
17. “Clamp” button on left side
18. Safety light barrier
19. Clamping unit with tensile force monitor
20. “Clamp” button on right side
21. Main switch
22. Fan
10
11
12
13
20
17
19
16
18
15
21
22
14
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1. Touch panel
All machine programs are edited, saved and brought up at the touch panel. In addition,
machine settings can be made there.
2. USB port
This port can be used to connect a USB storage device.
3. On switch
Used to switch on the taping machine. When pressed, the hood is automatically locked.
4. Ready indicator
-Operational readiness is indicated by a flashing signal lamp.
-The “On” operating state is indicated by a lit signal lamp.
5. Off switch
This switch can be used to deactivate the system. While the system is in a deactivated state,
the safety door can be opened.
6. Stop button
Press the stop button to stop the taping process.
7. Reset button / Fault indicator
The fault indicator lights up whenever a fault occurs. After being rectified, an active fault can
be cleared by pressing the “Reset” button.
8. Emergency stop button
Pressing the emergency stop button causes the taping machine to be stopped and switched
off immediately.
9. “Edit” switch
Set-up mode is activated via the “Edit” switch. Programs can be changed, deleted or copied,
and machine settings made, only with an active “Edit” switch setting.
10. Protective hood
The protective hood is automatically locked when the machine is switched on and serves to
protect the operator from moving parts during machine operation.
11. Line clamp on left side
The line connectors of the items for taping are inserted in the line clamp. The line clamp is
also used to clamp the lines.
12. Taping unit
The taping unit is used to wind adhesive tape around the items for taping.
13. Line clamp on right side
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The line connectors of the items for taping are inserted in the line clamp. The line clamp is
also used to clamp the lines.
14. Signal lamp tower
This indicates the status of the machine.
15. Compressed-air maintenance unit
At the compressed-air maintenance unit, there is a connection point for the compressed-air
supply for the machine. Also the compressed-air setting can be adjusted there.
16. Lifting column
Used for electrically-controlled height adjustment of the taping machine.
17. “Clamp” button on left side
This button is used to activate the line clamp.
18. Safety light barrier
The safety light barrier prevents persons reaching into the machine while it is running.
19. Clamping unit with tensile force monitor
The clamping unit is used to set up the machine according to the length of the line sets to be
processed. Tensile force monitoring prevents the lines and conductors sustaining damage
during the clamping and taping processes.
20. “Clamp” button on right side
This button is used to activate the line clamp.
21. Main switch
The main switch is used to switch on and switch off the power supply to the machine.
22. Fan
The fan serves to cool and ventilate the electronics section of the control cabinet.
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3.2 Taping unit
1
3
4
5
6
7
8
9
10
2
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1. Tape take-up mandrel with tape brake
The roll of adhesive tape is attached to the tape take-up mandrel by sliding it on laterally.
The tape pulling force can be adjusted via the tape brake.
2. Electronic winding aid
This serves to reduce the tape pulling force during the taping process.
3. Guide roller
The guide roller guides the adhesive tape.
4. Guide roller (offset)
The guide roller guides the adhesive tape.
5. Lower blade
This is used for the cutting of the tape upon completion of the taping process.
6. Hold-down device (retaining blade)
The tape holder fixes the adhesive tape in place during the cutting process
7. Upper blade
This is used for the cutting of the tape upon completion of the taping process.
8. End-of-tape sensor
This sensor detects when the roll of tape has been used up and a new roll of tape has to
be fitted.
9. Hold-down device (positioning mechanism)
The tape holder fixes the adhesive tape in place.
10. Positioning finger
This is used to set the adhesive tape in the correct position.
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3.3 Technical data for the KTS SpeedTec mini
Application
Taping of simple and small cable sets
Mains voltage
3-phase, 230V/400V (50Hz)
Power input
2100 W
Fuse protection rating
16 A max.
Control voltage
24 VDC
Pneumatic connection pressure
5,5-6 bar
Speed
100 -2000 rpm,
settable via touch panel
Feed distance
0-40 mm/rev.
Tape end detection
Contactless (using optical sensor)
Cable diameter
Up to 10 mm
Adhesive tape width
9mm
Material
Any commercially-available adhesive tape
Dimensions (H/W/D)
1700 mm / 1500 mm / 850mm
Weight
400 kg
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