Kaltenbach KPS Series User manual

MANUAL
KPS 515
Serial No. 2008.01.14564

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0General Safety Instructions ........................................................... 7
0.1 Remaining dangers ............................................................................ 9
0.2 Safety regulations ............................................................................ 10
1Machine Information ................................................................. 12
1.1 Preface and working possibilities ....................................................... 12
1.2 Features & technical specifications ..................................................... 13
1.2.1 Vertical punch unit ........................................................................... 13
1.2.2 Features KPS501 ............................................................................. 14
1.2.3 Features KPS503 ............................................................................. 15
1.2.4 Features KPS 506 ............................................................................ 16
1.2.5 Features KPS 515 ............................................................................ 17
1.2.6 Flat shear unit.................................................................................. 18
1.2.7 Horizontal Punch Unit....................................................................... 19
1.2.8 Angle shear (DC Type 160*160*15)................................................ 20
1.2.9 Angle shear (SC Type 200*200*20) ................................................. 21
1.2.10 Angle shear (SC Type 200*200*25) ................................................. 21
1.2.11 Material pusher M100P.................................................................... 22
1.2.12 Transport T10.................................................................................. 23
1.2.13 Cross transport ................................................................................ 24
1.2.14 Product output table ......................................................................... 26
1.2.15 Product push-off device ..................................................................... 26
1.2.16 Marking unit ................................................................................... 27
1.2.17 General.......................................................................................... 28
1.3 Machine Layout ............................................................................... 29
1.4 Safety provisions.............................................................................. 30
2Setup Environment..................................................................... 31
2.1 Machine Layout and main dimensions ................................................ 31
2.1.1 Main Dimensions ............................................................................. 32
2.2 Fundament...................................................................................... 33
2.3 Enviroments..................................................................................... 34
2.4 Installation safetys ............................................................................ 35
3Installation ............................................................................... 36
3.1 Package and Stocking ...................................................................... 36
3.2 Transport ........................................................................................ 37
3.2.1 Lifting instructions............................................................................. 37
3.3 Preparation for setup ........................................................................ 38
3.3.1 Preperations.................................................................................... 38
3.4 Setup ............................................................................................. 39

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3.4.1 Setup the safety fences and safety light guards .................................... 39
3.4.2 Anchoring and levelling.................................................................... 40
3.4.3 Electrical connections ....................................................................... 41
3.4.4 Pneumatic connections...................................................................... 42
3.5 Initial Commissioning ....................................................................... 43
3.6 Safety............................................................................................. 44
4Operation................................................................................ 45
4.1 Switching on the machine ................................................................. 45
4.2 Switching Off The Machine ............................................................... 45
4.3 Lock out procedure........................................................................... 46
4.4 Stop procedure................................................................................ 47
4.5 Operation controls ........................................................................... 48
4.5.1 Operation controls Functions ............................................................. 48
4.5.2 Touchscreen Button Functions............................................................. 49
4.6 Fitting Tools and equipment............................................................... 53
4.6.1 Fixing Punch Tools ........................................................................... 53
4.6.2 Removing Punch Tools ...................................................................... 53
4.6.3 Fixing the knife in the shear unit......................................................... 53
4.6.4 Removing the knife of the shear unit ................................................... 53
4.6.5 Tensiontorque knife bolts................................................................... 54
4.6.6 Drill changing.................................................................................. 55
4.6.7 Fitting the Toolholder magazine ......................................................... 56
4.7 Adjustment...................................................................................... 57
4.7.1 Feed and drill speed ........................................................................ 57
4.8 Pusher mounting adapter .................................................................. 59
4.9 Start Operation............................................................................... 60
4.9.1 Initializing sequence......................................................................... 60
4.10 Software description......................................................................... 61
4.10.1 Introduction..................................................................................... 61
4.10.2 System requirements......................................................................... 62
4.10.3 Installing the software....................................................................... 63
4.10.4 Order manager ............................................................................... 65
4.10.5 Pattern manager .............................................................................. 72
4.10.6 Nesting manager............................................................................. 73
4.10.7 Optimize manager........................................................................... 75
4.10.8 Output manager .............................................................................. 80
4.10.9 Profile library .................................................................................. 83
4.10.10 Adding new profiles and changing data ............................................. 84
4.10.11 Tool manager.................................................................................. 85
4.10.12 Operator menu................................................................................ 87
4.10.13 Extern file import.............................................................................. 92

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5Maintenance ............................................................................ 93
5.1 Maintenance ................................................................................... 93
5.1.1 Tool lubrication system...................................................................... 94
5.1.2 Lubrication ...................................................................................... 95
5.1.3 Lubrication points............................................................................. 96
5.1.4 Hydraulic system............................................................................ 107
5.1.5 Lubrication table ............................................................................ 107
6Technical Documentation.......................................................... 108
6.1 General Instructions........................................................................ 108
6.2 Tools ............................................................................................ 109
6.2.1 Punch and Dies General Information................................................. 109
6.2.2 Punch-Die Clearance ...................................................................... 111
6.2.3 Correct tool order KPS503.............................................................. 112
6.2.4 Minimum punch position KPS 501 (Peddinghaus type)........................ 113
6.2.5 Minimum punch position KPS 503 (Peddinghaus type)........................ 113
6.2.6 Minimum punch position KPS 506 (Peddinghaus type)........................ 113
6.2.7 Minimum puns position KPS 515 (Peddinghaus type).......................... 113
6.2.8 Flat Shear Unit............................................................................... 114
6.2.9 Angle Shear Unit ........................................................................... 116
6.2.10 Grinding requirements knives .......................................................... 117
6.2.11 Knife Block Guiding System............................................................. 119
6.2.12 Drills General Information ............................................................... 120
6.2.13 Drill Types and qualities.................................................................. 120
6.2.14 Recommended drill Suppliers........................................................... 121
6.2.15 Grinding the drills .......................................................................... 122
6.2.16 Grinding instructions ...................................................................... 122
6.2.17 Drill Cooling.................................................................................. 124
6.2.18 Solving drill problems..................................................................... 125
6.3 Spare Parts ................................................................................... 126
6.3.1 Spare parts punch KPS503 ............................................................. 126
6.3.2 Spare parts punch KPS506 ............................................................. 127
6.3.3 Spare parts punch KPS515 ............................................................. 128
6.3.4 Flat shear knives ............................................................................ 129
6.3.5 Spare parts angle knives................................................................. 130
6.3.6 Spare parts ball bearing spindle ...................................................... 131
6.3.7 Spare parts drill unit....................................................................... 132
6.3.8 Spare parts Tool Changer ............................................................... 133
6.3.9 Suggested Spare part kit................................................................. 134
6.4 Pneumatic drawings ....................................................................... 135
6.5 Hydraulic drawings........................................................................ 136
6.6 Electric drawings ........................................................................... 137

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7Appendix .............................................................................. 138

KPS SERIES General Safety Instructions
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0General Safety Instructions
The punching-shearing machine is built according to the current safety regulations.
The necessary provisions are made for a safe way of working for the operator.
In spite of all taken precautions, dangers may occur however while working with the
machine.
A total safety does not exist !
Therefore it is requested that, while working with or at the machine, the necessary
attention should be taken in consideration.
-
WARNING
Read and understand manual before set up, operate or
servicing this machine.
Failure to follow instructions could result in personal injury or
damage to equipment.

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The following conventions are used to indicate and classify precautions in this manual.
Always follow the information provide with them. Failure to follow precautions could
result in personal injury or damage to equipment.
The conventions meets the ANSI Z535.5-1997 Designs and Definitions:
SIGN DESCRIPTION
indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury. This signal
word is to be limited to the most extreme situations.
indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
indicates a potentially hazardous situation which, if not
avoided, may result in minor or major injury."
signs used to indicate a statement of company policy
directly or indirectly related to the safety of personnel or
protection of property. This signal word shall not be
associated directly with a hazard or hazardous situation
and shall not be used in place of DANGER, WARNING or
CAUTION.
signs used to indicate general instructions relative to safe
work
The signs DANGER, WARNING and CAUTION are preceed by the
logo
DANGE
R
W
ARNING
CAUTION
NOTIC
E
SAFETY FIRST

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0.1 Remaining dangers
When persons are in danger zones when the machine is switched on (what is not
allowed), the following dangers can arise:
•Moving parts of the machine can inflict grievous bodily harm.
•Moving parts of the machine and tools can grab in clothes by which these
persons can be seriously injured.
•The carriage can inflict grievous bodily harm by moving.
•The products, waste or trim pieces can inflict grievous bodily harm to persons
which are in danger areas like on or in the input and output conveyors or at
the ends of the machine.

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0.2 Safety regulations
In order to minimize the chance on possible remaining dangers the following
instructions have to be followed:
•The machine may only be operated by fully instructed staff.
•The machine may only be operated by staff who has read and understood the
manual.
•The competence to operate the machine has to be put down in writing and
followed.
•The machine may only be operated by staff which are commissioned by there
authority.
•Outsiders are not allowed to operate the machine without commission and
instruction.
•It is not allowed to make alterations or to carry out repairs to the machine
without the written permission of KALTENBACH in advance.
•Irregularities of the machine during operation have to be reported immediately
to the supplier.
•The operator has to take the responsibility that there are no persons in the
reach of the moving parts of the machine when the machine is turned on.
•It is not allowed to reach, to sit, or to enter in the reach of the moving parts of
the machine.
•Maintenance or repair activities are only allowed when the machine is
switched off according the LOCKOUT procedure, so that thoughtless switch on
is not possible.
•Check or adjust activities are only allowed when the machine is switched off
(emergency stop activated).
•Be sure that the machine is without pressure while disconnecting the pneumatic
or hydraulic pipes.
•Electrical activities must only be done by certified electricians!