Prebena 11-Z64 Installation instructions

PREBENA
Wilfried Bornemann GmbH & Co. KG
FASTENING TECHNOLOGY
PREBENA Telephone: [phone] / 9601-0 Email: info@pre ena.de
Wilfried Bornemann Gm H & Co. KG Telefax: +49(0)6044 / 9601-820 www.pre ena.de
Seestraße 20-26, D-63679 Schotten
Original operating manual
for stationary, compressed air-operated
industrial staplers
PREBENA MODULE -Z64
97509304

Page 2 of 44
Introduction
This instruction manual will help you to use the pneumatic PREBENA Module 11-Z64 industrial
stapler in a
•proper,
•safe and
•economic
manner.
In these operating manual. the PREBENA Module 11-Z64 industrial stapler is simply referred to as the
stapler.
We assume that every user of the stapler has knowledge of the handling of compressed air-operated
devices and the utilised materials. Persons without this knowledge must e instructed in the
operation of the stapler y an experienced user.
This instruction manual is intended for use y the following persons:
•Persons operating this stapler,
•persons who clean or use this stapler, or
•persons disposing of this stapler.
Each of these persons must have read and understood the contents of this instruction manual.
This instruction manual is an integral component of the product. It must always e kept at the
stapler. Hand over the instruction manual together with the stapler if you sell it or otherwise pass it
on.

Page 3 of 44
Contents
Design features ........................................................................................................................................6
General design features .......................................................................................................................6
Characteristics of the hazard warnings ................................................................................................6
Characteristics of the notes on damage to property or the environment ...........................................6
Safety .......................................................................................................................................................7
Intended use .........................................................................................................................................7
Improper use ........................................................................................................................................7
Avoiding risk of fatal injuries ................................................................................................................7
Avoiding risk of explosion .....................................................................................................................7
Avoiding damage to the stapler ...........................................................................................................7
Description ...............................................................................................................................................8
Information on the type plate ..............................................................................................................9
Preparing the stapler ............................................................................................................................ 0
Unpacking the stapler........................................................................................................................ 10
Checking the condition ...................................................................................................................... 10
Assembly instructions ...........................................................................................................................
Assem ling the stapler ...................................................................................................................... 11
Connecting the stapler to the compressed air supply....................................................................... 11
Connecting the stapler to the control line ........................................................................................ 13
Changing the magazine ..................................................................................................................... 14
Removing the magazine .................................................................................................................... 14
Installing the magazine ...................................................................................................................... 15
Operating the stapler ........................................................................................................................... 6
Regulating the stapler with the operating pressure ......................................................................... 16
Servicing the stapler ............................................................................................................................. 7
Cleaning the housing and outer surface ............................................................................................ 17
Oiling the stapler ............................................................................................................................... 18
Malfunctions ......................................................................................................................................... 9
Malfunction overview ....................................................................................................................... 19
Other malfunctions............................................................................................................................ 20

Page 4 of 44
Ordering accessories ............................................................................................................................. 2
Fasteners ........................................................................................................................................... 21
Disposing of the stapler ........................................................................................................................ 22
Technical details ................................................................................................................................... 23
Manufacturer's address ........................................................................................................................ 24
Warranty ............................................................................................................................................... 25
Circuit diagrams .................................................................................................................................... 26
Pneumatics diagram .......................................................................................................................... 26
Electrical diagram .............................................................................................................................. 27
Spare parts list ...................................................................................................................................... 29
Declaration of Incorporation in accordance with 2006/42/EC ........................................................... 43
Appendix to the Declaration of Incorporation .................................................................................... 44

Page 5 of 44
Design features
General design characteristics
Various elements of the instruction manual are marked with defined design characteristics. These
ena le you to easily differentiate etween
normal text,
•lists or
action steps.
Tips contain additional information such as specific details a out using the stapler in an economic
manner.
Characteristics of the hazard warnings
All the hazard warnings in this instruction manual have the same layout. On the left is a sym ol
indicating the type of danger. On the right, is another sym ol and a signal word descri ing the source
of the danger and notes on how to avoid it.
DANGER
Notes with the word DANGER warn a out hazards that will directly result
in serious or fatal injury.
WARNING
Notes with the word WARNING warn a out hazards that could result in
serious or fatal injury.
CAUTION
Warnings with the
word CAUTION warn a out hazards that could result in
minor to moderate injury.
Characteristics of the notes on damage to property or the environment
IMPORTANT
These notes warn a out hazards that could result in damage to property or the environment.

Page 6 of 44
Safety
When using the stapler, o serve and follow all warnings and instructions in this instruction manual
and on the stapler itself.
Intended use
When using the stapler, o serve and follow all warnings and instructions in this instruction manual
and on the stapler itself.
The PREBENA Module 11-Z64 stationary stapler is used for driving staples into wooden materials,
insulating material and plaster oard. Use with other materials is only permitted after consultation
with the manufacturer. Intended use also includes compliance with accident prevention regulations
and the statutory regulations and standards applica le at the place of use. Any other use is
considered improper use and may result in material damage or even personal injury.
Improper use
In particular, improper use is considered to e if the stapler is operated
•y persons who are not familiar with the use of staplers and the utilised materials,
•with a ridged circuit reaker,
•after it has een modified y the operator without authorisation,
•using fasteners that do not originate from PREBENA, see page 24.
PREBENA WILFRIED BORNEMANN GMBH & CO. KG will not accept any lia ility for damage caused as
the result of improper use.
Avoiding risk of fatal injuries
•Connecting the stapler to the regulating and compressed air network is prohi ited as long as
the stapler is not connected to the production system in the intended direction of
installation.
•Never point the stapler at people, animals or their ody parts.
•Do not allow children to play with packaging film - danger of suffocation.
Avoiding risk of explosion
•Do not use the stapler in potentially explosive environments.
•Never operate the stapler with oxygen or with other ignita le gases or gas mixtures.
•Do not expose the compressor to temperatures a ove 100 °C.
Avoiding damage to the stapler
•Never open the stapler housing. Always leave repair work to a qualified technician.
•Do not use the stapler if it has een dropped or damaged. Have the stapler checked y a
qualified technician efore putting it ack into operation.

Page 7 of 44
Description

Page 8 of 44
No.
Explanation
1
Fastening screw with nut
2
Interchangea le magazine
3
Retaining pawl
4
Sensor; magazine fill level
5
Sensor; feed monitoring
6
Bar ; staple
reloading channel
7
Bar ; staple infeed
8
Venting hole
9
Regulator connection socket
10
Clamping nut
11
Bump stop
12
NW10 compressed air connection
13
Driver
Information on the type plate
The type plate is affixed to the left-hand side of the housing. It contains the following information:
•Company name and country of origin,
•type designation of the stapler,
•type designation of the fasteners to e used.

Page 9 of 44
Preparing the stapler
Unpacking the stapler
Take the stapler out of its packaging.
Remove all packaging material such as plastic film and padding material.
WARNING
Risk of suffocation for children when playing with packaging film.
Do not allow children to play with packaging film.
Keep packaging material out of the reach of children.
Keep the packaging material for future use.
Keep the transport case for transporting the stapler.
The stapler may only e transported in the transport case.
Checking the condition
WARNING
Risk of injury when operating a damaged stapler or if
the accessories are
not attached properly.
Check the condition of the stapler every time efore using it.
Make sure that the stapler is in a flawless condition.
In particular, check the following points:
•The hose line must e undamaged.
•All parts of the stapler and all accessories must e securely fastened.
•The safety mechanisms must not e locked or otherwise impaired in their
functionality.
•No parts of the stapler or its accessories may display external damage such as
scratches or dents.
Scratches
in the paintwork of the housing or magazine are not considered to e
damage.
Do not connect a damaged stapler to a compressed air supply.
Have a damaged stapler repaired y a qualified technician efore putting it into operation.

Page 0 of 44
Assembly Instructions
Assembling the stapler
The assem ly procedure can vary on account of the differences in production systems.
CAUTION
When assem ling the drive stapler, ody parts could get clamped and
crushed etween the stapler and the production plant.
Have the installation tool ready at hand (ring/open-ended wrench SW24)
Place the stapler in the designated assem ly position and secure it with the fastening nut and
tool.
Tighten the fastening nut to 210 Nm.
The height is adjusted on the plant.
Connecting the stapler to the compressed air supply
Only connect the stapler to the compressed air supply after it has een attached to
the production system as descri ed in the installation instructions.
The stapler can e connected to a compressor or a compressed air system.

Page of 44
The stapler may only e operated with a compressor or a compressed air system under the
following conditions:
•The operating pressure of the compressor or compressed air system must not exceed the
maximum operating pressure for the stapler y more than 10%. Information a out the
operating pressure for the stapler can e found in this chapter.
•In the case of compressed air systems with a higher pressure, a pressure control valve
(pressure reducer) with a downstream pressure relief valve must e fitted in the
compressed air line.
•The compressed air must e filtered, dry and oiled with PREBENA special nailer oil.
•A compressed air conditioner must e mounted on the coupling side at the outlets for
the compressed air line to the stapler. This should comprise
- a filter,
- a water separator and
- an oiler.
•If an oiler is not installed, the length of the air line to the stapler must not exceed 10m.
Otherwise, two to five drops of PREBENA special nailer oil need to e poured directly
into the air inlet of the stapler every day efore putting it into operation.
•The compressed air system must e capa le of maintaining the operating pressure even
with the desired air extraction.
•The inside diameter of the air line must e at least 13 mm.
•The connection for the stapler must e fitted with a quick coupling with NW 10 and an
inside diameter of at least 10 mm.
CAUTION
Operating the stapler with compressed air systems that do not meet the
a ove requirements may cause damage to it.
Only operate the stapler with suita le compressed air systems.
Only use the stapler if it is in a flawless condition.
Check the condition of the stapler.
Check the compressed air hose connection for foreign odies and dirt and clean as necessary.
Set the operating pressure at the compressor pressure regulator to 4.5 - 7.5 ar.
WARNING
Unintentionally activating the stapler when connecting it to the
compressed air supply can result in serious or fatal injury.
Do not point the stapler at people or animals.
 Empty the magazine efore connecting the stapler.
CAUTION
Damaged hose lines can urst, and the escaping compressed air could
cause material damage.
Check the compressed air system and the stapler for material
damage efore connecting them.
 Only connect the stapler to a functioning compressed air system.

Page 2 of 44
Important
Damaged hose lines can urst, and the escaping compressed air could cause material damage.
Check the compressed air system and the stapler for damage efore connecting them.
 Only connect the stapler to a functioning compressed air system.
Push the quick-release lock (1) of the compressed air hose onto the connection (2) until it
audi ly engages.
Check the operating pressure indicated on the compressor pressure gauge.
Connecting the stapler to the control line
Only connect the stapler to the compressed air supply after it has een attached to the
production system as descri ed in installation instruction 2.
A 6-pin XLR type connector plug must e used. The pin assignment is descri ed in the chapter
"Circuit diagrams".
WARNING
Defective ca le connections and exposed contacts can result in personal
injury and material damage.
Check the ca le connection for possi le damage.
Only attach the stapler to a flawless ca le connection.
Push the connecting ca le (1) onto the connection socket (2) until it audi ly engages.

Page 3 of 44
Changing the magazine
The magazine is designed as an interchangea le magazine and is not loaded when it is installed on
the stapler. The magazine is detached from the device for reloading so that it can e conveniently
filled with staples at an external station.
The staples are delivered in an industrial packaging for quick and easy charging of the magazines.
Removing the magazine
Turn the retaining pawl (4) in the direction of the arrow and pull the magazine (1) ackwards off the
stapler.

Page 4 of 44
Installing the magazine
Attach the magazine in the reverse manner to removing it. Make sure that the guide rails do not
twist when inserting the magazine. Also make sure that the retaining pawl (4) is fully engaged y the
spring force. Push the magazine up to the stop uffer y exerting slight pressure on it. If this does not
work, loosen the lock nut (3) and readjust the position of the stop uffer with the thread. Then
tighten the nut again.
The procedure for changing the magazine is the same for all magazine types.
Which magazines can e used are shown in the overview elow:
Magazine design
PREBENA staples
Type Z50
Z50
Type Z55
Z55
Type Z64
Z64

Page 5 of 44
Operating the stapler
Regulating the stapler with the operating pressure
You can set the penetration depth of the stapler into the material y regulating the operating
pressure. At a higher operating pressure, the fasteners are driven deeper into the material; setting a
lower operating pressure reduces the penetration depth.
Set the operating pressure to achieve the required penetr
ation depth. This has the
following enefits:
•You save energy (compressed air),
•you reduce the noise level, and
•you reduce the wear of the stapler.
Proceed as follows to set the operating pressure:
Adjust the pressure at the pressure valve of the compressor or compressed air system.
O serve the pressure reading.
Checking the penetration depth
Shoot a staple into a sample workpiece with the same characteristics as the processing
material.
Repeat these steps until you have set the required penetration depth.

Page 6 of 44
Servicing the stapler
The stapler may only e serviced y persons who have the necessary knowledge, skills and
experience. Any work not descri ed here may only e performed y the manufacturer's customer
service team or y the manufacturer.
During all servicing work, the compressed air connection and the control line etween
the stapler and the production system must e disconnected.
WARNING
Unintentionally activating the stapler when emptying the magazine can
result in serious or fatal injury.
Disconnect the stapler from the compressed air supply efore
cleaning it.
 Remove the magazine and all staples from the feed channel and
on feed ridge.
Cleaning the housing and outer surface
Important
The stapler or accessories can e damaged y using unsuita le cleaning agents.
 Only use a dry, slightly moistened cloth or a cloth moistened with mild soapy water for
cleaning the stapler.
Light soiling
Wipe the stapler housing clean with a dry cloth.
Severe soiling
Wipe the stapler housing clean with a cloth lightly moistened with mild soapy water.
Then wipe the housing with a cloth slightly moistened with tap water.
Ru down with a dry, soft cloth.
Soiling in the discharge channel/feed ridge
The discharge channel and feed ridge
should e cleaned at regular intervals depending
on the discharge intensity.
Use of the staples can cause adhesive residue to accumulate in the discharge channel and on the
feed ridge.
Remove this residue using a compressed air gun and a fine cleaning rush.

Page 7 of 44
Oiling the stapler
Important
Inadequate lu rication or using incorrect lu ricants can cause damage to the stapler.
Only use PREBENA special nailer oil.
If an oiler is not fitted and the length of the air line to the stapler exceeds 10 m,
adequate
lu rication cannot e assured.
In this case, pour two to five drops of PREBENA special nailer oil directly into the connection
for the compressed air source every day efore putting the stapler into operation.

Page 8 of 44
Malfunctions
WARNING
Operating a damaged or malfunctioning stapler can result in serious or
fatal injury.
In the event of a malfunction, immediately disconnect the stapler
from the compressed air supply.
Remove the magazine and all staples from the feed channel and
on feed ridge.
 Do not use the stapler until the malfunction has een remedied.
Important
The stapler can e damaged y repairs undertaken y unauthorised persons.
Make sure that the stapler is only repaired y the manufacturer.
Malfunction overview
Possi le malfunctions and the necessary measures are listed in the overview elow.
Symptom
Possi le cause
Remedy
Stapler is losing
air.
Fastening screws have
ecome loose.
Notify customer service
.
A seal is defective.
Notify customer service
.
Operating
pressure too high.
Valve defective.
Immediately disconnect the stapler from
the compressed air supply.
Notify customer service.
Operating pressure set too
high or stapler damaged.
Reduce operating pressure.
If the pro lem persists:
Immediately disconnect the stapler from
the compressed air hose.
Notify customer service.
Fasteners are not
eing fully driven
in.
The operating pressure is too
low.
Increase operating pressure.
The driver tip on the stapler is
worn/ roken
Notify customer service.
Staples
cannot e
discharged.
The operating pressure is too
low.
Increase the operating pressure of the
compressed air system to the maximum
permissi le level.
The moving parts are stuck
together with lu ricant after
long storage.
Clean stapler
.
Set maximum operating pressure.
Perform test discharges.
When staples are discharged,
set the required operating pressure.
Otherwise notify customer service.
Discharge is
triggered without
Feed ridge/channel is soiled.
Clean feed
ridge/channel.
Incorrect fasteners have een
loaded.
Remove fasteners.
Fill stapler with PREBENA fasteners.

Page 9 of 44
a fastener eing
driven in.
The stapler is not adequately
lu ricated.
Fill PREBENA special nailer oil into the used
compressed air connection.
Fire a test discharge.
The
operating pressure is too
low.
Increase operating pressure.
The piston with the driver
does not return to the home
position after the driving-in
action.
Notify customer service.
The triggering action is not
completed.
Notify customer service.
The
driver is ent
.
Notify customer service.
The reloading
cycle is
interrupted.
Passage of the throttle valves
has changed.
Notify customer service.
Fastener has ecome wedged
during reloading.
Disconnect stapler from the compressed air
supply.
Remove fasteners from reloading opening.
Load new fasteners and fire a test
discharge.
Other malfunctions
If other malfunctions of the stapler have occurred which cannot e remedied y oiling and cleaning
it, you must notify the PREBENA service team.
Do not carry out any repair work on the stapler.
Make sure that all malfunctions of the stapler are remedied y the PREBENA service team.

Page 20 of 44
Ordering accessories
Accessories can e ordered from the manufacturer. Only use original PREBENA accessories, or
accessories that have een approved y PREBENA, to operate the stapler.
Product no.
Accessories
Z200.10
Special oil for compressed air nailers 1/2 litre
Z200.00
Small mist oiler
62151102.Z50
Interchangea le magazine for HK type Z50
62151202.Z55
Interchangea le
magazine for HK type Z55
62151402.Z64
Interchangea le magazine for HK type Z64
Ordering additional fasteners
The stapler may only e used with the respective PREBENA staples shown on the type plate.
Type
Length
Wire size
Spine width
Z50 CNKHA
CSVHA
-
ETA
CRFHA
-
ETA
50 mm
1.4 x 1.65 mm
11.2 mm
Z55 CNKHA
CSVHA
-
ETA
CRFHA
-
ETA
55 mm
1.4 x 1.65 mm
11.2 mm
Z64 CNKHA
CSVHA
-
ETA
CRFHA
-
ETA
64 mm
1.4 x 1.65 mm
11.2 mm