Rittal CW 120-M User manual

Operating instructions
Busbar machining, mobile CW 120-M
4055.800

Foreword
2
We reserve the right to make technical modifications.
Rittal busbar machining, mobile CW 120-M
Foreword
Dear Customer,
We thank you for choosing our Rittal product. Read these operating instructions
carefully before using your new unit for the first time and retain them together
with the supplied Product Control Card so they can be consulted when required.
We wish you every success.
Kind regards
Rittal GmbH & Co. KG
Rittal GmbH & Co. KG
Auf dem Stützelberg
35745 Herborn
Germany
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
www.rittal.com
We are always happy to answer any technical questions regarding our entire
range of products.
EN

Contents
Rittal busbar machining, mobile CW 120-M
We reserve the right to make technical modifications.
3
Contents
1 CE labelling ....................................................................... 4
2 Safety instructions.............................................................. 4
2.1 Symbols in these operating instructions ..................................................4
2.2 Symbols on the unit................................................................................4
2.3 General safety instructions ......................................................................5
2.4 Personal protective equipment ...............................................................6
2.5 Residual risks when using the unit .......................................................... 6
3 Proper usage..................................................................... 6
4 Scope of supply................................................................. 7
5 Technical specifications ..................................................... 7
6 Available accessories......................................................... 8
7 Unit description.................................................................. 8
8 Commissioning................................................................ 11
9 Bending busbars.............................................................. 13
10 Punching holes in the busbars.......................................... 15
11 Cutting busbars ............................................................... 18
12 Replacing the cutting blade .............................................. 19
13 Maintenance and inspection ............................................. 21
14 Dismantling and disposal.................................................. 23
15 Contacts.......................................................................... 24
EN

1 CE labelling
4
We reserve the right to make technical modifications.
Rittal busbar machining, mobile CW 120-M
1 CE labelling
Rittal GmbH & Co. KG hereby confirms that the "Busbar machining, mobile" is
compliant with the Machinery Directive 2006/42/EC and the EMC Directive
2014/30/EU. An appropriate declaration of conformity has been issued. It can be
found at the end of this document, on the Rittal Homepage or accompanies the
unit as separate document.
2 Safety instructions
2.1 Symbols in these operating instructions
The following symbols are used in this documentation:
Warning!
A hazardous situation which may lead to death or serious in-
jury if the instructions are not followed.
Caution!
Hazardous situation which may lead to (minor) injuries if the
instructions are not followed.
Note:
Important notices and indication of situations which may result in
material damage.
This symbol indicates an "action point" and shows that you should perform an
operation or work step.
2.2 Symbols on the unit
The following symbols are attached to the unit.
Warning of laser radiation.
Risk of small particles being ejected.
Risk of being crushed or cut by swinging workpieces.
Risk of being crushed or cut by moving unit components.
Observe the operating instructions.
EN

2 Safety instructions
Rittal busbar machining, mobile CW 120-M
We reserve the right to make technical modifications.
5
Wear safety goggles.
Maximum dimensions of workpieces.
2.3 General safety instructions
When working with high-pressure hydraulic units, improper handling and/or poor
maintenance can damage the unit and cause severe injuries. Consequently, ob-
serve all the following safety instructions and contact our service team should
you have any questions.
Caution…
– ... when handling hydraulic oil. The oil can become very hot after longer oper-
ation. There is a risk of injury!
– Long busbars can swing backwards quickly and unexpectedly when being
bent. Ensure that nobody is present in the work area. Risk of injury!
– To extend the service life of the unit, the hydraulic cylinder should not travel to
the limit stop under full pressure.
– Risk of environmental contamination! Collect any escaped hydraulic oil and
prevent it from entering the sewer system or the surface and ground water.
– Additional information: Actuating the emergency stop switch does not
switch off the power supply of the built-in socket for external devices!
Always…
– … machine busbars made of copper or aluminium.
– … position busbars centred and perpendicular in the unit.
– … remove objects and foreign bodies from the work area.
– … position busbars centred to the load piston so that the bending die does not
skew.
– … observe the maximum permitted dimensions of the workpieces.
– … support long busbars appropriately to prevent them from tilting.
– … inspect electrical and hydraulic connection lines for damage before deploy-
ing the unit.
– … ensure the secure footing of the unit.
– … observe the information contained in the operating instructions.
– … instruct new users in the safe use of the unit.
– … wear safety goggles when working with the unit.
– … observe the local, country-specific regulations.
– … store and deploy the unit in dry and well ventilated spaces.
Never…
– … deploy the unit when parts are damaged or missing.
– … make any changes to the unit or remove the warning signs.
– … intervene in the work area of the tools or the swivel area of the workpieces.
– … look intentionally and directly at the laser light.
– … open couplings under pressure.
– … apply pressure to unconnected hose couplings.
– … exceed the maximum operating pressure.
– … operate the unit unattended.
– … subject the unit to corrosive materials.
– … deploy the unit unless the operating instructions have been read and under-
stood completely.
EN

1 CE labelling
6
We reserve the right to make technical modifications.
Rittal busbar machining, mobile CW 120-M
– … store or operate the unit at temperatures above 45 °C (113 °F).

3 Proper usage
6
We reserve the right to make technical modifications.
Rittal busbar machining, mobile CW 120-M
– … deploy the unit in an explosion risk area.
2.4 Personal protective equipment
The operating and maintenance personnel must always wear personal protective
equipment when working on the unit. The personal protective equipment com-
prises at least the following components:
– Safety work shoes: for all work on the unit
– Safety goggles: for all work on the unit
– Gloves: for loading and unloading the unit
2.5 Residual risks when using the unit
There is the risk of oil escaping from the pump when the unit is transported hori-
zontally or has been tilted excessively.
When transporting the unit, ensure that it always remains upright.
During operation there is the risk that a hydraulic hose bursts or a screw fasten-
ing leaks that can result in oil escaping at high pressure.
Wear your personal protective equipment for all work performed on the unit
(see section 2.4 "Personal protective equipment").
There is the risk that small particles escape at high speed from the machining
area (e.g. the shattering of the rubber wiper when punching holes, the breakage
of tools or an incorrect tool combination when punching holes).
Wear your personal protective equipment for all work performed on the unit
(see section 2.4 "Personal protective equipment").
Because of its heavy weight, there is the risk of being crushed between the tools
and the unit main body when mounting the bending die or the bending mandrel.
Set up the unit with the necessary care and observe the maximum permitted
lifting weights for persons.
If the unit machines busbars made of an impermissible material or from an ex-
cessively thick material, there is the risk of the tools becoming damaged and tool
parts splitting off.
Perform machining on materials only in accordance with the proper usage (see
section 3 "Proper usage") and the technical specifications (see section 5
"Technical specifications").
If long busbars are machined with the unit, there is the risk that they fall off the
machining carriage.
Support long busbars with a suitable, stable support to prevent unwanted tilt-
ing and so prevent the risk of injury.
3 Proper usage
The "Busbar machining, mobile CW 120-M" (Model No. 4055.800) is a mobile
work station with several single-acting high-pressure hydraulic cylinders for
bending, hole punching and cutting of copper or aluminium busbars with a max-
imum width of 120 mm and a maximum thickness of 12 mm. The unit is not suit-
able for machining construction steel or tool steel. An integrated high-pressure
hydraulic pump serves as drive for the individual machining stations of the "Bus-
bar machining, mobile".
EN

4 Scope of supply
Rittal busbar machining, mobile CW 120-M
We reserve the right to make technical modifications.
7
Scope of supply
4 Scope of supply
Busbar machining, mobile CW 120-M (4055.800)
Foot-operated switch
Bending tool
Operating instructions
Tab. 1: Scope of supply
5 Technical specifications
Technical specifications
Model No. and designation 4055.800 Busbar machining, mobile CW 120-M
Max. pressure 700 bar (10150 psi)
Max. compressive force 230 kN (52200 lbs)
Max. delivery rate 1.95 l/min (0.5 gal/min). Side hydraulic outlet limited to 1.0 l/min.
Permissible materials Copper, aluminium
Max. busbar width 120 mm (4.72")
Max. busbar height 12 mm (0.47")
Min. hole diameter (punching) – Ø 6.6 mm for 0… 5 mm material thickness
– Ø 9.0 mm for 0… 6 mm material thickness
– Ø 11 mm for 0… 12 mm material thickness
Max. hole diameter (punching) Ø 21.5 mm for 0… 12 mm material thickness
Min. 50 mm (2")
Min. 100 mm (4")
Point laser (bending)
Line laser (cutting)
0.4 mW, Class 1 laser; MTBF>10,000 h
4.0 mW, Class 1 laser; MTBF>10,000 h
Weight 390 kg (858 lbs)
Min. product dimensions (W x H x D) 1380 mm x 1270 mm x 945 mm (54.3" x 50.0" x 37.2")
Mains connection 230 V, 50/60 Hz
Max. power consumption 2500 W, Imax = 10.9 A
Tab. 2: Technical specifications
EN

6 Available accessories
8
We reserve the right to make technical modifications.
Rittal busbar machining, mobile CW 120-M
6 Available accessories
Available accessories Model No.
Hydraulic cylinder 4055.806
Hydraulic hose (3 m) 4055.807
Male die, round 4055.740 – 4055.750
Female dies, round 4055.770 – 4055.780
Male and female dies for slots and special accessories 4055.791
Tab. 3: Available accessories
7 Unit description
The "Busbar machining, mobile" CW 120-M is a multifunctional work station
equipped with multiple single-acting hydraulic cylinders for the bending, hole
punching and cutting of busbars. The hydraulic pressure is produced by an in-
tegrated radial piston pump. The pump produces with maximum pressure of
700 bar a work force of approximately 23 tons.
The single-pedal safety foot-operated switch is connected to the "Busbar ma-
chining, mobile" via a socket (fig. 1, 4). Four push-buttons (fig. 1, 8, 12, 13 and
fig. 2, 19) serve to select the desired machining station. Machining is possible on
only one station. The cutting unit (fig. 1, 15) for shortening busbars as well as the
bending and hole-punching unit (fig. 1, 16) are surrounded by a stable, abrasion-
resistant table top (fig. 1, 1) made of stainless steel. The table top has an inte-
grated limit stop that can be extended to 1200 mm (fig. 2, 26) for use by all work
stations.
An additional hydraulic connection (fig. 1, 5) permits the connection of external
hydraulic units to augment the existing work stations. To simplify the machining
of long workpieces, the "Busbar machining, mobile" is equipped with an extend-
ible support roller (fig. 1,7).
Two emergency stop switches (fig. 1, 14 and fig. 2, 18) can stop the hydraulic
pump immediately in dangerous situations and allow the tool to be returned to
its initial position. The deployment of a frequency converter allows the travel
speed of the tools to be set using a potentiometer (fig. 1, 10). During hole cutting
and punching, the main body is protected with a stable safety protection hood
(fig. 1, 17). The height of the main body can be adjusted easily with a rotary knob
(fig. 1, 9) in accordance with the display for the height setting. Four lockable,
large drawers (fig. 1, 2) offer sufficient storage space for the deployed tools and
work aids. A collection vessel for copper scraps is located behind the door (fig. 2,
21) next to the electric switch cabinet (fig. 2, 22). The mains cable (fig. 2, 23) is
embedded in the side panel of the "Busbar machining, mobile" and, when re-
quired, can be extended to the maximum length of 4.5 m or rolled in completely.
EN

7 Unit description
Rittal busbar machining, mobile CW 120-M
We reserve the right to make technical modifications.
9
Fig. 1: Front view
Legend
1 Table top
2 Lockable drawer
3 Master switch
4 Connection for foot-operated switch (4-pole)
5 Hydraulic connection (700 bar) for additional units
6 Socket (230 V)
7 Extendible support roller
8 Selection push-button for additional hydraulic connection (external units)
9 Rotary knob for height adjustment
10 Potentiometer for speed control
11 ON/OFF push-button for point laser (bending)
12 Hole cutting selection push-button
13 Bending selection push-button
14 Emergency stop switch
15 Busbar cutting unit
16 Busbar bending and hole punching unit
17 Protective hood
EN

7 Unit description
10
We reserve the right to make technical modifications.
Rittal busbar machining, mobile CW 120-M
Fig. 2: Rear view
Legend
18 Emergency stop switch
19 Cutting selection push-button
20 ON/OFF push-button for line laser (cutting)
21 Door for removing the copper scraps
22 Electric switch cabinet
23 Extendible mains plug (230 V)
24 Rotary and lockable rollers
25 Handle
26 Extendible limit stop
27 Lock for limit stop
EN

8 Commissioning
Rittal busbar machining, mobile CW 120-M
We reserve the right to make technical modifications.
11
Fig. 3: Dimensions
8 Commissioning
You receive a fully mounted "Busbar machining, mobile" as well as detailed op-
erating instructions.
On receiving the goods, check them for possible transport damage and the
delivery for completeness (see section 4 "Scope of supply").
In the event of problems, contact the manufacturer or your vendor without de-
lay.
In any case, read the complete operating instructions as well as all supplied
documents before commissioning.
Caution!
There is a risk of injury when lifting the unit in its packaging
or if the lifted unit falls (total weight approx. 390 kg).
Please note the maximum weights that may be lifted by
persons. It may be necessary to use lifting gear.
Do not stand below the lifted unit.
EN

8 Commissioning
12
We reserve the right to make technical modifications.
Rittal busbar machining, mobile CW 120-M
Caution!
When recommissioning the unit, there is the risk that incor-
rect storage or missing corrosion protection can block unit
components and so cause dangers.
Before recommissioning, ensure the smooth running of all
components and the correct function of all safety equip-
ment (see section 13 "Maintenance and inspection").
Wear your personal protective equipment, in particular gloves and safety work
shoes, also for the transport and installation of the unit (see section 2.4 "Per-
sonal protective equipment").
Ensure that the surface on which the unit is placed is flat and sufficiently stable.
Lock the rollers of the "Busbar machining, mobile" at the installation location to
ensure the safe standing of the unit and to prevent an (inadvertent) movement
of the unit.
Inspect the mains cable and plug of the unit for damage. Do not use the unit
should there be any damage!
Extend the mains cable to the required length and insert in the mains plug.
Then insert the supply cable of the foot-operated switch in the 4-pole connec-
tor (fig. 1, 4).
Set the mains switch of the "Busbar machining, mobile" at (I) to place the unit
in ready mode.
The controller requires approx. 5 seconds until it is operational and the individ-
ual stations can be selected.
Warning!
If a dangerous situation occurs when working with the unit,
stop all dangerous movements of the unit without delay.
In a dangerous situation, press one of the red emergency
stop switches (14, 18) on the unit to stop the work opera-
tion!
As an alternative, press the foot-operated switch beyond
the first pressure point. This also causes the work opera-
tion to stop immediately.
After triggering an emergency stop:
Turn the emergency stop switch lightly so that it returns to its initial position.
The unit is returned to ready mode. The controller requires approx. 5 seconds
until it is operational and the individual stations can be selected. After activating
the foot pedal, the hydraulic can be activated again.
If the emergency stop was activated via the foot-operated switch: release the
foot-operated switch by pressing the blue silicone cover at the side (see fig. 4).
EN

9 Bending busbars
Rittal busbar machining, mobile CW 120-M
We reserve the right to make technical modifications.
13
Fig. 4: Releasing the foot-operated switch
Note:
The lasers are switched on and off with the push-buttons (fig. 1, 11
and fig. 2, 20). To extend the service life of the lasers, they switch
themselves off independently after 15 minutes. The lasers are
switched on again by briefly pressing the foot-operated switch or by
pressing the appropriate push-button.
9 Bending busbars
The copper or aluminium busbars are bent with a bending die (fig. 5, 31) that
bends the workpiece with both sides over a bending mandrel.
Fig. 5: Bending busbars
Legend
30 Locking screw for tools in the load piston
31 Bending die
32 Electronic angle shutdown switch
33 Setting screw for bending bracket
34 Angle scale
35 Plug
36 Socket
EN

9 Bending busbars
14
We reserve the right to make technical modifications.
Rittal busbar machining, mobile CW 120-M
Warning!
When bending busbars, swinging parts can be a risk for cut-
ting or crushing parts of the body.
Ensure that no persons or objects are present in the work
area.
In a dangerous situation, press one of the red emergency
stop switches on the unit or alternatively the foot-operated
switch beyond the first pressure point to stop the work op-
eration!
Press the "Bend" selection push-button.
The machining station is selected once the push-button illuminates green.
Insert the bending die (fig. 5, 31) in the tool holder of the load piston and tighten
the locking screw (fig. 5, 30).
Insert the electronic angle indicator (fig. 5, 32) in the half-open hole of the main
body.
Insert the plug (fig. 5, 35) of the connection cable in the socket (fig. 5, 36) be-
hind the work block.
Set the desired bending angle at the setting screw (fig. 5, 33) using the angle
scale (fig. 5, 34).
Hand-tighten the setting screw.
Note:
When bending busbars, a plastic (permanent) and an elastic
(spring-back) deformation of the workpiece occurs. To compensate
the elastic bending component and a spring-back of the material,
the bending angle should always be set 1 – 3° greater than the de-
sired angle.
Mark the bending line on the workpiece.
Alternatively, the dimension can also be set by the length limit stop equipped
with a tape measure (can be extended to 1224 mm).
Adjust the height of the main body with a rotary knob (fig. 1, 9) and align the
bending die centred with the workpiece.
Fig. 6: Alignment of the workpiece
Note:
There is the risk with non-centred bending of the material that the
bending die breaks, jams or the unit main body is damaged.
Ensure that the material is inserted correctly centred for the bend-
ing operation.
Place the workpiece between the bending die and the bending mandrel.
The material must lie flat on the table top. The busbar must be positioned so
that the centre of the bending corresponds to the laser point or the side edge
is aligned at the set limit stop.
Close the protective hood.
EN

10 Punching holes in the busbars
Rittal busbar machining, mobile CW 120-M
We reserve the right to make technical modifications.
15
Note:
The protective hood is connected with an internal safety switch. The
work operation cannot be started when the protective hood is
open. The operation can be stopped at any time by lifting the pro-
tective hood.
Warning!
When bending busbars, there is the risk that small particles
are ejected with high speed from the machining area.
Wear your personal protective equipment for all work per-
formed on the unit (see section 2.4 "Personal protective
equipment").
Start the bending operation by pressing the foot-operated switch to the first
pressure point (foot pedal pressed approximately half the distance, corre-
sponds to a force of approx. 20 kg).
The hydraulic pump is activated and feeds oil to the tool.
Keep the foot-operated switch pressed until the electronic angle shutdown
switch ends the bending operation.
The pump is deactivated and the tool travels back to its initial position.
Note:
Depending on the material thickness and properties, the angle set-
ting on the unit may need to be adjusted slightly to achieve the de-
sired bending angle of the busbar. Once the angle has been set
correctly, it does not need to be readjusted provided the same ma-
terial is machined.
To switch off the unit, set the mains switch at (0).
10 Punching holes in the busbars
Holes are punched in the copper or aluminium busbars with a male die (fig. 7,
41) and the appropriate female die (fig. 7, 44). Slot male and female dies have
additional pins (fig. 7, 48) or grooves (fig. 7, 49) to simplify an exact angular po-
sitioning.
The punched holes can have the following maximum dimensions:
– Round holes: Diameter from 6.6 mm to 21.5 mm
– Slots: 21 mm x 18 mm (width x length)
EN

10 Punching holes in the busbars
16
We reserve the right to make technical modifications.
Rittal busbar machining, mobile CW 120-M
Fig. 7: Punching holes in the busbars
Legend
40 Locking screw for tools in the load piston
41 Male die with neoprene wiper
42 Centring tip of the hole male die
43 Locking screw for the hole female die
44 Hole female die
45 Opening for punch waste
46 Male die for slots
47 Female die for slots
48 Positioning pin
49 Position groove for locking screw
Note:
Use only sharp male and female dies. Oil the male die regularly to
extend the service life of the tools and to simplify return travel to the
initial position.
Press the "Punch hole" selection push-button.
The machining station is selected once the push-button illuminates green.
To punch holes, remove the bending die and the electronic angle indicator
from the work block.
Insert the hole female die (fig. 7, 44) in the main body and tighten the locking
screw (fig. 7, 43). When a slot female die is used, the corresponding groove
(fig. 7, 49) must point upwards.
Insert the male die (fig. 7, 41) in the tool holder of the load piston and tighten
the locking screw (fig. 7, 40). For slot male dies (fig. 7, 46), ensure that the po-
sitioning pin (fig. 7, 48) sits correctly in the appropriate hole of the load piston
and the slot alignment matches the female die.
Warning!
If an incorrect tool combination is used, there is the risk that
tool parts split off and are ejected from the machining area.
Ensure that the correct tool combination is deployed.
Wear your personal protective equipment for all work per-
formed on the unit (see section 2.4 "Personal protective
equipment").
EN

10 Punching holes in the busbars
Rittal busbar machining, mobile CW 120-M
We reserve the right to make technical modifications.
17
Now mark and scratch the desired hole positions on the busbar.
Alternatively, the dimension can also be set by the length limit stop equipped
with a tape measure (can be extended to 1224 mm).
Adjust the height of the main body with a rotary knob (fig. 1, 9) to the punch
centre.
Fig. 8: Setting the punch centre
Set the centring tip of the male die (fig. 7, 42) directly at the centre mark. This
allows the hole pattern to be punched exactly.
Close the protective hood.
Note:
The protective hood is connected with an internal safety switch. The
work operation cannot be started when the protective hood is
open. The operation can be stopped at any time by lifting the pro-
tective hood.
Warning!
When punching holes, there is the risk that small particles
are ejected with high speed from the machining area.
Wear your personal protective equipment for all work per-
formed on the unit (see section 2.4 "Personal protective
equipment").
Start the punching operation by pressing the foot-operated switch to the first
pressure point (foot pedal pressed approximately half the distance, corre-
sponds to a force of approx. 20 kg).
The hydraulic pump is activated and feeds oil to the tool.
Keep the foot-operated switch pressed until the electronic end position switch
in the main body deactivates the hydraulic pump and the tool travels back to
its initial position.
Note:
The neoprene wiper presses the busbar against the female die until
the male die has travelled out of the material and the workpiece can
be removed.
To switch off the unit, set the mains switch at (0).
EN

11 Cutting busbars
18
We reserve the right to make technical modifications.
Rittal busbar machining, mobile CW 120-M
11 Cutting busbars
Warning!
When cutting busbars, the blade can be a risk for cutting or
crushing parts of the body.
Ensure that nobody intervenes in the cutting area, in par-
ticular, after starting a cutting operation.
In a dangerous situation, press one of the red emergency
stop switches on the unit or alternatively the foot-operated
switch beyond the first pressure point to stop the work op-
eration!
Busbars are cut with an 8 mm wide blade that presses an 8 mm wide strip out
of the busbar and so divides the workpiece dimension-conform.
Fig. 9: Cutting busbars
Legend
51 Side guide plate
52 Retainer with ball bearing
53 Locking lever for retainer
54 Clamping screw for retainer
55 High-pressure hydraulic cylinder
56 Limit stop with tape measure
57 Cutter bar with integrated line laser
58 Blade
Press the "Cut" selection push-button.
The machining station is selected once the push-button illuminates green.
Release the clamping lever on the side guide plate (fig. 9, 51) and adjust the
guide plate to the width of the busbar.
Ensure that the workpiece is fed centred in the cutting unit.
Mark the desired workpiece length centred on the busbar.
Now introduce the busbar from the side of the support roller (fig. 1, 5) starting
in the cutting unit.
Release the clamping screws (fig. 9, 54) and locking lever (fig. 9, 53) of the two
retainers, and adjust the retainer to the material thickness of the workpiece.
The correct setting of the guide plates and retainers ensures a better cutting
result.
Now push the busbar through the cutting unit until the length marking is locat-
ed exactly below the red laser line.
The workpiece with the correct length results on the side of the limit stop.
EN