Download Operator Manual Installation Instruction

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Operator Manual
Installation Instruction
DS6S01_EN_00
Shear cut knife holder
DS6-S
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245AC74003001
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This manual contains important information concerning the safe
use of the DIENES product.
The operator must ensure that all persons who are involved in
installation, operation and maintenance have read and understood
this manual.
The manual must be available at all times to the personnel - please
keep it in close proximity to the system.
The original version of this manual was produced in the German
language - all other language versions are translations.
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This Dienes product has been designed and manufactured in
accordance with the applicable basic safety requirements as per
the machinery directive 2006/42/EC, and is intended for installation
in a machine or production system. This results in interfaces to
neighbouring components. The resulting hazards must be taken
into consideration and evaluated by the manufacturer or operator,
and suitable protective measures must be taken.
For this purpose, DIENES provides an installation declaration in
accordance with appendix II part 2 section B of the machinery
directive 2006/42/EC, for use during the certification of the
machine or production system. Certification and CE marking are
carried out by the manufacturer or operator of the machine or
production system. This also applies if installation is carried out
by or supervised by DIENES.
This product must not be started up until certification of the
machine or production system has taken place.
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If the product described here is resold in an unchanged form, it is
essential that this operation manual is passed on to the new
owner.
This operation manual or parts thereof must not be duplicated
without written approval from DIENES Werke. The manual must
not be handed to third parties. The manual must not be duplicated
on electronic media.
The copyright to this operating manual remains vested in:
Dienes Werke, Overath.
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Signal words
Danger !
Denotes an immediate threat of danger. Death or extremely serious
injuries will occur if it is not avoided.
Warning !
Denotes a potentially dangerous situation. Serious injuries or
death may occur if it is not avoided.
Caution !
Denotes a potentially dangerous situation. Minor or slight injuries
may occur if it is not avoided.
Caution !
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Denotes a situation that will lead to damage to the device if it is not
avoided.
Note!
It is imperative that you observe this information.
It will help you in your daily work.
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1 Contents
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1
Contents ....................................................................................................................... 4
2
Product Description .................................................................................................... 6
2.1
Intended use ........................................................................................................................................ 6
2.2
Dienes knife holder type DS6-S (semi-automatic) .............................................................................. 7
2.3
Knife heads .......................................................................................................................................... 9
2.3.1
Shear cutting knife head with dished knife 130mm ...................................................................... 9
2.3.2
Shear cutting knife head with dished knife 150mm ...................................................................... 9
2.4
Adapter .............................................................................................................................................. 10
2.4.1
Dovetail adapter ......................................................................................................................... 10
2.4.2
Linear adapter with pinion adjusting mechanism ....................................................................... 11
2.5
Product data ...................................................................................................................................... 12
2.5.1
Technical Data ........................................................................................................................... 12
2.5.2
Energy supply ............................................................................................................................. 13
2.5.3
Prestressing forces and tightening torques for metric screws ................................................... 14
3
Safety .......................................................................................................................... 16
4
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3.1
Operator's duty of care ...................................................................................................................... 16
3.1.1
EC Machinery Directive .............................................................................................................. 17
3.1.2
Hazards state-of-the-art technology ........................................................................................... 17
3.1.3
Reasonably foreseeable misuse ................................................................................................ 17
3.1.4
Warranty and liability .................................................................................................................. 18
3.1.5
Spare parts and accessories ...................................................................................................... 18
3.2
General safety notices ....................................................................................................................... 19
3.2.1
Explanation of the safety symbols used ..................................................................................... 21
3.2.2
Attached warning labels and safety equipment.......................................................................... 22
3.3
Personal safety equipment ................................................................................................................ 23
Commissioning .......................................................................................................... 24
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4.1
Interfaces to neighbouring machine components .............................................................................. 24
4.2
Transport ........................................................................................................................................... 25
4.3
Assembly ........................................................................................................................................... 26
4.3.1
Alignment of the holder .............................................................................................................. 26
4.4
Commissioning .................................................................................................................................. 27
4.4.1
Parameter settings for top and bottom knives ............................................................................ 28
4.4.2
Connecting the compressed air supply ...................................................................................... 29
4.5
Basic alignment of the depth adjuster ............................................................................................... 30
4.5.1
Manually setting the knife overlap to zero .................................................................................. 30
4.5.2
Teaching the control unit ............................................................................................................ 31
5
Handling and operation ............................................................................................. 34
5.1
Safety instructions for the operator.................................................................................................... 34
5.1.1
Qualification of personnel ........................................................................................................... 35
5.2
Knife holder definitions ...................................................................................................................... 36
5.2.1
Knife holder Z1, drawing horizontal lift ....................................................................................... 36
5.2.2
Knife holder Z1, drawing horizontal lift ....................................................................................... 36
5.2.3
Knife holder Z1, drawing horizontal lift ....................................................................................... 37
5.2.4
Knife holder Z1, drawing horizontal lift ....................................................................................... 37
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5.3
Type of material guide ....................................................................................................................... 38
5.3.1
Tangential ................................................................................................................................... 38
5.3.2
Wrapped ..................................................................................................................................... 38
5.3.3
Specifying the axial offset........................................................................................................... 39
5.4
Adjusting the shear angle .................................................................................................................. 40
5.4.1
Web entry from the front, drawing horizontal lift (Z1 and Z2) ..................................................... 40
5.4.2
Web entry from the rear, drawing horizontal lift (Z3 and Z4) ..................................................... 41
5.4.3
Adjustment of the shear angle.................................................................................................... 42
5.4.4
Replacing the shear angle plate ................................................................................................. 43
5.5
Adjusting the knife holder .................................................................................................................. 45
5.5.1
Drawing of the shear cut knife holder type DS6 – S .................................................................. 45
5.5.2
Depth / overlap depth adjustment .............................................................................................. 47
5.5.3
Adjusting the cutting force .......................................................................................................... 49
5.6
Positioning the knife holder / Adjusting the format ............................................................................ 50
5.7
Dovetail adapter................................................................................................................................. 51
5.7.1
Linear adapter ............................................................................................................................ 52
5.7.2
Adjusting the clamping range ..................................................................................................... 52
5.8
Knife replacement .............................................................................................................................. 53
5.8.1
Adjusting the overlap depth after changing knifes ..................................................................... 56
5.8.2
Removing the "WKS" shear cut replacement head.................................................................... 58
6
Maintenance ............................................................................................................... 60
6.1
Safety instructions for servicing ......................................................................................................... 60
6.2
Service and cleaning work ................................................................................................................. 62
6.3
Lubrication ......................................................................................................................................... 63
6.3.1
Lubrication of the linear adapter ................................................................................................. 63
6.3.2
Knife holder lubrication ............................................................................................................... 63
Servicing .................................................................................................................... 64
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7
7.1
Safety instructions for maintenance .................................................................................................. 64
7.2
Remedial measures in the case of failures ....................................................................................... 66
7.2.1
Knife holder ................................................................................................................................ 66
8
Taking out of service (scrapping) ............................................................................ 67
8.1
9
10
Safety instructions ............................................................................................................................. 67
Accessories available from the DIENES company ................................................. 68
Regrinding service ................................................................................................. 70
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2 Product Description
2.1 Intended use
The shear cut knife holder type DS-6 is exclusively designed for:
•
Slitting a specified material web in conjunction with powered bottom
knives.
• Any other or further use is deemed improper use.
DIENES in Overath does not accept any liability for damage caused
during or through improper use and the user bears sole
responsibility for the risks associated with such use.
Using the product as intended also includes observance of the
operating manual, compliance with the manufacturer's operating,
maintenance and repair specifications, and the exclusive use of original
DIENES spare parts.
If the cutting tool is not used according to these specifications, we
cannot guarantee its safe operation.
The responsibility for injuries to persons and damage to property
resulting from improper use rests with the user as opposed to DIENES!
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2.2 Dienes knife holder type DS6-S (semi-automatic)
P1 Compressed air connection
1
2
3
4
5
6
7
8
9
10
Knife holder body
Knife head
Dished knife
Depth adjustment
Shear angle plate
Clamp lever
Retainer options
Adapter retainer
360° safety hand guard
Display / Control
P1
4
10
1
5
2
6
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3
9
8
2
7
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Fig. 1: Knife holder (version: 30mm lift, 1 compressed air
connection)
The knife holder is equipped with the following equipment versions,
features and options:
Knife holder body versions
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Knife holder with 30mm vertical lift
•
Knife holder with 50mm vertical lift
•
1 Compressed air connection, internal forced sequence control
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2 compressed air connections, requires an external forced
sequence control
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•
Knife head versions
•
Ø130mm shear cut knife head with dished knife
•
Ø150mm shear cut knife head with top knife
•
Razor blade cut Ø130mm 3 blades
Knife holder features
•
Depth adjusting screw and display with "Teach in" function for
precise overlap depth adjustment.
•
Toolless shear angle adjustment
•
Toolless knife head changing function
•
360° safety hand guard
Optional modules
•
Linear adapter
•
Special adapter
•
Adjusting slider (take note of infeed direction / head position)
•
Lubricating device (take note of infeed direction / head position)
•
Separating finger (requires an additional compressed air
connection)
•
Extraction hood (take note of infeed direction / head position)
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Dovetail adapter
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2.3 Knife heads
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The knife holder can be used with a number of different knife
heads and the knife heads can be changed at any time.
Caution!
The cutting point will be different for each knife head, depending
on its size.
For this reason, it is vital to take the required installation space or
cutting point into account in advance!
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2.3.1 Shear cutting knife head with dished knife 130mm
1
Prism (retainer)
Dished knife / transport cover
Ring nut
Safety screw
Compressed air inlet
Hand guard
Retainer options
360° safety hand guard
5
2
3
6
4
7
7
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1
2
3
4
5
6
7
8
2
8
Fig. 2: Shear cutting knife head with dished knife Ø130mm
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2.3.2 Shear cutting knife head with dished knife 150mm
1
Prism (retainer)
Dished knife / transport cover
Ring nut
Safety screw
Compressed air inlet
Hand guard
Retainer options
360° safety hand guard
5
2
3
6
4
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1
2
3
4
5
6
7
8
7
7
2
8
Fig. 3: Shear cutting knife head with dished knife Ø150mm
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2.4 Adapter
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The knife holder body can be equipped with different adapters.
The adapters suitable for fitting to the knife holder body are dovetail,
linear and special adapters.
Please note!
It will not be possible to change an adapter once it has been fitted.
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2.4.1 Dovetail adapter
The purpose of the dovetail adapter is to position the shear cut knife
holder on a dovetail rail and hold it in place with the setscrew.
1
2
3
4
Tightening screw adapter
Adapter
Adapter fixing screws
Clamping piece
1
2
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3
4
Fig. 4: Dovetail adapter
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2.4.2 Linear adapter with pinion adjusting mechanism
The purpose of the linear adapter is to slightly move the shear cut knife
holder on linear rails. The hand wheel and pinion are designed for fineadjusting the linear adapter's position. The shear cut knife holder is
fixed in the desired position through a strip steel clamp using the
clamping screw. The adapter is fastened to the knife head holder using
a clamping bolt and clamping screw.
1
2
3
4
5
6
7
8
9
Clamp lever clamp
Hand wheel pinion adjusting
mechanism
Top clamping piece
Pinion
Linear adapter
Linear carriage
Bottom clamping piece
Knife holder body
Tightening screw adapter
1
1
9
2
3
4
5
6
7
8
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Fig. 5: Linear adapter
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2.5 Product data
2.5.1 Technical Data
Component
Type:
Knife holder
DS6-S
Item no.:
245AC74003
Weight approx.: *1
Height: *1
ca. 4.6 kg
ca. 349 mm
Width: *1
ca. 38 mm
Depth: *1
ca. 182 mm
Vertical lift:
Horizontal lift
Knife dimensions
Cutting width *1
Compressed air supply:
Application range
Total lift
Fixed lift
Variable lift
30 mm
20 mm
10 mm
3 mm
Ø 130 x Ø 80 x s
from 45 mm
see section on Energy Supply
max. 2000 m/min
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*1 can vary according to option
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2.5.2 Energy supply
The knife holder has to be supplied with compressed air for operation.
The unit contains a battery for powering the electronics.
The compressed air must be dry, filtered and free from oil. It must be
conditioned in compliance with
- ISO 8573-1:2010 Class 7 for particle size
- ISO 8573-1:2010 Class 2 for bio-oils
- ISO 8573-1:2010 Class 4 for mineral oils
.
Required excess pressures
Knife holder vertical lift
4 – 6 bar
Knife holder horizontal lift
4 – 6 bar
Power supply for each knife holder (sensor)
Lithium ion battery
Units
9V / 1200mAh 1x
Please note
The required cutting pressure depends on the cutting speed and
the composition of the material and must be determined under
production conditions.
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However, the cutting pressure should not be higher than that
required to reliably cut the material web.
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2.5.3 Prestressing forces and tightening torques for metric screws
The permissible torques listed in the table below are to be understood only as approximate
recommended values and are not binding - see VDI 2230!
Tightening torques for steel set screws
DIN 912 / 931 / 933 / 934 strength classes 8.8 - 12.9
The table values for MA consider: a) Friction value q tot=0.14, b) utilisation of the minimum yield
strength=90%, c) torsion torque when tightening the frictional coefficient of q tot=0.14 applies for the
delivered version of screws and nuts without coating, lightly oiled.
Additional lubrication of the threads alters the frictional coefficient considerably and leads to uncertain
tightening conditions! Tightening methods and tools have different dispersions (see Tab.1/VDI 2230).
Standard thread
Dimension
Pitch P
0,7
M5
0,8
M6
1,0
M8
1,25
M 10
1,5
M 12
1,75
M 14
2,0
Prestressing force FV (N)
Tightening torque Ma
(Nm)
8.8
10.9
12.9
8.8
10.9
12.9
8,78
3900
5700
6700
3,0
4,4
5,1
14,2
6400
9300
10900
5,9
8,7
10
20,1
9000
13200
15400
10
15
18
36,6
16500
24200
28500
25
36
43
58,0
26000
38500
45000
49
72
84
84,3
38500
56000
66000
85
125
145
115
53000
77000
90000
135
200
235
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M4
Tension cross
secction
As / mm²
2,0
157
72000
106000
124000
210
310
365
M 18
2,5
193
91000
129000
151000
300
430
500
M 20
2,5
245
117000
166000
194000
425
610
710
M 22
2,5
303
146000
208000
243000
580
830
970
M 24
3,0
353
168000
239000
280000
730
1050
1220
M 27
3,0
459
221000
315000
370000
1100
1550
1800
M 30
3,5
561
270000
385000
450000
1450
2100
2450
M 33
3,5
694
335000
480000
560000
2000
2800
3400
M 36
4,0
817
395000
560000
660000
2600
3700
4300
M 39
4,0
976
475000
670000
790000
3400
4800
5600
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M 16
Fig. 6: Tightening torque standard threads
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Fine thread
Dimension
Pitch
P
M8
x1
M 10
x 1,25
M 12
x 1,25
M 12
x 1,5
M 14
x 1,5
M 16
x 1,5
M 18
x 1,5
M 20
x 1,5
M 22
x 1,5
M 24
x2
M 27
x2
M 30
x2
Tension cross
section
Prestressing force FV (N)
As / mm²
Tightening torque Ma (Nm)
8.8
10.9
12.9
8.8
10.9
12.9
39,2
18100
26500
31000
27
40
47
61,2
28500
41500
48500
54
79
93
92,1
43000
64000
74000
96
140
165
88,1
40500
60000
70000
92
135
155
125
58000
86000
100000
150
220
260
167
79000
116000 136000
230
340
390
216
106000 152000 177000
350
490
580
272
134000 191000 224000
480
690
800
333
166000 236000 275000
640
920
1070
384
189000 270000 315000
810
1160
1350
496
245000 350000 410000
1190
1700
2000
621
309000 440000 515000
1610
2300
2690
Fig. 7: Tightening torques fine threads
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3 Safety
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3.1 Operator's duty of care
The operator must ensure that all persons commissioned with
installation, operation or maintenance work have read and understood
the instructions in this manual.
The manual must be available to the personnel at all times; keep the
manual in the vicinity of the system.
All persons working with the product must observe the instructions in
this manual, in particular the safety instructions, as well as the rules and
regulations applicable for the site.
The generally accepted legal and other regulations and provisions
pertaining to the prevention of accidents (e.g. protective equipment)and
environmental protection must also be observed in addition to the safety
instructions mentioned in this manual.
Serious physical injury or damage to property can result in the event of
unqualified interventions in the device or failure to observe the warning
instructions given in this documentation or on the device. Accordingly,
only personnel with the relevant qualifications may undertake
interventions on this device.
Qualified personnel as defined in the safety-related instructions in this
documentation or on the product itself are those persons who
have undergone a course of instruction as operators handling knife
holders or cutting systems and are familiar with the operationrelated content of this documentation;
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•
•
or maintenance and service personnel who are qualified to repair
such knife holders or who are licensed to operate knife holders in
accordance with safety engineering standards.
Note!
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Only personnel with the relevant qualifications may undertake
interventions on this device. These employees must be thoroughly
acquainted with all sources of danger and maintenance measures
in accordance with the information in this documentation. A
prerequisite for perfect and safe operation of the product is correct
transport, correct storage, assembly and set-up, as well as care in
use and maintenance.
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3.1.1 EC Machinery Directive
This DIENES product is designed and manufactured in accordance with
the applicable basic safety requirements as per the Machinery Directive
2006/42/EC and is intended for installation in a machine or production
facility. This involves interfaces to neighbouring components. The
manufacturer or operator is liable for taking the resulting hazards into
consideration and assessing these and undertaking suitable protective
measures.
For this purpose DIENES provides a Declaration of Incorporation in
accordance with Annex II Part 1 Section B of the Machinery Directive
2006/42/EC used for the certification of the machine or production
facility. Certification and CE-marking are effected by the manufacturer
or operator of the machine or production facility. This is also applies to
the assembly or supervision of the assembly by DIENES.
Commissioning of the product is prohibited until such time as
certification of the machine or production facility has been completed.
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3.1.2 Hazards state-of-the-art technology
The DIENES product has been manufactured in accordance with the
state of the art and in accordance with the recognised technical safety
regulations.
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VE
The product is only to be operated if in technically good order and
condition as well as according to intended use, with safety and riskawareness and by observing the operating manual. In particular, any
faults which can have a detrimental effect on safety need to be rectified
or have to be resolved by a third party.
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3.1.3 Reasonably foreseeable misuse
Every use that exceeds maximum performance data is regarded as
improper use and is therefore prohibited.
0-
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RS
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3.1.4 Warranty and liability
Warranty and liability claims for potential personal injury or property
damage are excluded
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•
in compliance with contractual or legal provisions
•
in the event of incorrect or improper transport
•
in the event of incorrect or improper storage
•
in the case of operation that exceeds the specific performance data
•
in the event of improper / non-intended use of the product
•
in the event of arbitrary and unauthorised modifications
•
where maintenance work is not carried out or improperly executed
•
in the case of damaged sealing wax / seals
•
in the event of non-observance of Dienes specifications for new and
reground knives
3.1.5 Spare parts and accessories
0-
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VE
We point out that parts and accessories not supplied by DIENES as
spare parts and accessories have not been tested and approved by us.
Installing or attaching as well the use of such products may possibly
influence the constructive specific properties of the system. The
manufacturer bears no liability for damage caused through the use of
parts and accessories that are not original parts and accessories.
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3.2 General safety notices
Danger!
Voltage
Faulty electrical connections or unapproved live parts result in
serious injury or even death.
• Electrical connections must only be carried out by qualified
personnel.
• Any damaged cables or plugs need to be replaced immediately.
Warning!
Objects tossed around by rotating parts can cause serious injury
or even death.
• Remove objects and tools from rotating parts before putting these
into operation.
Warning!
Entanglement hazard
VE
Rotating parts can pull in parts of the body and cause severe
injuries or even death.
• Keep a sufficient distance to rotating machine components.
• Safeguard the machine against restarting and unintended
movement during assembly and maintenance work.
Caution!
Cutting hazard
There is a risk of being cut in the area of the knife edge.
• Always wear protective gloves when working on the knife holder.
• Safeguard the product against restarting and unintended movement
during assembly and maintenance work.
Caution!
0-
Crushing hazard
There is a risk of being crushed in the vicinity of the pneumatically
controlled knife holders.
• Safeguard the product against restarting and unintended movement
during assembly and maintenance work.
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Caution!
Hot surfaces
Hot machine parts can cause serious burns.
• Only ever touch machine parts while wearing protective gloves or
after the machine has been shutdown for a longer period of time.
Caution!
Laser radiation
•
0-
VE
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Avoid radiation of the eyes or skin by direct or scattered radiation.
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3.2.1 Explanation of the safety symbols used
Pictograms warn you against dangers and provide useful notes on safe
use:
General hazards
Cutting hazard
Electric current hazard
Rotating machine parts
Crushing and entanglement hazard
VE
Warning against hand injuries
Warning against hot surfaces
Warning against laser radiation
Damage to the device
0-
Lubricating specifications
Note
Information for daily use
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3.2.2 Attached warning labels and safety equipment
The warning labels affixed to the unit must be observed at all times.
Caution!
It is very important to remind the operating personnel to make
themselves familiar with the position of the individual emergency
stop switches before operating the system.
Warning!
Entanglement hazard
Rotating parts can pull in parts of the body and cause severe
injuries or even death.
• Keep at a safe distance from rotating machine components.
• Protect the machine from restarting and unintended movement
during assembly and maintenance work..
VE
• This label is attached to every
knife holder.
• It alerts people to the fact that
sharp cutting tools are in
operation, and to keep clear
of the blade during operation.
Fig. 8: Warning sign on the knife holder
1
2
3
Hand guard
Dished knife
360° safety hand guard
• The 360° safety hand guard
protrudes over the dished
knife in the idle position
1
0-
1
2
2
3
3
Fig. 9: 360° safety hand guard
DS6S01_EN_00
Please note!
22 / 70
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As this knife holder is only part of a complete system, the operator
of the system has to ensure that the system is protected during
operation.
This can be achieved by fitting light curtains or safety doors, for
example.
All warning labels and protective devices must be checked at least
once a week to make sure they are present and in proper working
order.
3.3 Personal safety equipment
Caution!
Cutting hazard
“Dienes” safety gloves must always be worn when working on the
cutting tools.
(Dienes Order No. =0FHANDS000001)
0-
VE
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4 Commissioning
4.1 Interfaces to neighbouring machine components
The DIENES product is designed and manufactured in accordance with
applicable basic safety requirements so that it presents no immediate
essential danger.
There are interfaces to neighbouring components due to the fact that
the DIENES product is intended for incorporation in an existing machine
or production facility.
Any existing shaft or other machine parts that give rise to serious
hazards in combination with the DIENES products must be given
particular consideration here.
The manufacturer is responsible for taking the resulting hazards into
consideration and assessing these and undertaking suitable protective
measures.
Commissioning is prohibited until such time as the operator has
ensured that the complete system complies with the applicable safety
requirements.
0-
VE
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4.2 Transport
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Note!
Individual knife holder types can weigh in excess of 25kg. Weight
information can be found in the technical data. Use suitable lifting
gear if necessary.
Caution!
Cutting hazard!
Extreme care and caution must always be taken when working on
the knife holder.
When the knife holder is being transported it must be ensured that
the knife cannot rotate, and that the knife edge is covered.
• Always wear protective gloves when working on the knife holder.
(Dienes order no.: 0FHANDS000001)
Caution!
Protect knife from slipping and knocks, since any knock will
damage the knife edge.
0-
VE
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4.3 Assembly
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4.3.1 Alignment of the holder
Caution!
Risk of cutting
Extreme care and caution must be taken when working with the
shear cut knife holder
• Always wear protective gloves when working on the knife holder.
(Dienes Order no.: 0FHANDS000001)
• Protect the machine from restarting and unintended movements.
Caution!
Knife holder
Intermediate adapter plate
Dished knife
Bottom knife
1
2
2
VE
1
2
3
4
minimum fixed lift + 1 mm
It is imperative to pay attention to the position of the shear angle
plate. See also "Checking the shear angle".
3
4
Fig. 10: Holder alignment in idle position, hole pattern
0-
Please note
When fitting the knife holder, it must be ensured that the holder is
aligned at a right angle.
Please take note of the following information concerning web
guidance and shear angle positioning.
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4.4 Commissioning
Warning
Before commissioning takes place it must be ensured that the
specified pneumatic pressures and electric voltages are not
exceeded, in order to prevent potential damage or injuries.
Unintentional operation is extremely dangerous for the operating
personnel.
Caution!
Before the quick-release couplings are plugged into the
compressed air supply rails of the machine, it must be ensured
that the system is depressurised.
If this is not the case the top knife may be destroyed by its
colliding with bottom knife, and the bottom knife may also be
damaged.
Suitable pressure adjustment and throttle devices must be
provided.
All clamping units on both the top knife holders and bottom knife
motors must be tightened
0-
VE
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RS
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4.4.1 Parameter settings for top and bottom knives
Care must be taken that the top knife and bottom knife are aligned
correctly to each other. The cutting position is determined by the bottom
knife cutting edge.
Align the knife holder to the bottom knife in compliance with the
standard values indicated.
In the idle position the axial distance between the top knife and the
bottom knife must be 0.8 mm.
1
2
3
Top knife
Gauge
Bottom knife
1
0.8 mm
2
approx. 0.8 mm
The depth adjustment must be set in such a way that the top knife
immerses approx. 0.8 mm below the bottom knife with a completed
vertical lift.
3
Fig. 11: Parameter settings, standard values between top knife and
bottom knife
VE
Please note
The values indicated here are standard values and may vary under
production conditions.
0-
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4.4.2 Connecting the compressed air supply
Caution
Before the quick-release couplings are plugged into the
compressed air supply rails of the machine, it must be ensured
that the system is depressurised.
Suitable pressure adjustment and throttle devices must be
provided.
The compressed air is supplied via hose connections between the
supply channel and the knife holder.
1
2
2
Knife holder
Compressed air connection
P1 vertical lift / horizontal lift
1
VE
Fig. 12: Compressed air supply.
Please note
The feed movement must take place in the correct order. The
vertical lift must be carried out first, and when this is fully
extended, the horizontal lift. During the retraction movement, the
horizontal lift is carried out first, followed by the vertical lift.
You will find information concerning connecting the compressed
air in the section "Energy supply".
0-
The amount of supply pressure that is required depends mainly on
the material that is being cut and the operating speed, and must be
individually determined under production conditions during
commissioning.
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4.5 Basic alignment of the depth adjuster
When the shear cut knife holder is put into operation for the first time,
the depth setting must be adjusted to the distances in the unit. To do
so, the knife overlap first has to be correctly set to zero and then
correspondingly saved in the electronic unit. To do so, proceed as
follows:
4.5.1 Manually setting the knife overlap to zero
1
2
3
4
1
Depth adjuster
Electronic unit
Vertical lift
Separation per 0.1mm notch
4
2
3
Fig. 13: Depth adjustment
1. Position the knife holder over a bottom knife.
VE
2. Turn the depth adjuster anticlockwise as far as the stop in order to
block the adjustable vertical lift. (Depth adjuster viewed from
above). The knife holder only performs the fixed lift.
Please note!
Each notch corresponds to a 0.1mm difference in the overlap
depth.
3. Check whether the knife head is fully extended and determine the
vertical distance between the knife head and bottom knife.
0-
4. Slowly turn the adjusting screw until the top knife is just about
touching the bottom knife. Now turn the adjusting screw back by
one notch and switch off the compressed air, and then turn the
adjusting screw forward by one notch again.
5. Now, use a gauge (plastic gauge) and move the knife holder over
the cutting grove and next to the bottom knife so that there is a axial
gap of 0.8mm between the two.
6. Increase the compressed air pressure to the operating pressure.
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4.5.2 Teaching the control unit
When setting up the unit for the first time, it will be necessary to perform
the following one-off actions.
1
2
3
4
5
Display
Activates the control and
changes the values +
Switches menus
Changes values –
Activates the change in
values and saves these
settings
1
2
4
3
5
Fig. 14: Display / Control
7. Pressing the button activates the control unit, after which the
"Position" menu or the menu that was last opened will be shown on
the screen. Confirm by pressing "S".
6
Menu name
Direction of the adjustment
Values
Unit of measurement
7
VE
6
7
8
9
Position
XXX
mm
8
9
Fig. 15: "Position" menu display
8. Press "M" to switch to the "Overlap" menu.
Overlap
0.0
0-
mm
Fig. 16: "Overlap" menu display
9. Adjust the value to "0.0" with the arrow buttons and confirm by
pressing "S".
10. Press "M" to switch to the "Knife diameter" menu
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Knife dia.
130.0
mm
Fig. 17: "Knife diameter" menu display
11. Enter the precise knife diameter established for the fitted dished
knife with the arrow buttons and confirm by pressing "S".
12. Press "M" to switch to the "Knife regrinding diameter".
Knife regr.
130.0
mm
Fig. 18: "Knife regrinding diameter" menu display
13. Adjust the value to the diameter of the knife used with the arrow
buttons and confirm by pressing "S".
VE
14. Press "M" to switch to the "0-point" menu.
0-point
XXX.X
mm
Fig. 19: "0-point" menu display
15. Shows the current distance to the zero point. Confirm by pressing
"S".
0-
16. Press "M" to switch to the "0-point" menu.
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Position
0.
mm
8
9
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Fig. 20: "Position" menu display
RS
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N
17. The display must show the value "0.0". This completes the basic
alignment and the knife holder is ready for operation again.
Please note!
The overlap value may have to be adjusted to the material
requirements.
0-
VE
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5 Handling and operation
5.1 Safety instructions for the operator
Warning !
It is imperative that the following safety instructions are observed
when operating the machine – this will prevent fatal personal
injuries, damage to the machines, other material damage and
damage to the environment.
Under no circumstances put your hand into the machine while it is
in operation!
Caution !
Cutting
hazard
and
crushing
VE
In case of careless handling, the operating personnel is exposed
to considerable risk in the traversing range of the positioning
slides of the pneumatically controlled knife holders.
“Dienes” safety gloves must always be worn when working on the
cutting tools.
(Dienes Order no.: 0FHANDS000001)
Caution !
All clamp levers and screws that have been unscrewed during a
change of format must be firmly tightened again afterwards.
Please note !
0-
The accident prevention regulations must be observed.
Safeguard an ample space around the working area before starting
adjustment work.
The sequence of the prescribed work steps must be observed
exactly.
The knife holders must always be depressurised when work is
being carried out on them.
In the case of swivelling systems it must be ensured that these are
operated without vibration and are gently swivelled into the end
positions.
The cutting system may only be operated by trained and
authorised operating personnel.
The operating instructions must be observed exactly.
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5.1.1 Qualification of personnel
Qualified personnel as defined in the safety-related instructions in this
documentation or on the product itself are those persons who
have undergone a course of instruction as operators handling knife
holders or cutting systems and are familiar with the operationrelated content of this documentation;
•
or maintenance and service personnel who are qualified to repair
such knife holders or who are licensed to operate knife holders in
accordance with safety engineering standards.
0-
VE
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•
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5.2 Knife holder definitions
The knife holders are defined by the knife head position and the
direction from which the web enters. The knife head can either be
positioned on the left or right and the web enter from the front or the
rear.
This is the basis for the four possible installation positions for knife
holders with drawing horizontal lift (Z1 - Z4).
5.2.1 Knife holder Z1, drawing horizontal lift
1
2
3
4
5
6
7
View from the front
Web direction from the front
Web direction from the rear
Knife head position left
Knife head position right
Shear angle plate
Drawing horizontal lift
1
6
4
4
7
2
Z1 = Knife head left, web entry from the front
VE
Fig. 21:
5.2.2 Knife holder Z1, drawing horizontal lift
View from the front
Web direction from the front
Web direction from the rear
Knife head position left
Knife head position right
Shear angle plate
Drawing horizontal lift
Fig. 22:
DS6S01_EN_00
1
5
0-
1
2
3
4
5
6
7
6
2
5
7
Z2 = Knife head right, web entry from the front
36 / 70
1
2
3
4
5
6
7
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5.2.3 Knife holder Z1, drawing horizontal lift
View from the front
Web direction from the front
Web direction from the rear
Knife head position left
Knife head position right
Shear angle plate
Drawing horizontal lift
1
3
6
Fig. 23:
4
4
7
Z3 = Knife head left, web entry from the rear
5.2.4 Knife holder Z1, drawing horizontal lift
View from the front
Web direction from the front
Web direction from the rear
Knife head position left
Knife head position right
Shear angle plate
Drawing horizontal lift
1
5
3
VE
1
2
3
4
5
6
7
Fig. 24:
6
5
7
Z4 = Knife head right, web entry from the rear
Please note!
0-
It is imperative to take into account the position of the shear angle
plate depending on the position of the knife head and the direction
of web entry.
The knife holders shown here are only intended to illustrate the
principle and may differ from the product in question.
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5.3.1 Tangential
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5.3 Type of material guide
The knife holder is at a 90° angle to the web.
1
2
Top knife
Bottom knife
90°
1
2
Fig. 25: Web tangential (schematic diagram)
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VE
5.3.2 Wrapped
The knife holder is located within the wrapping angle "W".
Top knife
Bottom knife
0-
1
2
1
2
Fig. 26: Wrapped web entry
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5.3.3 Specifying the axial offset
Please note!
The axial offset only has to be taken into account when using a
tangential cut.
1
2
3
4
5
Top knife
Bottom knife
Web entry from the front
Web entry from the rear
Axial offset
1
1
3
4
2
2
5
5
VE
Fig. 27: Axial offset (schematic diagram)
You will find the standard values for axial offset in the table below.
These values are mainly based on the diameter of the top knife and the
depth of immersion.
When determining the standard values, a depth of immersion of 0.8 mm
is assumed.
Ø Top knife
130 mm
150 mm
200 mm
Ø Bottom knife
150 – 250 mm
200 – 300 mm
Axial offset
10.167 mm
10.925 mm
12.624 mm
0-
Please contact DIENES if you require more information concerning
other knife pairs and depths of immersion.
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5.4 Adjusting the shear angle
The holder has been pre-set to Z1 30‘ at the factory. If it needs to be set
it to a different setting, this has to be done before the unit is
commissioned.
The adjustment of the shear angle plate depends on the two possible
knife head positions (left or right) and the two possible web entry
directions (from the front or the rear). This results in four possible
adjustment positions for the knife holder (Z1 – Z4).
5.4.1 Web entry from the front, drawing horizontal lift (Z1 and Z2)
1
2
3
4
5
6
7
8
9
10
Crossbar (machine frame)
Dovetail rail
Adapter
Knife holder
Depth adjuster
Shear angle plate
Web entry from the front
Top knife
Bottom knife
Web entry from the rear
1 2 3 4 5
Z1
6 7
Z2
7
VE
8
Fig. 28: View from the front
Z1
Side view
Z2
0-
6
7
Fig. 29: Top view
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1
2
3
4
5
6
7
8
9
10
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5.4.2 Web entry from the rear, drawing horizontal lift (Z3 and Z4)
Crossbar (machine frame)
Dovetail rail
Adapter
Knife holder
Depth adjuster
Shear angle plate
Web entry from the front
Top knife
Bottom knife
Web entry from the rear
1 2 3
Z3
4
5
6
Z4
7
10
8
Fig. 30: View from the front
Z4
VE
Z3
Side view
6
10
Fig. 31: Top view
0-
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5.4.3 Adjustment of the shear angle
An angle plate, inserted between the knife holder and the adapter, is
used to adjust the shear angle.
In order to change the angle plate, the shear cut knife holder must be
separated from the adapter. This allows access to the angle plate,
which can then be removed.
While replacing the angle plate, care must be taken to ensure that the
new angle plate is inserted in accordance with the web entry and the
necessary shear angle.
The shear angle can be identified by the marking on the angle plate
(see table).
Shear angle "W"
Marking
0
none
15’
30’
45’
0-
VE
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5.4.4 Replacing the shear angle plate
The unit is supplied with a factory-fitted 30‘ shear angle plate.
Depending on the material that is being cut, this plate may have to be
replaced with a shear angle plate with a different angle.
Caution!
Risk of cutting
Risk of cutting when working in the vicinity of the knife edge.
• Always wear protective gloves when working on the knife holder.
(Dienes Order no.: 0FHANDS000001)
• Protect the machine from restarting and unintended movements.
Caution!
Changing the top knife requires great care.
It is imperative to pay attention to the position of the shear angle
plate.
See chapter "Aligning the shear angle plate".
Knife holder
Knife head (left)
Angle plate (30‘)
Knife head retainer
Web entry from the front
Angle plate retainer
6
1
VE
1
2
3
4
5
6
2
3
3
4
4
5
5
0-
Fig. 32: Z1 = Knife head left, web entry from the front
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Web entry from the rear
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6
7
1
2
5
4
7
5
4
7
Fig. 33: Z3 = Knife head left, web entry from the rear
6
1
2
3
4
3
4
5
5
VE
Fig. 34: Z2 = Knife head right, web entry from the front
6
1
4
2
7
5
4
5
7
Fig. 35: Z4 = Knife head right, web entry from the rear
0-
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c
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5.5 Adjusting the knife holder
5.5.1 Drawing of the shear cut knife holder type DS6 – S
Caution!
Risk of cutting
Risk of cutting when working in the vicinity of the knife edge.
• Always wear protective gloves when working on the knife holder.
(Dienes Order no.: 0FHANDS000001)
• Protect the machine from restarting and unintended movements.
P1 Compressed air connection
vertical lift (4 – 6 bar)
9
10
11
12
13
14
Knife holder body
Adapter retainer
Knife head retainer
Knife head hand guard
Dished knife
Ring nut
Safety screw
Web entrance from the rear,
optional
Web entrance from the front,
standard
Depth adjustment
Depth adjustment control
Safety catch
Knife holder clamping screws
Retainer options
10
11
1
2
3
VE
1
2
3
4
5
6
7
8
P1
4
12
5
13
6
7
4
8
14
9
0-
Fig. 36: Knife holder
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15 Positioning pin
16 Dovetail adapter fastening
thread
17 Fixing thread clamping bolts
18 360° safety hand guard
15
16
17
90°
16
15
4
VE
18
Fig. 37: Knife holder
0-
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5.5.2 Depth / overlap depth adjustment
A prerequisite for setting the overlap depth is that the knife holder has
undergone a basic alignment.
Caution!
The work requires the utmost care.
1
2
3
4
5
Display
Activates the control and
changes the values +
Switches menus
Changes values –
Activates the change in
values and saves these
settings
1
2
4
3
5
Fig. 38: Display / Control
6
7
8
9
VE
1. Pressing the button activates the control unit, after which the
"Position" menu or the menu that was last opened will be shown on
the screen. Confirm by pressing "S".
6
Menu name
Direction of the adjustment
Values
Unit of measurement
7
Position
XXX
mm
8
9
Fig. 39: "Position" menu display
0-
2. Press "M" to switch to the "Overlap" menu.
Overlap
0.8
mm
Fig. 40: "Overlap" menu display
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Adjust the value to "0.8" with the arrow buttons and confirm by
pressing "S". (Guide)
RS
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3.
Please note!
The value for the overlap stated here is a guide value only and
might have to be adapted to the material being cut.
4. Press "M" to switch to the "Position" menu
10 Depth adjusting screw
6
7
Position.
0.8
mm
10
8
9
Fig. 41: "Position" menu display
5. Turn the depth adjusting screw screw in the direction indicated by
the arrow until the unit displays the value 0.0 and the arrow
extinguishes.
6. This completes the depth adjustment and the knife holder is ready
for operation again.
0-
VE
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5.5.3 Adjusting the cutting force
The required cutting pressure depends on the cutting speed and the
composition of the material web and must be determined under
production conditions.
However, the cutting pressure should only be set as high as is
necessary to cut the material web with certainty.
The cutting pressure results from the distance of the top knife to the
bottom knife, the spring restoring force and the set compressed air
loading.
Knife holders with CSL technology constitute a special case in which
the spring restoring force is eliminated with the result that a consistent
cutting pressure is achieved over the complete horizontal stroke.
Caution!
The maximum permissible operating pressure of 6 bar must not be
exceeded under any circumstances. Non-compliance will result in
failure of the knife holder. You will find information concerning the
max. operating pressure in the technical data sheet.
Note!
0-
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VE
All knife holders must have the same axial distance to the bottom
knife.
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5.6 Positioning the knife holder / Adjusting the format
The cutting position is determined by the cutting edge of the bottom
knives. The bottom knife of each knife pair must therefore be positioned
first. The top knife holder must then be aligned with the cutting edge of
the bottom knife.
Caution!
Risk of cutting
Disconnect the compressed air supply before making any
adjustments.
Risk of cutting when working in the vicinity of the knife edge.
• Always wear protective gloves when working on the knife holder.
(Dienes Order no.: 0FHANDS000001)
• Protect the machine from restarting and unintended movements.
Caution!
Top knife
Gauge
Bottom knife
1
0.8 mm
VE
1
2
3
2
ca. 0.8 mm
Only the knife holders that have been positioned and are needed
for cutting must be activated.
3
Fig. 42: Parameter settings, standard values top knife to bottom
knife
Please note
0-
The values stated here are guide values only and may vary under
production conditions.
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1
2
3
4
Clamping screw
Adapter
Clamping piece
Knife holder body
RS
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5.7 Dovetail adapter
1
4
2
3
Fig. 43: Clamping (schematic diagram)
1. Move the knife holders into the standby position.
2. Loosen the clamp on the adapter and move the knife holder over
the respective cutting groove.
3. Press the knife head downwards by hand and use the plastic gauge
to adjust the knife holder to the appropriate axial gap between the
dished knife and the cutting edge of the bottom knife. (Guide value
0.8 mm)
VE
4. Tighten the knife holder clamp again.
5. Reconnect the compressed air supply.
The work is now completed.
0-
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5.7.1 Linear adapter
1
1
2
Clamp lever
Knurled head screw for
adjusting the clamping force
3 Knurled disc for fine
adjustment of positioning
4 Top clamping piece
5 Pinion
6 Linear adapter
7 Guide carriage
8 Bottom clamping piece
9 Knife holder body
10 Adjusting nut for the
clamping range
2
3
4
5
6
6
7
8
6
Fig. 44: Clamping (schematic diagram)
1. Move the knife holders into the standby position.
2. Pull the clamp lever up to release the clamp.
3. Position the knife holder over the respective cutting groove.
4. Apply a pressure of approx. 2 bar to the knife holder at compressed
air connection P1. Ensure that the lift is complete.
VE
5. Use the knurled disc for the fine adjustment. Align the knife holder
to the required axial gap using a plastic gauge. (Guideline value 0.8
mm).
6. Retighten the clamp by pushing the clamp lever down.
7. Move the knife holder into the standby position and reconnect the
compressed air suppy.
The work is now completed.
5.7.2 Adjusting the clamping range
The adapter is designed for clamping strips with a thickness of approx.
1 mm. It may be necessary to adjust the clamping range.
The adjustment of the clamping range is described below.
0-
1. Open the clamp by releasing the clamp lever.
2. Loosen or tighten the "clamping range adjustment nut" depending
on the strip thickness.
3. Close the clamp using the clamp lever and check the clamping
force.
4. The clamping force can be fine-adjusted by turning the "clamping
force adjusting screw". The work is now completed.
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5.8 Knife replacement
Caution!
Risk
of
crushing
cutting
and
Risk of cutting when working in the vicinity of the knife edge.
• Always wear protective gloves when working on the knife holder.
(Dienes Order no.: 0FHANDS000001)
• Protect the machine from restarting and unintended movements.
Caution!
When cleaning the blade holder, please ensure that no cleaning
agent penetrates the bearings. Non-compliance will result in
premature failure of the knife holder.
Utmost cleanliness is important while working, since jammed dirt
particles affect the lateral trueness of the knife.
Check the new or newly ground knives for true running and lateral
deviation after fitting.
Ring nut
Safety screw
Dished knife
Knife head hand guard
360° safety hand guard
VE
1
2
3
4
5
4
1
2
3
5
Fig. 45: Knife replacement
0-
1. Disconnect the compressed air supply and protect it against being
connected again accidentally
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Block the blade carrier
e.g. using a box spanner
RS
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6
7
4
6
7
Fig. 46: Blocking the blade carrier
8. e.g. insert a box spanner / screwdriver into one of the two holes and
turn the blade carrier until the spanner / screwdriver engages. This
will stop the blade carrier from turning.
1
2
2x
VE
Fig. 47: Safety screw and ring nut
9. Loosen the safety screw.
10. Remove ring nut.
0-
3
Fig. 48: Dished knife
11. Remove the dished knife.
12. Clean all components thoroughly!
DS6S01_EN_00
54 / 70
RS
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3
3
5
Fig. 49: Fitting the dished knife
13. Fit the new knife to the blade carrier as shown in the diagram.
14. Screw the ring nut onto the blade carrier.
15. Tighten the retaining screw. Tightening torque 1 Nm.
16. Check concentricity of knife.
17. Check and if necessary correct the overlap depth.
18. Reconnect the compressed air supply. This completes the work and
the knife holder is ready for operation again.
Please note
VE
Only original DIENES cutting tools ensure trouble-free operation.
The diagrams are intended to clarify the principle and may deviate
from this actual product.
Dienes Service Line
Repeat orders and regrinding service at
Tel.: 02206 – 605160
www. dienes .de
0-
Fig. 50: Dienes Service Line
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5.8.1 Adjusting the overlap depth after changing knifes
If you need to use dished knifes with different regrinding stages, the
overlap depth has to be readjusetd after the knife has been changed.
Caution!
The work requires the utmost care.
1
2
3
4
5
Display
Activates the control and
changes the values +
Switches menus
Change values
Activates the change in
values and saves these
settings
1
2
4
3
5
Fig. 51: Display / Control
6
7
8
9
VE
1. Pressing the
button activates the control unit, after which the
"Position" menu will be shown on the screen. Confirm by pressing
"S".
6
Menu name
Direction of the adjustment
Values
Unit of measurement
7
Position
XXX
mm
8
9
Fig. 52: "Position" menu display
0-
2. Press "M" to switch to the "Knife regrinding diameter" menu.
DS6S01_EN_00
Knife regr.
129,5
mm
56 / 70
Fig. 53: "Knife regrinding diameter" menu display
RS
IO
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3. Adjust the value to the diameter of the knife used with the arrow
buttons and confirm by pressing "S".
In this example, this is Ø 129.5mm
4. Press "M" to switch to the "Position" menu
10 Depth adjusting screw
6
7
Position.
0,5
mm
10
8
9
Fig. 54: "Position" menu display
5. Turn the depth adjusting screw in the direction indicated by the
arrow until the unit displays the value 0.0.
6. This completes the knife change and the knife holder is ready for
operation again.
0-
VE
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5.8.2 Removing the "WKS" shear cut replacement head
Caution!
Risk of cutting
Risk of cutting when working in the vicinity of the knife edge.
• Always wear protective gloves when working on the knife holder.
(Dienes Order no.: 0FHANDS000001)
• Protect the machine from restarting and unintended movements.
When cleaning the blade holder, please ensure that no cleaning
agent penetrates the bearings.
• Do not use compressed air.
• Non-compliance will result in premature failure of the knife holder.
The knife head can be removed from the knife holder body for
maintenance purposes or to replace knifes. It is fitted with a quickrelease clamp for this purpose.
1
2
3
4
5
6
Knife head retainer
Knife head prism
Knife head
Shear angle plate
Safety catch
Eccentric clamp
1
4
2
5
6
VE
3
Fig. 55: WKS shear cut replacement head closed
Remove the knife head as described below:
1. Turn off the compressed air supply to the knife holder and
safeguard it against being turned on again accidentally. The knife
holder will be in the standby position.
0-
Removal
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Fig. 56: Removing the WKS shear cut replacement head
2. Hold the knife head with one hand, push up the safety catch with
the other and simultaneously pull up the clamp lever.
3. Turn the knife head and pull it downwards from the prism.
4. Clean all components thoroughly. Do not use compressed air for
this!
7
8
Centring pin
O-ring
7
8
VE
7
Fig. 57: Fitting the WKS shear cut replacement head (here with the
knife head left)
Assembly
5. Check the o-ring and replace with a new one if necessary.
6. Insert the knife head in the required alignment (left / right) into the
prism on the holder body.
7. Press the clamp leaver down until the safety catch engages.
0-
Caution!
If the knife's alignment is changed, the shear angle plate has to be
re-aligned accordingly. Please see the section on "Aligning the
shear angle plate".
8. Reconnect the compressed air supply, check the cutting
parameters and correct if necessary. This completes the work and
the knife holder is ready for operation again.
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6 Maintenance
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6.1 Safety instructions for servicing
It is imperative that the following safety instructions are observed
while servicing the machine – this will prevent fatal personal
injuries, damage to the machines, other material damage and
damage to the environment.
Danger!
Voltage
Faulty electrical connections or unapproved live parts lead to
serious injury or even death.
•
On principle, only a trained electrician may work on the machine's
electrics.
•
Replace any damaged cables or plugs immediately.
•
Before starting work, the electrical as well as pneumatic power
supply is to be disconnected and secured against accidental restart.
•
The handling regulations (e.g. earthing, ...) must be followed to the
letter for components which are at risk from static electricity.
VE
Warning!
Entanglement hazard
Rotating components can draw in body parts and cause serious
injury or even death.
•
Keep a sufficient distance away from rotating machine components.
•
Safeguard the machine against restarting and unintended
movement during assembly and maintenance work.
•
Under no circumstances put your hand into the machine while it is
in operation!
Caution!
0-
Cutting hazard
There is a risk of being cut in the area of the knife edge.
DS6S01_EN_00
•
Always wear protective gloves when working on the knife holder.
(Dienes Order no.: 0FHANDS000001)
•
Safeguard the machine against restarting and unintended
movement during maintenance work.
60 / 70
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Caution!
Only authorised personnel may carry out cleaning, lubrication and
servicing tasks – the operating instructions must be followed to
the letter.
Self-locking screws and nuts are always to be renewed.
All quoted screw torques are to be observed to the letter.
In the case of swivelling systems, it must be ensured that these
are operated without vibration and are gently swivelled into the
end positions.
The sequence of the prescribed work steps must be observed
exactly.
Note
The accident prevention regulations must be observed.
All consumables, lubricants and ancillary materials are to be
disposed of in an environmentally friendly manner.
Repairs may only be undertaken by authorised service engineers.
0-
VE
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6.2 Service and cleaning work
The shear cut knife holders are essentially maintenance-free.
However, it must be ensured that the sliding elements are cleaned at
regular intervals. Also the clamping bolts, the centring pin and the
installation surface must be kept clean at all times and greased lightly.
Caution!
Dust deposits must be vacuumed off. In order to prevent particles
penetrating the guides, compressed air should never be for
cleaning purposes.
Cleaning must be carried out at least every three months.
If dust deposits are extremely heavy, the machine must be cleaned
at more frequent intervals.
Apply a light coating of oil to parts of the machine that are at risk
of corrosion (blued or bare) at monthly intervals. Shorter intervals
may be required depending on the humidity.
This does not include the clamping strips, which must not be
lubricated because this would adversely affect the clamping effect.
Spray oil must be used that is compatible with the grease that is
used at the other lubricating points.
VE
For safety and quality reasons, the maintenance and assembly
work on the knife head must be carried out in the manufacturer’s
factory.
Note
More complicated maintenance and repair work must be carried
out in the manufacturer’s factory.
If equipment is dismantled on site, Molykote paste BR2 must be
used as the lubricant for sliding surfaces, and a lithium soapbased ball bearing grease with consistency class NGLI1 must be
used for ball bearings.
0-
Please note that any dust deposits that build up must be removed
using a vacuum cleaner only.
Cleaning with compressed air can lead to damage caused by fine
dust particles, which can penetrate moving components (linear
guides, linear drives etc.).
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6.3 Lubrication
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6.3.1 Lubrication of the linear adapter
Caution!
All lubricating points are marked as such with stickers.
There is a grease fitting on the side of each guide carriage. The cutting
units must be moved apart for lubricating.
Lithium soap-based grease in accordance with DIN 51825 with
consistency class NLGI2 in accordance with DIN 51818 must be used as
a lubricant.
With the guide carriage it must be ensured that enough grease is
pressed into the guides and that any internal soiling is flushed out by
moving the guide carriage sideways during the re-greasing procedure.
In order to minimise subsequent dust accumulation, all excess grease
that comes out of the guide carriage sealing lips at the sides must be
removed completely.
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6.3.2 Knife holder lubrication
The bearing points on the knife holder have lifetime lubrication,
meaning that re-greasing is not required.
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7 Servicing
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7.1 Safety instructions for maintenance
It is imperative that the following safety instructions are observed
when maintaining the machine - this will prevent fatal personal
injuries, damage to the machine, other material damage and
damage to the environment.
Danger!
Voltage
Faulty electrical connections or unapproved live parts lead to
serious injury or even death.
•
In principle, only a trained electrician may work on the machine's
electrics.
•
Replace any damaged cables or plugs immediately.
•
Before starting work, the electrical as well as pneumatic power
supply is to be disconnected and secured against accidental restart.
•
The handling regulations (e.g. earthing, etc.) must be followed to
the letter for components which are at risk from static electricity.
Warning!
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Entanglement hazard
Rotating parts can pull in parts of the body and cause severe
injuries or even death.
•
Keep a sufficient distance away from rotating machine components.
•
Safeguard the machine against restarting and unintended
movement during assembly and maintenance work.
•
Under no circumstances put your hand into the machine while it is
in operation!
Caution!
Cutting hazard!
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There is a risk of being cut in the area of the knife edge.
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•
Always wear protective gloves when working on the knife holder.
(Dienes Order no.: 0FHANDS000001)
•
Safeguard the machine against restarting and unintended
movement during maintenance work.
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Caution!
Only authorised personnel may carry out cleaning, lubrication and
servicing tasks – the operating instructions must be followed to
the letter.
Self-locking screws and nuts are always to be renewed.
All quoted screw torques are to be obeyed to the letter.
In the case of swivelling systems, it must be ensured that these
are operated without vibration and are gently swivelled into the
end positions.
The sequence of the prescribed work steps must be observed
exactly.
Note
The accident prevention regulations must be observed.
All consumables, lubricants and ancillary materials are to be
disposed of in an environmentally friendly manner.
Repairs may only be undertaken by authorised service engineers.
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7.2.1 Knife holder
Malfunction
•
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7.2 Remedial measures in the case of failures
Cause
Dished knife/ top knife does
•
not move into working position
•
•
•
Cut edge not exact
•
•
•
•
Remedy
Knife holder distorted during
•
fitting
No compressed air supply or
insufficient operating pressure •
Soiling of the knife holder or
•
gliding planes of the guides
Dished knife / top knife or
bottom knife damaged
Shear angle not correctly
aligned to the web
Overlap depth set incorrectly
Lateral contact pressure of the
dished knife / top knife too
high or too low
•
•
•
•
Compressed air escaping
from the knife holder
•
Operating pressure too high or •
gasket damaged
•
Knife service life too short
•
•
•
Cutting pressure too high
Shear angle incorrect
Knife overlap between top and
bottom knife insufficient, top
knife edge jumps onto the
outer diameter of the bottom
knife
Knives reground incorrectly
Lateral or height runout of the
bottom knife too big
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•
•
•
•
•
•
Replace cutting tools
Use the angle plate to align
the shear angle correctly
Correct depth adjustment
Correct contact pressure via
pressure adjustment /
adjusting screw
Correct operating pressure or
replace sealing elements
Correct operating pressure
Check positioning of the shear
angle plate (observe web
direction)
Check knife overlap and
readjust if necessary
Replace knives
Align bottom knife and replace
if necessary
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•
•
Reposition the tool holder on
the holder bar or adapter and
align at a right angle
Check the pressure supply
Clean and lubricate the knife
holder
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8 Taking out of service (scrapping)
8.1 Safety instructions
It is imperative that the following safety instructions are observed
during disassembly of the machine – this will prevent fatal
personal injuries, damage to the machines, other material damage
and damage to the environment.
Danger!
Voltage
The electric and pneumatic power supplies must be disconnected
before work is started.
Improper handling of the live parts can lead to serious injury and
even death.
Caution!
Cutting hazard
There is a risk of being cut in the area of the knife edge.
•
Always wear protective gloves when working on the knife holder.
(Dienes Order no.: 0FHANDS000001)
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Note
Dismantling must always be carried out by technically qualified
personnel.
Final taking out of service and disposal requires complete deinstallation of the power supply.
Machines that are being scrapped should be disposed of in
accordance with legal requirements and any local requirements
that exist.
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9 Accessories available from the DIENES company
Fig. 58: Dienes accessories
Protective gloves
Order No.:
0FHANDS000001
2
Exchange tools fopr PSGm19,
used for replacing the knife holder on the shear
cut knife holder PSGm19
3
Hexagon screwdriver
Size 3
4
Cross slot screwdriver
Size 2K
Order No.:
290A046002001
Order No.:
0FWERKZ000005
Order No.:
0FWERKZ000008
5
Torx screwdriver
Size = TX 20 x 100
6
Hook spanner
Order No.:
4959051683
Ø 48 – 53 mm
Order No.:
290B000028030
Ø 54 – 60 mm
Order No.:
290B000028040
Ø 68 – 75 mm
Order No.:
290B000028050
Ø 80 – 90 mm
Order No.:
290B000028060
Ø 101 – 109 mm
Order No.:
290B000029030
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1
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Order No.:
290B000028070
Ø 130 – 140 mm
Order No.:
290B000028080
Order No.:
290B000029050
Order No.:
290B000029100
Order No.:
290B000029080
Ø 150 – 160 mm
Ø 205 – 220 mm
Ø 224 – 239 mm
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Ø 110 – 120 mm
7
Adjustment device
used to adjust the knife overlap outside of the
cutting station.
8
Assembly tools
for easier knife replacement on the knife holders
9
Hexagon spanner set
Sizes = 1.5 - 2 – 2.5 - 3 - 4 - 5 - 6 - 8 - 10
Information on request from DIENES
Order No.:
4959050345
10
Feeler gauge set
Set sizes = from 0.05 – 0.3 mm with 0.05
increments, from
0.3 - 1mm with 0.1mm
increments
Order No.:
0FWERKZ000016
11
Grease press
with grease cartridge
Order No.:
0FFETTP000001
Information on request from DIENES
Please note !
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In addition Dienes knife cabinets, for safe storage of the knives,
and Dienes knife boxes, for safe transportation of the knives, are
also available on request, of course.
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10 Regrinding service
Dienes Group 48-hour knife regrinding service provided by the
manufacturer!
Even the best knives have to be replaced at some time.
Dienes has also made this procedure quicker and safer with
sophisticated replacement systems that ensure optimum protection
against injury.
The 48-regrinding service for the latest generation of CNC machines is
carried out with the same strict quality criteria that you would rightly
expect from knives from the Dienes group.
In addition to seminars and in-house training, the regrinding service is
an important module in the Dienes Service offer.
The regrinding service includes:
•
•
•
•
•
•
•
•
•
•
Hotline (optional)
Collection
Cleaning
Precision measurement
Group allocation
2-phase CNC/NC precision grinding
“ASO” anti dust surface (optional)
Testing
Protocol, test report (optional)
Shipment
Your partner at the cutting edge of competition worldwide.
Dienes Werke
Kölner Str. 7
D-51491 Overath
Tel. +49 2206 / 60 5 0
Fax +49 2206 / 60 5 111
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For round knives:
JOHANN KRUMM GmbH & Co.KG
Kölner Str. 7
D-51491 Overath
Tel. +49 2206 / 60 5 0
Fax +49 2206 / 60 5 111
For rotary shear knives:
Messerfabrik Neuenkamp GmbH
Neuenkamper Straße 27
D-42855 Remscheid
Tel. +49 2191 / 93 51-0
Fax +49 2191 / 34 09 06
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For straight knives:
Service Partners:
We would be glad to provide information about other service partners
on request.
www.dienes.de
www.messerservice.de
=== Ende der Liste für T extmar ke Inhalt ===
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