Download Operator Manual Installation Instruction
Transcript
RS IO N Operator Manual Installation Instruction DS6S01_EN_00 Shear cut knife holder DS6-S 0- VE 245AC74003001 Pos : 1 /C AD/2010/00 Allgemeines/01 Z u dies er Anl eitung @ 7\mod_1268045435622_4.doc x @ 79579 @ @ 1 RS IO N 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. VE 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. 0- 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. Pos : 2 /C AD/Allgemei n/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 2 / 70 Pos : 3 /C AD/2010/00 Allgemeines/02 Sig nal wörter @ 7\mod_1273154136756_4.doc x @ 84165 @ @ 1 RS IO N 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 ! VE 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. 0- Pos : 4 /C AD/Allgemei n/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 3 / 70 1 Contents RS IO N Pos : 5 /C AD/2010/01 Inahal tsangabe/01 Inhalts verzeic hnis 01 @ 7\mod_1273154249536_4.doc x @ 84183 @ 1 @ 1 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 VE 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 0- 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 DS6S01_EN_00 4 / 70 RS IO N 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 VE 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 0- Pos : 6 /C AD/Allgemei n/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 5 / 70 Pos : 7 /C AD/2010/02 Pr oduktbesc hreibung/2 Pr oduktbesc hreibung @ 7\mod_1273225228543_4.doc x @ 84273 @ 1 @ 1 Pos : 8 /C AD/2010/02 Pr oduktbesc hreibung/2.1 Besti mmumgsgemäß e Ver wendung/2.1 Besti mmungsgemäße Ver wendung MH D S-6 @ 12\mod_1362662049553_4.doc x @ 187247 @ 2 @ 1 RS IO N 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! 0- VE Pos : 9 /C AD/Allgemei n/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 6 / 70 Pos : 10 /CAD /Hal ter Sc her enschnitt/DS- 6/D S6- S_245AC74/Sc her enschnittmess erhalter Besc hr eibung D S6- S @ 13\mod_1376478112537_4.doc x @ 215805 @ 2 @ 1 RS IO N 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 VE 3 9 8 2 7 0- 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 DS6S01_EN_00 • Knife holder with 30mm vertical lift • Knife holder with 50mm vertical lift • 1 Compressed air connection, internal forced sequence control 7 / 70 2 compressed air connections, requires an external forced sequence control RS IO N • 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) VE Dovetail adapter 0- Pos : 11 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 • DS6S01_EN_00 8 / 70 2.3 Knife heads RS IO N Pos : 12.1 /CAD /Hal ter Sc her enschnitt/DS- 6/M ess er köpfe/D S6 Mes ser köpfe Ei nleitung @ 13\mod_1376565402812_4.doc x @ 216966 @ 2 @ 1 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! Pos : 12.2 /CAD /Hal ter Sc her enschnitt/DS- 6/M ess er köpfe/Scherensc hnitt Ø130/TM 130mm 245AC75 @ 13\mod_1376546099494_4.doc x @ 216619 @ 3 @ 1 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 VE 1 2 3 4 5 6 7 8 2 8 Fig. 2: Shear cutting knife head with dished knife Ø130mm Pos : 12.3 /CAD /Hal ter Sc her enschnitt/DS- 6/M ess er köpfe/Scherensc hnitt Ø150/TM Ø150mm 245AC72 @ 13\mod_1376564689509_4.doc x @ 216920 @ 3 @ 1 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 0- 1 2 3 4 5 6 7 8 7 7 2 8 Fig. 3: Shear cutting knife head with dished knife Ø150mm Pos : 13 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 9 / 70 2.4 Adapter RS IO N Pos : 14.1 /CAD /Hal ter Sc her enschnitt/DS- 6/Adapter /DS6 Adapter Ei nleitung @ 13\mod_1376567032206_4.doc x @ 216990 @ 2 @ 1 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. Pos : 14.2 /CAD /Allgemein/2 x Leerz eichen @ 2\mod_1148018579447_4.doc x @ 16425 @ @ 1 Pos : 14.3 /CAD /Hal ter Sc her enschnitt/DS- 6/Adapter /Sc hwalbens chwanzadapter @ 13\mod_1376567414141_4.doc x @ 217240 @ 3 @ 1 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 VE 3 4 Fig. 4: Dovetail adapter 0- Pos : 14.4 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 10 / 70 Pos : 14.5 /CAD /Hal ter Sc her enschnitt/DS- 6/Adapter /Li nearadapter mit Ritz el vers tell ung @ 13\mod_1376987939678_4.doc x @ 217382 @ 3 @ 1 RS IO N 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 0- Pos : 15 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 VE Fig. 5: Linear adapter DS6S01_EN_00 11 / 70 Pos : 16 /CAD /2010/02 Produktbes chr eibung/2.3 Produktdaten/2.3 Produktdaten @ 7 \mod_1273228635219_4.doc x @ 84333 @ 2 @ 1 Pos : 17 /CAD /Hal ter Sc her enschnitt/DS- 6/D S6- S_245AC74/T ec hnische D aten 245AC 74003001 @ 13\mod_1376991458033_4.doc x @ 217428 @ 3 @ 1 RS IO N 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 0- Pos : 18 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 VE *1 can vary according to option DS6S01_EN_00 12 / 70 Pos : 19 /CAD /2010/02 Produktbes chr eibung/2.3 Produktdaten/2.3.2 Energievers orgung/ M ess erhalter /2.3.2 D S6-S Energieversorgung 6 / 6 @ 13\mod_1376996802614_4.doc x @ 217451 @ 3 @ 1 RS IO N 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. 0- Pos : 20 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 VE However, the cutting pressure should not be higher than that required to reliably cut the material web. DS6S01_EN_00 13 / 70 Pos : 21 /CAD /2010/02 Produktbes chr eibung/2.3 Produktdaten/2.3.3 Anzi ehmomente /2.3.3 Anzi ehmomente @ 7\mod_1274434760181_4.doc x @ 85874 @ 3 @ 1 RS IO N 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 VE 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 0- M 16 Fig. 6: Tightening torque standard threads DS6S01_EN_00 14 / 70 RS IO N 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 0- VE Pos : 22 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 15 / 70 3 Safety Pos : 24 /CAD /2010/03 Sicher heit/3.1 Sorgfalts pflic ht des Betrei bers /3.1 Sorgfalts pflic ht des Betrei bers @ 7\mod_1273229383451_4.doc x @ 84375 @ 2 @ 1 RS IO N Pos : 23 /CAD /2010/03 Sicher heit/3 Sic her hei t @ 7\mod_1273229165515_4.doc x @ 84355 @ 1 @ 1 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; VE • • 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! 0- 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. Pos : 25 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 16 / 70 Pos : 26 /CAD /2010/03 Sicher heit/3.1 Sorgfalts pflic ht des Betrei bers /3.1.1 EG-M asc hinenrichtli nie @ 7\mod_1273229654152_4.doc x @ 84394 @ 3 @ 1 RS IO N 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. Pos : 27 /CAD /Allgemein/2 x Leerz eichen @ 2\mod_1148018579447_4.doc x @ 16425 @ @ 1 Pos : 28 /CAD /2010/03 Sicher heit/3.1 Sorgfalts pflic ht des Betrei bers /3.1.2 Stand der T echni k @ 10 \mod_1326702064630_4.doc x @ 135490 @ 3 @ 1 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. Pos : 29 /CAD /Allgemein/2 x Leerz eichen @ 2\mod_1148018579447_4.doc x @ 16425 @ @ 1 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. Pos : 30 /CAD /2010/03 Sicher heit/3.1 Sorgfalts pflic ht des Betrei bers /3.1.3. Vernünftiger weise vorhersehbarer Fehlgebrauc h @ 7\mod_1274440434487_4.doc x @ 85951 @ 3 @ 1 3.1.3 Reasonably foreseeable misuse Every use that exceeds maximum performance data is regarded as improper use and is therefore prohibited. 0- Pos : 31 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 17 / 70 Pos : 32 /CAD /2010/03 Sicher heit/3.1 Sorgfalts pflic ht des Betrei bers /3.1.4 Gewährleistung und Haftung @ 7\mod_1274440687638_4.doc x @ 85970 @ 3 @ 1 RS IO N 3.1.4 Warranty and liability Warranty and liability claims for potential personal injury or property damage are excluded Pos : 33 /CAD /Allgemein/2 x Leerz eichen @ 2\mod_1148018579447_4.doc x @ 16425 @ @ 1 Pos : 34 /CAD /2010/03 Sicher heit/3.1 Sorgfalts pflic ht des Betrei bers /3.1.5 Ers atz und Zubehörteile @ 10\mod_1329138833417_4.doc x @ 139347 @ 3 @ 1 • 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- Pos : 35 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 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. DS6S01_EN_00 18 / 70 Pos : 36 /CAD /2010/03 Sicher heit/3.2 Allgemeine Sicherheits hinweis e/3.2 Allgemei ne Sic her hei tshi nwei se @ 10 \mod_1326702688919_4.doc x @ 135512 @ 2 @ 1 RS IO N 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. DS6S01_EN_00 19 / 70 RS IO N 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 Pos : 37 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 Avoid radiation of the eyes or skin by direct or scattered radiation. DS6S01_EN_00 20 / 70 Pos : 38 /CAD /2010/03 Sicher heit/3.2 Allgemeine Sicherheits hinweis e/3.2.1 Er kl ärung der ver wendeten Sicher heits s ymbol e @ 7 \mod_1273233464723_4.doc x @ 84550 @ 3 @ 1 RS IO N 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 Pos : 39 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 21 / 70 Pos : 40 /CAD /Hal ter Sc her enschnitt/DS- 6/D S6- S_245AC74/MH _Angebrachte Warnhi nweis e und Sc hutz einrichtungen @ 13 \mod_1377002300610_4.doc x @ 217524 @ 3 @ 1 RS IO N 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 Pos : 41 /CAD /Allgemein/2 x Leerz eichen @ 2\mod_1148018579447_4.doc x @ 16425 @ @ 1 Pos : 42 /CAD /2010/03 Sicher heit/3.3 Persönliche Sc hutzausr üstung/3.3 Persönliche Sc hutzausrüstung @ 7\mod_1273233550191_4.doc x @ 84573 @ 2 @ 1 RS IO N 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 Pos : 43 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 23 / 70 Pos : 44 /CAD /2010/06 Inbetriebnahme/6 Inbetriebnahme @ 7\mod_1273480999795_4.doc x @ 84672 @ 1 @ 1 Pos : 45 /CAD /2010/06 Inbetriebnahme/6.1 Sc hni ttstellen benac hbarter Mas chi nenkomponenten/6.1 Sc hnitts tell en benac hbarter Komponenten @ 7\mod_1273481108325_4.doc x @ 84692 @ 2 @ 1 RS IO N 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 Pos : 46 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 24 / 70 4.2 Transport RS IO N Pos : 47 /CAD /2010/06 Inbetriebnahme/6.2 Tr ansport/6.2 Tr ansport M ess erhalter @ 7\mod_1277809711435_4.doc x @ 86951 @ 2 @ 1 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 Pos : 48 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 25 / 70 4.3 Assembly Pos : 50 /CAD /Hal ter Sc her enschnitt/DS- 6/D S6- S_245AC74/H alterausrichtung Bohrbil d @ 13\mod_1377007829279_4.doc x @ 217547 @ 3 @ 1 RS IO N Pos : 49 /CAD /2010/06 Inbetriebnahme/6.3 M ontage/6.3 M ontage @ 7\mod_1273484782661_4.doc x @ 84776 @ 2 @ 1 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. Pos : 51 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 26 / 70 Pos : 52 /CAD /2010/06 Inbetriebnahme/6.4 Erste Inbetriebnahme/6.4 Erste Inbetriebnahme @ 7\mod_1273485431752_4.doc x @ 84835 @ 2 @ 1 RS IO N 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 Pos : 53 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 27 / 70 Pos : 54 /CAD /2010/06 Inbetriebnahme/6.4 Erste Inbetriebnahme/6.4.1 PSGs-DF Eins tell par ameter 0,8 / 0,8 mm @ 7\mod_1279027282354_4.doc x @ 87403 @ 3 @ 1 RS IO N 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- Pos : 55 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 28 / 70 Pos : 56 /CAD /Hal ter Sc her enschnitt/DS- 6/D S6- S_245AC74/H erstellen der Druc kl uftvers orgung @ 13\mod_1377075340760_4.doc x @ 217652 @ 3 @ 1 RS IO N 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. Pos : 57 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 29 / 70 Pos : 58 /CAD /Hal ter Sc her enschnitt/DS- 6/D S6- S_245AC74/Grundjustage Tiefenei nstellung @ 13\mod_1377764806835_4.doc x @ 218868 @ 233 @ 1 RS IO N 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. DS6S01_EN_00 30 / 70 RS IO N 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 DS6S01_EN_00 31 / 70 RS IO N 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. DS6S01_EN_00 6 Position 0. mm 8 9 32 / 70 Fig. 20: "Position" menu display RS IO 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 Pos : 59 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 33 / 70 Pos : 60 /CAD /2010/07 Bedi enung und Betrieb/7 Bedi enung und Betrieb @ 7\mod_1273493791116_4.doc x @ 84911 @ 1 @ 1 Pos : 61 /CAD /2010/07 Bedi enung und Betrieb/7.1 Sicher heits hi nweis e für den Betrei ber/7.1 Sic her hei tshi nweise für den Bediener @ 7\mod_1273493905411_4.doc x @ 84931 @ 2 @ 1 RS IO N 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. DS6S01_EN_00 34 / 70 Pos : 63 /CAD /2010/07 Bedi enung und Betrieb/7.1 Sicher heits hi nweis e für den Betrei ber/7.1.1 Qualifi kati on des Personals @ 7 \mod_1273494107751_4.doc x @ 84950 @ 3 @ 1 RS IO N Pos : 62 /CAD /Allgemein/2 x Leerz eichen @ 2\mod_1148018579447_4.doc x @ 16425 @ @ 1 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 Pos : 64 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 • DS6S01_EN_00 35 / 70 Pos : 65 /CAD /2010/07 Bedi enung und Betrieb/7.2 D efi nition der Mes ser halter/7.2C D efi nition M ess erhalter DS6 Z 1-Z4 @ 13\mod_1377078298491_4.doc x @ 217750 @ 23333 @ 1 RS IO N 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 RS IO N 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. Pos : 66 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 37 / 70 Pos : 67 /CAD /2010/07 Bedi enung und Betrieb/7.3 Art der Materi alführ ung/7.3 Art der M aterialführung @ 7\mod_1273494602320_4.doc x @ 84970 @ 2 @ 1 Pos : 68 /CAD /2010/07 Bedi enung und Betrieb/7.3 Art der Materi alführ ung/7.3.1 T ang ential D S-6 @ 13\mod_1377083317825_4.doc x @ 217773 @ 3 @ 1 5.3.1 Tangential RS IO N 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) Pos : 69 /CAD /2010/07 Bedi enung und Betrieb/7.3 Art der Materi alführ ung/7.3.2 U msc hlungen D S-6 @ 13\mod_1377083591045_4.doc x @ 217796 @ 3 @ 1 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 Pos : 70 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 38 / 70 Pos : 71 /CAD /2010/07 Bedi enung und Betrieb/7.3 Art der Materi alführ ung/7.3.3 F estl egen des Ac hs vers atz @ 13 \mod_1377084760933_4.doc x @ 217819 @ 3 @ 1 RS IO N 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. Pos : 67 /CAD /Allgemein/=============== @ 0\mod130_1.doc x @ 2391 @ @ 1 Pos : 72 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 39 / 70 Pos : 73 /CAD /2010/07 Bedi enung und Betrieb/7.4 Ausrichten der Sc her wi nkel platte/7.4 Ausric hten der Scher winkelpl atte DS- 6 Z 1 - Z 4 @ 13\mod_1377163200777_4.doc x @ 217847 @ 233 @ 1 RS IO N 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 DS6S01_EN_00 40 / 70 1 2 3 4 5 6 7 8 9 10 RS IO N 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- Pos : 74 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 41 / 70 Pos : 75 /CAD /2010/07 Bedi enung und Betrieb/7.4 Ausrichten der Sc her wi nkel platte/7.4.1 Ei nstellung des Sc herwi nkels PSGm16 / PSGm19-DF @ 7\mod_1279089184700_4.doc x @ 87585 @ 3 @ 1 RS IO N 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 Pos : 76 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 42 / 70 Pos : 77 /CAD /Hal ter Sc her enschnitt/DS- 6/D S6- S_245AC74/Wec hsel der Scher winkel platte @ 13\mod_1377169861686_4.doc x @ 218271 @ 3 @ 1 RS IO N 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 DS6S01_EN_00 43 / 70 Web entry from the rear RS IO N 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- Pos : 78 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 44 / 70 Pos : 79 /CAD /2010/07 Bedi enung und Betrieb/7.5 H alter ei nstellen/7.5 Eins tell en der M ess erhalter @ 7\mod_1274448893975_4.doc x @ 86104 @ 2 @ 1 Pos : 80 /CAD /Hal ter Sc her enschnitt/DS- 6/D S6- S_245AC74/Skizz e D S-6; TM130; P1 @ 13\mod_1377867572836_4.doc x @ 218946 @ 3 @ 1 c RS IO N 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 DS6S01_EN_00 45 / 70 RS IO N 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- Pos : 81 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 46 / 70 Pos : 82 /CAD /Hal ter Sc her enschnitt/DS- 6/D S6- S_245AC74/Ti efenei nstellung /Ti efeneins tell ung / Ü berlappungsti efe @ 13\mod_1377862893348_4.doc x @ 218923 @ 3 @ 1 RS IO N 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 DS6S01_EN_00 47 / 70 Adjust the value to "0.8" with the arrow buttons and confirm by pressing "S". (Guide) RS IO N 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 Pos : 83 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 48 / 70 Pos : 84 /CAD /2010/07 Bedi enung und Betrieb/7.5 H alter ei nstellen/7.5.3 Eins tell en der Schnittkr aft @ 7\mod_1274764646359_4.doc x @ 86185 @ 3 @ 1 RS IO N 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- Pos : 85 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 VE All knife holders must have the same axial distance to the bottom knife. DS6S01_EN_00 49 / 70 Pos : 86.1 /CAD /Hal ter Sc her enschnitt/DS- 6/D S6- S_245AC74/H alter Positi oni eren F or matei nstellung @ 13\mod_1377591445646_4.doc x @ 218343 @ 2 @ 1 RS IO N 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. Pos : 86.2 /CAD /Hal ter Sc her enschnitt/DS- 6/D S6- S_245AC74/Sc hwal bensc hwanz @ 13\mod_1377594778983_4.doc x @ 218366 @ 2 @ 1 DS6S01_EN_00 50 / 70 1 2 3 4 Clamping screw Adapter Clamping piece Knife holder body RS IO N 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- Pos : 86.3 /CAD /Hal ter Sc her enschnitt/DS- 6/D S6- S_245AC74/Linear Adapter @ 13\mod_1377595065810_4.doc x @ 218389 @ 33 @ 1 DS6S01_EN_00 51 / 70 RS IO N 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. Pos : 87 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 52 / 70 Pos : 88 /CAD /Hal ter Sc her enschnitt/DS- 6/M ess er köpfe/Scher ensc hnitt Ø130/M ess er wec hs el D S6 130 @ 13\mod_1377606622126_4.doc x @ 218611 @ 2 @ 1 RS IO N 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 DS6S01_EN_00 53 / 70 Block the blade carrier e.g. using a box spanner RS IO N 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 IO N 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 Pos : 89 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 55 / 70 Pos : 90 /CAD /Hal ter Sc her enschnitt/DS- 6/D S6- S_245AC74/Einstellen der Ü berl appungsti efe nach Mess er wec hsel @ 13\mod_1377590347519_4.doc x @ 218320 @ 3 @ 1 RS IO N 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 N 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 Pos : 91 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 57 / 70 Pos : 92 /CAD /Hal ter Sc her enschnitt/DS- 6/D S6- S_245AC74/M ess er kopf Wec hs el WKS Ø130 @ 13\mod_1377695681469_4.doc x @ 218787 @ 3 @ 1 RS IO N 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 DS6S01_EN_00 58 / 70 RS IO N 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. Pos : 93 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 59 / 70 6 Maintenance Pos : 95 /CAD /2010/08 Wartung/8.1 Sicherheits hinweis e für die Wartung/8.1 Sicherheits hinweis e für die Wartung @ 7\mod_1274769361045_4.doc x @ 86244 @ 2 @ 1 RS IO N Pos : 94 /CAD /2010/08 Wartung/8 Wartung @ 7\mod_1274769178954_4.doc x @ 86224 @ 1 @ 1 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 RS IO N 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 Pos : 96 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 61 / 70 Pos : 97 /CAD /2010/08 Wartung/8.2 War tungs- und R einigungs maß nahmen/8.2 Wartungs- und Rei nigungsmaß nahmen @ 8\mod_1298020693102_4.doc x @ 104645 @ 2 @ 1 RS IO N 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.). Pos : 98 /CAD /Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 62 / 70 6.3 Lubrication P/CAD /2010/08 Wartung/8.3 Schmi erung/8.3.1Sc hmierstellen Lineradapter @ 12\mod_1358246926481_4.doc x @ 179767 @ 3 @ 1 RS IO N Pos : 99 /CAD /2010/08 Wartung/8.3 Schmi erung/8.3 Sc hmier ung @ 7\mod_1274769937004_4.doc x @ 86284 @ 2 @ 1 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. Pos : 101 /CAD/Allgemein/2 x Leerzeic hen @ 2\mod_1148018579447_4.doc x @ 16425 @ @ 1 Pos : 102 /CAD/2010/08 Wartung/8.3 Sc hmier ung/8.3.1 Sc hmierung M ess erhalter @ 7\mod_1277985958245_4.doc x @ 87074 @ 3 @ 1 VE 6.3.2 Knife holder lubrication The bearing points on the knife holder have lifetime lubrication, meaning that re-greasing is not required. 0- Pos : 103 /CAD/Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 63 / 70 7 Servicing Pos : 105 /CAD/2010/09 Instandhal tung/9.1 Sic herheits hinweise z ur Instandhaltung/9.1 Sic her hei tshi nweise für di e Instandhaltung @ 7\mod_1274778071388_4.doc x @ 86400 @ 2 @ 1 RS IO N Pos : 104 /CAD/2010/09 Instandhal tung/9 Instandhal tung @ 7\mod_1274777968227_4.doc x @ 86380 @ 1 @ 1 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! VE 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! 0- 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. 64 / 70 RS IO N 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. 0- VE Pos : 106 /CAD/Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 65 / 70 Pos : 107 /CAD/2010/09 Instandhal tung/9.8 F ehlfunkti on/9.8 Abhilfemaßnahmen bei Fehlfunktion @ 7\mod_1274785603282_4.doc x @ 86545 @ 2 @ 1 Pos : 108 /CAD/2010/09 Instandhal tung/9.8 F ehlfunkti on/9.8.1 M ess erhalter @ 7 \mod_1274785571485_4.doc x @ 86525 @ 3 @ 1 7.2.1 Knife holder Malfunction • RS IO N 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 VE • • • • • • 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 0- Pos : 109 /CAD/Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 • • 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 DS6S01_EN_00 66 / 70 Pos : 110 /CAD/2010/10 Auss erbetri ebnahme (Versc hrottung)/10 Auss erbetriebnahme (Verschr ottung) @ 7\mod_1274789868670_4.doc x @ 86622 @ 1 @ 1 Pos : 111 /CAD/2010/10 Auss erbetri ebnahme (Versc hrottung)/10.1 Sic her heitshi nweis e/10.1 Sic herheits hinweis e @ 7\mod_1274789733234_4.doc x @ 86603 @ 2 @ 1 RS IO N 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) VE 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. 0- Pos : 112 /CAD/Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 DS6S01_EN_00 67 / 70 Pos : 113 /CAD/2010/11 Z ubehör/11 bei F a. Dienes erhältliches Z ubehör @ 7\mod_1274790268233_4.doc x @ 86661 @ 1 @ 1 VE Pos : 114 /CAD/2010/11 Z ubehör/11.1 Zubehör/11.1 Zubehör allgemei n @ 7 \mod_1274790545573_4.doc x @ 86681 @ @ 1 RS IO N 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 0- 1 DS6S01_EN_00 68 / 70 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 RS IO N 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 ! 0- Pos : 115 /CAD/Allgemein/=============== @ 0\mod130_4.doc x @ 2392 @ @ 1 VE 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. DS6S01_EN_00 69 / 70 Pos : 116 /CAD/2010/13 N achschl eifs er vice/13 N ac hsc hleifser vic e @ 7\mod_1274960290418_4.doc x @ 86762 @ 1 @ 1 RS IO N 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 VE 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 0- 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 === DS6S01_EN_00 70 / 70