1

OPERATOR’S MANUAL

I. Installation ManualII. Operation ManualIII. Maintenance Manual

HYDRAULIC VARIABLE RAKE

GUILLOTINE SHEAR

HAGM 3021Serial No:

MVD INANTakım Tezgahları Sanayi A.Ş.

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IMPORTANT:

This protocol must be returned back to MVD INAN, being signed within 1 week after commissioning of the machine. This is the document forming the basis for the start of guarantee period.

Machine Type: HAGM 3021Series NumberDesign based on standard: prEN 13985:2001, CEI/IEC 60204-1997+A1:1999Customer

The following checks must be carried out by the customer or a qualified service engineer before the machine is commissioned.

1. Installation and levelling2. Oil level3. Electrical connections, correct voltage and fuses4. Hydraulic system5. Test Run6. Functional test

The undersigned declares that he /she has received the operator’s manual and CE declaration together with the machine. Furthermore, he/she shall ensure that the machine operating personnel reads and understands all of the instructions with regard to the use of the machine and its safety related aspects and the procedures in this manual is strictly adhered to.

Remarks:

Signature: Date:

Customer: Agent or MVD INAN Service Engineer

Name: Position:

Name:

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Table of ContentsImportant iTable of contents iiAttention iiiIntroduction 1I. INSTALLATION MANUAL 2I.1 Lifting and carrying 2I.2 Foundation 2I.3 Levelling 2I.4 Filling the oil tank 4I.5 Electrical mains connection 4I.6 Starting up the machine 4

II. OPERATION MANUAL 5II.1 PRODUCT INFORMATION 5II.1.1 General features 5II.1.2 Technical features 5II.1.3 Remarks 6II.2 SAFETY 6II.2.1 Instructions 6II.2.2 Safety equipments 7II.2.2.1 Control cabinet and electrical switchgear cabinet 7II.2.2.2 Fixed guards 7II.2.2.3 Light beams 7II.2.2.4 Safety switch and lock bar 7II.2.2.5 Foot pedal 8II.2.2.6 Adjustment of cut length 8II.2.2.7 Pressure relief valves 8II.2.2.8 Emergency stop button 8II.2.2.9 Reset button 8II.2.3 Liability 8II.3 OPERATION 8II.3.1 Modes of position switch 9II.3.2 Adjustment of cut length 9II.3.3 Back gauge adjustment 9II.3.4 To end the operation 12

III. MAINTENANCE MANUAL 13III.1 Lubrication 13III.2 Mechanical system maintenance 13III.3 Hydraulic system maintenance 13APPENDIX A: Explanatory wordlist 16APPENDIX B: Hydraulic circuit and equipments 17APPENDIX C: Electrical circuit and equipments 22APPENDIX D: Operation manual for digital control unit

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INTRODUCTION

This operator’s manual is designed to give supportive and corrective instructions to the operating and maintenance personnel concerning commissioning, operation and maintenance of the machine. It is separated into 3 parts : I. Installation Manual, II. Operation Manual, III. Maintenance Manual.

Unless it is permitted by written instruction of the manufacturer, any operation or adjustment, which is not in line with this operator’s manual, will be on customer’s own risk and manufacturer will have the right to end the guarantee period.

If any further technical information is required, our service department will be pleased to provide you on request.

For information or for spare parts and service please send your fax to:

MVD INANService Department Konya / TurkiyeTel: +90.332.2392233Fax: +90.332.2392121

service@mvdinan.com

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MVD INAN HAGMI. INSTALLATION MANUAL

I.1 Lifting and carrying

Machine, which is loaded and send safely, when received by customer, must be unpacked and checked to see if there is anything damaged or missing. Steel ropes must be used to hang the machine from the 4 lifting extensions on both columns of the machine (See figure-1). It is the customer’s responsibility to lift, carry and place the machine safely and suitably regarding regulations.

The machine must be well cleaned and the rust preventive coating on the metal surfaces must be cleared of by appropriate chemicals, kerosene or petrol. It is suggested to coat these surfaces with a thin layer of machine oil. See also Operation’s manual section II.3.3.

I.2 Foundation

The foundation upon which the machine is to be installed should be concrete and must be levelled and flat. Sufficient space should be left around the machine in order to allow inspection and maintenance operations in addition to safe handling of work pieces and cutting tools.

During bending operations, the force exerted must be absorbed by the concrete foundation The foundation must also bear the machine weight and to keep the machine fixed during any earthquake shake. See Figure1 as reference.

Attention: It is a must for customer to fix the machine by anchor bolts to the ground and also to make the ground connection from the earth connection built into switchgear cabinet to the ground line of the factory.

I.3 Levelling

While placing the machine on the foundation prepared, 20 mm. thick iron plates must be supplied under each corner of the machine and the machine must be levelled both lengthwise and crosswise. The levelling of the machine is maintained by the 4 bolts(1) in fig. 1 on the foot of the machine and fixing is maintained by the nuts(3) on the studs(2) in fig.1. A water level must be placed on the lower table and levelling must be made within acceptable inclines as follows:

Crosswise levelling : about 0.1 mm/m. (machine depth) Lengthwise levelling : about 0.2 mm/m. (machine length)

Anchor bolts are not included as a part of machine and can be supplied at extra price.

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HAGM 3020LIFTING AND FOUNDATION OF MACHINE

FIGURE

1-2

I.4 Filling the oil tank

Fill the oil tank up to 3-4 cm. below the top cover of the tank, with one of the below mentioned oil. The trouble free functioning of the hydraulic system is very much dependant on the quality and condition (cleanliness and purity) of the hydraulic oil which is used. The oil must possess the following minimum properties:Viscosity at 40 °C : 46 cStViscosity index : approx. 105Examples : Shell Tellus 46, BP Energol HLP 46, Esso Nuto H 46 , Aral oil 46, :

Mobil DTE 25

I.5 Electrical main supply connection

The machine’s electrical connection is ready for use. Only the 3 phases of supply voltage has to be connected to the main switch on the cabinet. The earth connection must be made to the earth terminal. For the main supply, shielded cable must be used and the shield must be fixed to the metal gland at the entrance of the cabinet.

Electrical connections are to be made by properly qualified personnel and in accordance with the applicable standards. The cross-section of the connection cable must suit the total power required as mentioned on the machine plate.

The rotation of motor is limited to one direction. When all electrical connections are made, safety conditions are maintained and the start button is pressed, if the motor does not rotate, just interchange the main switch connections of two phases and it will rotate. See also section I.6.

I.6 Starting up the machine

The shop and machine main switches are turned on, emergency stop buttons are freed and then the reset button is pressed. The power light on the machines electrical cabinet shall then come on. (If not, control the main supply circuit and light beams at the rear). When start button is pressed, the motor will rotate. If the power light does not come on, then there is some problem due to the safeguarding system established and the machine won’t work. In this case, the light beams and switch of safety bar underneath upper beam is checked to see it is closed. Then the safety “reset” button is pressed again. If there is still problem, MVD INAN or the Agent must be contacted.

ATTENTION

• Do not operate the machine before reading the “operator’s manual”.

• The machine must be fixed to the concrete floor as described in section I.2.

• Before starting the machine, be sure the tank is full of oil.

• Input voltage will be 380-400 volts and current will be 50 Hz.

• The cable of mains supply will be 4 x 6 mm². R, S, T for the phases and GND for the

ground (Earth) line of the building.

• For the safe of the pump, the rotation of motor is limited to be in one direction only. So if

the motor does not start, two of the phases (R, S, T) must be in interchanged from the

connection of the main electricity switch on the cabinet.

• The electricity cabinet shall be kept close when operating.

• Operations such as welding, grinding must not be carried on or by the machine.

• Do not make any readjustment on the set positions of the hydraulic valves.

• The machine shall be operated only by the responsible who read and comply with

operator’s manual.

• Inform the agent or manufacturer for any problem occur.

MVD INAN HAGMII. OPERATION MANUAL

II.1 PRODUCT INFORMATION

II.1.1 General features1. Swing beam type movement of the upper beam,2. Rigid and robust structure due to completely welded steel construction of side

housing, table and tank.3. Most precise machining of the constructions carried on CNC machining centre,4. Parallel operation of hydraulic cylinders,5. Compact and mono block hydraulic system,6. Pressure relief valves to eliminate the risk of access pressure rise,7. High strength hold-down system with pressure adjustment,8. Illumination of blades,9. Cutting length adjustment,10. Highly wear resistant and tough blades, made of imported European steel with 2

cutting edges of upper blades and 4 cutting edges in lower ones,11. Position switch for different modes of operation,12. Light beams at the rear side,13. Emergency stop and reset facilities,14. Motorised back gauge and position controller with ± 0,1 mm. positioning

accuracy.

II.1.2 Technical features

HGM 2504 3006 3008 3010 3013 3016 3020 4006 4008 4010 4012 4014 4016 6006 6008 6010

Cutting Capacity 4 6 8 10 13 16 20 6 8 10 12 14 16 6 8 10 mm.

Cutting Lenght A 2550 3050 3050 3050 3050 3050 3050 4050 4050 4050 4050 4050 4050 6100 6100 6100 mm.

Shearing Angle 1,5 1,5 1,9 2 2,1 2,25 2,75 1,5 1,5 1,5 1,8 1,8 2 1 1 1,1 Degree

Holddown Cylinders 10 12 13 14 14 17 17 17 17 17 18 18 18 26 27 28 Unit

Strokes Per Minute 30 18/30 20/35 13/19 10/14 7/10 7/10 10/14 13/20 11/17 9/15 6/20 5/16 9/12 10/16 6/10 min.

Clearance Between Columns B 2700 3230 3230 3240 3240 3280 3280 4230 4240 4240 4320 4350 4375 6250 6300 6350 mm.

Height of Worktable C 850 850 850 850 850 850 900 850 850 900 900 900 900 900 900 900 mm.

Widht of Worktable D 400 500 580 600 620 625 655 600 630 635 660 660 680 750 750 750 mm.

Throat Depth E -- -- 250 250 250 200 150 250 250 250 250 250 100 250 100 100 mm.

Overall Length F 3800 4300 4300 4350 4400 4450 4450 5340 5370 5350 5450 5450 5480 7350 6800 6900 mm.

Overall Height H 1400 1600 2120 2200 2400 2400 2600 2130 2200 2380 2400 2400 2420 2350 2350 2500 mm.

Overall Depth (excl. Front supports) G 2100 2620 3050 3100 3150 3250 3450 2900 2950 3050 3300 3300 3350 3050 2350 2500 mm.

Oil Tank 140 160 230 230 230 315 350 220 220 280 370 370 370 230 350 400 lt.

Motor Power 11 11 15 22 22 30 45 11 22 22 30 30 30 15 22 37 Kw.

Weight (Approx.) 4,5 6 8 10 12,5 16,5 21 11 13 18,5 19 20 25 25 27 30 Ton

● Special capacity machine can be manufactured upon request. ● Technical specifications are subject to change without notice.

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II.1.3 Remarks

1. The hydraulic pump must never be run without oil, since it will be damaged. The oil level must always be checked before starting the motor.

2. Any adjustment on hydraulic valves may only be permitted by manufacturer’s notice.3. Electrical and mechanical connections, which are not made properly by qualified

personnel, will be at customer’s risk.4. The customer will make sure that there is a minimum of 500 lux local lighting or

daylight at the blades area.

II.2. SAFETY

II.2.1 Instructions

• The capacity of the machine must not be exceeded.• Only one piece of sheet must be cut at each cutting stroke.• Only properly qualified personnel may operate the machine.• Before starting the machine all area around the machine must be cleared of obstacles

which may cause falling, tripping or slipping hazards.• Operation manual of digital position control unit must be well understood and referred

by the operators. Refer to Appendix D.• Operator must be sure there is no one behind, within or on the machine while

operating.• Safety is maintained by fixed guards at the front part of the tools area and at the side

gaps. At the rear part, 3 light beams maintain control for entrance to the work area.• The limit switches at top and bottom points prevent excessive and continuous

pressure rise, which also prevents temperature rise of the oil.• Adjustment mode for adjustment of blade gap after grinding.• Operators should take care of the control panel and foot pedal cable not to be

damaged during handling of material or due to any misuse or falling objects.• Electrical cabinet shall be kept close during operation. Anyone except the properly

qualified maintenance personnel is not allowed to open it anytime.• It is forbidden to hold naked flame against the machine, or to carry on welding or

grinding of the work pieces on or around the machine.• The operators should wear according to the related regulations. (ie. durable clothing,

which does not hang loose, as well as industrial shoes with steel toecaps, industrial gloves etc.)

• During the maintenance and repair work, the main switch shall be turned off to the “0”position and locked by a padlock for safety reasons.

• In case it is needed emergency stop buttons are available on the foot pedal stand and on control panel.

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II.2.2 Safety Equipments

II.2.2.1 Control cabinet and electrical switchgear cabinet

This switchgear cabinet carries main switch, pedal cable connection and main supply entrance gland. The control cabinet carries power light, reset button, start button, stop button, emergency stop button, position controller, mode selector switch and also a key to lock the control facilities.

Attention: The operation manual of position control unit in Appendix D must be completely read and understood by the operating personnel before starting the machine.

II.2.2.2 Fixed guards

In the front and at both sides there are guards fixed by bolts. These guards won’t let operators hand to reach to blades and hold-down cylinders. The distance of these guards are determined according to the standard.

Attention: The fixed guards and other covers around shall never be taken out at operation stage. As this area is the most dangerous part of the machine, any operator shall strictly be responsible for this.

II.2.2.3 Light Beams

Light beams are AOPD (active opto-electronic protective device), which form an optical curtain at the rear side. It is operative if the red indicator lights are on. If there is any obstacle in between sender and receiver units or if they are misaligned, the red light will be off and the machine will show an emergency stop characteristics.

The distance of the light beams from the back gauge is 1 m. and the reference distance from blades can be find on the machine plate. It is strictly forbidden to change the distance lower than the mentioned value. In case there is any deficiency in the stopping behaviour of the system, MVD INAN or the Agent must be contacted immediately.

ATTENTION! Light beams sense the passing of people. It does not sense if there is anyone already inside the machine area. It is full responsibility of the operator to check if there is anyone behind or within machine before he resets and starts the machine.

II.2.2.4 Safety switch and lock bar

Safety switch and the lock bar are placed underneath the down stroking upper beam. The lock bar is pulled out of the housing and the switch pressing on the bar is freed to off position, and the machine acts like at stop position. Then the bar must be pushed into the housing on the side column, so that it also maintains a safety means to stop the gravity fall of the beam. But, note that the bar is not designed to bear the weight of the beam not to stop the cylinder force.

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II.2.2.5 Foot pedal

Cutting operations are performed by pressing the foot pedal. When the pedal is pressed the beam moves down. When it is left free, the beam either stops or moves up according to the mode of the position switch.

2.2.6 Adjustment of cut length

The cut length is adjusted by the use of a time relay or a potentiometer placed on the control panel. The system is time based. When the time set by relay or potentiometer is reached the beam automatically stops. Then when the pedal is left free it may move up according to the mode position switch.

2.2.7 Pressure relief valves

Hydraulic system is equipped with several pressure relief valves, which limit the maximum operating pressures at different lines of the system and maintain safe working condition.

II.2.2.8 Emergency stop button

It is used for emergency stops and for stopping at the end of operating the machine. It is designed to stop all movements and controls immediately. To restart, its head must be rotated to free. When the reset button is pressed, the white power light will come on and the start button may then be pressed.

II.2.2.9 Reset buttons

This button is to turn off the reset light. Reset light checks the safety system. In case of any interruption or fault of the safe guarding system, the system locks the operating system, until the safety related fault is cleared and the reset button is pressed. Note that the fault may be due to light beams, safety lock bar switch or emergency stops.

II.2.3 Liability

MVD INAN hydraulic guillotine shears are designed and produced to cut plate materials. The operator manuals of the machine and back gauge position controller unit must be the primary basis for using the machine. MVD INAN has no liability for any damage or its consequences, which is incurred due to the incompetent use of the machine.

II.3 OPERATION

The shop and machine main switches are turned on and the reset button is pressed. The power light on the machines electrical cabinet shall then come on (if not, control the main supply circuit, light beams alignment and safety bar switch). Pressing start button,

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the motor will start rotating. If the power light does not come in any case, observe other safety related components and relays, or contact MVD INAN or the agent.II.3.1 Modes of position switch

There are two modes, which can be selected from position switch. First mode is for blade gap adjustment (see section II.3.2) after grinding of the blades and second mode is for cutting operation at desired length. In the first mode beam moves down as the pedal is pressed and stops when the pedal is left free. For return, position switch is turned to 2nd position, pedal is pressed and left free.

In mode 2, the upper beam moves down when the pedal is pressed and returns when it is left free. The beam stroke is limited basically by the machine construction, but also by upper and lower limit switches. The switch positions are adjusted before delivery and user will not need readjustment. See also section II.2.6, where the stroke may also be adjusted through a time relay or a potentiometer placed on the control panel.

II.3.2 Adjustment of Blade Gap

Before starting to cut, the blade gap is adjusted by rotating the arm on the side column of the machine. The scale and arrow must show the thickness to be cut. During the adjustment, the fixing handles on both sides are loosened at first and then tightened strongly after adjustment.

The scale around the gap adjustment arm is prepared according to mild steel (St 37-42). When the sheet material is harder, the gap needs to be increased, or when the sheet material is softer, the gap needs to be decreased. Figure 2 gives supportive information on determination of the gap according to the section of the sheet metal. Note that, excessive opening of the gap with respect to the sheet thickness, may cause the sheet metal to go in between the upper and lower blades and may damage the beam or the table. It is suggested to adjust the gap from the scale at ± 1 mm. thickness tolerance.

Do not forget to readjust the scale after grinding of blades. For several grindings, only the adjustment of the scale will be enough, but when the thickness of blades tb<15mm, 1 mm. thick sheet metal may be placed behind the blades or the lower blade support needs readjustment. (See Figure 3).

After grinding and fixing the blades, upper beam must be lowered in the 1st mode of position switch and machine must be stopped completely. At this point feeler gauges must be used to adjust blade gap to 0,1 mm. and then the scale must be set to 1 mm. It is suggested to check this gap to be precise throughout the whole length. Deviations may cause collision and breaking of the blades. Note also that, there are mechanical limitations for maximum and minimum gaps, so after setting the scale, these limits should be readjusted to prevent collision of upper and lower blades.

II.3.3 Back gauge adjustment

Back gauge system is controlled by position controller (See appendix D), which is placed on the control panel. The calibration and resetting is completed before delivery. The calibration may be made at the minimum position where the back gauge touches the front limit switch. At this point pressing the stop button of the controller will reset the position to the datum value in controller parameters.

For any problem, the manual of the position controller must be referred. (App.D)

ADJUSTMENT OF BLADE GAP

The indicator fit around the arm on the left side of the machine is prepared for blade gap adjustment of mild steel St 37- St 42. For harder materials gap may be increased, and for softer materials it may be decreased.

8=0.10 X T ( St 37- St42)

SMALL GAP

INCREASE THE BLADE GAP.

LARGE GAP

DECREASETHEBLADEGAP

CORRECT GAP

DO NOT MAKE ANY EXTRA ADJUSTMENT

MVD HAGM 3020ADJUSTMENT OF BLADE GAP

FIGURE

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ADJUSTMENT OF BLADE GAPFIGURE

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HAGM 3020

13

II.3.4 Ending the operation

Motor stop button is pressed, control lock key is turned off and the key is removed. Main switch is turned off to “0” position. It shall be locked by a padlock when machine is not operated and also when it is maintained.

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MVD INAN HGMIII. MAINTENANCE MANUAL

Maintenance may only be carried by properly qualified maintenance personnel or by a service technician of MVD INAN or the Agent. The machine is designed to carry out maintenance and lubrication safely.

Attentio n : During the maintenance and repair work, the main switch shall be turned off to the “0” position and locked by a padlock for safety reasons.Also the lock bar shall be placed into the side column for mechanical safety. See II.2.2.4.

III.1 Lubrication

Back gauge slide ways and screws must be cleaned and lubricated by oil everyday. Roller bearings must be greased once a week. (See Figure 4) The swing beam axis must be greased once a month inside for roller bearing and once a week outside for frictional bearings. During continuous use and heavy work conditions, it is suggested to lubricate them more frequently.

Attention: The cylinder joints of the machine will never be lubricated.

III.2 Mechanical system maintenance

Everyday, the tightness of upper and lower blade bolts must be checked (See Figure3). Every week the blade clearance between the blades must be assured to correspond to the scale (The clearance will be 10% of the sheet thickness for mild steel).

Additionally, tightness of all bolts and nuts on the machine must be checked regularly every 15 days and also when there is any irregularity on the operating behaviour.

Any other adjustment and problem may be referred to MVD INAN or the agent.

III.3 Hydraulic system maintenance

Level of oil in the tank must be checked daily. It must be 3-5 cm. below the top cover. The oil must be clean. So, it must be checked that the filter works properly. If filter is

dirty, the manometer at the top of the filter will reach the red region. In such case the filtering element in the filter body has to be replaced. The quality and cleanliness of the oil is of primary concern in hydraulic systems. Improper and dirty oil will shorten the life of the system and will cause unexpected problems.

After 2000 operating hours or 1 year, whichever is earlier, drain off the oil from the tap at the bottom of the tank. It is suggested to use a flexible hose to connect this point to an empty oil tank or place the tank hole underneath the tap.

To refill the machine’s oil tank, the cap at the top surface must be removed. The filtering element must be in place to protect fall of materials other than oil. Oil may either

0 -

Oil to be used.SHELL ROTELLA 30 or 40MOBIL ENGINE OIL 30 or 40

!LUBRICATION POINTS. I

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DETAIL-A

LUBRICATION CHART.

VA MVD HAGM 3020LUBRICATION CHART

FIGURE

4

@ Grease to be used.SHELL ALVANIA R3MOBIL LUX EP-3

LUBRICATION POINTSYMBOL

LUBRICATION FREQUENCY

1 @ Once a week.

2 @ Once a week.

3 0 - Everyday

4 0 - Everyday

5 @ Once in a month.

MAKINA SANAVIA.$

15

be pumped by a manual pumping device our poured directly into the hall. The oil mentioned in section I.4 must be used. During this process maintenance personnel shall supply a ladder or platform and place it safely.

Attention: Wear protective clothing while changing the oil.

In addition to change of oil, the element of the filter shown in the hydraulic diagram shall also be replaced every year. Other hydraulic elements may be ordered regarding the drawings in Appendix B: Hydraulic System

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Appendix A: Explanatory wordlist

Hydraulic swing-beam guillotine shea r : Machine designed to transmit energy to the moving beam by hydraulic means principally for the purpose of shearing of sheet metal between blades along straight lines.Bea m : Main reciprocating machine member, which holds upper blade. Table: Stationary table which holds lower blade.Upper blades: Blades with cutting edge less than 90º. Lower blades: Blades with 90º cutting edges.Cut cyli n d e rs : Placed one on each column and turns hydraulic pressure to mechanical force and exerts it onto the beam to cut the sheet metal.Return cylinders: Cylinders which move the beam up.Back gauge : The gauge against which the plate to be cut is positioned to maintain the cut width all along the cut length. Its position is adjusted by the position controller on the control panel.

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APPENDIX B: Hydraulic system and equipments

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RES?M NOBH-026

NU. I PART NAHE I REHARKS

01 I HYDRAULIC CYLINDER

02 COHPACT SEAL (B+S PCBOA-2000NCROQ)

03 BEARIN6 BAND. (2,5X15 C380)

04 I BEARIN6 BAND {2,5X25 C380)

05 I O-RIN6 (tb3,53X196,2)

06 I SUPPORTIN6 RIN6 tb(196,2X202,5)11,25

07 I NUTRIN6 tb(120X140)116

08 I SUPPORTIN6 RIN6 tb(120X140)13

MVVD A SANAVI

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HAGM 3013LEFT CUTTING CYLINDER

GROUP NU. PAGE NU

NU. I PART NAHE I REHARKS

01 I HYDRAULIC CYLINDER

02 COHPACT SEAL (B+S PCBOA-2000NCROQ)

03 BEARIN6 BAND. (2,5X15 C380)

04 I BEARIN6 BAND {2,5X25 C380)

05 I O-RIN6 (tb3,53X196,2)

06 I SUPPORTIN6 RIN6 tb(196,2X202,5)11,25

07 I NUTRIN6 tb(120X140)116

08 I SUPPORTIN6 RIN6 tb(120X140)13

1 4 9

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HAGM 3013RIGHT CUTTING CYLINDER

GROUP NU. PAGE NU

02

NU PART NAME /BRAND CODE

01 PISTON ARM

02 BODY

03 PISTON

04 SPRING

05 CONNECTION FLANGE

06 NUTRING (/)(27X36)/6 PU KASTA$ K21-027/1

07 D-RING (/)2X15

08 1'116 NUT

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HAGM 3020HOLDDOWN CYLINDER

FIGURE

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APPENDIX C: Electrical system and equipments

18

APPENDIX D: Digital position control unit

19

Delem

Manual version V0504

DAC-350

Operation manualVersion V7

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V0297, 0.2

Delem

PREFACE

This manual describes the operation of the Delem control type DAC-350 and is meant for operators who are instructed for operation of the total machine.

Only authorised people should be able to create new or edit existing programs.

The control has therefore a keyswitch to prevent uncontrolled programming. With the keyswitch in the off position the operator can only execute a selected program but not change the parameters to wrong, unwanted values.

V0504, 0.3

Delem DAC-350 OPERATION MANUAL

CONTENTS PAGE

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2

CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11.1. Operation modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11.2. Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

2. Frontpanel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

3. Programming mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13.1. Data preparation/Data editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23.1.1. General program parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

“ Product copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43.1.2. Specific step parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43.1.3. Programmable on/off outputs per step. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.73.2. Program selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.83.3. Program constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

“ Page 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 “ Page 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 “ Page 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 “ Page 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 “ Page 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 “ Page 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16 “ Page 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17

3.4. Backup and Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18

4. Automatic production mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1“ Service screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

5. Manual production mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1“ Service screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4

Delem 1. Introduction

V0899, 1.1

1.1. Operation modes

The DAC-350 is a programmable backgauge control which allows programming the backgauge position and several function parameters. The control can specifically be used as shear control including angle, gap and stroke control. The angle, gap and stroke control are optional axes which can be enabled depending on the application of the machine.

If enabled the angle, stroke length and gap settings are automatically calculated. These calculations depend on the programmed sheet thickness and the used material.

It is possible to create your own programs step by step in a userfriendly way via menu driven programming:

- Programming mode for preparing or editing your data.

The DAC 350 has 2 operating modes:

- automatic mode, to run a complete program consisting of a set of steps with several programmable parameters.

- manual mode, to run one set of parameters for single cuts. The programmed parameters and the backgauge position are controlled after pushing the start-button. The backgauge, angle and gap can also be displaced manually by means of the handwheel.

Manual movement:

- By pushing this key the handwheel will be activated for manual movement of the available axes.

Each of these modes can be selected with the mentioned frontpanel pushbuttons. The selected mode will be indicated with a lightning LED in the pushbutton.

Delem 1.2. Options

V0899, 1.2

Options are machine-dependent. They can be installed later as upgrades, to add additional functionality to the controller.The following options are available.

Floppy driveThe DAC-350 can be equipped with a floppy drive unit for 3½” HD floppy disks to read or write programs to or from disk.

Serial communicationThe DAC-350 can be connected to a pc for serial communication. If this option is installed, communication settings must be programmed.

Load positionA load position can be programmed in the controller. Then the backgauge will move to a preprogrammed position to allow loading of a product, before moving to the first position of a cutting program.

Delem

V0297, 2.1

2. Frontpanel

The frontpanel with LCD display consists of the following items:

- Display: Monochrome LCD-screen including backlight.

- Mode keys including LED indication:

| | |Manual mode Programming mode Automatic mode

- handwheel selection button

- Keyboard

cursor up key,to select the previous parameter

Start buttonStop button

cursor down key, 10 numerical keys (0-9)to select the next parameter

To leave aprogramming plus/minus toggle selection

decimal point

clear key, to delete an input value

enter key, to confirm a programmed value

V0297, 2.2

Delem

previous next • Select/delete programstep step • parameter overview in ‘hand-mode’ and ‘auto-mode’.

- Key switch, with position "1" for free programming and position "0" to prevent the programming of new programs or changing existing programs.

Delem 3. Programming mode

V1198, 3.1

- Select the programming mode by pushing the indicated key. The programming mode is active when the LED in this key is on. Programming can only be done when the controller is in stopped position.

You will see the following menu-overview on the screen:

The programming possibilities can be selected by entering the required number and pushing the enter key.

1= DATA PREPARATION . . . . . . . . . . . . . . . . See paragraph 3.1This selection is to create a new, non-existing program.

2= DATA EDITING . . . . . . . . . . . . . . . . . . . . . . See paragraph 3.1This selection is to change an existing program.This program is the actual program in the automatic production mode and can be selected from the memory by menu number 3.

3= PROGRAM SELECTION . . . . . . . . . . . . . . . See paragraph 3.2This choice will give an overview of the programs as stored in the memory. The available programs are listed by the programnumber.

4= PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . See paragraph 3.3This choice will list general parameters like inch/mm-selection, programming language etc.

5= BACKUP AND RESTORE . . . . . . . . . . . . . . See paragraph 3.4To write programs to floppy disk or read programs from it. This function is optional.

If option 5 is available, press this key to make it visible.

Delem 3.1. Data preparation/Data editing

V0899, 3.2

3.1.1. General program parameters

For creating a new program the following parameters will appear on the screen to be programmed.

• Program number

The programnumber is a free programmable number of up to 4 digits. Range: 0 - 9999

• Material type

Four material types can be selected.The material type will be used for angle and gap calculation. The corresponding angle and gap values depend on the manufacturer settings.Range: 1 - 4

• Materialthickness

The thickness of the used material.Range: 0.1 - maximum thickness. Maximum value depends on the corresponding machine parameter setting.

• Retract distance

The programmed retract distance for the backgauge will be executed in every step of the program.Range: 0 - maximum backgauge position. Maximum value depends on the corresponding machine parameter setting.

This parameter is only shown if the Retract function is used.

Delem

V0504, 3.3

X-Cor

Correction of the X-axis position, valid for each step. This correction also applies to the X2-axis, if installed.

Range: -9.9 - 9.9 mm

Load (optional)

To determine whether or not to use a load position for this program. Only possible, if this option is installed.0 = no load position1 = use load position 12 = use load position 2

The load positions can be programmed with the parameter Load Position in menu 4, 'Parameters'.

Offset

Sheet position offset. This programmable offset is meant to take sheet displacement on the table into account. In other words, the operator may place the sheet on a desired place on the table. The offset must be programmed according to the required sheet position as shown in the picture below:

When programming the parameter "SHEET POSITION OFFSET", the following steps are carried out:• all "stroke" value(s) will be adapted in cutting programs;• the control checks in each program step whether the sum of "LENGTH" and "SHEET

POSITION OFFSET" is greater than the maximum cutting length. If so, the error message** OFFSET + LENGTH > MAX LENGTH ** will be generated.

When the "Sheet Position Offset" value is greater than 0 (offset is active ), the symbol is shown in the production modes as a reminder for the user that the sheet has to be placed on the correct position.

Delem

V0504, 3.4

“ Product copy

When you are in ‘DATA EDITING’ you can copy the active product. Go with the cursor keys to the parameter PROG-NR.Type the new product number and confirm with the ENTER-key. The controller displays the following message (see figure below).

If you choose 1, then the new product number is active.

3.1.2. Specific step parameters

After entering the retract distance, the parameters for the first step will appear on the screen.

• Length.

The material length to be cut. Range: 0.0 - 10000 mm

• Backgauge position XM.

The required backgauge position must be entered at this parameter. Range: minimum position - maximum position

It is also possible to enter a negative value for XM. In that case, the value is interpreted as a displacement value (chaining). This value is then substracted from the actual X-axis position. This can only be done to move to a lower position and is not allowed at the first

Delem

V0504, 3.5

step.

• Second backgauge position X2 (OPTIONAL)

When the backgauge (or frontgauge) is equipped with a second axis, then the position can be programmed with this parameter. Default value is equal to the programmed value of XM. X2 can be adjusted afterwards.Range: minimum position - maximum position

• Repetition.

The number of times that the programmed step is repeated before the next step will be executed.Range: 0 - 999

The value 0 can be used to indicate that the programmed step must be skipped. This cannot be done for the first step of a program. The repetition number is also used for the number of chained dimensions to be executed.

• X Speed

Speed of the X-axis, which can be programmed differently for each step in a percentage of the maximum speed.Range: 0 - 100 %

The specific shear parameters for the optional axes cut-angle, cut-gap and cut-stroke are only present if one or more of these optional axes have been activated.

• Angle (α)

Automatic calculated angle, which can also be changed within the program for every step. Range: 0 - maximum possible angle

• Gap (G)

Automatic calculated gap distance, which can also be programmed differently for every step.Range: 0 - 9.99 mm

• Stroke (S)

Stroke limit of the cut.Range: 0 - maximum possible stroke

• Z-axis position (OPTIONAL)

When the backgauge is equipped with a Z-axis, then the position can be programmed with this parameter.

Delem

V0504, 3.6

Depending on the machine configuration the Z-axis position- can automatically be computed or- can manually be programmed

The computed value is determined by the following formula: Auto computed value Z-axis = value ‘length’ - ‘Z-offset’

Type Enter to accept the computed value. The ‘Z-offset’ parameter is to be programmed in the program constants.

Range: minimum position - maximum position

• Cutting force

Force with which the plate is cut. A calculated value is offered, based on plate material and thickness. You can accept the offered value or program another value. Only available if pressure control is installed on the machine.

• Clamping force

Force with which the plate is clamped on the table. A calculated value is offered, which is a percentage of the cutting force. You can accept the offered value or program another value. Only available if pressure control is installed on the machine.

Delem 3.1.3. Programmable on/off outputs per step.

V0504, 3.7

There are either 4 or 8 independent, programmable outputs available. These outputs are freely programmable for any required purpose. The number of available outputs (4 or 8) depends on machine settings.

• F1 - F4 / F1 - F8

Range: 0 - 1 in which "0" means off and "1" means on (function output active)

• FThis parameter is the decimal value, calculated from the combined binary value of the function outputs. F1 is the least signifcant bit (LSB), F4 (or F8) is the most significant bit (MSB). When one of the function parameters F1 - F8 is changed, the resulting value F is automatically changed as well. When F is changed, the parameters F1 - F8 are also changed accordingly. In case the outputs are used for binary combinations, programming F is more user-friendly.Whether or not this parameter is available depends on machine settings.

Range: 0 - 15 or 0 - 255

After the last input of all the parameters in the first step the question appears if a new step is required. Entering zero will stop further programming and with 1 a next step will be added to the program. This question will only appear in the data preparation mode. The maximal number of steps per program is 99.

Delem 3.2. Program selection

V0297, 3.8

With choice number 3 in the menu the overview of the available programs in the controller memory will be listed.

An existing program can be selected by entering the required number. A program can be deleted

by pushing the key and entering the program to be deleted: this key has a toggle function

and must be pressed again to return to the selection mode.

It is also possible to delete all the programs at once. In the delete mode you have to program

“-1". After the confirmation of this choice with the enter-key the controller returns with a

question. When you select ‘1' the contents of the program memory is erased.

When you have created more programs than can be listed on one screenpage, you can list the

next page with help of the -key

In the upper right corner the used memory contents with respect to the memory capacity will be

indicated in a percentage value.

Delem

V0504, 3.9

3.3. Program constants

The controller has specific operator selectable and adjustable parameters which are divided over five pages.

Software versionAt the right hand side in the upper part of the first four screens the version number of the controller software is mentioned. Example: V7.1

“ Page 1.

• Inch select 1/0 (IS)The programming unit for the backgauge position, the actual position read-out, the retraction value, material thickness, the material length, gap and stroke can be set in mm or inches.0 = mm1 = Inches

• Language selection (LG)The following languages can be selected:

0 = English (GB)1 = German (D )2 = Danish (DK)3 = French (F )4 = Italian (I )5 = Dutch (NL)6 = Finnish (FI)7 = Czech/Slovak (CS)8 = Spanish (ESP)

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V0504, 3.10

“ Page 2.

• Shear stress material 1-4 (S1-4)

Material constant, used for calculation of cutting force. The following table shows the default values for these parameters. You can change these values if necessary.

Nr. Name Shear stress value [KN/mm2]

1 Steel 80.0

2 Aluminium 26.0

3 Zinc 0.253

4 Stainless Steel 87.0

• Clamping force factor (CF)

Calculation factor of the clamping force, programmed as a percentage of the cutting force.

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V0504, 3.11

“ Page 3.

• Chaining mode (CH)You can set by this parameter if the incremental value must be subtracted from the previous target position or the actual position:

Xn+1 = Xn target - Xincr. orXn+1 = Xn actual - Xincr.

0 = New position is relative to previous programmed position1 = New position is relative to actual position

• Stockcount mode (CN)To set for the stockcounter in up- or downcounting direction. In the downcounting mode, the controller will go automatically to stop when "zero" has been reached.Range: 0= downcounting

1= upcounting

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V0504, 3.12

• Z-offset (ZO)The Z-offset is the distance between the plate side and the Z-axis. Default: 10mm.Range: 0 - 999mm.

Only used in case of automatically computed Z-axis position.

• Load position (L1/L2, optional)

X-axis position for loading products in case the load position option is used. The use of a Load position can be activated in a program. If it is active and a program is started, the X-axis will move to the load position before moving to the position of the first step.

Range: 0 - 16000 mm

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V0504, 3.13

“ Page 4.

• X-reference correction (CR)When the display gives a backgauge position which does not correspond with the actual mechanical position, the difference can be corrected by this parameter value. Program the calculated difference.Range: -99.99 - +99.99 mmDefault: 0.00

Example:When the programmed and displayed value = 250 and the actual, mechanical position value = 252 the CR parameter = -2.

• X2-reference correction (C2)When the display gives a X2-backgauge position which does not correspond with the actual mechanical position, the difference can be corrected by this parameter value. Program the calculated difference.Range: -99.99 - +99.99 mmDefault: 0.00

Example:When the programmed and displayed value = 250 and the actual, mechanical position value = 252 the C2 parameter = -2.

• Z-reference correction (CZ)When the display gives a Z-axis position which does not correspond with the actual mechanical position, the difference can be corrected by this parameter value. Program the calculated difference.Range: -99.99 - +99.99 mmDefault: 0.00

Example:When the programmed and displayed value = 250 and the actual, mechanical position value = 252 the CR parameter = -2.

V0897, 3.14

Delem • Auto X-ref. search (AR)

After switching on the controller and pressing start, the backgauge will search automatically for the reference position. It is also possible to disactivate this automatic reference search. This means that the controller will memorize its actual backgauge position after power down.

Range: 1 = automatic reference search always.0 = memorisation of the backgauge position

Default: 1

V0899, 3.15

Delem

“ Page 5.

Communication Parameters (optional)

Serial communication is an option that can be installed on the controller. If installed, the following parameters can be programmed. For successful communication, both sides of the serial link must have similar communication settings.

• Parity 0/1/2 (PY)

Parity check for serial communication:0 = none1 = odd2 = even

• Stop bits (SB)

The number of stop bits (1 or 2)

Delem “ Page 6.

V0899, 3.16

• Baudrate (BR)

To set the proper baudrate for communication:1 = 300 baud2 = 600 baud3 = 1200 baud4 = 2400 baud5 = 4800 baud6 = 9600 baud

Delem “ Page 7.

V0897, 3.17

Maintenance view

The last page in the parameter constants has been reserved for maintenance information. This

page can be found using the -key in the parameter constants selection.

These parameters can not be programmed, or changed.

• Hours

The machine hours, running machine will be indicated.

• Nr strokes

The number of strokes that the shearing beam has made will be indicated.

Delem

V1198, 3.18

3.4. Backup and Restore

If this option is installed, it is possible to save programs on a floppy disk or read them from it. After pressing 5 in the main menu, the “Backup and Restore” menu appears.

Backup

To make a backup, choose 1 in the “Backup and Restore” menu. An overview appears of all programs that are stored in the controllers’ memory.

Type the number of the program that you want to save on floppy disk and press <enter>. The program is now saved to floppy disk. If a backup was succesfull, the number will be marked with a ‘>’ sign. If not, a message will appear that the backup did not work and the number will be marked with a ‘-’ sign. In case a program under the same name already exists on the floppy disk, the controller will issue a warning on the screen. Then you can choose either to replace that program with your backup (1) or to cancel the backup operation (0).

To save all programs, press ‘0' and then <enter>. The program will ask for a confirmation by pressing ‘1’. If some of the programs already exist on the floppy disk, they will be replaced. The markings ‘>’ and ‘-’ will appear to indicate whether a backup was succesfull or not.

Delem

V1198, 3.19

Restore

To restore a program from floppy disk, choose 2 in the “Backup and Restore” menu. An overview appears of all programs that are stored on the floppy disk.

Type the number of the program that you want to read from floppy disk and press <enter>. The program is now loaded into the controller. If a restore was succesfull, the number will be marked with a ‘>’ sign. If not, a message will appear that the restore did not work and the number will be marked with a ‘-’ sign. In case a program under the same name already exists in the controller memory, the controller will issue a warning on the screen. Then you can choose either to replace that program with the new program from floppy disk (1) or to cancel the restore operation (0).

To load all programs from the floppy disk, press ‘0' and then <enter>. The program will ask for a confirmation by pressing ‘1’. If some of the programs already exist in the controller, they will be replaced. The markings ‘>’ and ‘-’ will appear to indicate wheter a backup was succesfull or not.

In the upper right corner of the screen is indicated the percentage of memory that is occupied by the existing programs in the controller. Watch the amount of memory that is occupied before loading more programs in the controller. Make a backup on another floppy, if necessary.

Delem

V1198, 4.1

4. Automatic production mode

- Select the automatic mode by pushing the indicated key.The required program to be made in production should be first selected in the programming menu choice 3.

In automatic mode you will see the following screen in the started situation .

In this screen you see in the upperrow the following information from left to right:

- Step 1/10: 1 Indicates which step is the actual step.10 Indicates how many steps are included in the selected program.

- Rep 1/3: 1 Indicates which step is actual of the total repetitionnumber.3 Indicates how many times the actual program step should be

repeated.

- Prog 1234: Indicates the selected programnumber

In the rest of the screen the programmed backgauge position XM is displayed and at the right side the actual position X.The stockcount parameter QM can be set to the required number of products and the actual productcounter Q is displayed at the right side.

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V0899, 4.2

The other values for the programmed parameters like thickness, materialtype, etc. can be checked

by pressing the -key:

The parameters cannot be changed in this field. Editing the program can only be done via the menu- selection 2. By pressing the -key you get the next page with parameters.

To return to the backgauge position and stockcountinformation (main screen ‘auto’-mode) the

-key should be pressed again (toggle function).

V0897, 4.3

Delem

By pressing the -key you activate the manual movement menu in which you can adjust the

X-axis with the handwheel. This option is only active when the controller is in the ‘stop’ mode,

and can be used as ‘teach-in’ function.

By pressing the -key or the cursor key you can adjust the angle and the gap (teach in).

To return to the mainscreen of the ‘auto-mode’ press the -key again (toggle function)

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V0897, 4.4

“ Service screens

When you push the END-key in the mainscreen of the ‘auto’- mode (not handwheel selection) a status-overview for service purposes is displayed (two screens).

After pushing the END-key again you return to the main screen of the ‘Auto’-mode (toggle function).

Delem

V0897, 5.1

5. Manual production mode

- Select the manual mode by pushing the indicated key. This mode gives the possibility to program all parameters for a single step. This mode can be used for test cuts or fast programming of single cuts.

The following screen is then active in the started situation.

The stockcount value can be programmed directly in the zoomed picture.The backgauge position X can be programmed in the parameters of this single step and the control will drive the backgauge to that position after starting the control and displaying abovementioned screen. Also the other parameters can be programmed like the "auto-mode".

With the -key you get the parameter overview (first page). This is a toggle function.

V0899, 5.2

Delem

The angle, gap and stroke parameters are automatically computed.By pressing the cursor key or the -key you get the next page with parameters.

By pressing the -key (toggle function) you get the manual movement menu in which you can adjust the X-axis with the handwheel. This option is only active when the controller is in the‘stop’-mode.

V0897, 5.3

Delem

With the cursor key or the you can adjust the angle or the gap (teach in function).

Delem

V0897, 5.4

“ Service screens

By pressing the END-key (only at the thickness parameter) in the parameter overview menu of the handmode you get a status-overview for service purposes (two screens).

Again pushing the END-key results in the main parameter screen of the handmode (toggle function).