Fully automatic, pneumatic machine to install eyelets and washers

Transcription

1 Operating Manual Fully automatic, pneumatic machine to install eyelets and washers Warning: Spandex accepts no liability for the incorrect use of the equipment Distributed by Spandex. Spandex Group, Excelsiorlaan 55, B-1930 Zaventem, Belgium Tel. +32 (0) Fax +32 (0)

2 Index 1 Introduction Introduction Machine identification and "Œ" marking 3 2 Technical Data Machine specifications and operation Main technical data 4 3 Installation Installation position requirements Pneumatic installation Transport Unloading and levelling Lighting conditions Learning instructions 6 4 Machine operation Machine description Checking the machine before starting Eyelet setting Other machine applications 7 5 Adjustments Warnings about the adjustments Changing of the press tool Laser pointer adjustments Precutting Maintenance 13 7 Failures Troubleshooting 14 8 Safety Safety devices 15 9 Annex Spare part listing Supplied tooling 16 2

3 1. Introduction 1.1 Introduction EP-300 Pro eyelet press has been designed to install eyelets (grommets) and washers, allowing for the punching and installation of the eyelet and washer, as a single process. This unit has been specially manufactured to install exclusively ImagePerfect 12mm clear eyelets. EP-300 Pro has been designed to work with PVC banners, corrugated PP sheets, cardboard, HDPE banners, etc. This unit is not suitable to work on fabrics as it will create wrinkles on the material as it is not possible to make cutting adjustments on the tooling. The standard eyelets for this press are Ø12mm. Warnings Knowledge of the machine will help to prevent operational errors. Please read the operating manual carefully to ensure safe and efficient use of the machine. 1.2 Machine identification and "Œ" Each machine has a data plate on the side, made of aluminium, on which following specifications are listed: --Manufacturer s name. --Year of production. --Model and serial number. --Maximum air pressure (in bars). -- Œ mark. --Weight 3

4 2. Technical data 2.1 Machine specifications and operation EP-300 Pro is mounted on a stainless steel platform with lockable wheels. It has been designed to install fully automatic eyelets (grommets) and washers, only eyelets or is possible just to punch holes on the material. All of the machine s parts (fixed and moving), such as pneumatic cylinder, setting dies, safety devices, deposits, eyelets and washers raceways, electronic controls are located in the main body. Inside the red cover are the pneumatic and electronic controls and the pneumatic cylinder that drives the machine. On the right-hand side is the laser pointer which allows for accurate setting and the ON / OFF switch and on the left-hand side is the pneumatic connection. The EP-300 Pro is delivered on wheels to work either at ground level or on a table. If the customer needs to work in a fixed location, the brakes on the wheels should be engaged for safety reasons. Once the machine has been located and before the pneumatic line has been connected, verify that it has not been damaged in transit and that it does not have any loose parts. The EP-300 Pro does not allow for adjustments to be made to the pressure settings. The operation of the machine is very simple (see Fig. 1,2,3): (A) (G) fig.2 (H) (C) (E) (B) (D) (J) (F) (I) fig.1 fig.3 As seen on Fig. 1, the eyelets are in drum A and the washers are in drum C. Both have a 220 V motor. When the motor is engaged the eyelets and washers travel down the channels (B and D) towards the installation area (J) where the press tool is located to allow for installation of the eyelets. 1. Before we starting, the eyelet and the washer are already in the drums. 2. Engage the ON/OFF button to begin the cycle. 3. Engage the foot pedal (F) to begin the installation. 4. The axle of the main pneumatic cylinder descends. 5. The press tool automatically punches the material and inserts the eyelet and washer in a single process. 6. All parts will return to their starting positions, leaving the machine ready for another cycle.... Fig. 1, 2, 3: (A) Eyelet drum - (B) Eyelet channel - (C) Washer drum - (D) Washer channel - (E) Safety cover - (F) Foot pedal (also re-start button) - (G) ON/OFF switch - (H) Laser pointer - (I) Pneumatic connection - (J) Installation area. Important notice: The EP-300 is a pneumatic press, so in order to run any adjustments or maintenance on it, the pneumatic connection must be set to the closed position (see page 6, Fig. 6). The ON / OFF switch on the right-hand side only disconnects the electric motor and the laser pointer; it does not affect the pneumatic parts of the machine. If the switch is in the OFF position, the machine will work without the laser pointer on the electric motor. 4

5 2.2 Main technical data The main technical data of this machine are: Height x Width x Depth 74 cm x 68 cm x 40 cm. Weight 58 Kgs. Air pressure 6 bars / 87 psi. 3. Installation 3.1 Installation position requirements A minimum space is recommended to allow for a safe workingspace in all directions. Warning: Please note that both the electrical wire and the pneumatic line should never be completely stretched. 3.2 Pneumatic installation The machine has an air inlet valve, with an easy connecting coupler (ISO 6150-B standard) Ø8 mm, located on the left-hand side of the machine (I). During maintenance operations or adjustments, this must be set to a CLOSE position (see page 6, Fig. 6). For optimal operation, the supply of compressed air should be 6 bars/cm2. It is important that the pressure doesn t drop after one or two installations as the machine might not have enough power to punch the material and install the eyelet. If this happens, you may require a bigger compressor with more output (litres/minute). We would recommend that the flexible pneumatic line from the compressor or the pneumatic installation travels from above to avoid injury to the operator or damage to the equipment. The compressor or local air installation should be equipped with an air filter. (I) 3.3 Transport Always unload the crate with a forklift, securing the load with slings on the sides. To transport the machine to its permanent location, the following precautions should be taken in account: - Never stand beneath the wooden crate. - Use protective gloves. - Avoid balancing the machine. - Never overturn the machine. - Lift or move the load gently. - Do not make sudden movements. - Always move the machine in an upright position The machine is delivered with appropriate packaging to avoid damage in transit. In the event that it is necessary to transport the machine after its initial installation and the customer does not have the original packaging, we would recommend the use of reinforced, wooden packaging. 5

6 3.4 Unloading and levelling The EP-300 Pro is delivered, secured to the wooden crate by screws on both sides. Please follow these steps: --Open the wooden crate. --Remove the protective film that secures the machine. --Remove the 4 screws on the base of the crate. --Move the machine to its location. If the machine will be operated on a workshop, it must be sufficently strong and level. Before the machine is operated, the four brakes must be engaged on the wheels. 3.5 Lighting conditions The safe operation and servicing of the machine requires appropriate lighting. 3.6 Attention Please read these instructions carefully before starting: - Before connecting the machine to the power supply, compressor or pneumatic installation, it should be placed in its permanent location. - The cleaning, handling or replacement of parts should always be completed with the air inlet valve closed and the power shut off. - The safety devices, stickers and warning signs that highlight dangerous areas must not be removed from the machine. - The machine has an air inlet valve I (page 4, Fig. 3) to manually open and close the air supply to the machine. When the machine is not in use, it should be closed (see fig. 6) to avoid accidental use. For safety reasons, we would also suggest disconneting the pneumatic line from the compressor/air supply. - The machine has an ON/OFF switch (G), (page 4, Fig. 2). When the machine is not in use, it should be in the (not illuminated) OFF position. For safety reasons, we would also suggest unplugging the electrical cord from the socket. (J) fig.5 The operator should pay attention to the position of the air inlet valve (I) (See page 4, Fig. 3) located on the left-hand side of the machine. When the valve changes its position from open to closed, the compressed air inside the machine is expelled, thereby preventing any unwanted action if the pedal is pressed accidentially. Closed position Open position fig.6 Please note on the pictures that when the valve is CLOSED, the pressure reading on the gauge is 0 bars, and when the valve is in the OPEN position, the pressure reading should be on 6 bars. fig.7 6

7 4. Machine description 4.1 Machine description This machine has been engineered to automatically install eyelets and washers in PVC coated materials and in other plasticized materials, but not with fabrics as it could create wrinkles due to its setting system. The maximum cutting diameter is 12 mm. The machine cuts the material and installs the eyelets and washers in a single operation. The press tool has been designed to work only with 12mm eyelets. Eyelet (K): --Head diameter «D». --Eyelet height «L». --Internal hole diameter «d». Washer (L): --Oudside diameter «F». --Washer height «H». --Internal hole diameter «i». (K) (L) fig.6 If you need to install different size eyelets, you will require a different machine. Spandex accepts no responsibility when the machine is used differently to the instructions covered in this operating manual. 4.2 Checking the machine before starting Before using the machine for the first time, or when adjustments or part replacements are made, we would advise that the machine is checked to ensure that it has not been damaged. fig.9 (I) 4.3 Eyelet setting fig.10 (G) 1. Check that the air inlet valve I is in the OPEN position (page 6, Fig. 7). 2. Check that the switch (G) is in the ON position (with the green light illuminated). 3. As soon as the machine is in the ON position, the motors on both drums will start to turn. The brushes push out the eyelets and washers filling the channels. To extend the life of the motors, they will stop when the machine has not been used for a period of seconds. 4. Place the material on over the stainless steel plate and underneath the safety cover (E) (see page 10, Fig. 11). 5. Press the pedal (F) so that the main shaft descends, cutting the material and insterting the eyelet. 6. It is important to understand that if your foot is removed from the pedal pedal too quickly, the setting might not be correct. (E) (Material) fig Other machine applications The punching tool can also be used to punch holes in the material without inserting eyelets. The hole diameter will not be more than 12mm. 7

8 5. Adjustments 5.1 Warning about the adjustments The parts that should be replaced on a regular basis due to normal use are the cutting part of the press tool (the bottom part M ) and the setting part of the press tool (the top part N ). These parts will need to be replaced more regulary when either the cutting or the setting is not accurate. We would recommend, always having a spare set of these parts available. (12mm Part-No. MIPEP303) Doing maintenance, if it is necessary to remove parts designed for operator safety (such as the safety cover or the stainless steel plate) please ensure these are replaced and fastened securely. WARNING: When changing the press tool or during the installation of optional equipment or during any other handling, ensure the air inlet valve is set to a closed position (page 6, Fig. 6) and the ON/OFF switch (G) should be set to off (not illuminated). (N) (M) fig Changing of the press tool Whenever the press tool is changed, you should follow these steps: Warning: To install a new press tool it will be necessary to take out the safety cover E (see page 7, Fig. 11). This must ALWAYS be replaced otherwise the machine will not function. Please be very careful while making adjustments, always ensuring that your hands and fingers are clear of the setting area (J) (see page 6, Fig.5) and ensure that nobody can press the pedal (F) (see page 1, Fig. 1). 8

9 Set the ON/OFF siwtch to the OFF position. Slide the eyelet channel gently with your hand (in order not to damage the spring) While you are still holding it, turn the small metal part clock wise so the eyelets at the bottom stay away from the top part of the press tool. Press the foot pedal, holding it down. Without releasing it, shut off the air inlet valve so the axle of the cylinder stays in its lower position. When the valve changes its position from open to closed, the compressed air inside the machine is expelled, preventing any unexpected action from the pneumatic cylinder. With an allen wrench, loosen the three screws on top of the safety cover on the front of the machine to gain access to the setting area. With an allen wrech, remove the fixing screw from the top part of the press tool. 9

10 Repeat the operation with the fixing screw on the bottom part of the press tool. Open the air inlet valve so the axle of the cylinder moves to its upper position. Once the cylinder is up, close the air inlet valve again. It is possible that the top part of the press tool will stay in the lower position as per the picture such that the operator will have to remove it from the cylinder axle. Once it is free, remove it from the setting area. With your finger underneath the frame of the machine, raise the bottom part of the press tool until you can remove it with your hand. Before installing the new press tool, put both parts together (left: bottom part / right: top part) 10

11 With both parts of the press tool together, install them at the bottom of the setting area. Replace the safety cover. As the safety cover has to make contact with the security valve, begin the installation sideways at the point marked by the arrow and then tighten the three fixing screws on the front. Open the air inlet valve. Press the pedal and WITHOUT releasing it, close the air inlet valve again so that the axle stays in its lower position. With an allen wrench, through the gap in the safety cover, tighten the top fixing screw. Tighten the bottom fixing screw. Open the air inlet valve so that the axle of the cylinder moves to its upper position. Set the switch to the ON position so that the motors start to turn and the laser is on. If the safety cover is not in its correct position, the machine will not work (for safety reasons). Machine is now ready to use. 11

12 5.3 Laser pointer adjustments The EP-300 Pro is equipped with a laser pointer for accurate setting. The base of the laser has two fixing screws (see arrows in Fig. 13) to adjust the position in the setting area. When working with different material thicknesses, you might need to adjust the laser pointer (for example when moving from banner to 4mm corrugated sheets). fig.12 fig.13 Warning: To avoid laser damage to the eyes, users should avoid direct eye contact with the laser. With a pen draw a circle and a cross on a blank banner. Check the laser to ensure the pointer is centered. With an allen wrench loosen the two fixing screws on the base (Fig. 13). Do not loosen the top fixing screw as it holds the laser on its base. Realign the laser and check again to ensure it is centered. 12

13 5.4 Precutting The EP-300 Pro has been designed to work with PVC banners, corrugated PP sheets, cardboard, HDPE banners etc. but not with fabrics, as it might create wrinkles in the material. An additional option is to precut the material. Precutting can be especially useful on heavy banners, particularly on the corners, if the banner is welded, due to thickness. Slide the eyelet channel gently with your hand (in order not to damage the spring). While you are still holding it, turn the small metal part the eyelets at the bottom stay away from the top part of the press tool. With your thumb, hold the washer that is ready to be delivered to the setting area. This is to prevent the washer from coming down when the banner is cut. Do not release your thumb from the washer. Press the foot pedal to perform the cutting operation. Once the cutting has been made and without moving the banner from the setting area, move the small metal part that holds the eyelet channel back to its original position. Machine is now ready to install an eyelet on the precut banner. 13

14 6. Maintenance The only part of the machine that needs to be lubricated is the part shown on the picture below. We would recommend lubricating the part monthly but maintenance intervals might be shorter depending on the frequency of use of the machine. Follow the first step in the precutting section 5.4 (sliding the eyelet channel). Press the foot pedal and without releasing your foot, close the air inlet valve so cylinder axle is in its lower position. Loosen the three screws to remove the safety cover. With a brush or finger, apply the lubricant around the cylinder. Replace the safety cover. Open the air inlet valve. Return the eyelet channel to its original position. For the optimum use of the EP-300 Pro, it is important that the machine is clean. Cleaning should always be done with 1) the main air inlet valve set to the closed position and 2) the main switch set to the OFF position (not illuminated). It is especially important to ensure that the eyelet and washer channels are clean. We would recommend doing this at the end of the day with compressed air. Any debris in the channels may prevent movement of the eyelets and washers. The same applies to any debris inside the drums. It is also important to clean the setting area, especially the top part of the punching tool. We would recommend doing this with an air gun through the gap on the safety cover in the front of the machine. This should be done at least once per day, but it might be necessary to do it more often depending on the type of materials being used. The foot pedal should always be clean and clear of any debris that could hinder normal use. If the machine is not in use for a long period of time, please follow this recommendations: 1. Disconnect the machine from the compressor and power source. 2. Clean the machine and cover it to protect it from humidity and dust. 14

15 7. Failures 7.1 Troubleshooting Problem Cause Solution The machine does not work. The machine does not cut. The eyelet is crushed when setting. The eyelet does not close completely. Washers /eyelets do not leave the drums The machine leaks air. 1. Check that the pneumatic line is connected to the compressor. 2. Check that the air inlet valve is in the OPEN position. 3. Check that the main switch of the machine is in the ON-position. 3. Check that the air pressure on the gauge is 6 bars. 4. Check that the safety cover contact with the microvalve. 1. Check that the air pressure on the gauge is 6 bars. 2. The edge of the bottom part of the press tool is worn out or damaged. 3. The bottom part of the press tool is full of debris. 1. Check that the pressure at the gauge is no more than 6 bars. 1. Check that the pressure on the gauge is 6 bars. 1. Check that there is nothing blocking the exit in the drums. 2. Check that the drums are not overloaded, especially on the washer drum. 1. Check that the air inlet valve is completely in the OPEN position. 1. Connect the pneumatic line. 2. Open the air inlet valve. 4. Change the position to ON. 3. Adjust the pressure gauge until the manometer shows the correct pressure. 4. Reposition the safety cover. 1. Adjust the pressure gauge until the manometer shows the correct pressure. 2. Change the press tool. 3. With a screwdriver, clean the area underneath the stainless steel plate where material debris may build up. 1. Adjust the pressure until the manometer shows 6 bars. 1. Adjust the pressure until the manometer shows 6 bars. 1. Stop the drums (ON/OFF switch) and clear the hole where the eyelets/washers leave. 2. Lighten the load so the brushes turn freely. 1. Move the valve to fully open. When it is not fully open the air will be expelled. 15

16 8. Safety 8.1 Safety devices The machine has a range of protection devices to prevent access to dangerous ares (except when required for maintenance or repairs) to prevent operator injury. The dangerous part of the machine is the setting area J, where there is the risk of crush injuries to fingers or hands. The dangerous area J is protected by the following devices: 1. Acrylic safety cover Front (E) and Back (O): Prevent access of fingers or hands to the setting area 2. Stainless steel plate: Prevents access of fingers or hands to the setting area. 3. General air inlet valve: The valve allows for the manual opening or closing of the pneumatic air supply from the compressor or general air installations. As a safety device, it has a decompressing system when the valve changes position from open to closed. The compressed air inside the machine is expelled, preventing any unexpected movement from the pneumatic cylinder when making adjustments to the machine. 4. Switch: In the ON position the motors turn and the laser pointer is engaged. It is important to be aware that even with the switch in the OFF position, it is possible to set eyelets. 5. Security microvalve Q : If the safety cover (E) is not on in position, the pneumatic cylinder will not work. This security device prevents operator injury when the air inlet valve is in the OPEN position and the safety cover has been removed. (P) (P) (Q) (E) (I) (O) Close position Open position There are a series of labels on the machine that the operator should read: --Label Read manual : This label on the left-hand side of the cover explains that is mandatory for the operator to read the operating manual. --Label Danger : This label on the front of the cover informs the operator that there is the risk of crush injury to fingers and hands when working in this are. --Label Disconnect the machine before removing the safety cover : This label on the right-hand side of the cover informs the operator that, before removing the safety cover the machine must be disconnected: a) the air inlet valve in the closed position b) the main switch in the OFF position. 16

17 Operating Manual 9. Annex 9.1 Spare part listing 12mm press tool MIPEP303 Reference Description Safety cover (front) Safety cover (back) Motor (eyelets or washers) Eyelet channel spring Engine brushes 9.2 Necessary tools Allen wrench # 2.5 and # 3.0 Distributed by Spandex. Spandex Group, Excelsiorlaan 55, B-1930 Zaventem, Belgium Tel. +32 (0) Fax +32 (0)