Blue Max Mini Modular Plus User manual

Operating manual

BlueMax Mini Modular Plus

1. Foreword

1. Introduction 89

2. Important notes 89

Revision service 89

Updating 89

3. Validity of this operating manual 89

Application 89

4. Owner‘s personal responsibility 89

5. Service 89

2. EC declaration and protocols

1. EC Declaration of Conformity 90

2. Important note 91

3. Verification of instruction 91

3. General safety rules

1. Information on signs, symbols and markings 92

2. General 93

3. Safety advice for the user company 94

4. Noise 94

5. Oils, greases and other chemical substances 94

6. Residual risk

7. Safety advice for operating personnel 95

8. Safety advice for operating the machine 95

9. Safety advice for carrying out maintenance work 95

10. Training / instruction 95

11. Personal protective equipment 96

4. Purpose / operating principle

1. General information 98

2. Intended use 98

3. Foreseeable incorrect use 98

4. Operating principle and description of the machine 99

5. Rating plate 99

6. Limit values 99

7. Liability 99

5. Technical information

1. Safety precautions 100

2. Attachment points 100

3. Technical Specifications 101

4. Equipment 102

Programming digital display 104

Setting 106

5. Guards 106

6. Noise mission 107

7. Aligning / fastening 107

General information 107

8. Connections required 107

Main power connection 107

Compressed air connection 108

9. Transportation 108

Transportation on fork lift truck or pallet jack 108

10. Internal handling 108

11. Checking delivery for missing items 108

12. Dealing with shipping damage 108

13. Measures on temporary storage 108

14. Site of installation 109

15. Safety guards to be provided by the owner 109

16. Permissible ambient conditions 109

17. Removing preservatives 109

18. Electrics 109

19. Compressed air connection 109

20. Suction extractor 109

6. Start up / trial run

1. General 111

2. Safety check 111

3. Malfunctions on start-up 111

4. Starting up for the first time 111

5. Machine versions supplied 112

6. Interchangeable drilling units 113

Interchangeable drilling unit, 3 spindles Selekta 113

Interchangeable drilling unit, System 32 hole line 113

Interchangeable drilling unit, System 32 hole line 90° 113

7. Other accessories 113

8. Assemblies 114

Press-in frame for the interchangeable drilling unit,

6 spindles 114

Centre stop 115

Continuation stops 115

Drilling depth settings 118

Drum stop 118

Hold-down clamp 118

Converting from manual operation to foot pedal 119

Connecting foot switch for a machine

with horizontal drilling unit 119

Connecting foot switch for a machine

without horizontal drilling unit 120

9. Carrying out trial run 121

10. Concluding start-up 121

7. Setting up

1. Preparing machine 122

Readiness for use 122

Connecting to extractor system 122

Connecting to compressed air supply 123

Connecting to power supply 123

Switching on 124

Operating 124

Drilling hole line, interchangeable drilling unit,

9 spindles 125

Inserting hinges 126

2. Setting up (preparing for work) 126

Tools used (drill bits) 126

Interchangeable drilling unit, 6 spindles,

Interchangeable drilling unit, 3 spindles (Selekta 22/9) 127

Interchangeable drilling unit, 9 spindles 127

Interchangeable drilling unit, 90°, 9 spindles 128

Changing interchangeable drilling units 128

Cleaning 128

Fitting drilling units 129

Checking switch for proper working order 129

Setting drilling depth, vertical drilling unit 130

Drilling with horizontal drilling unit 130

Settings on the back of the machine 131

Limiting drilling stroke for drilling hole lines 132

3. Hold-down clamp and centre stop 132

Hold-down clamp 132

Centre stop 133

Setting the drum stops 133

Pendulum stops 133

8. Operation

1. Safety check 134

General information 134

Readiness for use 134

Control panel 135

2. Switching on 136

Preparatory work 136

3. Operating 136

Hold-down clamp 137

Fitting Hettich hinges 137

Drilling 138

Pressing in 138

Contents

109

4. Malfunctions during operation 139

Troubleshooting 139

5. Checks during operations 139

Checks for proper working order 139

9. Servicing / care

1. General information 140

Working on electrical components 140

2. Instructing maintenance personnel 140

3. Making the machine safe on shutdown 141

4. Cleaning the machine 141

Electric motors 141

5. Servicing work 141

Servicing and maintenance 141

Servicing unit 142

6. Instructions on inspections 142

General 142

10. Malfunctions / troubleshooting

1. General information 143

2. Malfunctions caused by the owner 143

3. Troubleshooting 143

General causes of malfunction 143

Malfunctions while machine is operating 143

4. Reporting malfunctions 143

11. Dismantling / disposal

1. General information 144

Before dismantling 144

2. Taking out of service 144

3. Dismantling 145

General information 145

Dismantling the machine / system 145

4. Hazardous substances / disposal 145

Protecting the environment 145

Scrapping 145

Oil and oily wastes 145

12. Replacement parts lists

1. Base frame 147

2. Work surface 147

3. Eccentric tensioner 148

4. Guide frame 148

5. Foot extension 149

6. Suction extractor 149

7. Cable drag chain 150

8. Console 150

9. Lifting cylinder 151

10. Drill depth stop 152

11. Adjustable stop 152

12. Clamping element 153

13. Motor with support 154

14. Centre stop 154

15. Press-in frame 155

16. Hold-down clamp, rear 155

17. Hold-down clamp, front 155

18. Drum stop 156

19. Horizontal drilling unit 157

20. Interchangeable drilling unit, 90°, 9 spindles 158

21. Interchangeable drilling unit, 9 spindles 159

22. Interchangeable drilling unit, 6 spindles 159

23. Interchangeable drilling unit, 3 spindles,

Selekta (22/9) 159

24. Pneumatics diagram 160

25. Circuit diagram 161

13. Replacement part numbers

1. List of replacement part numbers with designation 162

14. Instructions for installing accessories

1. Press-in frame 164

2. Converting from pushbutton to foot switch 164

Connecting foot switch for a machine

with horizontal drilling unit 165

3. Installing laser 166

4. Installing support block 167

1. Foreword

1. Introduction 89

2. Important notes 89

Revision service 89

Updating 89

3. Validity of this operating manual 89

Application 89

4. Owner‘s personal responsibility 89

5. Service 89

Foreword

WARNING

Read these operating instructions carefully in order

to obtain a thorough understanding of the machine

and how to handle and maintain it. Operate the

machine in the proper manner as described in these

instructions so as to avoid injury and damage to the

system. Do not operate the machine on the basis of

suppositions. Keep these operating instructions to

hand and consult them if you are in any doubt as

to carrying out any particular procedure.

If any questions remain unanswered after reading

through the instructions, you must not put the

machine into operation.

Settle any unanswered questions first by consulting

Paul Hettich GmbH & Co. KG.

These operating instructions are intended to make it easier

for you to become familiarised with the machine and use its

capabilities in the proper manner.

The operating instructions contain important information on

operating the machine in a safe, proper and cost effective

manner. Following them will help to avoid hazards, repair

costs and down times, enhance reliability and prolong service

life.

Existing national regulations on preventing accidents and on

protecting the environment are also applicable.

The machine will only be assembled and

installed by persons instructed to do so by

Paul Hettich GmbH & Co. KG. This also applies in

particular to starting it up for the first time.

The operating instructions must be available at the machine

all the time. The operating instructions must be read and

applied by any person entrusted with working with / on the

machine, e.g.:

• Operation

• Including setting up, troubleshooting while working,

disposal of production waste, care, disposing of

consumables and auxiliary substances,

• Maintenance

• Servicing, inspection, repair

• Transportation

given the task.

1. Introduction

The main objective of this operating manual is to protect

“man and machine“ in accordance with the EC Machinery

Directives. It is intended for all persons involved in working

with and on this machine or system, in particular the

operating personnel.

• As operating / servicing personnel, first read this operating

manual and familiarise yourself with using the machine

and operating it safely as well as with how to perform

the necessary set-up, servicing and / or repair work in the

proper way while meeting the safety requirements.

• Your personal safety and that of your surroundings as

well as safe machine operation without risk to other

property or the environment will only be ensured if you

are familiar with and follow all of the information in this

operating manual as well as in pertinent health and safety

regulations.

• As customer and / or owner, make sure that this operating

manual is given to your operating / servicing personnel

before putting the machine / system into service for the

first time, that it remains available directly at the machine

at all times and that all persons concerned observe the

information and warnings provided in this operating

manual, the code of practice applicable to the site of

installation as well as the regulations on occupational

health and safety etc.

In other words, this operating manual does not release the

owner from the duty to devise his or her own health and

safety rules as well as safe work procedures tailored to his

or her production requirements / needs, to any specific

system / machine combination, to specific installation

conditions, to specific modes of connection and/or tool and

component properties etc., and to apply these, have them

applied and monitor their observance.

2. Important notes

Revision service

This operating manual is not subject to any revision service.

If changes / additions are made after the machine has been

delivered, it is the responsibility of the owner to update

this operating manual using his or her own addenda or any

addenda provided by Paul Hettich GmbH & Co. KG.

The right is at all times reserved to amend and improve

all technical specifications, details and illustrations in the

interest of technical progress.

Updating

The laws, provisions, regulations, directives, codes of practice

etc. specified in this operating manual as well as statements

derived from them were up to date at the time this manual

was compiled.

They must be heeded in their latest, applicable wording,

updated at the responsibility of the owner and always applied

in their more restrictive (stringent) wording.

We also point out that the content of this operating manual

is not part of any earlier agreement, assurance or legal

relationship or intended to amend such. All obligations on the

part of Paul Hettich GmbH & Co. KG arise from the pertinent

supply contract that also contains the complete and solely

applicable warranty arrangements or draws attention to

these. Statements made in this operating manual neither

extend nor restrict these warranty provisions.

3. Validity of this operating manual

• This operating manual only applies to this machine.

• Please always quote the machine no. in all queries and

orders for replacement parts.

Statements made in this operating manual in relation to

items of equipment not included with the machine are for

information only. They do not give rise to any legal claim to

the machine being equipped with these items.

Application

This operating manual has been produced in compliance

with EC directives, European (harmonised) standards etc.

References to occupational health and safety, environmental

protection and safety provisions may not yet conform

to harmonised accident prevention regulations (UVV) /

statutory accident insurance regulations (GUV) applicable

in Germany or to the DIN standards or technical regulations

stated in the appendix to the German Equipment Safety Act

(Gerätesicherheitsgesetz (GSG)).

The customer / owner is personally responsible for:

• regarding specified laws, regulations, directives etc., as the

basis for safe handling and maintenance practice,

• implementing and observing them in line with national /

regional / company-internal regulations,

• providing supplementary safety or protective equipment

prescribed by the responsible local, regional or national

authorities and for fitting them before using the machine /

system for the first time.

Operating instructions:

Paul Hettich GmbH & Co. KG

The copyright to this operating manual remains with

Paul Hettich GmbH & Co. KG.

These operating instructions are intended for the operating

personnel. They contain regulations and drawings of a

technical nature that must not be duplicated either in whole

or in part, distributed, used without permission for advertising

purposes or communicated to others.

Reproduction either in whole or in part is not permitted.

4. Owner‘s personal responsibility

The customer or owner is personally responsible for ensuring

that:

• provisions on occupational health and safety, environmental

protection and disposal are observed in relation to the

machine, handling it as well as in the course of inspections,

servicing and repair measures,

• no improper changes or modifications are made to the

machine and safety guards,

• the machine is not used in any inappropriate, improper or

non-intended manner.

5. Service

Customer Service

Paul Hettich GmbH & Co. KG

Vahrenkampstrasse 12 - 16

D-32278 Kirchlengern

2. EC declaration and protocols

1. EC Declaration of Conformity 90

2. Important note 91

3. Verification of instruction 91 1. EC Declaration of Conformity

EC declaration and protocols

EC Declaration of Conformity is enclosed loose.

2. Important note

Information for the owner

In addition to these operating instructions and the accident

prevention regulations in force in the country of use or at

the place of application, it is also necessary to follow the

recognised code of safe and proper working practice.

Without the consent of Paul Hettich GmbH & Co. KG, the

machine owner must not make any additions, alterations or

modifications to the machine that may affect safety.

Replacement parts used must meet the technical

requirements defined by Paul Hettich GmbH & Co. KG. This is

always ensured when using genuine replacement parts from

the applicable replacement parts list.

Only ever deploy trained or instructed personnel and clearly

define personnel responsibilities with regard to operating,

servicing and repair.

Use for other purposes and modifications

We expressly point out that the EC declaration shall become

null and void if modifications / changes etc. are made to the

machines listed above.

The company making the modification must amend the EC

declaration and extend or make out new documentation to

reflect the latest modification

(Art. 8 (6) of the EC Machinery Directive).

Name Date

from / to

Type of instruction received Signature of

the person

instructed

Instructor Person instructed Operation Safety rules Servicing

3. Verification of instruction

By signing this protocol the undersigned confirm that the

following details and specifications are correct.

Confirmation

I hereby confirm that I have read and understood the

operating manual for the machine:

Designation BlueMax Mini Modular Plus

Type Automatic drilling and insertion machine

Machine no.

have read and understood.

I furthermore undertake to observe and follow the general

safety precautions, the servicing and care instructions

as well as power-up and operating instructions and the

provisions relating to malfunctions. I am aware that any

failure to observe these instructions and provisions may lead

to accidents, put persons at risk and result in damage to

property and the machine.

General safety rules

3. General safety rules

1. Information on signs, symbols and markings 92

2. General 93

3. Safety advice for the user company 94

4. Noise 94

5. Oils, greases and other chemical substances 94

6. Residual risk 94

7. Safety advice for operating personnel 95

8. Safety advice for operating the machine 95

9. Safety advice for carrying out maintenance work 95

10. Training / instruction 95

11. Personal protective equipment 96

1. Information on signs, symbols and markings

The safety advice in the operating instructions is structured as

follows:

DANGER

This danger advice draws attention to an immediately

dangerous situation that will lead to death or serious

injuries if the safety measures are not followed.

WARNING

This danger note draws attention to a potentially

dangerous situation that may lead to death or serious

injuries if the safety measures are not followed.

CAUTION

This danger note draws attention to a potentially

dangerous situation that may lead to minor or slight

injuries if the safety measures are not followed.

NOTE

This advice draws attention to potential damage

to property or to a process of particular interest /

importance that may occur if the safety measures are not

followed.

In the operating instructions, hazard points are identified as

follows:

DANGER

Danger from electric shock!

Working on live components in the improper manner

presents a danger to life!

Work on electrical equipment must only be carried out

by authorised electricians!

WARNING

Hearing damage warning!

Some areas of the facility can reach noise levels of

over 80 dB (A).

Wear ear protectors when working in noisy areas!

WARNING

Danger from wood dust!

Wood dust can affect the respiratory tract. For this

reason, wear a dust protection mask.

WARNING

Fire risk!

Grinding and welding work must never be performed

on this machine.

Follow welding regulations and accident prevention

regulations.

WARNING

Explosion protection

Machine is not explosion-protected. Do not install

near paint shops.

WARNING

Warning - Hand injuries!

Hands could be crushed, drawn in or otherwise injured.

Never reach into the system‘s moving parts!

Wear hand protection!

WARNING

Warning - Hot surfaces / objects!

There is a risk of injury from touching hot surfaces

(e.g. electric motors).

Do not touch!

2. General

The machine described in the operating instructions is built to

the state of the art and safe to operate.

It complies with DIN EN 12100.

Hazard zones are made safe in compliance with the

regulations. However, the machine may present hazards if

it is used by untrained personnel improperly or not for the

intended purpose.

This may then result in risks to life and limb, jeopardise the

machine and prevent it from working efficiently.

Any person given the task of installing, starting, operating,

servicing or repairing the machine at the user‘s premises must

have read and understood these instructions, in particular the

section on “Safety precautions“.

In his or her own interest, the safety officer at the user

company should obtain written conformation from operating

personnel that they have received instruction and training

and are familiar with all safety precautions before they use

the machine for the first time.

The safety guards must never be removed or taken out of

operation.

If safety guards need removing for maintenance and repair

work, they must be refitted as soon as such work has been

completed.

The machine must only be used if it is in proper working order

and operated by trained, authorised personnel.

Work requiring specialised knowledge (e.g. electrical,

pneumatic system) must only be carried out by persons

specifically trained and suitable to do so.

Before attempting any work on the machine, turn the main

switch to the “0“ position (OFF), make the machine safe and

disconnect from the compressed air supply.

Switch off energy sources before carrying out repair, servicing,

installation or cleaning work.

Energy sources:

• Electrical energy

• Pneumatic energy

CAUTION

Danger from residual energy!

Stored energy will not be dissipated even after switching

the system off at the main switch.

Dissipate residual or stored energy!

Switch off / dissipate energy sources:

For safety regulations applicable to third party devices, refer

to the documentation from the third party manufacturers

(operating instructions for bought in units).

Electrical energy via the motor switch / machine‘s main

switch. Additionally attach a notice when servicing or other

work is being carried out on the machine.

Fig. 3: Main switch

(viewed by the operator, on the right hand side of the

machine frame)

Fig. 4: Motor protection circuit breaker

CAUTION

Warning - Hand injuries!

The main switch only shuts down the drive system, not

the pneumatic system!

The machine has no emergency stop button or

emergency stop facility. This means it is necessary to

take particular care when handling and working on

this machine.

Pneumatic energy through the supply connection on the

machine frame. Make sure that all machine components are

depressurised and any stored energy is dissipated. As part of

the installation process, the owner will provide a mechanical

main cock at which the machine can be disconnected from

the compressed air supply.

Fig. 5: Pneumatic system servicing unit

(viewed by the operator, on the left hand rear side of the

machine frame)

3. Safety advice for the user company

All persons entrusted with operating the machine (including

line managers) must familiarise themselves with the section

on “Safety advice“.

The safety advice must be followed.

The machine must only be operated if it is in proper working

order. The user company will issue clear responsibilities, e.g.

for servicing, cleaning or repair, and ensure that the persons

carrying out this type of work have received the training

necessary for it.

The safety regulations applicable in the owner‘s country must

also be observed. Refrain from any work that adversely affects

operating safety.

The operating personnel will check the machine for changes

or malfunctions, report such to the safety officer responsible

and, if necessary, take the machine out of operation.

Only appropriate tools must be used for the work that needs

to be done; remove tools after completing work. The place at

which staff work must be selected in such a way as to ensure

that work operations can be viewed at all times, the machine

can always be stopped immediately and safety is never at risk.

General safety rules

WARNING

Never:

• reach into the machine when it is operating,

• remove covers and take safety guards out of operation,

• hinder unobstructed access to the controls,

• continue operating the machine if changes occur that

adversely affect safety and

• manipulate or circumvent safety guards.

4. Noise

The weighted equivalent continuous sound level

is > 80 dB (A).

WARNING

Hearing damage warning!

Local conditions may produce elevated sound pressure

and cause noise induced hearing loss!

Operating personnel must be provided with appropriate

protective equipment or be protected by other measures!

Wear ear protectors when working with the machine!

5. Oils, greases and other chemical substances

When handling oils, greases and other chemical substances,

you must observe and follow the applicable regulations and

safety data sheets of the manufacturers of these substances

with regard to storing, handling, using and disposing of them.

When working with caustic substances, you must wear

protective equipment of suitable material (safety goggles,

rubber gloves, rubber boots, protective clothing).

In the event of contact with the eyes or skin, immediately

rinse the area affected with copious quantities of water.

Appropriate facilities (eye wash bottle, wash basin, shower)

must be provided near the work area.

6. Residual risk

CAUTION

Residual hazards!

Handling the machine involves residual hazards that could

not be eliminated by design measures.

Pay attention to the residual risks in the Technical

Documentation!

The machine reflects the state of the art and is built in

accordance with recognised safety regulations. All the same,

the user or third parties may still be exposed to hazards.

The machine must be used

• for the intended purpose

• in an absolutely safe state.

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