Original-Betriebsanleitung Palettenträger pneumatisch betätigt

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Original-Betriebsanleitung

Palettenträger – pneumatisch betätigt

Translation of the Original Operating Instructions Pneumatically Operated Pallet Support

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Version 1.0 | 062018

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Entsorgung

These operating instructions describe in detail the use, installation, assembly and maintenance of the pallet support. The efficiency of the pallet support depends primarily on correct use and careful maintenance. These operating instructions serve as the leading document and are provided on delivery of the product. The personnel must have carefully read and understood the operating instructions before beginning any work. Observance of all safety instructions and instructions for use in these operating instructions is the basic prerequisite for safe work with the pallet support. In addition to the regulations listed here, the local and user-related operating instructions and the professional accident prevention regulations are to be observed.

1.1 Manufacturer Details

Distribution partner:

RÖHM GmbH

Heinrich-Röhm-Straße 50 89567 Sontheim/Brenz Germany

Contact:

Tel.: +49 (0) 7325 160 Fax: +49 (0) 7325 16492 Web: www.roehm.biz

Manufacturer:

Kraftek

16 Rue Claude Chappe Z.A. de la Haute Limougère 37230 Fondettes

France Contact:

Tel.: +33 (0) 247 428240 Web: www.kraftek.fr

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1.2 Copyright

These operating instructions are protected by copyright and are intended for internal purposes only.

The forwarding of the operating instructions to third parties, reproduction by any means - even in part - as well as use and/or communication of the content without the permission of the manufacturer are prohibited (except for internal purposes).

Infringements will lead to claims for compensation. We reserve the right to assert further claims.

1.3 Warranty and Liability

All information and instructions in these operating instructions are given in good faith on the basis of our experience and knowledge to date.

The products of RÖHM GmbH are subject to constant further development.

The manufacturer therefore reserves the right to make any modifications and improvements deemed useful. However, there is no obligation to extend these modifications and extensions to previously delivered pallet supports.

The pallet support is constructed exclusively for the purpose specified under intended use. Any use beyond this is deemed to be inappropriate.

RÖHM GmbH is not liable for damage resulting from such use. The risk is borne solely by the owner.

Product liability for consequential damage of any type is excluded for damage and operational interruptions resulting from operating errors, failure to observe these operating instructions or incorrect maintenance by unauthorised personnel.

RÖHM GmbH expressly points out that replacement and wear parts supplied by the manufacturer must be authorised by RÖHM GmbH. The company RÖHM GmbH does not accept liability for unauthorised replacement and wear parts. This applies to both product liability for consequential damage of all types and to liability for damage to property.

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About these Operating Instructions All unauthorised conversions, modifications to the pallet support and/or

changes in conditions are not permitted for safety reasons and exclude all liability of RÖHM GmbH for any damage which may result. If modifications to the pallet support are necessary or the area of use differs from the intended use, this must be agreed with the express permission of RÖHM GmbH.

The statutory and contractually agreed terms and conditions apply.

The following damage or defects are excluded from the warranty

■ caused by the operator due to non-compliance with the written instructions of the seller with regard to

□ commissioning (e. g. incorrect construction and assembly work),

□ operation and

□ maintenance of the equipment (insofar as this maintenance has not been contractually taken over by the manufacturer);

■ caused by technical operating conditions unknown to the manufacturer (e. g. chemical or electrolytic influences) and/or machine specifications;

■ caused by natural wear;

■ caused by force majeure;

■ caused by incorrect operation of all types or by incorrect use or operation of the pallet support. This also includes loading beyond the specified load limits (e. g. speed, pressure, force etc.).

This also includes damage caused

■ if the customer or third parties carry out modifications or repairs to the services / products of the manufacturer without prior permission of the manufacturer. Excepted from this are damage or defects which have occurred which were demonstrably not due to these modifications or repairs.

■ which occur due to use of the pallet support under altered operating conditions (e. g. materials, tools, cutting parameters, programs etc.), in particular without consulting and obtaining written authorisation from the seller or manufacturer;

■ which are due to altered environmental conditions.

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1.4 Conventions of Presentation

1.4.1 Text Display

To improve legibility and comprehension of the text, the following conventions were agreed:

Text type Marking Function

Operating instruction 1., 2., etc.

Marks a sequence of actions

 Marks an individual operating

instruction

 Intermediate

result Marks the intermediate result of an operating instruction

 End result Marks the end result of an operating instruction

List ■ Marks elements

of a list

□ Marks comments within a list

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1.4.2 Display of Safety and Warning Instructions

Safety and warning instructions are marked by pictograms. The signal word and the colouring show the level of danger.

Observe the safety instructions to prevent personal injury and damage to property.

Danger

Indicates an imminently dangerous situation

which may lead to death or permanent personal injury if not avoided.

 List of all measures which must be taken to prevent consequences.

Warning

Indicates a possible danger

which may lead to death or serious injuries if not prevented.

Caution

which may lead to minor or serious injuries if not prevented.

Notice

which may lead to damage to property if not avoided.

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Safety

2 Safety 2.1 Intended Use

The pallet support was developed and designed for installation on a machine table or a comparable mounting device. Only zero point clamping systems may be installed in the recesses (zero point clamping system holder) of the pallet support which are intended for this purpose. The diameter of the recesses in the pallet support and the zero point clamping systems must match.

With the zero point clamping systems installed, the purpose of the pallet support is to position and clamp clamping pallets, clamping towers and other clamping devices.

Use as intended also includes that all maintenance work is carried out in accordance with the intervals (see Chapter 9.3 Maintenance Interval on page 58) .

The permissible usage and environmental conditions must be observed (see Chapter 3.2 Technical Specifications on page 44).

2.2 Improper Use

If the pallet support is operated for a purpose other than the intended use as specified in these operating instructions, this is deemed to be improper use.

Any utilisation beyond the scope of the intended use poses risks and is not approved by RÖHM GmbH.

Improper use refers to the following:

■ use of the pallet support without attachment to a machine table or a comparable mounting device;

■ use of the pallet support in combination with unauthorised fixing screws;

■ use of the pallet support without authorised zero point clamping systems;

■ fitting of pull studs with unauthorised fixing screws;

■ complete and permanent insertion and immersion of the pallet support for electrical erosion.

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Safety

2.3 Obligations of the Owner

Before work on and with the pallet support is commenced, the owner must ensure

■ that the operating instructions are available to the responsible personnel;

■ that the responsible personnel are sufficiently qualified for their work;

□ This applies in particular to assembly, maintenance and repair.

■ that the responsible personnel have read and understood the operating instructions;

□ RÖHM GmbH recommends that this be documented in a suitable form.

■ that all safety equipment is correctly mounted and operational;

□ Safety equipment must never be by-passed, manipulated or shut down.

■ that the pallet support is in perfect working order;

■ that all damaged and defective parts are replaced immediately.

2.4 Qualification of Operating and Specialist Personnel

Personnel without experience of operating clamping fixtures are exposed to increased risks of injury in the event of incorrect conduct, especially during assembly and maintenance work, due to the clamping movements and forces which occur on the clamping fixtures.

Therefore, the pallet support may only be used, set up or repaired by persons who have received special training or instruction for this purpose or who have extensive experience.

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Safety

2.5 Personal Protective Equipment

When working on and with the pallet support, personal protective equipment must be worn. The owner is responsible for providing personal protective equipment.

■ Personal protective equipment must be in perfect condition when carrying out work. Defective safety equipment is to be replaced immediately.

■ Observe information on personal protective equipment posted in the working area.

Wear ear protection Wear foot protection Wear hand protection

2.6 General Dangers

When using the pallet support there is a special potential of residual risks

■ during assembly and set-up work,

■ during operation and

■ during maintenance and service work.

This potential risk cannot be completely eliminated considering the functional availability of the pallet support. Therefore, all individual regulations of these operating instructions are to be observed.

2.6.1 Danger of Crushing Hands

In the case of assembly and set-up work, there is an increased danger of crushing of hands, as during this work hands are used without protection at the point of danger. The point of danger is situated directly between the machine table and the pallet support.

If fingers are in the danger zone at this time, this may result in serious crushing injuries.

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Safety

2.6.2 Injuries to Eyes and Hands due to Swarf

Sharp metal chips may be produced during machining of metal. During maintenance work, there is a possibility of coming into contact with swarf. If sharp metal chips are stirred up, these may cause eye injuries and cuts.

To prevent eye injuries and cuts, wear eye protection and hand protection during maintenance work.

2.6.3 Skin Irritation due to Operating Materials

During maintenance work, there is a possibility of coming into contact with lubricant. The lubricant consists of substances which may lead to skin irritations in the event of frequent skin contact.

In order to minimise the risk of skin irritations, wear long work clothing and avoid contact with the lubricant.

2.7 Procedure in the Event of Danger and Accidents

In the event of danger and accidents, it must be ensured that first aid measures can be taken immediately.

1. Shut the machine down immediately via the Emergency-Stop button.

2. Remove the person involved from the danger zone and sit or lay the person down.

3. Call a doctor.

 Do not make any changes to the accident site.

4. Administer first aid.

 Stop any bleeding.

 Cool burns.

5. Report all accidents to a superior.

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About this Pallet Support

3 About this Pallet Support 3.1 Product Description

1

2 3 4

1 Zero point clamping system

2 Holder of zero point clamping system

3 Pallet support

4 Coupling

The pallet support is a coupling system which can be installed on a machine table or a suitable assembly device with fixing screws.

With a pallet support (3), depending on the design, 1, 2, 4 or 6 zero point clamping systems (1) can be positioned and fixed. To do this, the zero point clamping system is inserted in the holder (2) and installed.

The pallet support is supplied with pressure via a centrally situated coupling (4).

■ Releasing the pressure clamps the zero point clamping systems.

■ Application of pressure releases the zero point clamping systems.

Activation is carried out pneumatically.

The pallet support with the installed zero point clamping systems enables fast and accurately repeatable clamping of clamping pallets, clamping towers and other clamping pieces on which the corresponding draw bolts are

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3.2 Technical Specifications

The following list describes the main data of the pallet support and of the zero point clamping systems (EASYLOCK).

Dimensions of pallet support Article number Product

designation Length

[mm] Width

[mm] Height

[mm]

1314882 TF20.200.200.5 8-1-BPI112-I

200 200 43

1314884 TF20.400.200.5 8-2-BPI112

400 200 43

1314886 TF20.350.350.5

8-4-BPI112 350 350 43

1352604 TF20.600.350.6

4-6-BPI112 600 350 43

1313928 TF20.200.200.5 8-1-BPI138-I

200 200 43

1313930 TF20.400.200.5 8-2-BPI138

400 200 43

1313932 TF20.350.350.5

8-4-BPI138 350 350 43

1313934 TF20.600.350.6

4-6-BPI138 600 350 49

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Article number Product

designation Inside micro- meter [mm]

Number of EASY- LOCKS

Pressure to open [bars]

1314882 TF20.200.200.5

8-1-BPI112-I 0 1 8-12

1314884 TF20.400.200.5 8-2-BPI112

200 2 8-12

1314886 TF20.350.350.5 8-4-BPI112

200 4 8-12

1352604 TF20.600.350.6

4-6-BPI112 200 6 8-12

1313928 TF20.200.200.5

8-1-BPI138-I 0 1 6-10

1313930 TF20.400.200.5 8-2-BPI138

200 2 6-10

1313932 TF20.350.350.5 8-4-BPI138

200 4 6-10

1313934 TF20.600.350.6

4-6-BPI138 200 6 6-10

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About this Pallet Support Groove spacing [mm]

Article

number Product

designation 50 63 100 125

1314882 TF20.200.200.5 8-1-BPI112-I

x x

1314884 TF20.400.200.5 8-2-BPI112

x x

1314886 TF20.350.350.5

8-4-BPI112 x x x x

1352604 TF20.600.350.6

4-6-BPI112 x x x x

1313928 TF20.200.200.5 8-1-BPI138-I

x x

1313930 TF20.400.200.5 8-2-BPI138

x x

1313932 TF20.350.350.5

8-4-BPI138 x x x x

1313934 TF20.600.350.6

4-6-BPI138 x x x x

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3.2.1 Environmental and Operational Conditions

The pallet support is designed for the following environmental and operating conditions:

Ambient temperature at place of operation

+5 °C to +70 °C

Ambient temperature for storage -5 °C to +85 °C

Pollution of the environment caused by the machine itself is permitted.

However, perfect operation of the pallet support must be ensured and checked regularly. In addition, the pallet support must be cleaned in accordance with the cleaning interval.

3.2.2 Permissible Operating Materials

The compressed air must meet the following requirements:

■ dry and free of water;

■ filtered to 10 μ;

■ oiled.

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Transport

4 Transport

4.1 Personal Protective Equipment

4.2 Transporting the Pallet Support

Warning

Crushing injuries in the event of unsecured transport of the pallet support.

Falling of the pallet support.

 Use suitable hoisting gear and slings.

 Wear personal protective equipment.

 Do not remain under suspended loads.

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Transport All 2, 4 and 6 sizes of the pallet support are fitted with an M10 thread (1) to

screw in a transport lug. The M10 thread (1) is fitted in the centre of the pallet support.

1

Transporting the size 1 pallet support:

 The size 1 pallet support can be transported by hand.

Ensure that the transport route does not represent a risk of tripping.

Transporting size 2, 4 and 6 pallet supports:

RÖHM GmbH recommends transporting size 2, 4 and 6 pallet supports with hoisting tackle.

Transporing the pallet support with a crane:

1. Fit transport lug to the M10 (1).

2. Attach suitable slings to the transport lug and the lifting tackle.

3. Lift the pallet support and transport it to the required position.

4. Set the pallet support down and remove the slings.

5. Remove the transport lug after transport.

 Pallet support transported with a crane.

If no lifting tackle is available, two persons should transport the size 4 and 6 pallet supports and ensure an ergonomic posture.

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Assembly

5 Assembly

Warning

Crushing injuries due to insufficient securing on assembly, incorrect tightening torque of the screws.

Crushing due to falling of the pallet support.

 Use tapped holes for transport purposes.

 Wear personal protective equipment.

 Observe tightening torque of the screws.

5.1 Personal Protective Equipment

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Assembly

5.2 Pre-Conditions on the Machine Table

The machine table (reference plane) on which the pallet support is mounted must meet the following requirements:

■ The surface of the machine table (reference plane) must have an evenness of 0.03 mm.

■ The contact surfaces of the machine table and pallet support must have an equivalent surface.

■ The machine table must be free of impact loads.

5.3 Mounting the Pallet Support on the Machine Table

1 3

2

4

5

1 Zero point clamping system

2 Pallet support

3 Fixing screws with slot nuts

4 Fixing screws

5 Machine table

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Assembly Mounting the pallet support on the machine table

1. Free the contact surface of the (5) and the underside of the pallet support (2) of dirt.

2. Place the pallet support in the required position on the machine table.

3. There are two ways to fix the pallet support to the machine table:

a) screw the fixing screws (4) directly into the machine table;

b) position the slot nuts in the T-slot of the machine table and screw the fixing screws (3) into the slot nuts.

 The pallet support is installed.

Permissible fixing screws and tightening torque

Screw type Outer Ø Quality class Tightening

torque

DIN EN ISO 4762 M10 12.9 79 Nm

5.4 Installing the Zero Point Clamping System on the Pallet Support

The exact description of installation of the (1) on the pallet support is given in the relevant OEM operating manual of the EASYLOCK zero point clamping system.

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Commissioning

6 Commissioning

Condition

Before commissioning the pallet support, the following requirements must be met:

■ the connection coupling of the pallet support must be compatible with the main supply coupling (compressed air).

■ the zero point clamping system must be correctly mounted on the pallet support.

■ the fixing screws are tightened with the correct tightening torque.

The pallet support is aligned on the machine table as follows:

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Operation

7 Operation

Condition

■ The holder of the pallet support matches the geometry of the zero point clamping system.

■ The mounting surfaces of the pallet support and of the zero point clamping system are free of swarf and other dirt.

Clamping the zero point clamping systems in the pallet support:

 In order to clamp the zero point clamping systems in the pallet support, detach the connection line from the pallet support.

 The zero point clamping systems in the pallet support are in clamping position.

Releasing the zero point clamping systems in the pallet support:

 In order to release the zero point clamping systems in the pallet support, connect the connection line to the pallet support and apply pressure.

 The zero point clamping systems in the pallet support are in release position.

Condition on the connection line Position of the zero point clamping system

Connection line depressurised The zero point clamping system is in clamping position.

Connection line under pressure (8 - 12 bars)

The zero point clamping system is in release position.

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Decommissioning and Storage

8 Decommissioning and Storage

Condition

Before decommissioning the pallet support, the following requirements must be met:

■ The main supply (compressed air) must be switched off.

■ The pallet support must not contain residues of hydraulic oil.

Storage

■ The pallet support must be free of lubricant and swarf.

■ The zero point clamping system must be oiled to protect it against rust.

■ If the pallet support is made of steel, this must also be oiled to protect it against rust.

■ The pallet support must be stored flat and free of dirt.

For the pallet support, the following anti-rust oil is permitted as per EC 1907/2006 (REACH) and EC 1272/2008:

■ Neutrafilm H55 FUCH

Before restarting, the maintenance work is to be carried out (see Chapter 9.3 Maintenance Interval on page 58).

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Maintenance

9 Maintenance

The state of maintenance of the pallet support has an important effect on operation, clamping force, accuracy and service life.

9.1 Safety during Maintenance

Warning

Eye injuries and cuts due to sharp metal chips.

If sharp metal chips are stirred up, these may cause eye injuries and cuts.

 Wear eye and hand protection when using blower air.

Caution

Skin irritations due to contact with lubricants.

The constituents of the lubricant may cause irritations in the event of contact with the skin.

 When handling the pallet support, wear safety goggles, long work clothes and gloves.

 Avoid skin contact with lubricants.

Notice

Damage to property due to undiscovered damage or dirt on the clamping system.

If the pallet support is damaged or there is dirt on the functional surfaces, tools may be damaged or parts incorrectly machined.

 Immediately shut the pallet support down in the event of visible damage or signs of functional faults.

 Only put the pallet support back into operation when the damage has been eliminated.

It is recommended to replace the complete pallet support.

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Maintenance

9.2 Personal Protective Equipment

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Maintenance

9.3 Maintenance Interval

The regular maintenance work is described in the following:

Activity Interval

In the event of heavy soiling

Every 6 months Annually

Cleaning the

pallet support x x

Cleaning the

circuits x x

If the pallet support has not been used for more than 6 months, the circuits are to be cleaned.

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Maintenance

9.4 Maintenance Work

9.4.1 Cleaning the Pallet Support

Free the pallet support from solidified lubricant and swarf which impair the function of or damage the zero point clamping systems.

 Remove solidified lubricant and swarf from the pallet support in order to ensure correct operation of the zero point clamping systems.

 The pallet support is cleaned.

9.4.2 Cleaning the Circuits

Completely empty the circuits to remove all traces of condensation water.

 Completely empty the circuits of the pallet support and clean with a suitable brush. Ensure that no residue remains in the circuit.

 The circuits are cleaned.

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Troubleshooting

10 Troubleshooting

Fault Possible cause Measure

The pallet cannot be lifted although the compressed air supply is activated.

■ The pallet and the zero point clamping system are not aligned parallel to each other

■ Insufficient pressure

■ Check elements for impact loads, swarf and other foreign bodies

■ Check correct connection of the correction line

The pallet is not firmly in place although the compressed air supply is deactivated.

■ The pallet and the zero point clamping system are not aligned parallel to each other

■ Check elements for impact loads, swarf and other foreign bodies

■ Contact Customer Service

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Disposal

11 Disposal

If the pallet support is finally disassembled or dismantled, the materials must be disposed of in an environmentally way in accordance with the valid regulations:

■ Metals

Metals must be recycled. They must be disposed of in accordance with the valid regulations and the applicable local provisions. Obtain relevant information from the authorities.

■ Rubber (e.g. O-rings)

They must be disposed of in accordance with the valid regulations and the applicable local provisions. Obtain relevant information from the authorities.

Original-Betriebsanleitung Palettenträger pneumatisch betätigt