CNC-Step flowJET 2015 Operating Instructions Manual Download

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Operating Instructions

flowJET Waterjet cutting machine

CNC-STEP GmbH & Co.KG ▪ Siemensstrasse 13-15
▪ 47608 Geldern ▪ Germany

Page 33

Support: +49 (0)2831/91021-50

02/06/2020

2 . 7

S e c u r i n g a g a i n s t A c c i d e n t a l S t a r t i n g

WARNING!
Danger to life through uncontrolled restart!

Uncontrolled or un-authorized restart can cause
serious personal injury or death!

- Before restarting ensure that the cause for the

emergency stop has been eliminated, that all
safety devices have been reassembled and are
functional.

- Observe the following instructions to prevent un-

authorized starts.

Securing Main Switch

Fig.10: Securing main switch

To turn off the power supply move the switch to the "0" po-

sition.

Lock the switch with a Pad-Lock (Fig. 10).

Keep the pad-lock key in a secure area to prevent un-author-

ized access.

Summary of Contents for flowJET 2015

Page 1: ...02 06 2020 02 06 20202020 06 02 Operating Instructions flowJET Rev 05 2020 Subject to changes 2015 2515 3015 https www cnc step com ...

Page 2: ... based on a low warpage steel construction The linear movement of the sled is carried out via racks driven by powerful stepper motors The machine is therefore designed for 3D travel and high speeds The portal sits on a pool of water with an integrated air chamber to lower and raise the water level These operating instructions describe the installation commissioning and maintenance of the CNC water...

Page 3: ...o High or Low Temperatures 18 2 2 4 Danger of Fire 18 2 2 5 Danger of Radiation 19 2 2 6 Danger from Chemical Compounds 20 2 2 7 General Dangers in the Workplace 21 2 3 Responsibility of the Operator 22 2 4 Staff Requirements 24 2 4 1 Qualifications 24 2 4 2 Training 25 2 5 Personal Protection Equipment 26 2 6 Safety Systems 28 2 6 1 Description of the Installed Safety Devices 28 2 6 2 Safety Devi...

Page 4: ...3 5 Lubricants 45 3 6 Emissions 45 3 7 Name Plate 45 4 ASSEMBLY AND COMMISSIONING 46 4 1 Overview 46 4 2 Short Description 47 4 3 Description of Sub Assemblies 49 4 3 1 Y Axis with Slide 49 4 3 2 Z Axis with Slide 50 4 3 3 X Axis with Slide 50 4 3 4 Operating Software 51 4 3 5 Controller 51 4 3 6 Accessory Holder Fehler Textmarke nicht definiert 4 4 User Controls 53 4 5 Connections 54 4 6 Working ...

Page 5: ...2 2 Adjusting Tabletop Fehler Textmarke nicht definiert 6 3 Installation 68 6 3 1 Connecting the Computer 71 6 3 2 Connecting the Stepper Motors 71 6 3 3 Installing Accessories 72 6 4 Connecting to Power Supply 73 6 5 Commissioning 74 7 OPERATION 75 7 1 Safety Instruction for Operation 75 7 2 Important Steps before Operation 75 7 3 Switching On Procedure 76 7 4 Important Steps during Operation 77 ...

Page 6: ...ken after Maintenance Procedure 100 9 TROUBLE SHOOTING 101 9 1 Safety during Trouble Shooting 101 9 2 Table of Faults 103 9 3 Fault Repair 105 9 3 1 Releasing the Emergency Stop Switch 105 9 3 2 Changing the Electrical Fuse 106 9 4 Start up after Fault Repair 109 10 DISASSEMBLING AND DISPOSAL 110 10 1 Safety during Disassembling and Disposal 110 10 2 Disassembling 111 10 3 Waste Disposal 111 CAUTI...

Page 7: ...l accident prevention regulations and general safety rules must be applied during the operation of the machine Illustrations or graphical representations in this manual serve the fundamental understanding and may differ from the actual con struction of the machine In addition to these instructions the instructions in the annexure of the assembled components apply accordingly 1 2 Explanation of Sym...

Page 8: ... property if ignored ATTENTION The symbols or a combination of symbols highlight potential dangers that can result in injury to persons or damage to property if ignored Important safety symbols To draw attention to special dangers the following symbols are used in the safety instructions DANGER A combination of this symbol and warning indicate danger of potential electrocution which could result i...

Page 9: ...ding knowledge and experience The manufacturer assumes no liability for damages due to Failure to comply with the instructions in this manual Non specified use Operations by unqualified staff Unauthorized alterations or modifications Technical changes Use of unauthorized spare parts For special designs additional ordering options or due to some late technical modifications the actual delivery may ...

Page 10: ...opyrighted and designed exclusively for internal purposes Release of the manual to third parties reproductions of any type or form extracts or parts thereof and communication of the con tents are not permitted without the written permission of the man ufacturer except for internal purposes Any breach of this obliga tion shall result in liability for damages The right to any further claims remains ...

Page 11: ...c glass and ceramics with high water pressure up to 3800bar For various materials an abra sive unit must also be used Only purified water but no salt free water may be used for cutting The machine has its own control system Intended use also includes the adherence to all information in this manual as well as the instructions pertaining to the components Any use exceeding or differing from the appr...

Page 12: ... of the machine with a technical fault Operating the machine in an explosive environment Any claims resulting from misuse or incorrect handling of the machine will not be entertained 2 2 Basic Dangers In the following section remaining risks are listed which have been identified based on a risk assessment The safety instructions and warnings given in the other chapters of this manual must be obser...

Page 13: ...ly qualified electricians can work on the electrical systems In case of damage to the insulation disconnect the power supply immediately and arrange for repairs During all work on the electrical systems disconnect from the mains and verify that the disconnected parts are free of voltage These five rules apply Disconnect from main supply Secure against accidental reactivating Check for current Chec...

Page 14: ... the capacitors time to discharge the stored current 2 2 2 Danger of Mechanical Parts High pressure Waterjet WARNING Risk of injury from high pressure water jet The high pressure water jet can lead to severe personal injury or property damage Before starting work make sure that all covers and safety devices are installed and working properly Do not reach into the beam during operation Before repla...

Page 15: ...ing parts and their end stops Never reach between the machine and rails Only perform maintenance on linear guides when machine is switched off Always wear protective clothing in the work area Toothed Rack WARNING Risk of injury by moving rack and pinion gear While operating clothing hair or body parts could get caught in the rack and pinion leading to serious injury Never reach over toothed rack w...

Page 16: ... tools may be ejected from the work area causing serious injury to face or eyes Always wear face and eye protection gloves and safety shoes In the event of an injury contact the medical personnel Uncontrolled restart WARNING Uncontrolled restart can cause serious personal injury or death The machine could move unexpectedly or change direction unexpectedly resulting in injury Keep body parts away f...

Page 17: ...and valve If an abrasive conveyor is installed there will be pressure in the line to the abrasive dispenser The Conveyor is to be switched off when working on the machine thereby releasing the pressure Tools Caution Risk of injury due to negligent handling of tools Negligent handling of the tools can cause bruises or cut injuries Tools are to be handled carefully and according to their intended st...

Page 18: ...these surfaces could result in severe burns to the skin When operating the tools or workpieces always wear heat resistant clothing and gloves Before starting work ensure that all surfaces have reached ambient room temperature 2 2 4 Danger of Fire Highly flammable materials WARNING Danger of fire through flammable materials Do not smoke near the working or danger area and avoid open flames or other...

Page 19: ...rty Persons with Pacemakers should not work on or approach the machine The Pacemaker may be affected Persons with metal implants should not work on or approach the machine The implants may heat up or be pulled towards the machine Do not wear any jewellery like rings necklaces watches etc when operating the machine Do not place any electronic equipment near the magnetic fields as these may be damag...

Page 20: ...ter can result in irritation or chemical burning Wear protective clothing and chemical resistant protective gloves when handling contaminated water Avoid direct skin contact Remove skin impurities immediately especially before breaks and after finishing work Only eat and drink in the designated break room Fig 1 CAUTION Health risk from exposure to Cutting water Contact with cutting water can be de...

Page 21: ... General Dangers in the Workplace Loud noise WARNING Danger of damage to hearing from loud noise The noise levels in the work area can cause serious damage to your hearing Always wear ear protection If possible only cut beneath Water Level Noise will increase dramatically when cutting above water level Avoid exposure to noise where possible Water Fig 2 WARNING Risk of slipping through water When w...

Page 22: ...chine is used in the commercial sector Therefore the operator of the machine is subject to the statutory requirements for operational safety In addition to the safety instructions mentioned in this manual the valid safety regulations and rules for accident prevention as well as the environmental protection law must be observed The following must be adhered to The operator has to be informed about ...

Page 23: ... provide the necessary protective equipment for the staff The operator is responsible for keeping the protective device technically faultless and keeping it up to date The safety device is part of the declaration of conformity and must function properly The operator is responsible for ensuring that the machine is al ways in perfect technical condition therefore the following ap plies The operator ...

Page 24: ...ult in significant injury or damage to persons and property Therefore Operations only to be carried out by qualified staff Unqualified personnel are to remain clear of the working area Only persons whose work performance is reliable may be con sidered as staff Persons whose ability to perform is influenced or impaired by drugs alcohol or pharmaceuticals are not to be considered The manual requires...

Page 25: ...evant standards and regulations Qualified Staff Qualified Staff with professional training knowledge and expe rience as well as knowledge of the relevant regulations that can carry out operations or tasks assigned to them and are able to de tect and avoid potential dangers independently Manufacturer Certain functions may only be carried out by qualified persons from the Manufacturer For informatio...

Page 26: ...d equipment Below is a list describing the required protective clothes and equipment Protective Work Clothing Must be tight fitting work clothing with a low tensile strength narrow or tight sleeves and no protruding parts Chemical resistant gloves As protection for the hands against chemical irritants Ear protection As a protection against hearing damage due to noise Safety helmet Industrial safet...

Page 27: ...KG Siemensstrasse 13 15 47608 Geldern Germany Page 27 Support 49 0 2831 91021 50 02 06 2020 Hair Net To protect the hair from being caught in machinery or rotation tools Safety Shoes As a protection against heavy falling objects and to provide trac tion on slippery surfaces ...

Page 28: ...y trip switches are accessible 2 6 1 Description of the Installed Safety Devices Emergency Stop Switch Fig 3 Emergency Stop Switch By pressing the emergency stop button Fig 3 an emergency stop is triggered and the drive motors are physically discon nected preventing any movement After the emergency stop button has been pressed it must be un locked by twisting so that restarting is possible WARNING...

Page 29: ... 06 2020 Location of the Emergency Switches The illustration shows the location of the Emergency Stop Switches This symbol indicates an Emergency Stop Switch Fig 4 Position of the Emergency stop switches Top view 1 Emergency Stop switch on left front of machine 2 Emergency Stop switch on Control panel 3 Emergency Stop switch on right back of machine 1 3 2 ...

Page 30: ...unction Abb 6 Main switch The main switch is also an emergency stop button By turning the main switch to the 0 position the power supply is immedi ately disconnected and an emergency stop is triggered WARNING Danger to life through uncontrolled restart Uncontrolled restart can cause serious personal injury or death Before restarting ensure that the cause for the emergency stop has been eliminated ...

Page 31: ...s Safety Fences and Covers The Machine is to be installed as part of a system Before using the machine ensure that all safety fences or covers are installed and connected to the main controller on the safety circuit Covers serve to protect against debris dust or parts that may eject from the working area Fences serve to protect the working area from intrusion while machine is running Use the corre...

Page 32: ...doors and maintenance accesses They prevent starting when open or turn off the machine if opened while running the ma chine 2 6 3 Device for releasing pressure in Lines and valves Manual Pressure Release Valve If the machine is not in use for a longer period or when working on the machine for maintenance the pressure in the lines and valves must be released must be released This is done through a ...

Page 33: ...tart can cause serious personal injury or death Before restarting ensure that the cause for the emergency stop has been eliminated that all safety devices have been reassembled and are functional Observe the following instructions to prevent un authorized starts Securing Main Switch Fig 10 Securing main switch 1 To turn off the power supply move the switch to the 0 po sition 2 Lock the switch with...

Page 34: ...er Emergency Stop immediately Rescue persons from the danger area when it is safe to do so Start first aid measures if necessary Alert rescue services In case of fire if there is no immediate danger to life use fire extinguishers to control the fire until fire services arrive Inform the responsible persons immediately Keep access roads clear for emergency vehicles Direct rescue services onto the p...

Page 35: ...ng Water Cutting water contains substances after use from the material that has been cut This water may only be disposed of via the normal sewer with the help of a cleaning system and an official permit in Germany The operator must inform himself about the respective obliga tions in other countries regarding disposal and observe these laws and regulations Abrasives The abrasive mixes with the cutt...

Page 36: ...resulting in risk of injury due to hazards not recognized in the absence of a visible warning sign Regularly maintain all labels signs and symbols so they are clearly visible and readable Replace any damaged or illegible labels or signs 2 10 1 Advisory Signs Refer to User Manual Do not use the machine until the described signs and symbols have been understood by referring to the user manual 2 10 2...

Page 37: ...d Wearing jewellery which may get caught in the workings of the machine possibly causing injury or death is prohibited in the ar eas displaying this sign Operating while wearing neckties prohibited Persons wearing a necktie are prohibited from entering the area displaying this sign The necktie may get caught in the work ings of the machine causing injury or death Operating with long hair is prohib...

Page 38: ...ons can open doors with this sign and should keep clear of the area Automatic Start The signals a flashing light or acoustic siren denote the auto matic starting of production line machines At this point all work in the area must be complete After the signal clear the area immediately Avoid any moving parts that may cause injury Hot Surfaces Hot surfaces tools liquids and other potential hazards m...

Page 39: ...ces A conventional telephone may be used in an emergency to con tact emergency services and alert responsible persons The following information will be required Who is calling Nature of the emergency How many persons affected injured Where did the incident take place Respond to any questions asked Fire Extinguisher Guideline for using fire extinguisher Before activating the fire extinguisher ensur...

Page 40: ...ovide first aid to patients If any items are used in the first aid kit this must be noted and replacements provided Emergency Exit In case of emergency use this exit to leave the area Emergency Phone This phone may only be used in an emergency Use the phone to alert the emergency services The following information will be required Who is calling Nature of the emergency How many persons affected in...

Page 41: ...ication flowJET 2015 flowJET 2515 flowJET 3015 Length X 2400 mm 2400 mm 2400 mm Width Y 2900 mm 3400 mm 3900 mm Height Z 4000 mm 4000 mm 4000 mm Weight distrib uted on 6 feet ca 1500 kg ca 1900 kg ca 2300 kg Overall weight with Pump and Water ca 4200 kg ca 4850 kg ca 5500 kg Clamping area LxW 1700 x 2200 mm 1700 x 2700 mm 1700 x 3200 mm Bridge Clearance 300 mm machining possible up to 200 mm depen...

Page 42: ...min1 depending on form complexity and ramp speed Steps X Y Z 0 0213 0 0113 mm Reverse direction correction ca 0 045 mm Position Error Can be calibrated Reference Limit switches 3x Magnetic contactless on all axis Work Area Monitoring Software Controlled Linear guides X Y Z HIWIN 20 mm Pre tensioned with 4 slides per axis Drives X Y Z 3x Stepper Motor 9 4 Ampere 9 3 Nm holding Torque Drive type X Y...

Page 43: ...021 50 02 06 2020 3 2 Power Supply Electrical total Description Value Unit Voltage 380 V Frequency 50 Hz Power consumption maximum 17 or 32 kW Pneumatik Port Description Value Unit Dry Pressured Air without oil min 8 max 10 bar Water connection Description Value Unit Water pressure min 3 bar Flow Rate 15 kW min 2 l min Flow Rate 30 kW min 5 l min ...

Page 44: ...l Description Value Unit Current maximum 32 A Power consumption maximum 15 or 30 kW Drive motors X Y Z Description Value Unit Max current per Motor 9 4 A Holding Torque 9 33 Nm 3 4 Operating Requirements Environment Description Value Unit Temperature range 16 30 C Max Humidity 60 Duty Cycle Description Value Unit Max run time without stopping Runtime of the orifice h Rest period required to next r...

Page 45: ...nthetic Long life Grease 20 Grams per Ball Nut 3 6 Emissions Description Value Unit Sound emissions without Waterjet ca 50 dB A Sound emissions with Waterjet un der Water 70 dB A Sound emissions with Waterjet over water 110 dB A 3 7 Name Plate Fig 12 Name Plate The name plate is attached to the frame of the machine next to the controller box and contains the following information Manufacturer Type...

Page 46: ... 1 Y Axis with slide Y Bridge Chapter 4 3 1 Y Axis with Slide page 49 2 Cable channel 3 Z Axis with slide Chapter 4 3 2 Z Axis with Slide page 50 4 Working table 5 X Axis with slide Chapter 4 3 3 X Axis with Slide page 51 6 Operator station with software Chapter 4 3 4 Operating Software page 51 7 Controller Chapter 4 3 5 Controller page 52 8 Water Basin 9 10 High Pressure Line Abrasive Feeder Sepa...

Page 47: ...alled before the machine will be ready for cutting High Pressure Pump to produce the High Pressure Water Jet Abrasive feed to cut harder materials On the work table Fig Fehler Verweisquelle konnte nicht gefunden werden 4 the workpiece is clamped In the accessory holder Fig Fehler Verweisquelle konnte nicht gefunden werden 8 the cutting head is attached to process the workpiece All movements of the...

Page 48: ...ill be saved in either HPGL dxf AI etc formats This data will be opened in the CNC controlling software e g WinPCNC op tional to be run on the machine All operational parameters can be set up in the software to con trol feed rates cutting depths scale etc The motion commands are given from the software to the CNC stepper motors to per form the required movements The four stepper motors X Y Z and 4...

Page 49: ...e 49 Support 49 0 2831 91021 50 02 06 2020 4 3 Description of Sub Assemblies 4 3 1 Y Axis with Slide Fig 14 Y Slide 1 Linear Guides Fig 25 Y Rack 2 Rack The two linear guides Fig 14 1 and the rack Fig 15 2 are found on the Y bridge Fig 13 1 and form the Y axis on which the Abrasive Dosage and the Cutting Head are moved 1 2 ...

Page 50: ...e two linear guides Fig 16 1 form the Z Axis on which the milling spindle optional will be moved in the Z direction 4 3 3 X Axis with Slide Fig 17 X Slide 1 Linear Guides 2 Rack The figure shows the X linear guides Fig 17 1 and the X rack Fig 17 2 on one side of the machine The second X axis with rack and guide is found on the other side of the machine Both the X rails form the X axis on which the...

Page 51: ...available in the software user manual supplied with the software 4 3 5 Controller Fig 19 Controller The controller controls the stepper motors for each axis The controller Fig 19 is connected to the PC by a parallel port connection RS232 It is possible to connect the PC directly to the controller via parallel port if one is using WinPCNC Econ omy WinPCNC Profi has an axis controller and will conne...

Page 52: ...y a frequency inverter and therefore has its own control system which is activated via a signal 0 10V There is a separate user manual for the unit 4 3 7 Abrasive Conveyor Optional When cutting materials such as steel an abrasive is required to cut them For this purpose this is stored in a conveyor as seen in the picture The abrasive conveyor pushes it forwards it to the abrasive dosage with the he...

Page 53: ...ing Valve The cutting valve helps to maintain the pressure in the line This reduces the on and off time of the pump and reduces downtime between cuts The valve also holds back the water when driving over workpieces without cutting There is a sepa rate maintenance manual for this purpose In case of malfunc tion the rupee disc of the HD pump may break The valve is controlled by compressed air 4 4 Us...

Page 54: ...06 2020 4 5 Connections Connections on the controller Fig 24 controller front view 1 Connection computer with software 2 Connection Handwheel 3 Connection High Pressure Pump 4 Connection Abrasive Conveyor and Dosage 5 Connection Control panel 6 Connection Power for Controller Fig 25 controller Rear view 1 Connection Pressurized Air 2 Power supply 380 V 16A ...

Page 55: ...e 55 Support 49 0 2831 91021 50 02 06 2020 4 6 Working and Danger Areas Working areas PC not supplied Inside the clamping area while the machine is switched off Inside the cutting area while the machine is switched off Abrasive Conveyor while filling Danger areas Complete machine while in operation Fig 26 Complete Machine ...

Page 56: ...d loads When lifting loads life threatening danger exists by falling or uncontrolled swinging of objects Therefore Before moving the machine drain the water in the tub and dispose of it in an environmentally friendly manner as well as residues The attachment points aside the basin are only designed for the weight of the tub without water Never lift tub full of water Never step under hanging or sus...

Page 57: ... attention to the markings on the container Attach the hoists hook that it is above the centre of gravity Lift carefully and observe if the load starts tipping over If necessary modify or move the sling or harness Inappropriate Transportation CAUTION Damage caused by inappropriate transportation Inappropriate transportation can cause significant ma terial damage to property Therefore Take care whi...

Page 58: ...iate a customer complaint Complain about any deficiency once it is detected Damage claims can be asserted only within the applicable time limits 5 3 Packaging 5 3 1 About Packaging The individual containers are packed according to the expected transportation conditions Only environmentally friendly materi als are used for the packaging The packaging is intended to protect the individual components...

Page 59: ...tainer with caution do not drop or expose to collisions Do not stack Do not stack anything on top of the marked packages or contain ers Keep dry Protect packages or containers against moisture and keep them dry CAUTION Environmental damage caused by inappropriate disposal Packaging materials are valuable raw materials In many cases these may be used further or can be sensibly re used and recycled ...

Page 60: ...h a crane under the following conditions Cranes and hoisting devices must be designed for the weight of the containers The operator must be authorized to operate the crane or hoist Attaching Safety equipment Safety helmet Fig 27 Attach lifting straps 1 Attach ropes belts or multi position hanger according to fig 27 and secure pallet against sliding 2 Check whether the containers are going to be da...

Page 61: ...Transportation of pallets with a forklift Containers which are mounted on pallets can be transported with a forklift under the following conditions The forklift must be designed for the weight of the container The container must be firmly secured to the pallet The operator of the forklift must be authorized to use the equipment according to the local industrial regulations Anchor Points ...

Page 62: ... container and start transportation 5 6 Storage Storage of the containers Store containers under the following conditions Do not store outdoors Store dry and dust free Do not expose to aggressive media Protect from solar radiation Avoid mechanical agitation Storage temperature 15 to 35 C Relative Humidity max 60 During storage longer than 3 months the general condition of all parts and the packagi...

Page 63: ...through hanging or suspended loads When lifting loads life threatening danger exists by falling or uncontrolled swinging of objects Therefore Never step under hanging or suspended container or loads Only move loads under supervision Use only approved hoisting devices and sling gear with suffi cient carrying capacity Do not use torn or damaged ropes or straps Do not fasten ropes and straps at sharp...

Page 64: ...t the assembly place Loosely stacked or spread parts and tools may cause accidents Mount components correctly Comply with re quired bolt torques Secure components to ensure that they do not fall Before commissioning the following steps must be adhered to Ensure that all installation steps have been followed according to the instruction manual Ensure that no persons are inside the working area of t...

Page 65: ...er to persons due to inadequate load bearing structures Overloading of floors could lead to serious injury or death as well as damage to property If the machine is installed on a suspended floor the dynamic load capability must be observed Uneven surface CAUTION Damage resulting from installation on uneven surfaces An installation on an uneven surface may cause deformation within the CNC machine T...

Page 66: ...spirit level capable of 0 02mm accuracy Fig 30 is included in the scope of delivery Use the supplied spirit level to level out the CNC machine correctly This is best done on the Linear guides Adjustments can be made on the feet found on each corner of the machine This is to be done before filling with water and checked after filling the water basin Fig 31 adjustable foot 1 Loosen the lock nut Fig ...

Page 67: ...ment The basin has sensors Fig 33 arrow that continuously check the water level in a specified range The lower one is to check the minimum water level This is used to maintain the 600mm of water under the beam which absorbs the residual energy of the beam The upper one is against overflowing of the pelvis in case the overflow Fig 33 should be clogged If one of the sen sors is hit it will send an e...

Page 68: ...ed to the workpiece height By pressing the upper button Fig 36 1 a valve at the air inlet of the tank is opened and filled with compressed air This allows the water level to be raised by up to 70mm Pressing the lower button Fig 36 2 opens a valve to release the pressure The water level can be lowered as a result The valves for lifting and lowering Fig 37 arrow are located on the right rear side of...

Page 69: ...yor and Dosage Optional The Abrasive Conveyor is an added option that is delivered in Com bination with the abrasive Dosage The abrasive conveyor is connected to the control cabinet via a 5 pin Harting plug The conveyor is switched on via the switch at the front Fig 39 arrow switch on The conveyor is loaded with the appropriate abrasive from above by opening the lid Fig 39 arrow lid Filling should...

Page 70: ...ts the programmed amount of the abrasive to the hose connected to the cutting nozzle via a belt drive There the abrasive is drawn in by the vacuum of the water jet and used for cutting 6 2 7 High Pressure Pump The high pressure pump gives the water jet the 3800 bar pressure It works like a crankshaft motor and compacts the water up to 3800bar via pistons This is transported via the high pressure l...

Page 71: ... end to the computer s network port The power supply of the computer must also be connected to the ecu Fig 42 2 Staff Operator Attach cable from computer to the controller Fig 42 1 6 3 2 Connecting the Control Panel CAUTION Risk of stumbling and resulting injury through cables lying around Cables lying around on the floor are a source for slipping and stumbling and can result in serious injuries A...

Page 72: ...essure Pump Control Panel Abrasive Conveyor Handwheel optional PC with operating software 2 Fasten clips where required 6 3 3 Installing Accessories The installation of the accessories must be done according to the relevant accessory instruction manual WARNING Risk of injury due to incorrectly mounted accessories Incorrectly mounted accessories may fall off or cause object to be ejected during ope...

Page 73: ... in serious injuries Always cover any exposed cables lying on the floor Do not route cables across sharp edges or corners Avoid rubbing of cables on machine Always ensure that cable channels are visible Staff Electrician 1 Compare the power supply available with the requirements of the machine and connect only if the values match 2 Before connecting power to the machine ensure that the supply has ...

Page 74: ...abi net Chapter 6 3 1 Connecting the Computer on Page 71 6 Ensure all additional Options e g Abrasive Conveyor and Dosage are installed and connected to the Power Supply 7 Ensure the Operating Software is installed on the Computer and ready for use 8 Ensure the fixed fit of all connectors 9 Connect Pressurized Air to the Control Cabinet 10 Make sure Water basin is filled to the right level min 600...

Page 75: ...all covers and safety devices are installed and work properly Ensure that no persons are inside the working area of the machine Never disable or bridge safety devices 7 2 Important Steps before Operation 1 Ensure that all covers have been installed and fastened properly 2 Check that all plugs sockets and High Pressure Connec tions are securely mounted 3 Ensure that all emergency stop switches have...

Page 76: ...n Changing Cutting nozzle page Fehler Textmarke nicht definiert 4 Ensure that no other work pieces or equipment is in the working areas of the machine 5 Check Water level of the Water Basin 6 Ensure that there are no persons inside the working area 7 Ensure that the correct accessories Abrasive Conveyor have been switched on 8 Make sure Air pressure is connected to all necessary parts 9 Turn the m...

Page 77: ...quipment Protective clothing Safety shoes Safety goggles Safety gloves 1 Steggitter auf Schäden überprüfen und bei Bedarf Teile aus tauschen 2 Parallelität und Ebenheit des Steggitters überprüfen z B mit einer langen Wasserwaage 3 Auf dem Steggitter direkt die Werkstücke befestigen z B mit Gewindestangen und mit Spannlaschen oder mit Gewichten gegen Verrutschen fixieren 7 4 2 Operating of the Mach...

Page 78: ...oning properly Do not reach into the beam during operation Before replacing the nozzles always pull the mains plug of the pump or switch off the machine and secure it against turning back on Use only original OEM accessories and spare parts Moving Axis WARNING Risk of injury by moving axis Collisions between persons and machine Y Axis moving parts Rotational axis Tools may lead to serious injuries...

Page 79: ...020 Rack and Pinion WARNING Risk of injury by moving rack and pinion gear While operating clothing hair or body parts could get caught in the rack and pinion leading to serious injury Never reach over rack and pinion when machine is switched on Maintenance may only be performed while the machine is turned off Always wear protective clothing in the working area ...

Page 80: ...he machine The implants may heat up or be pulled towards the machine Do not wear any jewellery like rings necklaces watches etc when operating the machine Do not place any electronic equipment near the magnetic fields as these may be damaged Do not place any data storage devices or credit cards etc near the magnetic fields as these may be wiped out Falling materials WARNING Risk of injury by falli...

Page 81: ...ork area against accidental access Highly flammable materials WARNING Danger of fire through flammable materials Organic dust from wood or coal and inorganic dust from Magnesium Aluminium Zink or Titanium may start combusting which may result in serious injury or death Do not smoke near the working or danger area and avoid open flames or other potential fire risks Always have a fire extinguisher n...

Page 82: ... Geldern Germany Page 82 Support 49 0 2831 91021 50 02 06 2020 Cutting Water CAUTION Health risk from exposure to cutting fluids Contact with Cutting fluids can result in illness Avoid direct skin contact Wash skin immediately after contact with cutting fluid Avoid breathing fumes or gases from cutting ...

Page 83: ...d to run the ma chine The work process is done by the CNC operating software and Stepper Motor controllers To reduce the wear and tear of components do not exceed 80 of the maximum traverse speed see Chapter 3 3 Power Us age Drive Motors page 44 For further information see user manual for the software installed Operation of the accessories will be explained in the user manual for the respective ac...

Page 84: ...Page 84 Support 49 0 2831 91021 50 02 06 2020 7 4 3 Changing Cutting Nozzle Staff Operator Safety equipment Protective clothing Safety shoes Safety gloves Fig 44 Main Switch 1 Turn the main switch to the 0 or Off position Fig 44 Fig 45 Lock the main switch 2 Lock the switch in the off position to prevent restart Fig 45 ...

Page 85: ...CAUTION Danger of injury from hot surfaces Workpieces and the nozzle may heat up to high temperatures Contact with these surfaces could result in severe burns to the skin When changing nozzle always wear protective gloves 5 Retract Cutting Nozzle Fig 47 1 This normally sits loose in a boring of the mixing chamber After extraction thor oughly clean all parts Fig 47 Cutting Nozzle Holder 6 Check Mix...

Page 86: ...sition 9 Start the machine Should some water leak out on the side of the leakage holes at the cutting nozzle dismantle the nozzle and check cleanliness Should the cleanliness be given then pull the machine a little while at a standstill without pressure on the line open the manual valve 7 5 Switching Off Machine Fig 49 Manual Valve Fig 50 Manual Valve 1 Turn off main switch of High Pressure Pump 2...

Page 87: ...r Operation Staff Operator Safety equipment Protective clothing Safety shoes Safety gloves 1 Turning off the machine Chapter 7 5 Switching Off Ma chine page 85 CAUTION Danger of injury from debris Chips or shavings can be sharp edged and can cause deep cut wounds Always wear protective gloves when removing debris from the machine 2 Clean the machine Chapter 8 4 1 Cleaning Machine page 92 ...

Page 88: ...sible and the power supply must be switched off Emergency Stop In the event of a dangerous situation act as follows 1 Press emergency stop immediately 2 If there is no danger for your own health rescue persons out of the danger area 3 If necessary start first aid measures 4 Alert fire and rescue service 5 Inform person in charge of location 6 Switch off machine and secure against restart 7 Clear a...

Page 89: ...ies Prior to maintenance work switch off machine and secure against restart Wait till all parts came to a complete standstill Wear tight fitting protective clothing with low tensile strength in the danger area Electrical system DANGER Life threatening danger by electrocution Contact with live or electrified parts can present a life threatening danger Activated electrical components can cause uncon...

Page 90: ...ts have been removed ensure correct re assembly re install all fastening elements and observe torque specification for screws and bolts Before restarting observe the following Ensure that all maintenance work has been done according to user manual and has been completed Ensure that there are no persons in the working area of the machine Ensure that all covers and safety switches are installed and ...

Page 91: ...he manufacturer If any uncertainty exists please contact the manufacturer Loss of Guarantee The use of incorrect spare parts may result in the loss off guarantee on the machine Spare parts may be ordered from the manufacturer or the agents For contact details see page 2 A complete parts list is available on request When ordering spare parts please quote the following Model Serial No Amount Descrip...

Page 92: ... Cleaning Ma chine page 92 Operator Check high Pressure tubing and Connectors for leaks Operator Check rubber splash protection for damage re place it if necessary Chapter Fehler Verweisquelle konnte nicht gefunden werden Fehler Verweisquelle konnte nicht gefunden werden auf Seite 92 Operator Check machine for damage or wear Qualified staff 10 operating hours Lubricate linear guides and rack Chapt...

Page 93: ... will prevent any moving parts from sticking Staff Operator Safety equipment Protective clothing Safety shoes Safety gloves 1 Turn off the machine Chapter 7 5 Switching Off Ma chine page 85 2 CAUTION Danger of injury from debris Chips or shavings can be sharp edged and can cause deep cut wounds Always wear protective gloves when removing debris from the machine Clear the machine of any debris 3 Cl...

Page 94: ...2 Protection Cover Inspection or Replacement Check protective cover for damage Staff Operator Safety equipment Protective clothing Safety shoes Fig 51 main switch 1 Turn the main switch to the 0 or Off position Fig 51 Fig 52 protective cover 2 Check the protective cover Fig 52 arrow surrounding the cutting nozzle for damage If the protective cover is damaged replace it ...

Page 95: ... or Off position Fig 53 Fig 54 protective cover 2 CAUTION Danger of injury from hot surfaces through the Focussing tube and the Cutting nozzle holder Parts may heat up to high temperatures Contact with these surfaces could result in severe burns Ensure that the tools or tool holder have cooled to ambient temperature When changing tools always wear gloves Push protective Cover Fig 54 Arrow downward...

Page 96: ...d staff Safety equipment Protective clothing Safety shoes Chemical resistant glove 1 Switch off machine and secure against restarting Caution Health risk from exposure to oils and grease Contact with Toxic coolants can result in illness Avoid direct skin contact Remove oil or grease from skin immediately Avoid breathing fumes or gasses from oils or grease Fig 55 X axis 2 Grease both sides of the X...

Page 97: ... Fig 56 Y axis 3 Grease the linear guides Fig 56 1 of the Y axis with light machine grease using a lint free cloth Fig 57 Y axis 4 Grease the rack Fig 57 2 of the Y axis with a light ma chine grease using a lint free cloth Fig 58 Z axis 5 Grease the linear guides Fig 58 1 and the rack Fig 58 2 of the Z axis with a light machine oil using a lint free cloth 1 2 1 2 ...

Page 98: ...ainst restarting Caution Health risk from exposure to oils and grease Contact with Toxic coolants can result in illness Avoid direct skin contact Remove oil or grease from skin immediately Avoid breathing fumes or gasses from oils or grease Fig 59 Grease nipple X axis 2 Remove protective cap from the grease nipple of the X axis Fig 59 1 if present If there are no protective caps on the grease nipp...

Page 99: ...ve protective cap from the grease nipple of the Y axis Fig 60 1 if present If there are no protective caps on the grease nipples clean the nipples before using 3 Attach grease gun to the grease nipple 4 Press grease gun once or twice 5 Remove grease gun 6 Replace grease nipple cap 7 Repeat steps 2 6 for all grease nipples Grease nipple on the Z axis 4x Fig 61 Grease nipples Z axis ar rows The grea...

Page 100: ...tch off machine and secure against restarting 2 Position Z axis so that the grease nipples are aligned with the holes in the cover Fig 61 2 3 Remove protective caps from the grease nipple of the Z axis Fig 62 1 if present If there are no protective caps on the grease nipples clean the nipples before using 4 Attach grease gun to the grease nipple 5 Press the grease gun once or twice 6 Remove the gr...

Page 101: ... work and before restarting the machine carry out the following steps 1 Check that all screws and bolts have been replaced and tightened 2 Check if all removed safety devices and covers have been replaced and are functional 3 Ensure that all used tools materials and other equipment has been removed from the work area 4 Clean work area and remove any spilled liquids working materials tools etc 5 En...

Page 102: ...t note of each page 9 1 Safety during Trouble Shooting Electrical system DANGER Risk of death by electrocution Contact with live electrical parts presents an imminent danger to persons and may also cause uncontrolled movements of the machine which may lead to serious injury Before beginning work turn off the main electricity supply to the machine and secure against being turned on accidently Movin...

Page 103: ...ace for the assembly work Pay attention to orderliness and cleanliness at the assembly place Loosely stacked or spread parts and tools may cause accidents Mount components correctly Comply with re quired bolt torques Secure components to ensure that they do not fall Before restarting the machine the following steps must be adhered to Ensure that all installation steps have been followed according ...

Page 104: ...e nature or the type of fault either qualified staff or the operator may clear the fault The following table of faults shows who may clear the fault 9 2 Table of Faults Fault Possible cause Troubleshooting Repair by Smoking control unit Control unit defective Switch off main power sup ply immediately and contact the manufacturer Manufac turer Machine is not starting Emergency stop acti vated Relea...

Page 105: ...available or increase If no change valve needs mainte nance Operator Pump does not deliver Water pressure not high enough Increase Water pressure if necessary install Pre pres sure Pump Qualified Personnel Pump does not deliver Error message from the Controller Eliminate error and Confirm on Controls Operator No sand supply Sand is too moist Exchange Abrasive Operator No sand supply Conveyor is no...

Page 106: ...the Emergency Stop Switch Staff Operator 1 Establish the cause of the fault and repair Fig 63 Emergency stop switch 2 Release the emergency stop switch by twisting Fig 63 Fig 64 controller If the emergency stop switch on the controller Fig 64 arrow is pressed it will need a double unlocking action Then confirm errors in the control If necessary also confirm on the control of the High Pressure pump...

Page 107: ... the Electrical Fuse Staff Electrician Special tool Square key DANGER Risk of death by electrocution The controller is not protected by any safety devices If the main power supply is on there is danger of touching electrified components causing injury or death Always switch off the main power supply and secure against accidental switching on before working on the controller unit ...

Page 108: ... the 0 position Fig 65 Fig 66 Secure main switch 2 Secure against restarting by using a padlock Fig 66 DANGER Risk of death by electrocution from stored energy Electrical charge may be stored in electrical components which could result in electrocution causing injury or death Before commencing work turn of the power and wait for 10 min before continuing to allow condensers time to discharge the st...

Page 109: ...3 15 47608 Geldern Germany Page 109 Support 49 0 2831 91021 50 02 06 2020 Fig 67 Controller 3 Open the controller using the square key supplied Fig 67 1 4 Open the door of the controller unit 5 Change fuse or switch on fuse 6 Close and lock door with square key 7 Switch on main power supply 1 ...

Page 110: ...Support 49 0 2831 91021 50 02 06 2020 9 4 Start up after Fault Repair After repairing a fault carry out the following steps to restart 1 Reset the emergency stop switches 2 Acknowledge the faults in the controlling software 3 Ensure that there are no persons in the danger area 4 Restart operating according to chapter 7 Operation ...

Page 111: ...10 1 Safety during Disassembling and Disposal Incorrect disassembling WARNING Risk of injury caused by incorrect disassembling Stored residual energies sharp edged parts spikes and corners on and in the machine or from the in stalled tools can cause injuries Prior to starting work ensure that there is sufficient space Handle sharp edged parts with care Pay attention to orderliness and cleanliness ...

Page 112: ...lean assemblies and components professionally and dispose of in accordance with the valid local labour and environmental pro tection regulations 10 3 Waste Disposal Provided that no agreement regarding return or disposal has been made recycle disassembled parts Scrap the metals Recycle plastic components Dispose of remaining components according to the material characteristics CAUTION Environmenta...

Page 113: ...ccessories Machine extensions Abrasive conveyor with Dosage Work holding Clamps nuts Tools for various applications Nozzles with various Diameters for different pressures Focusing tubes Hardware and Software PC s and Monitors Radio remote control CAD CAM software font packs specialized software If interested please contact our Customer Service by email or phone We will be pleased to advise you and...

Page 114: ...Service Address CNC STEP GmbH Co KG Siemensstraße 13 15 D 47608 Geldern Phone 49 0 2831 91021 50 Mo Fr 07 00 15 00 hrs Mobile 49 0 2831 91021 20 Only in urgent cases Mo Th 15 30 18 00 hrs Fax 49 0 2831 91021 99 E Mail support cnc step de Web https www cnc step com If you have questions please contact our customer service via e mail or phone We advise you gladly Numerous suggestions and information...

Page 115: ...t compatible control PC and the download of the TeamViewer software version from our website 1 Download the TeamViewer version from our website https www cnc step com support teamviewer and run the program The following picture appears Fig 68 2 The software directly generates your ID identification number and a password With this access data you can contact our support department by phone With the...

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CNC-Step flowJET 2015, Operating Instructions Manual

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