Perfecta 115 TV Service Instructions Manual Download Page 5 | Manualshive

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1/01 E Service Instructions

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Summary of Contents for 115 TV

Page 1: ...1 01 E Service Instructions 1 The Service Instructions manual belongs to the hands of the repair and maintenance personnel PERFECTA 76 92 115 132 168 UC TV SERVICE INSTRUCTIONS Servo ...

Page 2: ... Knife Beam Guideways 13 Readjusting the Knife Cut Through Position 15 Non RepeatDevice 15 Cutting System Maintenance 18 CuttingTable 18 Backgauge Drive System 18 BackgaugeGuidance 19 ThreadBacklashCompensation 20 Measuring System 21 Calibrating the Measuring System 21 Setting the Proximity Switches 21 Hydraulic Clamping System 22 Pre Clamping 24 CutTriggering 25 MainClamping 26 Decompression 27 C...

Page 3: ...are 35 UC Software Change 35 TV Software Change 36 Settings OperatingData 37 Service Nenu 39 I O Test Menu 41 KeyboardCode 45 Sensor Test Menu 46 Activating the Differential Display 47 SpeedMenu 49 Character Set Menu 50 Texts Menu 50 Knife Control Control Switches 51 PSG 16 Light Guard 62 ErrorMessages 63 ...

Page 4: ...of work Open switch cabinets and switching rooms do not only col lectdustthatleadstofailures but also involve danger to life and limb You are encouraged to take theopportunityPERFECTAof fers you to have your techni cians trained at our Training Centre Safety Inspection Due to their way of operation con sisting of hazardous movements such as clamping and cutting guillotinesmustmeetanumberof safety ...

Page 5: ...1 01 E Service Instructions 5 Fig 2 ...

Page 6: ...er oper atedatstopposition anysubse quent cut triggering is disabled The display reads Error 28 Safety Module Detecting Error Bypressingthe C key concrete Error 7 appears Knife Overrun After turning off and on the ma chine the subsequent cut can be restarted by the knife pushbut tons If there is another overrun at the UDC slight pre stopping correc tion can be performed by turning forward the enti...

Page 7: ...kedstate clutch OFF isnot undercut Checking the Bearing Play For machine sizes 115 and 132 only De energize the clutch No perceptible play in the bear ing must appear when the fly wheelrimtopispulledandpushed by hand In case of evident play replace the antifriction bearings Caution Bringtheknifebeamtoitslow ermost position prior to dis mantling the clutch brake as sembly as the brake becomes ineff...

Page 8: ...pres sion springs are relieved Malfunctions in the Knife Drive The following malfunctions may occur in the knife drive and are not indicated by the computer control system as error codes The main motor cannot be started Remedy Switch S56 for Manual Crank ing refer to the Operating In structions manual under the fly wheel guard is locked Unlock the switch The flywheel guard is not prop erly closed ...

Page 9: ...s is decisive to obtain a high quality and high accuracy cut Gap Between the Knife Back and the Clamp Edge Machine Size 76 Fig 7 Slacken screws 3 to release clamp guideway 4 at the clamp left and right rear sides Adjust required gaps by means of shims5tobeinsertedbetween clamp 1 and clamp guideway 4 Inserting shims reduces the gap by the shim thickness while re moving shims widens the gap The shim...

Page 10: ...ght sides Slightly turning eccentric pins4 both sides uniformly moves the clamp away from or towads the cutting line Check gap s across the entire cutting width with a feeler gauge Whenjammingthenuts ensure that the positions of the eccentric pins are locked Fig 8 Fig 9 Play in the Clamp Guideways Machine Size 76 Fig 7 Slacken screws 6 of adjusting strip 7 Move adjusting strip 7 against clamp guid...

Page 11: ...rews 6 Slightly slacken screws 7 on adjusting strip 8 Reset adjusting strip 8 against guide blocks 9 by adjusting screws6 until playa between the adjustingstripandtheguideblock is 0 05 mm Whenperformingthisadjustment ensure that guide blocks 9 rest ontheoppositesideofguidestrip 10 For this purpose press the clamp towards the knife Aftercompletingtheadjustment tighten the screws and nuts and check ...

Page 12: ...f the cross beam Turn clamping lever pivot pin 2 from the machine back using key surface 3 After checking for parallelism with paper strips tighten clamp ing screw 1 MachineSizes115 132 Fig 14 The clamping principle is shown in Fig 13 Remove the clamping system front and rear paneling under the cutting table Slacken screw 1 on the front lower cross beam Gently turn clamping lever pivot pin2 or3 by...

Page 13: ...es 2 on the machine frameandguidestrips3 Theguide strips have been adjusted with respect to the knife beam with shims4 so that gaps required for establishing the necessary lubrication film is 0 05 mm Checking the play Push the knife beam without knife against the frame from the rear at the top and bottom posi tions Check the play between the knife beam and the guide strip on the left and right sid...

Page 14: ...Important Check the light guards for proper functioning Checking the play Push the knife beam without knife against the frame from the rear at the top and bottom posi tions Check the play between the knife beam and the guide strip on the left and right sides using a feeler gauge If required readjust gap s as fol lows Set the knife beam to medium feed height and push it against the frame Remove the...

Page 15: ... Remove the tool after setting 5 6 3 3 1 Fig 19 Non Repeat Device Theupperdeadcentreoftheknife beam is stopped and controlled by control switchesS52andS54 and is monitored by the safety processor control system which immediatelystopstheknifetravel incaseofanyirregularities Refer to Setting the Automatic Stop ping Device In addition all PERFECTA guillotines are provided with a mechanicalnon repeatd...

Page 16: ...anual Crank ing Set the spring contact switch so that the cam follower still travels ap prox 1 5 mm beyond the switching point Machine Size 92 Fig 21 Catch2 connected with solenoid Y80 through chain 1 forms gap s 0 6 1 0 mm with the stop located on the machine frame whenthesolenoidisdead Atthis position S81 is operated In the energizedstate byactivatingthe manual clutch refer to Manual Cranking in...

Page 17: ...168 Fig 23 S81 Y80 Fig 22 S82 1 4 2 3 Important Whenthecatchrestsontheknife beam contour with Y80 being dead S82 must not yet be oper ated except machine size 168 Locking pin1 is guided by bush2 supported by machine frame 3 Solenoid Y80 withdraws this pin against pull back spring4 so that a gap of s 2 3 mm is obtained betweenknifebeamslidesurface 5 on the frame and the face of the locking pin Adju...

Page 18: ...andimprovestheslidingprop erties Duetotheabrasioncausedbythe cutting stock the treatment must be repeated from time to time If small deposits of rust should have built up as a result of insuf ficientcareornegligence remove them immediately Never use abrasive cloth or sand paper Ti tanium fleece or a conventional householdfibrescouringpadhas proven useful for this purpose When treating the table al...

Page 19: ...uge in no load condition The play should be within the limits of 0 03 0 04 mm by Depending upon the operating conditions the guide column shouldbecleanedwithwhitespirit onceperyear Thelubricationcy cle specified under Lubrication in the Operatring Instructions manual or in the lubrication chart onthebackofthemachineshould be kept Machine Sizes 76 and 92 Thebackgaugesofthe76and92 sizeguillotinesare...

Page 20: ...e specified lubrication cycle once per year Referto Lubrication intheOper ating Instructions manu al or to the lubrication chart on the back of the machine Fig 26 Machine Sizes 168 Fig 25 Backgauge 1 is guided by a car riage2which runonrollers moves along a profile guideway beam 3 fitted over the cutting table If you find any play on the back gauge check setting screws4 on the side of the backgaug...

Page 21: ...e menu Type in through the keyboard the actualmeasurementbetweenthe knife back and the backgauge and press the enter key to accept it This will change the machine internal measuring system to the value entered From the actual position known from the entry a forward travel will take place until a zero pulse is recognised This detects and stores the distance between the last millimeter measurement d...

Page 22: ... clamping pressure re lief valves M1 Test point for free circu lation and pre clamping M2 Clamping pressure test point Z1 T2 Return line to oil tank In the hydraulic circuit diagram ___ Pressurized oil line ____ Passive oil line The spatial assignment of the equipment on the control as semblyisshowninFig 28 VD2 Fast speed pressure relief valve VD3 Clamping pressure relief valve clamping pressure v...

Page 23: ...are Machine at Basic Position free circulation Fig 29 The main motor is on The pump runs The knife beam and the clamp are at their topmost posi tions Multi way valves VW1 and VW2 are at rest Y1 Y2 not operated The oil flow returns to the tank via RV1 VW1 VW2 VDRandFwith almost no pressure Fig 29 ...

Page 24: ...ressure builds up from pump P via RV1 VW1 VW2 as well as VD1 and VD1 1 which de terminethevalueofthepressure The oil flow is applied to the fast speed piston The plunger of cyl inder Z comes out and moves the clamp down Via SRV the big cylinder chamber fills up with oil When the clamp touches down the oil returns to the tank through VD1 and VD1 1 Fig 30 ...

Page 25: ...ctivates Y1 VW1 and Y2 VW2 This blocks the oil circulation and applies the entire oil flow to the fast speed piston of cylinder Z The plunger comes out with fast speed and movestheclampdown ViaSRV the big cylinder chamber fills up with oil When the clamp touches down VD2 responds due to an increase in pressure Fig 31 ...

Page 26: ...1 01 E Service Instructions 26 Main Clamping Fig 32 Due to the overflowing of VD2 the main pressure preset by clamping pressure valve builds up in the fast speed and main cylinder chambers Fig 32 ...

Page 27: ...ompression Fig 33 After the knife has cut through thecomputercontrolsystemturns offY1 VW1whichthengoesopen Thepressureexistinginthecylin der chamber can thus relax The oil flow from the pump returns to the tank via VW1 VDR and F Fig 33 ...

Page 28: ...For the 76 and 92 machines the clamp is brought to its topmost positionbyacompressionspring andbytensionspringsonthe115 and 132 size machines This forces the oil out of the cylinder chambers into the tank The last section of the stroke is damped without any jerks before the end position in the cylinder is reached The basic position as shown in Fig 29 is restored Fig 34 Stroke Limit Function Youcan...

Page 29: ...nut Gently readjust the setting spindle clockwise to speed up anticlockwise to slow down Tighten the lock nut VD3 The clamping pressure valve is set to the maximum clamping pressurerequiredfortherespec tivemachinesizes Changingthe setting is not necessary and may cause damage to the machine Fig 35 Hydraulic Clamping System Settings MPa Important Insufficient alignment of the machineatitsplaceofins...

Page 30: ...tain from PERFECTA Stock dependent empirical val ues can be obtained from the tables in the Cutting Compen dium Figs 6 to 10 They represent reference values for about 2 3 of the maximum feed height and cutting width The Operating Instructions manual shows the diagrams of the clamping pressure curves for the individual machine sizes as a functionofscaling Therangesof low medium and high as signed t...

Page 31: ...essure is available Defective pump Replace the pump VD1 VD1 1orVD2isoverflown Repair may for safety reasons onlybeperformedbytrainedper sonnel When the required pressure is available Check the machine for proper alignment and in conjunction therewith for free movement of the clamp Check for possible canting of the clamp draw rods Readjusttheclampguideways if necessary The clamp moves up slowly af ...

Page 32: ...n the suction line and the pump is not tight Re tighten the connection Defective pump Replace the pump The clamp comes down slowly and with heavy noise only the clamp does not release the pile any more Remedy Rapid speed is blocked by the STV stop valve Check the stop valve Preclampingwiththepedaldoes not work Remedy The rapid speed line is blocked by stop valve STV Check the stop valve Check the ...

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