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EVM S4
Service Number : Technical Customer Service Dept. - 0049 (0) 521 783-479
Schüco International KG
Karolinenstraße 1–15 · 33609 Bielefeld
Phone +49 521 783-0
Fax +49 521 783-451
www.schueco.de · info@schueco.com
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OPERATING INSTRUCTIONS EVM S4
Caution
These operating instructions contain
important safety instructions
and should always be read prior to
commissioning and operation of
EVM S4!
Please read the general safety instructions in the chapter entitled “Basic
Safety Instructions”.
It is prohibited to copy these operating instructions or transfer data contained herein to third parties.
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1 Table of Contents
1 Table of Contents...................................................................................................................................3
2 Basic Safety Instructions........................................................................................................................4
2.1 General Safety Instructions...............................................................................................................4
2.1.1 Symbols and instruction signs..................................................................................................4
2.2 Operating Instructions Guide ............................................................................................................5
2.2.1 Definition of used terms............................................................................................................5
2.3 Aim of the Operating Instructions......................................................................................................5
2.4 Manufacturer’s Operating Instructions ..............................................................................................6
2.4.1 Owner’s operating instructions .................................................................................................6
2.4.2 Information for the owner .........................................................................................................6
2.5 Owner Requirements ........................................................................................................................7
2.6 Operator Requirements.....................................................................................................................8
2.6.1 Instructing and training .............................................................................................................8
2.7 Working on the Equipment................................................................................................................9
2.7.1 Work on electrical equipment ...................................................................................................9
2.7.2 Work on pneumatic equipment.................................................................................................9
2.7.3 Work on hydraulic equipment...................................................................................................9
2.7.4 Personal safety equipment.....................................................................................................10
2.8 Potential Machine Risks..................................................................................................................11
2.9 Mechanical Risks ............................................................................................................................11
2.10 Switching Off the Machine (Disconnecting the Air Supply).............................................................11
2.11 First Reaction to Faults ...................................................................................................................11
2.12 Intended Use...................................................................................................................................12
2.13 Environmental Protection Regulations............................................................................................12
2.14 Transportation .................................................................................................................................12
2.15 Installation Site Requirements ........................................................................................................12
3 Definition of Terms ...............................................................................................................................13
3.1 Pressing Head Columns .................................................................................................................13
3.2 Variable Column..............................................................................................................................13
3.3 Pressing Unit...................................................................................................................................14
3.4 Control Panel ..................................................................................................................................14
4 Preliminary Measures ..........................................................................................................................15
5 Operating Instructions ..........................................................................................................................16
5.1 Setting the Column Distance ..........................................................................................................16
5.2 Inserting the Profile .........................................................................................................................18
5.3 Setting the Lower Pressing Height..................................................................................................19
5.4 Setting the Upper Pressing Height..................................................................................................20
5.5 Setting the Stop Block.....................................................................................................................21
5.6 Setting the Pressing Measurement.................................................................................................21
5.7 Changing the Pressing Tool............................................................................................................21
5.8 Setting the Reference Forks Unit....................................................................................................22
6 Pressing Process .................................................................................................................................23
6.1 Switching on the Electromagnet .....................................................................................................23
6.2 Switching on the Hydraulics ............................................................................................................23
6.3 Inserting and Lowering the Frames ................................................................................................23
6.4 Centring the Profile Frames ............................................................................................................24
6.5 Positioning and Locking the Stop Block..........................................................................................25
6.6 Pressing ..........................................................................................................................................26
7 Maintenance Plan ................................................................................................................................27
8 Troubleshooting....................................................................................................................................29
9 Technical Data .....................................................................................................................................30
10 Declaration of Conformity.....................................................................................................................31
11 Wiring Diagrams...................................................................................................................................32
11.1 Electrical Wiring Diagram................................................................................................................32
11.2 Pneumatics Diagram.......................................................................................................................38
11.3 Hydraulics Diagram.........................................................................................................................39
11.4 Spare Parts List...............................................................................................................................40
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The following symbols indicate important safety, installation and operating instructions in this document.
Safety instructions
Danger of falling over during transport due to the pressing head columns’ high centre of
gravity!
Only operate the machine when the protective covers are closed!
Never insert hands into areas of operation while the machine is running!
Danger: Body parts may be crushed, cut or drawn into the machine!
Always disconnect the machine from energy supplies (compressed air supply and power
supply) before carrying out maintenance or repair work which requires the protective covers
or casing to be opened!
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The following definitions apply for these operating instructions in accordance with EC MACHINERY
DIRECTIVE 89/392:
Danger areas: Each area in and around the machine in which there is a risk to human health
and safety.
Endangered person: Each person who is completely or only partly in the danger area.
Operator(s): The person(s) responsible for normal machine operation, i.e. operation,
installation, cleaning etc.
Maintenance personnel: The person(s) responsible for machine settings, inspection, maintenance,
repairs, transportation, etc.
Safety commissioner: The person responsible for regular safety device checks, the machine key and
machine monitoring during test mode.
Schüco shall not be liable for damages and risks which occur due to the following reasons:
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Should you require any further information, please contact the Schüco Customer Service Dept.. If the
machine is sold or passed on to a new owner, the operating instructions have to be handed over. If required,
further copies of the operating instructions or parts thereof can be purchased.
You, the owner, are obliged to provide operating instructions for your company.
Your operating instructions should enable risk-free functioning and risk-free operating of the machine whilst
taking the special characteristics of our company, including your experiences and respective valid laws and
directives, into consideration. The operating instructions have to be maintained and kept up-to-date. You are
obliged to eliminate every possible risk at the machine including any risks which arise during operation. If this
is not completely possible, you have to clearly indicate the risks in your operating instructions and/or affix
respective warning signs to the machine. Your operating instructions should always be kept to hand at the
machine for the operating personnel.
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− The owner has to ensure that no unauthorised persons operate the machine.
− Children are not permitted to operate the machine.
− The owner is obliged to provide the system operator with the respective operating instructions for this
machine. The owner has to ensure that the operator has read and understood the operating
instructions.
− In addition to these operating instructions, generally applicable statutory and further compulsory
accident prevention and environmental protection regulations have to be observed and instructed!
− The machine should only be operated by people who can be entrusted with correct machine
operation. Due to their technical qualifications, these people should be able to operate the machine
correctly after reading the operating in addition to these operating instructions.
− It is essential that the operator recognises potential risks which can result from machine operation.
With the help of these operating instructions, the owner has to provide in-house operating instructions which
contain all the user-specific information for safe operation of the extension modules. The instructions should
also describe potential risks, functioning of protective devices and the safety-compatible attitude and
behaviour of individuals and their area of work (commissioning, operating, installation and repair personnel,
etc.).
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The owner is responsible for briefing personnel. The owner has to inform the operator about accident risks,
integrated safety devices, noise emission risks and the general accident regulations specified in international
and national installation site directives.
Prior to machine operation, the operating personnel should receive instructions about all the machine
functions and be briefed about all the instructions, information and general accident regulations specified in
these operating instructions. Unauthorised machine modifications are strictly prohibited.
Operators should never take drugs, intoxicants, certain medicines or drink alcohol before or whilst operating
the machine. Factors such as tiredness, stress or illness can impair correct machine operation. Smoking is
strictly prohibited during machine operation!
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The wires of the mains lead at the main switch are still live even after the main switch has
been switched off. They are marked with a voltage warning sign.
− Ensure that the switch cabinet is always closed! Access should be restricted to authorised personnel
who have a switch cabinet key.
− Regularly check electrical equipment!
− Re-tighten any loose connections!
− Immediately replace damaged lines!
− Always depressurise the hydraulic system prior to maintenance and repair work and switch off the
main voltage supply.
− Do not loosen or re-tighten hydraulic lines (only when the hydraulic system is shut down).
− Never loosen or re-tighten screws and bolts at valves and pumps (only when the hydraulic system is
shut down).
− Always remain at a safe distance from the hydraulic system if hydraulic lines or individual components
rupture or burst.
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After completion of the tasks and prior to machine commissioning or resuming production ensure
that:
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Nevertheless, EVM S4 can still present the following risks if it is not used for its intended purpose, if the
operator is not sufficiently qualified or if the operating instructions are not observed:
These operating instructions contain important information about possible risks and should be read carefully
prior to installation and commissioning of EVM S4!
For reasons of safety, it has to be guaranteed that everybody involved with machine installation, operation,
maintenance and repair work in the owner's company has read and understand the entire operating
instructions.
Immediately shut down the machine if a fault occurs which impairs safety. Only put the
machine back into operation after the fault has been completely eliminated.
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2.14 Transportation
If a machine falls down/over during vehicle loading/unloading or during transportation, it can cause extremely
serious injuries or death. Therefore, always ensure when lifting or transporting that:
− Transport work is only carried out by qualified and authorised persons in accordance with these and
other general safety and accident prevention regulations.
− Load suspension and movement restricting devices comply with the specifications of the accident
prevention regulations; the lifting capacity should exceed the weight of the machine considerably.
− The machine is lifted in the middle and balanced.
− The machine does not fall over.
− No person or body parts are underneath the raised machine or machine parts.
− The transportation routes are blocked off and marked accordingly to ensure that unauthorised persons
are not in the danger area.
− The machine is always stored and transported in a horizontal position!
− The transport safety devices removed after installation are replaced if the machine is relocated at a
later date.
− Space required for the machine after considering the models and accessories.
− Size of the additionally required work space for handling tools.
− Access possibilities for the necessary maintenance and repair work.
− Nobody except the operator should be in the immediate vicinity of the machine during operation.
− Lighting at the workplace has to be suitable for the daily tasks.
− The floor should be level and structurally safe for the load. (For machine weight see chapt. Technical
Data.)
− The machine is intended for indoor use only and should be operated frost-proof.
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3 Definition of Terms
3.1 Pressing Head Columns
Fixed column
Linear columns
Variable column
Assembly floor
Stop block
Lifting frame
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Tool holder
Pressing tool
Profile support
Stop block
Lift/Lower frames
Pressing
Centre frames
“Two-hand operating
button”
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4 Preliminary Measures
Connect the power supply.
Turn the main switch at the switch cabinet to
“On”.
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5 Operating Instructions
5.1 Setting the Column Distance
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Linear column
Reflection strip
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Lift/Lower frames
Pressing
Centre frames
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Height Adjustment
Star wheel
Star knob
Profile supports
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6 Pressing Process
6.1 Switching on the Electromagnet
Make sure that the electromagnet has been
activated.
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6.6 Pressing
The “Position stop block” button stops flashing and
lights up continuously once locked.
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7 Maintenance Plan
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We recommend keeping a service book for scheduled maintenance intervals according to specified
operating periods.
• Visual inspection
• Checks for unusual vibrations
• Checks for increased noise levels
• Checks for leakages
• Checks for cleanliness of the unit
(no obstructions in the cooling air lines)
• Pressure check
(feed level 1: 40 bar; feed level 2: 120 bar; pressing: 120 bar)
• Oil level check
(if necessary, fill with: ARAL VITAM DE 46 HLPD according to DIN 51524)
• Oil temperature check
(max. 70°C)
• Use oil analysis to check hydraulic oil
(if necessary, flush hydraulic system or renew hydraulic oil)
• Check functioning of the hydraulic unit
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8 Troubleshooting
Fault Cause Remedy
- Hydraulic unit does not start - No compressed air supply - Connect compressed air supply (5 – 6 bar)
- Compressed air supply too - Increase compressed air supply (5 – 6 bar)
low
- Emergency Off triggered - Deactivate Emergency Off
- Electromagnet (variable - Activate electromagnet
column) not activated
- Distance measuring unit - Reflection plate at the fixed - Clean reflection plate
displays “LOW” column soiled
- Reference forks units do not - EVM S4 on “stand-by” - Re-press “Hydraulic pump On/Off” button
move forwards
- Lifting frame not in lower - Check lifting frame clearance
end position
- Lifting frame cannot be - Reference forks units not in - Ensure that reference forks units are in rear
lifted/lowered rear end position end position
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9 Technical Data
Mains voltage: 400V / 50Hz
Control voltage: 24VDC
Operating pressure, pneumatics: 5 - 6 bar
Operating pressure, hydraulics: 120 bar
Connected load: 5.8 KW
Max. mounting floor size: Art. no.: 282 400: 4610mm x 5590mm
Art. no.: 282 795: 4610mm x 6570mm
Art. no.: 282 880: 5590mm x 6570mm
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10 Declaration of Conformity
EG-Konformitätserklärung
EC Declaration of Conformity
Déclaration de conformité CE
Gemäß Richtlinie 89/392/EWG (93/68/EWG) (EG-Maschinenrichtlinie) Anhang II A
Gemäß Richtlinie 73/23/EWG (Niederspannungsrichtlinie)
As per guidelines 89/392/EEC (EC guidelines for machinery) appendix II A
As per guidelines 73/23/EEC
Selon les instructions 89/392/CEE (instructions CE pour machines) annexe II A
Selon les instructions 73/23/CEE
Art-Nr. - article number –no d’article: 282 400, 282 795, 282 880
□ Wurde die Maschine und alle zur Beurteilung der Sicherheit der Maschine notwendigen Unterlagen
zur Durchführung einer EG-Bemusterungsprüfung vorgeführt. Die Übereinstimmung der Maschine
wurde unter der Prüfungsnummer ………….. bescheinigt.
□ The machinery and all the documentation required to access the safety of it for performing an EC
construction plan test have been presented. Conformity of the machinery is certified under test
number ……………
□ La machine et la documentation nécessaire du test de sécurité CE, sont été présenté. La conformité
de la machine est certifiée sous le numéro de test …………..
Die angewendeten EG-Normen wurden veröffentlicht:
The applied EC standards were published: / les normes CE appliquées sont publique sur :
Darüber hinaus wurden folgend nationale technische Normen und Spezifikationen angewandt :
Additionally, the following national technical standards and specifications were applied:
Les normes et spécifications techniques nationales suivantes sont été en plus appliquées :
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11 Wiring Diagrams
11.1 Electrical Wiring Diagram
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HYDRAULICS
13 8 Thrustor 16/25/100
14 16 Pressing cylinder 12/20/50
15 1 Hydraulic tank BAK 30
16 1 Elec. motor 5.5 KW - B5 - BG112 - 1450 1/min.
17 1 Pump holder/ Coupler PL250
18 1 Gear pump MLPDG2/11DCO01F
19 1 Hydraulic hose PHD 210x600 A/L
20 1 Return filter TEF55.10VG
21 1 Tank aeration EBF 50
22 1 Oil sight glass KO01
23 1 Assembly plate EM213/3X2F
24 1 Pressure control valve EVM103/ABX2F
25 1 4/3-port directional control valve 4D0132070302B1GAG
26 1 Pressure control valve ZDRP015S0D1
27 1 4/3-port directional control valve 4D0132080302B1GAG
28 2 Bulkhead stuffing box SV12L
29 1 4/2-port directional control valve 4D01110601B1GAG
30 2 Pressure gauge stop valve FPEA1G1/4"
31 2 Glycerine pressure gauge GMM 63-250
Electricity
32 4 Positioning indicator height adjustment OP3-B-2.0-DX-RB12-R-P6
33 8 Positioning indicator pressing measurement OP3-B-0,75-DX-F14-R-P6
34 2 Digital column distance indicator (CODIX 529) 6.529.012.300
35 8 Thrustor switch 1736560
36 2 Line laser LAS 63/07
37 2 Laser distance sensor SENSICK DT 60-P113
38 2 Reflector plate
39 1 Electromagnet plate SQ 303KD50
40 1 Control unit for magnet plate NCU/+/230V
41 1 Signal lamp switch cabinet 8wD44-88
42 1 Energy chain I 27I.10.125.0
43 1 Energy chain II E 333.50.100/100.0
Mechanics
44 4 Centre points 5mm or 3mm EV-SK-044-TE
45 4 Threaded rod for stop block EV-SK-120-TE
46 4 Brave lever for stop block EV-SK-030-TE
47 16 Pressure roller tool holder EV-SK-058-TE
48 4 Spacer for centre point 5mm EV-SK-110-TE
49 4 Spacer for centre point 3mm EV-SK-110-TE
50 16 Resetter pressing tool holder EV-SK-008-BG
51 8 Profile support EV-SK-064-TE
52 4 Separator profile support 10mm EV-HV-006-TE
53 4 Separator profile support 30mm EV-HV-005-TE
54 4 Profile limit stop lifting frame EV-HG-011-TE
55 2 Profile limit stop lifting frame short EV-HG-012-TE
56 8 Ball caster with threaded stem free column SR04-045
57 4 Ball bearing for linear column 6301 RS
58 4 Pressing tool 3mm left/right 282796
59 4 Pressing tool 5mm left/right 282794
60 4 Pressing tool 7mm left/right 282793
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