OPERATION AND MAINTENANCE MANUAL FASTENER INSTALLATION PRESS SERIAL NUMBER RAM CAP

Transcription

1 OPERATION AND MAINTENANCE MANUAL FOR PEMSERTER SERIES 4 - AF FASTENER INSTALLATION PRESS SERIAL NUMBER RAM CAP NOTE: Your New PEMSERTER Series 4 AF Fastener Installation Press has been assigned a Serial Number as indicated above. This Number Must Be Referenced In all Correspondence PennEngineering 5190 OLD EASTON ROAD DANBORO, PENNSYLVANIA PART NUMBER Revised Edition C (21-JAN-2016) English Version

2 Read Manual Before Operating Press! FOREWORD Thank you for purchasing a PEMSERTER Series 4 AF press. With the proper care and maintenance, your press will install millions of fasteners safely, quickly and consistently. The press has a maximum 12,000 lbs (54kN) capacity with an 18 inch (450 mm) throat. The press is covered by a two (2) year limited warranty. Should any questions or problems arise concerning your Series 4 AF press, contact the PennEngineering Service Department. Toll-free telephone number (in North America) or (in Mainland China) Set-up, Training and Repair Service is available to you as long as you own your press. Free telephone instruction and Service is available for the lifetime of your press by calling the PennEngineering Service Department. SHIPPING DAMAGE The PEMSERTER Series 4 AF press has been shipped to you packaged to withstand normal handling during transit. Upon receipt, the unit should be checked for any damage that may have occurred during shipment due to improper handling. Should any damage be found, the transportation company who delivered the unit must be immediately notified as should the PennEngineering Service Department. SECIFICATIONS: Ram Force to 12,000 lbf (1.8 to 53.4 kn) Air Requirements to 100 PSI (6 to 7 BAR) Air Line... ½ (12mm) I.D. Minimum line flow Throat Depth (45cm) Weight lbs (390 kg) Electrical (North America). 120VAC,60Hz, 4A, 1φ Electrical (Europe and Pacific 230VAC,50Hz, 2A, 1φ Rim). Ambient Temperature F to 120 F (-29 C to 49 C) Ambient Humidity... 0% to 80% (Not reflective of inlet air) Air Consumption... Approx. 2.3 liters/sec at 1 atm (4.9 scfm) 20 insertions per minute at 20 kn (4500 lbf) Electrical Power Consumption Approx. 200 Watts with autofeed bowl running 2

3 SAFETY The Series 4 AF was designed to conform to applicable ISO, ANSI, OSHA, CEN and CSA safety standards. The Series 4 AF is compliant to applicable European Union (EU) directives and bears the CE Mark. The Series 4 AF conforms to the essential requirements of the following directives: 2006/42/EC Machinery Directive 2006/95/EC Low voltage Directive Applicable Standards: EN 12100:2010, EN :2006+A1:2009 EN ISO :2008+AC:2009 Please read and follow the safety precautions listed below. GENERAL SAFETY PRECAUTIONS Always use safety goggles when operating or maintaining the press. Always disconnect the air supply before maintaining the press. Always shut off the electrical power and remove the power cord before servicing the press. Ear Protection is recommended. Before using the press, make sure that a shutoff device has been fitted on the air supply line and the location is easily accessible, so that the air supply to the press can be shut off in an emergency. Check the air hose and fittings regularly for wear. Use only approved parts for maintenance and repairs. Do not use chipped, cracked or damaged accessories and tools. Attach air line securely. Keep body parts away from moving parts. Never wear jewelry, loose clothing or anything that could get caught in moving parts. If a new user is operating the press, be sure these instructions are readily available. Do not use the press in any way other than for its intended purposes. Do not modify the press. WARNING: The PEMSERTER Series 4 AF press is equipped with a point-of-operation safety device to protect the operator from potential injury. A detailed explanation of the safety system can be found in Section 4 Operator Safety of this manual. ANSI specification Number B , Section 5 states "It is the employer's responsibility to ensure the usage of a point-of-operation safety or guard or a properly applied and adjusted point-of-operation safety device on every operation performed on a press production system." It is important that employers ensure that their operators understand and are trained to properly set-up the Series 4 AF safety system before operation. IMPORTANT: The setup gap, as explained later in this manual, must not exceed 7/32 of an inch (5,5 mm) between the punch and anvil, with the ram fully extended by gravity, to comply with most major safety standards which set the limit at ¼ or 6mm (Figure 4.0). These include standards published by ISO, ANSI, OSHA, CEN and CSA. 3

4 Label Definition Press Series 4 Auto Feed Plate Warning Plate General Warning Label There are items that require attention. These are specified in the operator s manual. CAUTION: Laser Radiation. Do not stare into beam. Class 2 laser product. Per EN and ANSI Z136.1: Class 2 lasers are low power devices emitting visible radiation in the wavelength range 400mm to 700mm. Momentary viewing is not considered hazardous since the upper radiant power limit on this type of device is less than the MPE (Maximum Permissible Exposure) for momentary exposure of 0.25 second or less. Intentional extended viewing, however, is considered hazardous. Never aim the spotting light anywhere except at the workpiece. Eye Protection Label Eye protection must be worn when operating the press. Pinch Point Label Keep hands away from area. Electrical Shock/Electrocution Warning Label Electrical shock hazard. Do not touch. Read Manual Label Read the content before operation. 4

5 WARRANTY PennEngineering warrants that this product, when correctly used according to directions and under normal operating conditions, will be free from defects in material and workmanship for a period of two (2) years from the date of purchase. This warranty shall not apply to any product which has been altered, changed or repaired, normal maintenance excluded, except as authorized by PennEngineering. This warranty shall not apply to any product that has been subject to misuse, negligence or accident. The purchaser s exclusive and sole remedy shall be limited to repair, modification or replacement at the discretion of PennEngineering. In no event shall PennEngineering be liable for the cost of any indirect or consequential damage. In no case shall PennEngineering s liability exceed the purchase price of the product. This warranty is exclusive and in lieu of all other warranties. No oral or written information by PennEngineering, its employees, representatives, distributors or agents shall increase the scope of the above warranty or create any new warranty. 5

6 PEMSERTER SERIES 4 AF PRESS OPERATION MANUAL TABLE OF CONTENTS Page AIR SUPPLY PREPARATION... 7 UNPACKING AND INITIAL SET-UP PRESS FAMILIARIZATION OPERATOR SAFETY TOOLING SET-UP TOUCH-SCREEN CONTROLS PRESS OPERATION PRESS MAINTENANCE AND ADJUSTMENTS TROUBLE SHOOTING GUIDE RECOMMENDED SPARE PARTS PNEUMATIC DIAGRAM ELECTRIC DIAGRAM

7 AIR SUPPLY PREPARATION 7

8 AIR SUPPLY PREPARATION Recommended Air Supply Hook-Up Arrangement Proper air supply is very important to the performance and maintenance of the press. Following these simple guidelines will ensure good press performance. Air Quality - The quality of the air supply is very important. The air must be clean and dry. Moisture and debris will contaminate the valve systems and lead to press performance and maintenance problems. 5-micron rated air is recommended. Air Supply Flow - Use a minimum 12mm (1/2 ) inside diameter line and fittings from the compressed air source to the press. Shop pressure ranging between 6 to 7.5 BAR (90 psi to 110 psi) is acceptable. Inadequate air flow will affect press performance. Air Consumption Average air consumption running at 20 kn (4500 lbf) at 20 insertions per minute is about 2.3 liters/sec at 1 atm. (4.9 scfm). Air Supply Flow requirements are higher than those reflected by these values as air is not being consumed during the entire cycle time. Piping Installation Proper piping hook-up will help achieve the above requirements. See figure 1.0 on the next page. Connect to your supply line with a pipe pointing upwards that curves over and down. This arrangement will help prevent water and compressor oil from entering the press. Connect to that drop with your supply fitting for a 12mm (1/2 ) or larger hose. Continue the end of the drop to a drain valve. This will help collect additional water and oil and allow the system to be purged. If your factory air supply falls short of the above recommendations, an air reservoir tank of an appropriate size for your location can be used. An auxiliary filter/separator installed immediately outside the machine is recommended. CAUTION: Before connecting air supply to the press, ensure initial press set-up is complete and the ram force is set at the minimum (Ram Force knob turned completely counter-clockwise). Install An Appropriate Power Cord. The press is equipped with a Male IEC 320/CEE22 Universal Connector for power. Outside North America, unless special arrangements have been made, a customer supplied power cord must be installed. No other electrical system modifications are necessary. Connection should be in accordance with your local electrical code. Install The Foot Switch Plug the foot switch into the receptacle located at the lower left corner of the front of the electrical enclosure. 8

9 9

10 UNPACKING AND INITIAL SET-UP 10

11 UNPACKING AND INITIAL SET-UP Select a clean, well-lit area to place your Series 4 AF press. Check that the floor is in good condition and capable of supporting the weight of the press, stand and operator. Provide an area around the press that will allow for the removal of the top cover and clearance for opening the doors. A minimum of (3) feet (60 cm) along each side and behind the press is recommended (Figure 2.0). Carefully remove the crating and packing materials around the press and stand. Remove the box strapped to the crate containing assembly hardware, footswitch, tooling, etc. Position the stand with the press mounting holes as shown (Figure 2.0). The Series 4AF press may be bolted to the floor. Use appropriate fasteners for the type of floor. Use steel bolts of 10mm (3/8 ) diameter. Remove the top cover from the press. Observe the red warning tags. Follow the instructions and remove only the items required for shipping. CAUTION: Do not remove the remaining warning tags until all instructions are read and understood. Attach shackles and a chain through the (2) press lifting holes (Figure 3.0). The press weighs approximately 858 pounds (390 kg). Unbolt, then lift the press with the base from the pallet and put the press to the floor. WARNING: Do not lift the assembled press and stand by the stand. The assembled press and stand is top heavy and may fall if tilted beyond 10º of vertical. 11

12 12

13 Bowl Positioning: Need to rotate 90º. After placing the press on the floor, turn the bowl plate 90 degrees. Use 5/32 Allen key to remove the screws which fixed the bowl plate, then turn the bowl plate 90 degrees, replace and tighten the screws. Correct Position 13

14 PRESS FAMILIARIZATION 14

15 Identifying Major Components of the Press This section introduces the user to the major components of the press. Frame The frame is the structure of the press. The main section is made of solid steel with welded components that form the base and the other support sections. All parts are directly or indirectly mounted onto the frame. Operator Controls All the operator controls are located on the control panel except the foot pedal. These include the Touch Screen, the E-Stop button and the Power button. Touch Screen - This is the primary interface to the press control system (the PLC). It is used for installation and automatic feed setup and configuration, feedback to the user and diagnostics. The screen displays text and graphical information and allows the operator to make selections by touching different parts of the screen as indicated by what is displayed on the screen. Detailed explanations of each screen are provided in Press set-up and operation of this manual. E-Stop Button - Pressing this button disconnects power to the quick exhaust/supply valve. When pressure is exhausted, all pneumatic motion stops. During an E-Stop condition all outputs are turned off. The control system remains on-line and detects the E-stop. Power Button - When the press is off, pressing this button will provide power to the press control system which will initialize the press. Press this button to turn the press off. Power will be switched off from the control system and all moving components including the quick exhaust/supply valve. Foot Pedal - The foot pedal is used by the operator to control the start of a press cycle. It frees the operator to use his hands to manipulate the workpiece. Electrical Enclosure The Electrical Enclosure, on the right side of the press, houses the press control system (PLC) and various electrical components and distribution terminals. Electric Power and the Foot Pedal connect to this enclosure. The door is key-locked and located on the back is the electrical on-off switch. This switch must be ON for the press to be powered on. Turning off this switch removes all power to the press. The electrical power cord plugs in next to the switch. Removing the power cord can be used to lock out all power to press when performing maintenance. Vibratory Feeder Bowl (Automatic Fastener Feeding Component) The Vibratory Feeder Bowl, on the left side of the press, is used for automatic feeding of fasteners. It is an electrically driven device, which holds and moves different types of fasteners. Various types of tooling components are attached to the bowl to orient the fasteners being fed out of the bowl. The vibratory bowl comes equipped with a "Universal Escapement" adapter, which is used for all nut-type 15

16 tooling and some stud-type tooling. The Vibratory Feeder Bowl is controlled by a dial and a switch on the Bowl Control Box, above the bowl. Bowl Amplitude Dial - The bowl's amplitude or force of vibration is regulated by a dial control. The amplitude adjustment is used to control the feed rate and performance of the automatic feeding process. Bowl Three Mode Switch - A 3 position switch is used to select whether the bowl is always on, always off or automatically controlled by the PLC. When the switch is set to auto, the PLC turns on the bowl during run mode and during diagnostics. During run mode the PLC will turn the bowl off if there is a period of inactivity. The PLC will restart the bowl automatically when the next fastener is fed. When loading or unloading fasteners, turn the bowl ON/OFF as desired. Return the switch to AUTO when finished. Shuttle Support Assembly (Automatic Fastener Feeding Component) The Shuttle Support Assembly located next to the Vibratory Feeder Bowl is used to hold and actuate tooling shuttle components, route air supplies and hold the Stud-in-tube-Sensor (Optional) and "Puffer" Flow Control Valve. The Shuttle Air Cylinder on the Shuttle Support Assembly actuates tooling shuttles. The shuttle receives the parts fed from the vibratory feeder bowl, singulates the parts and feeds them out to the punch/anvil area. The Shuttle Support Assembly is aligned with the vibratory feeder bowl. Proper alignment is important to the functioning of the shuttle tooling. Stud-in-tube Sensor - The PLC uses this ring sensor to monitor and control the feeding process of stud-type tooling. (Optional) 16

17 STUD IN TUBE SENSOR ASSY Puffer Flow Control Valve - This valve controls the air flow to the Vibratory Feeder Bowl tooling attachments and is used to regulate various aspects of the escapement and nutgate performance. Slide and Gripper Assembly (Automatic Fastener Feeding Component) The Slide and Gripper Assembly mounted to the top of the frame throat is used to hold top-feed tooling components and has two pneumatic actuators. The two actuators are a linear slide cylinder and a parallel acting gripper. The gripper is used to actuate the tooling jaws that hold fasteners. The gripper opens and closes to receive and release fasteners. The gripper is attached to the end of the linear slide. The linear slide is used to move the gripper and jaws from its retracted position out to the punch position. This system is used to feed fasteners out to tooling punches. The Slide and Gripper Assembly also holds tube extension tooling for stud-type tooling. The Slide and Gripper Assembly can be removed for special workpiece accessibility. Air Supply Inlet System The supply of compressed air enters the press in the back through a system, which includes a filter/regulator and an electrically controlled quick exhaust/supply valve. The regulator is manually set to control the supply line pressure. Turning on the quick exhaust/supply valve supplies air to the press. When the quick exhaust/supply valve is turned off the valve closes and exhausts all downstream compressed air in the press quickly. 17

18 (Note: If the pressure gage display range is not 0.05~0.10Mp, Please open the rear cover plate, and then adjust the pressure relief valve to standard value 0.05-~0.10 Mp) Pressure regulator Pressure gage Tooling Storage Cabinet The Tooling Storage cabinet is located on the bottom of the press. 18

19 Item Description Qty. 1 Vibratory Feeder Bowl 1 2 Shuttle Support Assembly 1 3 Tooling Storage Enclosure 1 4 Electrical Enclosure 1 5 Top Cover 1 6 Lifting Holes 1 7 Punch 1 8 Slide and Gripper Assembly 1 9 Anvil 1 10 Anvil Holder Assembly 1 PRESS RIGHT SIDE FIGURE

20 Item Description Qty. 1 Touch Screen 1 2 Power Button 1 3 Ram Force/Air Pressure Adjustment 1 4 E-stop Button 1 OPERATOR CONTROL PANEL FIGURE

21 PRESS ASSEMBLY FIGURE 3.2 (CONTINUED) 21

22 PRESS ASSEMBLY FIGURE 3.2 CONTINUED 22

23 SENSOR BRACKET SMC BJ SENSOR SMC D-C73L ANVIL HOLDER HANGER ASSEMBLY FOR S4AF SPRING EXTENSION E ANVIL-AS REQUIRED 1 18 PUNCH-AS REQUIRED BUSHING RAM RAM JAM NUT ALL PS-4 MODELS RAM, PS4 AF /8 NPT AIR PILOTED VALVE ASSEMBLY,MAIN CYLINDER WITH MAGNETIC RING LEVER 18 TO 1 SERIES 4 PRESS THROUGH PIPE (B) LIFT CYL ASSY 9/16 PS PLATE CROSS PIN RAM MOD PS CLEVIS BRASS ASSY BALL ACT./VALVE KIT PIVOT BLOCK PLATE BEARING CUSHION TYPE,ASSY PIN DOWEL 3/4 GROOVED 2IN LINK LEVER VALVE FLOWCNTRL 5/32OD,10/324J FLT AUX REGU. ASSY. PS4 AF 1 ITEM PART NUMBER DESCRIPION QTY PRESS ASSEMBLY FIGURE 3.2 CONTINUED 23

24 VALVE MAIN CYLINDER AIR CUSHION ADJUSTMENT (EXTEND STROKE) MAIN VALVE BOWL PRESSURE GAGE (0.05~0.1MP) AIR CUSHION ADJUSTMENT (RETRACT STROKE) On/Off Safety Valve SOFT START-UP VALVE REGULATORS AIR FILTER REAR VIEW FIGURE

25 XX =INCHS [XX]=CENTIMETERS PRESS THROAT DIMENSIONS FIGURE

26 SLIDE AND GRIPPER ASSEMBLY ANVIL HOLDER ASSEMBLY PUNCH AND ANVIL AREA DETAIL FIGURE

27 OPERATOR SAFETY 27

28 OPERATOR SAFETY An important feature of the PEMSERTER Series 4 Model AF press is its "Point of Operation" safety. When the footswitch is depressed, the ram extends. At the end of the ram stroke, the ram cross pin actuates the ball valve and safety set point sensor causing the installation force to be applied to the ram assembly and punch. If an obstruction, greater than the set gap between the punch and the anvil, is encountered, the ball valve and safety setpoint sensor will not be actuated and the installation force will not be applied. Important: The gap must not exceed 7/32 of an inch (5,5 mm) set gap between the punch and anvil, with the ram fully extended by gravity, to comply with most major safety standards which set the limit at ¼ or 6mm (Figure 4.0). These include standards published by ISO, ANSI, OSHA, CEN and CSA. 28

29 29 (74.6mm)

30 AIRBORNE NOISE EMISSIONS A PEMSERTER Series 4 -AF Model fastener installation press was set at the maximum ram force and cycled continuously. Sound pressure was measured at a distance of 1 meter from the surface of the press at a height of 1.6 meters from the floor at a worst case point (behind the press, near the installation force cylinder). Equivalent continuous A-weighted sound pressure = 53.5 db Peak C-weighted instantaneous sound pressure = 87.0dB Sound pressure was measured at the operator's working level (area in front of the press). Equivalent continuous A-weighted sound pressure = 45.0 db Peak C-weighted instantaneous sound pressure = 87.3 db Equipment used during testing: Description: Sound Level Meter Description: Noise Dosimeter Manufacturer: General Radio Manufacturer: Metrosonics Model: 1565-B Model: db307 Class 2A Serial Number: Serial Number:

31 TOOLING SET-UP 31

32 STANDARD PUNCH AND ANVILS 1. Refer to the tooling guide for the appropriate punch and anvil for the fastener being installed. 2. Set the ram force to OFF. Disconnect the air supply to the press. The ram will extend. Remove the punch by loosening the (2) set screws in the ram bushing. Install the new punch and tighten the (2) set screws. 3. Set the ram force to OFF. Connect the air supply to the press (Click the MAIN AIR button on the screen). The ram will retract. 4. Loosen the set screws in the front of the anvil holder and remove the anvil and anvil adapter ( ), and then loosen the set screw in the side of the anvil adapter ( ) and remove the anvil. Install the new anvil into the anvil adapter and tighten the set screw, and install the anvil adapter and a new anvil into the anvil holder and tighten the set screws. (Figure 5.0). 5. Turn on the Press and select manual type, press foot pedal. then get into adjust safety Point and Force(See Setup Procedure in Touchscreen Controls section of manual).press the foot pedal button, then get into RUN MODE. 6. Set the ram force to OFF. Turn off the air supply to the press. Check the alignment of the outside diameters of the punch and anvil. If necessary, use the special fixture ( ) aligns the anvil to the punch. Loosen the bolts in the anvil holder, reposition the anvil holder and then torque the anvil holder bolts to 100 foot pounds (136 Nm). 32

33 ANVIL AND ANVIL HOLDER (STANDARD) FIGURE

34 Stud Escapement and Nut Gate The purpose of an escapement is to properly align the fasteners so that other tooling can deliver and position them at the ram/anvil area, properly positioned for insertion. Escapements are installed on the outside/top part of the vibratory bowl. The escapements used with nuts have two parts: (1) the first part of the escapement is called the nut gate adapter. The nut gate adapter is placed upon the escapement adapter with two positioning pins. (2) The second piece is called the nut gate. The nut gate provides a fastener-specific machined channel which will funnel only properly aligned nuts to the shuttle. The nut gate is positioned on top of the nut gate adapter with the same two positioning pins and is secured in place with one thumb screw. The escapements used with studs are stud specific. The escapement is mounted onto the escapement adapter with the nut gate adapter removed. After mounting an escapement, push the puffer air hose into the escapement air intake connector. The puffer has two functions: (1) to blow excess and misaligned fasteners off the top part of the bowl s ramp, back into the bowl and; (2) to create a slight vacuum (only when inserting nuts) which helps pull the nuts into the escapement channel. Adjust the puffer air pressure by turning the puffer s flow-control knob. Excess/Misaligned nuts and studs should be blown back into the bowl, while correctly oriented nuts should be gently drawn into the channel. This knob is located below the escapement mounting area. Shuttle And Tube The purpose of a shuttle is to move the fasteners, one at a time, from the escapement to the mouth of its mated plastic tube which will then transport the fasteners to the punch/anvil area. To prevent fasteners from becoming misaligned, each shuttle and each tube is designed to be part specific. For this reason the shuttles are typically left attached to their mated tubes and handled as one assembly. When installing a shuttle: (1) attach it to the shuttle air cylinder. This air cylinder is mounted on the same bracket that will support the shuttle after it is installed. The function of this air cylinder is to push and pull the shuttle s slide back and forth. To attach the air cylinder to the shuttle, slide the shuttle s clevis over the tip on the end of the cylinder rod; (2) position the shuttle over the two positioning pins then secure it in place with its one tee handle. Be sure to maintain a gap of about 1mm (.040 ) between the shuttle and the escapement. Tube Extension, Jaws, Punch Slide the punch into the bottom of the ram bushing and secure it by tightening the two setscrews. Loosen the set screws ( ) in the front of the anvil holder and remove the anvil and anvil adapter ( ), and then loosen the set screw in the side of the anvil adapter ( ) and remove the original anvil. Install the new anvil into the anvil adapter and tighten the set screw, finally install the anvil adapter and new anvil into the anvil holder and tighten the set screws of anvil holder. (Figure 5.0) Install the set of jaws on the gripper assembly. Locate each jaw using the two positioning pins provided, and then secure it by tightening its thumbscrew. For nut insertion, twist the tubing 180 degrees (so the nut will be positioned shank-side down) and slide the end of the tube over the fitting on the left jaw 34

35 For studs, slide the tubing thru the tubing guide ( ) in the rear of the press to the hanger assembly. Insert the tubing into the tube extension and insert the tube extension into the tube hanger. (Figure 3.2), Attach the other end of the tubing to the shuttle assembly. NOTE: If using the optional Stud-In-Tube Sensor, be sure the tubing always runs through the Stud-in-Tube sensor. 35

36 ITEM DESCRIPTION ITEM DESCRIPTION 1 FEEDER BOWL 8 TRANSPARENT SHUTTLE GUARD 2 RETAINING HANDLE 9 PUFFER FLOW CONTROL VALVE 3 NUT GATE 10 SHUTTLE SUPPORT ASSEMBLY 4 NUT GATE ADAPTER 11 FEEDER BASE 5 ESCAPEMENT ADAPTER 12 CLEVIS 6 HANDLE 13 TUBING ADAPTER 7 SHUTTLE AIR CYLINDER FIGURE 5-1 FEEDER BOWL SYSTEM WITH NUT TOOLING 36

37 ITEM DESCRIPTION ITEM DESCRIPTION 1 FEEDER BOWL 8 PUFFER FLOW CONTROL VALVE 2 RETAINING HANDLE 9 SHUTTLE SUPPORT ASSEMBLY 3 STUD ESCAPEMENT 10 RING SENSOR(OPTION) 4 HANDLE 11 FEEDER BOWL BASE 5 ESCAPEMENT ADAPTER 12 TUBING ADAPTER 6 SHUTTLE AIR CYLINDER 13 STUD SHUTTLE ASSEMBLY 7 TRANSPARENT SHUTTLE GUARD 14 CLEVIS FIGURE 5-2 FEEDER BOWL SYSTEM WITH STUD TOOLING 37

38 ITEM DESCRIPTION 1 PUNCH ASSEMBLY 2 JAW ASSEMBLY 3 ANVIL ASSEMBLY 4 TUBING 5 SHUTTLE ASSEMBLY 6 NUT GATE FIGURE 5-3 TOP FEED NUT TOOLING PACKAGE 38

39 ITEM DESCRIPTION 1 SHUTTLE ASSEMBLY 2 TUBING 3 TUBE EXTENSION 4 PUNCH ASSEMBLY 5 ANVIL ASSEMBLY 6 RIGHT HAND JAW 7 LEFT HAND JAW 8 STUD ESCAPEMENT FIGURE 5-4 TOP FEED STUD/STANDOFF TOOLING PACKAGE 39

40 ITEM DESCRIPTION 1 SHUTTLE ASSEMBLY 2 TUBING 3 TUBE EXTENSION 4 PUNCH ASSEMBLY 5 ANVIL ASSEMBLY 6 RIGHT HAND JAW 7 LEFT HAND JAW 8 STUD ESCAPEMENT FIGURE 5-5 TOP FEED STANDOFF PIN TYPE TOOLING PACKAGE 40

41 TOUCH-SCREEN CONTROLS 41

42 1. Title Screen: Here you may find the PennEngineering and our Sales Representative s address and phone numbers. PLC Version is the version number of PLC software. Screen Version is the version number of Screen software. Hardware Version is the model number of the press. [CONTINUE] to Access Code Screen 42

43 2. PASSWORD Screen This screen appears and limits access to different levels of functions depending on which access codes have been established. See 12 SECURITY CODES Setup Screen. If the access code is set to 0000 then this screen will be bypassed and the touchscreen menu will proceed to the next function. This same screen appears in different places for Operator Access, Setup Access and Maintenance Access. To proceed to the next screen: Enter the Correct 4-digit Access Code. [ ] Proceeds to the appropriate screen If in Operator Access Screen Proceeds to Mode Selection to See 3 Mode Selection Screen If in Maintenance Access Screen - Proceeds to Maintenance Menu Screen to See 7 Maintenance Menu Screen If the access code is forgotten, call your PennEngineering Service Representative. 43

44 3. MODE SCREEN TOOL SET-UP : - Proceeds to a setup process, which allows the operator to select the installation mode. RECALL LAST JOB : - Proceeds directly to safety setup of press using the values defined in the last setup, even if the press had been turned off. MAINTENANCE : - If the Maintenance access code has been set this button proceeds to Maintenance Access Screen. MAIN AIR : - Turns the main air on and off. BACK : - Proceeds to previous screen. 44

45 4. TOOLING SELECTION Screen TOP FEED NUTS/SO - Top Feed Nut and Short Standoff Mode is for automatic feeding of nuts to the Top Feed Hanger Assembly, for punch pick-up through the internal hole of the fastener. (Range: S-256/M2 ~S-M6) See Tooling description of tools and operation. STUDS/BSO -Top Feed Stud and Blind Standoff Mode is for automatic feeding of studs and blind standoffs to the Top Feed Hanger Assembly, for punch pick-up by vacuum.(range,fh-m2.5~ M6 length 30mm)See Tooling description of tools and operation. LONG STANDOFFS - Top Feed Long Standoff Mode is for automatic feeding of longer standoffs to Top Feed Hanger Assembly, for punch pick-up through the internal hole of the fastener.(range: SO-M3~M5 length 17mm)See Tooling description of tools and operation. MANUAL Manual Mode means that the operator must manually place a fastener and no automatic feeding is enabled. Fastener and workpiece must be manually placed together between the tooling. BACK - Back to previous screen. 45

46 5. SETUP MODE Screen Safety Set Point - Safety point setup is the position of installation. The operator positions the materials for an installation, but the press does not actually install the fastener. Once this position is set during the setup process, press yes button. Set Force - Adjust the pressure regulator to set the installation force. Once the installation force is verified during the setup process, press yes button. Blower Time - Allows the blower time for automatic feed modes to be adjusted. The blower time is the duration that the air stays on to blow the fastener from the shuttle mechanism through the feed tubing to the insertion area. Touch the number button to adjust the blower time. Suggest to set at 1.0 second. BACK Proceeds to previous screen. SETUP PROCEDURE 1. Set the force regulator to Zero. 2. Use 3/4 wrench to loosen the jam nut under the anvil holder, and use the 3/32 inch Allen wrench to loosen the two screws in the front of the anvil holder. 3. Adjust the anvil down using the bushing under the anvil holder with 3/32 Allen key. Turn the Allen key 6 times so the anvil is about.25 below the anvil holder surface. 4. Place the workpiece in position on the anvil. In Automatic tooling mode, use the anvil pin for alignment in workpiece mounting hole. In Manual tooling mode, use the fastener to align the workpiece mounting hole. 5. For automatic tooling mode, press FEED button, the machine will feed one fastener. (This step is not required in manual tooling mode). 46

47 6. Press the foot pedal, the ram will descend and will remain in the down position. (In automatic tooling mode, the jaws will extend and the punch will pick up the fastener before descending. 7. Adjust the bushing under the anvil holder with 3/32 Allen key to adjust the anvil up until the workpiece or fastener touches the fastener or punch. 8. Adjust the bushing under the anvil holder, until the Safety Set Point Sensor On appears on the Setup screen. Continue to raise the anvil until the Safety Set Point Sensor On message disappears, then turn the bushing (1/2) turn, so the Safety Set Point Sensor On message appears again. 9. Adjust the pressure regulator to the required installation force so the fastener is pressed into the workpiece. 10. Tighten the set screws in the front of anvil holder using the 3/32 inch Allen key and tighten the bushing nut under the anvil holder using the 3/4 inch wrench. 11. Press yes buttons on the right side of Safety Set Point and Set Force buttons to activate. 12. Set up is complete and the following screen will appear. 13. Press the footpedal to proceed to Run Mode. 47

48 6. RUN MODE Screen Blower Time - Allows the blower time for automatic feed modes to be adjusted. The blower time is the duration that the air stays on to blow the fastener from the shuttle mechanism through the feed tubing to the insertion area. Touch the number button to adjust the blower time. Suggest to set to 1.0 second. Dwell high force/punch time, suggest to setup at 0.5~1.0S Workpieces - Left side shows the workpieces quantities which have been installed. Right side shows the setup quantity. Fasteners - Left side shows the fastener quantities which have been installed. Right side shows the setup quantity. 48

49 [AUTO] Toggles Workpiece Complete Screen to automatically return to run screen after a brief flash. [MANUAL] Toggles Workpiece Complete Screen to require the operator to touch the reset button on the screen, when the Workpiece Complete Message Screen appears. [OFF] Toggles Workpiece Complete Screen to not appear. REDO In any automatic tooling mode, it enables the press to attempt another insertion without feeding another fastener. Touch this button and the button flashes. Depress the foot pedal and the ram will extend, insert and return again without feeding a new fastener. This function can be used for a restrike of a partially installed fastener or for a manual insertion during an automatic feed run without leaving the run screen. FEED - By pushing this button the operator can cause the system to feed a fastener to the workpiece area, without activating the ram. This feature is also used if a fastener is lost during the standard feed process. "-1 Shift Decrement Button, Touch this button and touch either the Workpieces Button or the Fasteners Button to decrement the current count by 1." BACK - Proceeds to previous screen and saves the last job. MODE - Returns to mode screen and saves the last job. 49

50 7.MAINTENANCE Screen In MODE SCREEN, press MAINTENANCE button to get into maintenance screen. This screen allows the operator to access the maintenance functions. Here the operator can access certain setup screen, a maintenance control screen and automatic feed tooling test modes. PLC I/O - Proceeds to PLC Inputs/Outputs Control Screen, which allows maintenance personnel to independently control PLC Input/Output signals for diagnostic purposes. SETTING - Proceeds to Setting screen, which allows maintenance personnel to adjust the Slide Retract timer setting and turn On/Off Stud-in-tube sensor. TOOLING TEST Proceeds to Test Tooling / Settings screen, which allows maintenance personnel to test auto tooling and machine. SECURITY CODES - Proceeds to Security code setup screen. This screen allows the operator to enter and change the operator access and maintenance access codes. BALL VALVE CHECK - Proceeds to the Ball Valve Check screen. This test is part of the daily maintenance for the press and verifies the ball valve is functioning properly. BACK - Proceeds to previous screen. 50

51 8. PLC Input/Output Control Screen This screen alows the operator to view the status of all input signals to the PLC and control all of the output signals from the PLC. Each output button allows an output control signal to be turned on and off. The small numbers inside each display and button correspond to the wired location on the PLC. [00-10 INPUT SIGNALS] Each Display shows the status of one input, if the button is dark, the input signal is ON. [01-14 OUTPUT SIGNALS] Each Button controls one output, if the button is dark, the output signal is ON. Some buttons are interlocked to function safely and properly. Touch a light button to turn an output ON. Touch a dark button to turn an output OFF. [03 PUFFER] - The one exceptional button. If the operator touches the light button, the output will cycle on and off, simulating the program cycle for nut feed modes. If the operator touches the cycling button, the output will remain steady on, simulating the program cycle for stud feed modes. If the operator touches the dark button, the output will turn off. WARNING: Use Button [11 Ram Boost], with care. The press will go into high force on any object between the punch and the anvil. For safety reasons, this button can only be activated only when the [01 Ram 1] button is ON. 51

52 9.SETTINGS Screen Slide Retract Timing - Top feed slide timing adjustment, suggest to setup at seconds. ENABLE Stud-In-Tube Sensor - Toggles whether stud-in-tube sensor is on or off. Dark is ON and enabled. NOTE: The Stud-In-Tube sensor is an option, not standard. BACK - Proceeds to previous screen. 52

53 10. TOOLING TEST Screen Select one fastener type then get into TEST screen. For example, if select TOP FEED NUTS/SO mode then will get below screen. Blower Time - Allows the blower time for automatic feed modes to be adjusted. The blower time is the duration that the air stays on to blow the fastener from the shuttle mechanism through the feed tubing to the insertion area. Touch the number button to adjust the blower time. Suggest to set to 1.0 second. 53

54 Cycle Count Preset Enter the number of cycles for the test. The press will stop the testing after reaching the set cycle count. Current Cycle Count Actual cycles have been done. The machine will stop when Current Cycle Count is equal to Cycle Count Preset. ZERO Press this button to zero the Current Cycle Count. NOTE: Setup is the same in LONG STANDOFFS, but in STUDS/BSO the operator can select Enable Vacuum Check. ENABLE VACUUM CHECK This button will turn the Vacuum Check function on and off. If the press is operating in stud mode, this feature will check for the presence of the fastener on the vacuum punch. Press the [START] button, and the below screen will appear. Press the foot pedal to start the test. NOTE: To stop the test, press the START button again. 54

55 11. SECURITY CODES Setup Screen This screen allows the operator to enter and change the operator access and maintenance access codes. The initial settings of the two are zero, disabling each access screen. IMPORTANT: Upon receipt of the Series 4 Auto Feed Press, immediately establish a Maintenance Access Code. The maintenance access screens allow operation of the press without the standard safeguards in place. Only trained personnel should use the functions accessible on the Maintenance Menu Screen. 55

56 12. BALL VALVE CHECK Screen IMPORTANT: Requirement to do daily safety checking. The main air must be connected to the press before safety checking. Process: 12.1 Adjust the force between 1,000 lbs to 2,000 lbs 12.2 Press the button Ball Valve Check 12.3 If the ball valve passes the test, the screen below appears. Then press BACK button to MODE SCREEN. 56

57 12.4 If the ball valve fails the test the screen below appears: Note: If the Ball Valve Failed screen appears, the screen will be locked and the press will not function, even if the operator presses the EMERGENCY BUTTON or restarts the press. The ball valve must be replaced for the press to function. Please contact the PennEngineering Service Department or your locally distributor If ball valve has been replaced, repeat test again 57

58 13. Attention Screen EMERGENCY STOP button has been activated. Main Air has been shut down. Press RESET button will get into Title screen. The vacuum input signal was lost. 58

59 Lift cylinder top sensor failed. In automatic mode or manual mode, the safety set point sensor signal was lost during the down stroke. 59

60 Main cylinder bottom sensor failed, normally open or close. The system failed to detect a fastener after 5 tries. 60

61 Safety set point sensor failed, normally open or close. The fasteners per workpiece count is reached. 61

62 Workpiece count is reached. 62

63 PRESS OPERATION 63

64 PRESS OPERATION Before operating the press Install the tooling (See Tooling Section 5) Check air supply be sure it is connected and that the pressure is between 6 and 7 BAR (90 to 100 psi) Check electrical power supply be sure the ON/OFF switch in the back is in the ON position. Always wear eye protection when operating the press Always keep all body parts as far away from moving parts as possible. Test the ball valve every day (Refer to Page 56). Test the safety system every day (Refer to Page 72) Running the press: (The instructions given are for a standard new job setup. For the different options see Section 5 Touchscreen Controls.) Turn On the Press push the power button. Setup Access press [CONTINUE] on the Title screen to proceed to the Mode screen. Select Setup Type press either [TOOL SETUP] to setup a new job [RECALL LAST JOB] to select the same job that was last run. Select Tooling Type press selection Adjust Safety Point and Force See Setup Procedure in Touchscreen Controls section of manual. Press the foot pedal button, then get into RUN MODE 64

65 IMPORTANT: The ram must contact the fastener fully in the workpiece (but not installed) and both the fastener and workpiece must be flat to the punch and anvil. The gap between the punch and the anvil must not exceed 5.5mm (7/32 ) to conform to internationally recognized safety standards. This means that the stacked height of the fastener and the workpiece before installation must not exceed 5.5mm (7/32 ). See drawings on next page for examples of proper and improper setup. Install Fastener Position the workpiece properly, flat on the anvil or fastener. Step on the foot pedal. The ram will extend and install the fastener. The press will then get ready to install the next fastener. EXAMPLES: Nut Setup Stud Setup Standoff Setup 65

66 PRESS MAINTENANCE AND ADJUSTMENTS 66

67 PRESS MAINTENANCE WARNING: DISCONNECT THE AIR SUPPLY BEFORE PERFORMING ANY MAINTENANCE. WARNING: COMPLETE THE FOLLOWING MAINTENANCE EVERY DAY 1. Before running press, check the safety pressure gage, ensure the pressure into 0.05~0.10 Mp (Refer to figure 3.3) 2. Perform the safety stop distance test (pencil testing). (Page 72) 3. Test E-Stop button. Press the button and power will be disconnected to the quick exhaust/supply valve and all pneumatic motion stops. 4. Check Ball Valve operation. IMPORTANT: COMPLETE THE FOLLOWING MAINTENANCE EVERY WEEK. 1. Lubricate all pivot points with a good quality lubricating oil, such as SAE (Refer to Figure 7.0). 2. Spray the upper and lower portion of the ram with WD-40, CRC 5-56 or equivalent. Wipe clean with a cloth and respray with a light coat. 3. The MAIN AIR FILTER is equipped with an automatic drain (Figure 7.1). If an excessive amount of liquid (over 1/2 inch or 12mm) is in the filter bowl, manual draining and cleaning is required to clean the filter bowl. Remove the filter bowl and clean with a clean cloth and soap. Wipe the bowl dry and re-install. Never clean the filter bowl with solvents. Solvents may weaken the bowl material resulting in bowl deterioration. 67

68 OIL LUBE OIL OIL SPRAY LUBE OIL LUBRICATION POINTS FIGURE7.0 68

69 On/Off Safety valve Soft Start-up Valve Adjustment screw For soft start valve Air Filter Regulators FILTER DRAIN MAIN AIR FILTER FIGURE

70 IMPORTANT: COMPLETE THE FOLLOWING MAINTENANCE EVERY (1) MONTHS. Check Vibratory Bowl Check Tooling Adapter Check Tooling Alignment Check Actuator Movement Check for dirt, powder, or any other material in bowl, clean as needed. Check the inside surfaces of the bowl, the surfaces should have an even sand blasted finish. If parts of the bowl become polished and shiny, the bowl surface should be sand blasted. Check the surface of the tooling nut gate adapter plate. The top surface should have an even sand blasted finish. If areas of the plate become polished and shiny, the plate should be sand blasted. Check Punch and Anvil alignment Check Jaw to Punch alignment Check Bowl to Shuttle alignment Check Shuttle Cylinder moves freely Check Slide moves freely Check Gripper moves freely Check lift Cylinder moves freely. 70

71 WARNING: DISCONNECT THE AIR SUPPLY BEFORE PERFORMING ANY MAINTENANCE. IMPORTANT: COMPLETE THE FOLLOWING MAINTENANCE EVERY (6) MONTHS. FLOW CONTROL VALVE ADJUSTMENTS All FLOW CONTROL VALVES are set at the factory for optimum press performance. Incorrectly altering these settings may cause press damage. However, as press components wear or are replaced, they may require the following adjustments. FLOW CONTROL VALVE FUNCTIONS Lift Cylinder Flow Control Valve The Lift Cylinder Flow Control Valve controls the speed at which the ram descends and regulates the amount of air exhausted from the lift cylinder when the footswitch is depressed. Slide & Gripper Assembly Flow Control Valve The flow control valve installed on the slide & gripper assembly controls the speed of movement when it extends and retracts. To check the movement, from the Maintenance screen, select PLC I/O. In the PLC I/O screen, press the slide button, by turning this button on/off will extend (on) and retract (off) the slide. If the movement is not smooth, adjust the flow control valve to adjust the speed. Check Vibratory Bowl Magnet Gaps Gap between magnetic coils and striker plate should be 0.9 to 1.0 mm ( ) and parallel. Adjust with screws as needed. Be sure to keep coils and plates parallel. Soft Start Valve Adjustment Turn the Main Air off and select the Maintenance screen and then PLC I/O. In the PLC I/O screen, press the MAIN AIR button and the ram will retract. If the retracting speed is too fast, use the screwdriver to turn the adjustment screw on the soft start valve up; if the retracting speed is too slow, turn the adjustment screw down. (Refer to Figure7.1) Air Cushion Adjustment With the power on and the main air on select the PLC I/O screen from the Maintenance screen. Extend the ram by pressing the 01 Ram button. With the ram extended, push 11 Ram Boost button, the press will go into high force. Toggle button 11 to extend and retract the main cylinder. Observe the movement and adjust the air cushions using an Allen wrench until the movement on both ends is smooth. (Refer to Figure 3.3) WARNING: Use Button [11 Ram Boost], with care. The press will go into high force on any object between the punch and the anvil. For safety reasons, this button can only be activated only when the [01 Ram 1] button are ON. 71

72 FINAL ADJUSTMENT An additional adjustment may be required based on the press' actual operation. For example: If, after all adjustments are made, the ram descends too slowly, adjust lift cylinder flow control valve counterclockwise to increase the amount of air exhausted from the lift cylinder. PEMSERTER Series 4, AF Maintenance Procedures Testing the Safety Stop Distance ( Pencil Test ) Purpose: To check that the safety system is operating properly. Why: The safety system of the press is the most important system. It is designed to be self-diagnosing and so no single component fault will compromise the system. However, a check should always be done as a final test of the system. How Often: Perform Daily Tools Needed: Wooden Lead Pencil (Any standard pencil will do but the one commonly used is a wooded lead pencil with a 6.3mm- 7.6mm ( ) flat-to-flat hexagon (6-sided) cross section.) Install Tooling - any punch and anvil set can be used. Standard flat punch and anvil for a Series 4 AF are 16mm (.625 ) in diameter and 102mm (4.0 ) long & 76mm (3.0 ) long.(ensure that the distance of 0.10mm or only touch the punch and anvil ) Turn On the Press push the power button. Select Setup Type press [TOOL SETUP] Select Tooling Type select a [Manual] tooling mode Adjust Force Adjust Air Pressure Adjustment to 12000psi. Press the foot pedal button, and then get into RUN MODE. Start to enter the safety testing Test Safety System - Test that the safety system is functioning properly. Use the following test: a) After completing the safety setup step with nothing between the punch and the anvil. Place a wooden lead pencil on the anvil. b) Wear eye protection, keep body parts away from moving parts, as far as possible. c) Step on the footpedal. d) The ram will extend, the punch will contact the pencil and the press will indicate a safety fault. e) If the wood of the pencil is broken, the press has failed the safety test. Turn the press off. Remove and Lock out the power and air supply. Contact your service representative. 72

73 TROUBLE SHOOTING GUIDE 73

74 WARNING: DISCONNECT THE AIR SUPPLY BEFORE PERFORMING ANY WORK THAT REQUIRES REMOVING OR OPENING THE COVERS. TROUBLE SHOOTING GUIDE PROBLEM CAUSE CORRECTIVE ACTION The press will not start. (Light not lit) Electric Power Cord not connected. No power to the press. Connect power cord Turn on. Ram will not retract Exhaust Muffler clogged on Main Valve Assembly. Replace Exhaust Muffler. Fastener will not install. Flow control Valve adjustment required. No air supplied to press. Ram Bushing improperly adjusted. Workpiece material too hard. Punch and anvil lengths incorrect. Incorrect fastener installation hole size in workpiece. Main Valve jammed. 74 Fully close Flow Control Valve by turning clockwise. Then, open valve by turning counter-clockwise approximately ¼ turns. Ensure Ram does not slam when retracting. Check press air supply connections and main air supply. Adjust Ram Bushing per Tooling Set-Up and Operation section. Check hardness of workpiece and compare with PEM fastener catalog specifications. Combined length of punch and anvil must total 7 inches (178 mm), Measure hole size and compare with PEM fastener catalog specification. Remove Main Valve Assembly. Disassemble Valve and clean in mineral spirits. Replace Valve if necessary. Clean air filters.