Lissmac SBM-XL S2B2 Owner's manual

LISSMAC Maschinenbau GmbH

SBM-XL 1000/1500 S2B2 60

Lissmac

METAL PROCESSING

OPERATING MANUAL

STEEL PROCESSING MACHINE

SBM-XL 1000 S2B2

SBM-XL 1500 S2B2

LISSMAC Maschinenbau GmbH

Lanzstrasse 4

D-88410 Bad Wurzach

Telefon +49 (0) 7564 / 307 - 0

Telefax +49 (0) 7564 / 307 - 500

[email protected]

www.lissmac.com

LISSMAC Maschinenbau GmbH

SBM-XL 1000/1500 S2B2 60

Lissmac

Imprint

SBM-XL 1000/1500 S2B2 Page 2

Imprint

Operating manual for the steel processing machine LISSMAC

SBM-XL 1000/1500 S2B2

Stand 05-2017

Translation of the original operating manual

Manufacturer:

LISSMAC

Maschinenbau GmbH

Lanzstraße 4

D-88140 Bad Wurzach

Telephone: +49 (0) 7564 / 307 - 0

Fax: +49 (0) 7564 / 307 - 500

E-mail: [email protected]

Web: www.lissmac.com

The dissemination or duplication of this operating manual and

the reuse or disclosure of its contents are forbidden unless

explicitly permitted. Non-compliance is subject to compensation

model, or design patent registration.

Table of Contents

SBM-XL 1000/1500 S2B2 Page 3

Table of Contents

Imprint ...................................................................................................................................... 2

Table of Contents ..................................................................................................................... 3

List of figures ............................................................................................................................ 7

1General ............................................................................................................................. 9

1.1About this manual ...................................................................................................... 9

1.1.1Changes/Reservations ..................................................................................... 11

1.1.2Packaging and Storage .................................................................................... 11

1.1.3Characters and symbols ................................................................................... 12

1.1.4Documentation .................................................................................................. 14

1.1.5Additional documents ....................................................................................... 14

1.1.6Warranty and liability ........................................................................................ 15

1.2Use ........................................................................................................................... 16

1.2.1Appropriate usage ............................................................................................ 16

1.2.2Non-intended use ............................................................................................. 17

1.2.3Residual risks ................................................................................................... 18

1.3Safety instructions .................................................................................................... 19

1.3.1Environmental protection .................................................................................. 19

1.3.2Disposal ............................................................................................................ 19

1.3.3Notes on electrical/electronic components ....................................................... 20

1.4Emissions and exposures ........................................................................................ 22

1.4.1Noise emission ................................................................................................. 22

1.4.2Dust emission ................................................................................................... 23

1.5Special risks ............................................................................................................. 23

1.5.1Electric power ................................................................................................... 23

1.5.2Dust emission ................................................................................................... 24

1.5.3Fire hazard ........................................................................................................ 24

1.5.4Explosion hazard .............................................................................................. 25

1.6Labelling ................................................................................................................... 25

1.6.1Signs and labels ............................................................................................... 25

1.6.2Unit type plate ................................................................................................... 29

1.7Personal – Qualifications and duties ........................................................................ 30

1.7.1Personal protective equipment ......................................................................... 33

1.7.2Contact person for service and operation ......................................................... 33

2Description ...................................................................................................................... 33

2.1Operating and danger instructions ........................................................................... 33

2.2Structure of the front of the steel processing machine. ............................................ 34

2.3Extraction system (optional) ..................................................................................... 35

2.4Structure of the back of the steel processing machine ............................................ 36

2.5Machining units - abrasive belts ............................................................................... 37

Table of Contents

SBM-XL 1000/1500 S2B2 Page 4

2.6Machining unit - brush belts ..................................................................................... 39

2.7Control elements ...................................................................................................... 41

2.8Safety equipment ..................................................................................................... 42

2.9Hydraulics ................................................................................................................ 44

2.9.1Hydraulic oil tank .............................................................................................. 44

2.9.2Hydraulic pump ................................................................................................. 45

2.10Electrical system ...................................................................................................... 46

2.10.1Control cabinet .................................................................................................. 47

2.10.2Electric motors for drive, feed, height adjustment ............................................. 48

3Operation ........................................................................................................................ 50

3.1Transporting the unit ................................................................................................ 50

3.2Installing and connecting the unit ............................................................................. 51

3.2.1Installing the unit ............................................................................................... 51

3.2.2Connect the unit to electricity ............................................................................ 52

3.2.3Connect the unit to the extraction system. ........................................................ 53

3.3Function ................................................................................................................... 54

3.4Putting the unit into operation .................................................................................. 55

3.4.1Control panel .................................................................................................... 56

3.4.2Operation using the touch screen ..................................................................... 57

3.4.3Changing the touch screen language ............................................................... 58

3.5Grinding workpiece .................................................................................................. 59

3.5.1Turn on the unit ................................................................................................. 59

3.5.2Workpiece thickness setting for manual sheet metal processing ..................... 61

3.5.3Set workpiece thickness and grinding units for automatic mode ...................... 65

3.5.4Setting feed ....................................................................................................... 68

3.5.5Starting the machining process ........................................................................ 69

3.6Turning the machining units on and off .................................................................... 72

3.6.1Turning on and off the grinding unit and brush unit .......................................... 72

3.6.2Select grinding unit and brush unit automatic mode ......................................... 74

3.7Wear correction ........................................................................................................ 75

3.7.1Wear correction - manual mode. ...................................................................... 75

3.7.2Wear correction - automatic mode .................................................................... 77

3.8Turning off the unit ................................................................................................... 78

3.9Turning the unit back on after activating the EMERGENCY STOP. ........................ 80

3.10Removing material jams .......................................................................................... 81

3.10.1Reverse mode .................................................................................................. 83

3.11Replacing abrasive and brush belts ......................................................................... 84

3.11.1Replacing the abrasive belts of the S-units ...................................................... 85

3.11.2Removing B-unit brush belts ............................................................................. 94

3.11.3Measuring the wear of the S-unit abrasive belt and adjusting .......................... 99

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SBM-XL 1000/1500 S2B2 Page 5

3.11.4Measuring wear of upper and lower brush belts of B-units and adjusting. ..... 103

4Service .......................................................................................................................... 105

4.1General service work ............................................................................................. 106

4.2Maintenance, Service and Troubleshooting ........................................................... 106

4.3Tightening and replacing V-belts ........................................................................... 107

4.3.1Replace V-belts in S units. .............................................................................. 107

4.3.2Replace V-belts in B units. .............................................................................. 109

4.4Checking safety equipment .................................................................................... 112

4.5Lubricating the unit ................................................................................................. 114

4.6Tightening the conveyor belt .................................................................................. 116

4.6.1Tightening the conveyor belt ........................................................................... 116

4.7Hydraulic system .................................................................................................... 117

4.7.1Check hydraulic oil level ................................................................................. 117

4.7.2Change hydraulic oil ....................................................................................... 118

4.8Electrical system .................................................................................................... 120

4.8.1Changing the filter pad on the control cabinet ................................................ 120

4.9Cleaning the unit. ................................................................................................... 122

4.9.1Cleaning the collection trough ........................................................................ 124

4.9.2Clean extraction duct. ..................................................................................... 125

5Technical data /Tables .................................................................................................. 126

5.1Electrical system .................................................................................................... 126

5.2Grinding units ......................................................................................................... 126

5.3Brush units ............................................................................................................. 126

5.4Other motors .......................................................................................................... 127

5.4.1Feed motors .................................................................................................... 127

5.4.2Actuator motors .............................................................................................. 127

5.5Material processing ................................................................................................ 127

5.6Noise emission ....................................................................................................... 127

5.7Miscellaneous ........................................................................................................ 127

5.8Service schedule / Service intervals ...................................................................... 128

5.9Tightening torques ................................................................................................. 128

5.10Operating material / Service material ..................................................................... 128

5.11Tools, abrasive and brush belts ............................................................................. 129

5.12Tool requirements for own coating ......................................................................... 130

6Error messages ............................................................................................................. 130

7Warranty ........................................................................................................................ 136

8Installation and removal, transport ................................................................................ 137

8.1Transport data, dimension and weight ................................................................... 138

8.1.1weight ............................................................................................................. 138

8.1.2Dimensions ..................................................................................................... 138

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SBM-XL 1000/1500 S2B2 Page 6

8.2Installation of the unit ............................................................................................. 138

8.2.1Preparation and installation ............................................................................ 139

8.2.2Recommissioning ........................................................................................... 140

8.3Decommissioning, storage and recommissioning .................................................. 141

8.3.1Decommissioning ........................................................................................... 141

8.3.2Packaging and Storage .................................................................................. 141

8.4Removal and disposal ............................................................................................ 141

List of figures

SBM-XL 1000/1500 S2B2 Page 7

List of figures

Figure 1Unit type plate ...................................................................................................... 29

Figure 2Components of the unit (front) .............................................................................. 34

Figure 3Extraction system (optional) ................................................................................. 35

Figure 4Components of the unit, back ............................................................................... 36

Figure 5Machining unit - upper loading side (S-unit) ......................................................... 37

Figure 6Guide plate - abrasive belts .................................................................................. 37

Figure 7Machining unit - lower loading side (S-unit) ......................................................... 38

Figure 8Machining unit - upper output side (B-unit) .......................................................... 39

Figure 9Machining unit - lower output side (B-unit) ........................................................... 39

Figure 10Control and display elements (front side) ......................................................... 41

Figure 11 Front safety equipment .................................................................................... 42

Figure 12Back safety equipment ..................................................................................... 43

Figure 13Hydraulic oil tank .............................................................................................. 44

Figure 14Hydraulic oil pump ............................................................................................ 45

Figure 15Control cabinet .................................................................................................. 47

Figure 16Electric motors .................................................................................................. 48

Figure 17Electric motor - feed .......................................................................................... 49

Figure 18Transport equipment for the crane ................................................................... 50

Figure 19Connect extraction system (optional) ............................................................... 53

Figure 20Control unit ....................................................................................................... 56

Figure 21Control elements on the control panel .............................................................. 56

Figure 22Main menu of user control ................................................................................ 57

Figure 23Operating elements main menu ........................................................................ 57

Figure 24Select language ................................................................................................ 58

Figure 25Turn on the unit ................................................................................................. 59

Figure 26Acknowledge EMERGENCY STOP ................................................................. 60

Figure 27Park position of machining units ....................................................................... 62

Figure 28Setting workpiece thickness in manual mode ................................................... 63

Figure 29Query material passage free ............................................................................ 64

Figure 30Setting workpiece thicknesses in automatic mode I ......................................... 65

Figure 31Setting workpiece thicknesses in automatic mode II ........................................ 66

Figure 32Material passage free automatic mode ............................................................. 67

Figure 33Setting feed ....................................................................................................... 68

Figure 34Starting the machining process ........................................................................ 70

Figure 35Place on the workpiece ..................................................................................... 71

Figure 36Turning the machining units on and off ............................................................. 72

Figure 37Processing combinations automatic mode ....................................................... 74

Figure 38Wear correction ................................................................................................ 75

Figure 39Wear correction - automatic mode .................................................................... 77

Figure 40Turning off the machine .................................................................................... 78

Figure 41Turn off the unit main switch. ............................................................................ 79

Figure 42Acknowledge EMERGENCY STOP ................................................................. 80

Figure 43Material jams .................................................................................................... 82

Figure 44Reverse mode .................................................................................................. 83

List of figures

SBM-XL 1000/1500 S2B2 Page 8

Figure 45Tool change upper grinding unit ....................................................................... 85

Figure 46Material passage free tool replacement ............................................................ 86

Figure 47Removing abrasive belts of the upper S-units (I) .............................................. 87

Figure 48Removing abrasive belts of the upper S-units (II) ............................................. 88

Figure 49Tool change lower grinding unit ........................................................................ 90

Figure 50Material passage free tool replacement ............................................................ 91

Figure 51Removing abrasive belts on lower S-units ........................................................ 92

Figure 52Feed plates and protective strips ...................................................................... 95

Figure 53Tool change brush belt B-units ......................................................................... 95

Figure 54Material passage free tool replacement ............................................................ 96

Figure 55Removing B-unit brush belts ............................................................................. 97

Figure 56Adjusting the abrasive belts of the upper S-units (I) ......................................... 99

Figure 57Adjust the upper grinding unit (II) .................................................................... 100

Figure 58Adjusting the abrasive belts of the lower S-units (I) ........................................ 101

Figure 59Adjust the lower grinding unit (II) .................................................................... 101

Figure 60Adjusting brush belts of B-units (I) .................................................................. 103

Figure 61Adjusting brush belts of B-units (II) ................................................................. 104

Figure 62V-belts in S units ............................................................................................. 107

Figure 63V-belts in B units (I) ........................................................................................ 109

Figure 64V-belts in B units (II) ....................................................................................... 110

Figure 65Safety equipment ............................................................................................ 112

Figure 66Front lubrication points ................................................................................... 114

Figure 67Rear lubrication points .................................................................................... 115

Figure 68Conveyor belt .................................................................................................. 116

Figure 69Hydraulic oil tank ............................................................................................ 117

Figure 70Change hydraulic oil ....................................................................................... 118

Figure 71Control cabinet ................................................................................................ 120

Figure 72Cleaning interval ............................................................................................. 123

Figure 73Collection trough ............................................................................................. 124

Figure 74Dust extraction shaft ....................................................................................... 125

Figure 75Touch screen error messages ........................................................................ 130

Figure 76Error message wear limit reached .................................................................. 132

Figure 77Error message measurement equipment laying on ........................................ 133

Figure 78Error message door open ............................................................................... 134

Figure 79Error message no references ......................................................................... 135

Figure 80Transport equipment for the crane ................................................................. 137

Figure 81installation of the unit ...................................................................................... 139

General

SBM-XL 1000/1500 S2B2 Page 9

1 General

During all activities follow the instructions in your operating manual.

1.1 About this manual

Please follow:

 This operating manual is written for the operating, maintenance

and service personnel.

 This operating manual should put you in the position to operate

the unit safely and utilise the allowed intended applications.

 It also provides you information about the function of important

assemblies and components.

 In these operating instructions specific terms are used. To

avoid misunderstandings, the same terms should always be

used.

 Only qualified, knowledgeable and trained personnel should

work on this unit. Each person responsible for operating and

maintenance work on the machine must have read and

understood this operating manual.

 The manufacturer's documentation and the applicable

regulations at the location of use, for example accident

prevention regulations, as well as the recognized technical

regulations for safety and proper work, must be followed.

 The operating manual is to be supplemented by directives for

accident prevention and environmental protection, according to

national requirements.

 The operating manual and the manufacturer's documentation

are a part of the product. Make sure that they are available

over the entire service life of the system and are visible at all

times.

 Pass on the operating manual and manufacturer's

documentation to the next owner of the unit and stress the

importance of the documentation.

The manual make it easier to:

 Become familiar with the system.

 Avoid breakdowns due to improper operation.

General

SBM-XL 1000/1500 S2B2 Page 10

Following the operating manual:

 Helps to avoid dangers.

 Increases the reliability in use.

 Increases the service life of the system.

 Reduces maintenance costs and downtimes.

Always place this operating manual easily accessible in the fixture

provided for it and attached in the control cabinet.

If you have received other information on the unit (for example

technical additional information) from us, this information must also be

observed and added to the operating manual.

If you do not understand the operating manual or individual chapters,

you should ask us before you begin with the corresponding activity on

the machine.

Lissmac Maschinenbau GmbH has no liability for the safe function of

the system, if:

 Handling does not correspond to normal use.

There are no warranty claims for:

 Operating errors.

 Insufficient service.

 Incorrect operating material.

 Other purposes of use that are not mentioned in the operating

manual.

General

SBM-XL 1000/1500 S2B2 Page 11

Warranty and liability conditions of the general terms and conditions of

Lissmac GmbH are not expanded through the preceding information.

We reserve the right for changes without previous notice in the course

of technical further development. This operating manual also describes

optional equipment that is possibly not present on the unit. Data and

images of this operating manual may not be copied, nor used for

purposes of competition.

Translations are performed to the best of our knowledge. Liability for

translation errors and all results occurring from them cannot be

applied, even if the translation is by us or ordered by us.

The German text is and remains governing for all liability and warranty

claims.

1.1.1 Changes/Reservations

We attempt for this operating manual to be correct and up-to-date. To

maintain our technological lead, it can be necessary to change the

product without advance notice and to perform their operation. We

accept no liability for malfunctions, breakdowns and damage caused

by this.

Please also observe possible included additional information.

1.1.2 Packaging and Storage

To ensure sufficient protection during shipping, the unit and its

components are carefully packaged. When receiving the unit, the

packaging and the system should be checked for damage.

In the case of damage, the unit must not be put into operation. Even

damaged cable and plugs represent a safety risk and must not be

used. In this case, please contact Lissmac GmbH.

If the unit is not immediately put into operation after unpacking, it must

be protected from moisture and dirt.

General

SBM-XL 1000/1500 S2B2 Page 12

1.1.3 Characters and symbols

The characters and symbols should help to use the operating manual

and the unit quickly and safely.

Potential dangers are shown through danger, warning, caution and

attention symbols. Depending on the severity of the danger, these are

marked with color and a signal word.

Danger symbol

DANGER:

Here the source of the danger is named.

Here the possible results are mentioned.

Here the actions for preventing the danger are named.

The danger symbol indicates an immediately threatening danger with

the signal word DANGER. If it is not avoided, the result is death and/or

serious injury.

Warning symbol

Warning

Here the source of the danger is named.

Here the possible results are mentioned.

Here the actions for preventing the danger are named.

The warning symbol indicates a possibly threatening danger with the

signal word WARNING. If it is not avoided, the result is death and/or

serious injury.

General

SBM-XL 1000/1500 S2B2 Page 13

Caution symbol

Caution Here the source of the danger is named.

Here the possible results are mentioned.

Here the actions for preventing the danger are named.

The caution symbol indicates a possible dangerous situation with the

signal word CAUTION. If it is not prevented, medium or slight injuries

and property damage can result.

Attention symbol

Attention The attention symbol indicates a possible dangerous situation with the

signal word ATTENTION. If it is no prevented, property damage can

result.

i Information

Information gives a brief summary at the beginning of a main chapter

about the contents of the following chapter. In addition it informs about

the most effective and most practical utilization of the unit and this

operating manual.

 Handling step

The defined sequence of the handling steps makes proper and safe

handling of the unit easier.

 Result

Here the results of a sequence of handling steps described.

(1) Position numbers

Position numbers in assembly illustrations are shown in the text with

parentheses. ()

General

SBM-XL 1000/1500 S2B2 Page 14

1.1.4 Documentation

One copy of this operating manual in paper form must be accessible to

the authorized service and operating personnel at any time.

During the transfer of the system to the new operating company, the

complete documentation must also be transferred.

Before operating the unit for the first time and before beginning with

any type of work on the unit, this operating manual must be read

carefully and understood.

This operating manual should make you familiar with the basic work

and activities on the unit.

This operating manual includes important information for using the unit

safely and properly.

Following this helps:

 To avoid danger.

 To reduce repair costs and downtimes.

 To increase the reliability, availability and service life of the unit.

Irrespective of this operating manual, the valid laws, ordinances,

guidelines and standards of the country and location of use must be

observed.

The use of the unit is described in this operating manual.

1.1.5 Additional documents

Additional documentation of the respective manufacturers of individual

components of the machine are available as supplements to this

operating manual:

 Operating manual - Industrial vacuum cleaner for continuous

operation, TEKA model 2N.

 Operating Manual - TOSHIBA Frequency Converter Series VF

S11 (esco Drive Technology).

 Circuit diagrams

General

SBM-XL 1000/1500 S2B2 Page 15

1.1.6 Warranty and liability

The General Terms and Conditions (AGB´s) of Lissmac GmbH apply.

These are available for the purchaser or operating company at the

latest by the closing of the contract.

Warranty and material defect claims can be taken from the AGB's.

General

SBM-XL 1000/1500 S2B2 Page 16

1.2 Use

1.2.1 Appropriate usage

The unit meets the state of the art and complies with the valid safety

regulations at the time of placing on the market in the scope of its

intended use.

Neither the foreseeable misuse nor the residual risks can be prevented

in the construction without restricting the intended functionality of the

unit.

The unit is designed and laid out:

 For a dry, two-sided deburring and edge rounding of punch,

laser and fine plasma cut workpieces of steel and steel alloys,

with the minimum dimensions: 150 x 50 x 0.5mm and a max.

thickness of 50 mm. Refer to Chap. 5

 For removal of an oxide coating on the outer and inner

contours from up to 20 mm thick sheet metal.

 Workpieces up to a warpage of maximum 3mm can be

processed.

 For the processing of workpieces exclusively of steel and steel

alloys.

 This machine may only be used as a system with a dry dust

extractor provided for it and which is approved.

The operation is permitted exclusively in interior rooms and must meet

the following conditions:

 Fortified, level floor with a carrying capacity of at least 1600

kg/sqm.

 Ambient temperature from +10° C to +40° C.

 Humidity 5 – 95 % (not condensing).

The unit is exclusively intended for commercial use.

General

SBM-XL 1000/1500 S2B2 Page 17

The unit must be operated in compliance with the specifications in the

technical documentation from trained users.

Any non-intended use or all activities on this unit not described in this

operating manual are impermissible misuse outside of the legal liability

limits of the manufacturer.

i Strictly forbidden is the processing of workpieces of aluminum,

aluminum alloys, titanium, magnesium and the respective alloys.

1.2.2 Non-intended use

The warranty obligation of manufacturer is voided for non-intended use

or misuse of the unit and the operating company is solely responsible.

Non-intended uses are:

 Processing of workpieces of aluminum, aluminum alloys,

titanium, magnesium and the respective alloys.

 Processing non-metallic workpieces.

 Operating with removed, defective or overridden safety

equipment.

 Operating under incorrectly performed or neglected service

and/or maintenance work.

 Operating with unobserved service work.

 Operating with neglected measurements and tests for early

detection of damages and/or wear.

 Operating with customizations, not approved constructional

modifications of the unit.

The manufacturer accepts no liability for damages which occur from

non-intended use.

General

SBM-XL 1000/1500 S2B2 Page 18

1.2.3 Residual risks

The residual risks are analyzed and assessed before beginning the

design and planning of the unit.

Existing residual risks are noted in the documentation.

Avoid residual risks by practical implementation and observation of the

following:

 The special warnings on the unit.

 The general safety instructions in this operating manual.

 The special warnings on this operating manual.

Risks to life/danger of injury to persons can occur on the unit, e.g.,

through:

 Misuse.

 Improper handling.

 Missing safety equipment.

 Defective or damaged components.

 Handling/use of the unit by untrained, unauthorized personnel.

Dangers to the environment can occur by the unit, e.g. from:

 Improper handling.

 Operating materials, lubricants, etc.

 Noise, dust emissions.

Property damage on the unit can occur, e.g., from:

 Improper handling.

 Non-conformance to operating and service specifications.

 Unsuitable operating materials.

General

SBM-XL 1000/1500 S2B2 Page 19

Property damage on other property in the operating area of the unit

occur, e.g., from:

 Improper handling.

 Unsuitable operating materials.

Performance and/or functionality restrictions on the unit can occur, e.g.

from:

 Improper handling.

 Improper service and/or repair.

 Non-conformance to the service intervals.

 Unsuitable operating materials.

1.3 Safety instructions

The SBM-XL S2B2 steel processing machine is constructed with the

latest technology and to recognized safety system regulations.

However, due to the intended use of the unit neither the foreseeable

misuse nor the residual risks can be avoided completely, without

restricting the intended functionality. This condition does present

danger for life and limb for the operating, service and maintenance

personnel, which can, however, be minimized by following and

conforming to the basic safety instructions.

 The machine is to be used only for intended use in technically

faultless condition and in observance of safety instructions.

1.3.1 Environmental protection

Packaging material, cleaning agents, used or residual operating

materials, as well as removed wear parts, such as grinding belts,

transport belts, etc, must be take to recycling corresponding to the

valid regulations for environmental protection at the place of use.

1.3.2 Disposal

Proper disposal avoids negative influences on humans and the

environment and enables recycling of valuable raw materials.

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Lissmac SBM-XL S2B2, SBM-XL 1000 S2B2, SBM-XL 1500 S2B2 Owner's manual

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