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Operating instructions

Fully automatic crimping machine

Gamma 333 PC
Gamma 333 PC B

Art.No. 0026215 Version 4

Publisher
Komax AG
Industriestrasse 6
CH-6036 Dierikon-Lucerne, Switzerland
Phone
Fax
E-mail
Internet

+41 41 455 0 455


+41 41 450 4 266
info.din@komaxgroup.com
www.komaxgroup.com

Date issued

Version number

Pages with changes

1998
June 2003
June 2004
January 2007
March 2009

Version 1
Version 2
Version 2.1
Version 3
Version 4

None; rst version


completely revised
Chapter 10 / page 1014 revised
completely revised
completely revised

Reproduction of these instructions or parts of them in whatever form is not permitted without express written permission from the publisher.
Komax reserves the right to make technical changes necessary to improve the machine that
could diverge from gures and information in these instructions.

2009 by Komax AG, Wire Processing Systems

lu

Table of contents

Part A
Information for every machine user

Part B
Information for the machine operator

Part C
Information for the service technician

Part A
1. Product description..................................................................................................................13
1.1 The operating instructions .............................................................................................14
1.1.1 Layout of the instructions ................................................................................14
1.1.2 Size of the instructions......................................................................................14
1.1.3 Updating of the instructions .............................................................................15
1.2 Other types of documentation ......................................................................................15
1.3 Personnel qualications and training ............................................................................16
1.3.1 Personnel qualications ....................................................................................16
1.3.2 Training .............................................................................................................16
1.4 Machine identication ....................................................................................................17
1.5 Technical data / scope of performance .........................................................................18
1.6 Conformity......................................................................................................................19
1.7 Accessories ..................................................................................................................110

2. Safety .........................................................................................................................................23
2.1 Explanation of notes ......................................................................................................23
2.2 Safety notes ...................................................................................................................23
2.2.1 Personal protection ...........................................................................................23
2.2.2 Machine protection ...........................................................................................25
2.2.3 General safety notes ........................................................................................25
2.3 Safety features ...............................................................................................................26
2.4 The RCS safety system ..................................................................................................28

3. Transport ...................................................................................................................................31

4. Items included in the delivery / incoming inspection ...........................................................41

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5. Installation.................................................................................................................................53
5.1 Installation site ...............................................................................................................53
5.2 Installation ......................................................................................................................54

Part B
6. Machine overview and functions ............................................................................................63
6.1 Basic machine ................................................................................................................63
6.1.1 Straightening unit ..............................................................................................65
6.1.2 Transport unit ....................................................................................................65
6.1.2.1 Gamma 333 PC ...................................................................................65
6.1.2.2 Gamma 333 PC-B ...............................................................................65
6.1.2.3 Encoder ...............................................................................................66
6.1.2 Swivel and pull-off unit on side 1 ......................................................................66
6.1.3 Cutting head .....................................................................................................68
6.1.4 Swivel and pull-off unit on side 2 ......................................................................69
6.1.4.1 Good/bad sorting...............................................................................610
6.1.5 Hold-up device ...............................................................................................610
6.1.6 Wire deposit system and conveyor belt .........................................................611
6.1.7 Maintenance unit ............................................................................................611
6.2 Control system .............................................................................................................612
6.2.1 Control cabinet ...............................................................................................612
6.3 Front control panel ......................................................................................................615
6.4 Sensors ........................................................................................................................616

7. Machine operation ...................................................................................................................73


7.1 Checks prior to startup ..................................................................................................73
7.2 Switching the machine ON and OFF .............................................................................74
7.3 Selecting the operating mode ......................................................................................74
7.4 Safety cover ..................................................................................................................75
7.5 Preparing the machine for production ..........................................................................75
7.5.1 Knot detection .................................................................................................75
7.5.2 Straightening unit ..............................................................................................75
7.5.3 Wire guide parts ................................................................................................76
7.5.4 Wire draw-in ......................................................................................................77
7.5.5 Pull-off unit on side 1 and side 2 ......................................................................77
7.5.6 Crimping module ..............................................................................................78
7.6 The tool drawer ..............................................................................................................79

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8. Software instructions .....................................................................................................................


The machine operator will need the software instructions most often for his daily work. They describe actual production and setup operations. These instructions have their own table of contents.

Part C
9. Maintenance .............................................................................................................................93
9.1 Notes on maintenance ...................................................................................................93
9.2. Maintenance plan ..........................................................................................................94
9.2.1 Daily maintenance.............................................................................................94
9.2.2 Weekly maintenance .........................................................................................94
9.2.3 Monthly maintenance........................................................................................96
9.2.4 Maintenance every six months .........................................................................97
9.3 Explanation of maintenance procedures........................................................................99
9.3.1 Maintenance unit ..............................................................................................99
9.3.2 Cutting head ...................................................................................................910
9.3.3 Grippers on side 1 and side 2 .........................................................................910

10. Settings and adjustments ....................................................................................................103


10.1 Blade blocks and blades ............................................................................................103
10.1.1 Disassembling the blade blocks ...................................................................103
10.1.2 Assembling the blade blocks ........................................................................103
10.1.3 Changing the blades .....................................................................................104
10.2 Mechanical settings and adjustments........................................................................105
10.2.1 Guide parts and bearings .............................................................................105
10.2.2 Toothed belts ................................................................................................106
10.2.2.1 Mounting a toothed belt ..................................................................107
10.2.2.1.1 Toothed belt for transport unit on Gamma 333 PC ......................107
10.2.2.1.2 Toothed belt for transport unit on Gamma 333 PC-B...................108
10.2.2.1.3 Replacing the drive belt for the swivel head on side 1 and side 2109
10.2.2.1.4 Replacing the drive belt for the cutting head..............................1010
10.2.2.2 Operating problems associated with toothed belt drives ..............1010
10.2.3 Setting the guide for the pull-off unit on side 2 ..........................................1011
10.2.3.1 Positioning the toothed rack (user side) ........................................1011
10.2.3.2 Positioning the counter guide (at the back) ...................................1012
10.2.3.3 Final step and setting-check ........................................................1012

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10.2.4 Calibrating the machine ..............................................................................1014


10.2.4.1 Calibrating the axes (mechanical) ..................................................1014
10.2.4.2 Calibrating the axes under TopWin ................................................1014
10.2.4.3 Calibration procedure ...................................................................1015
10.2.5 Wire feed unit ..............................................................................................1017
10.2.5.1 Gamma 333 PC .............................................................................1017
10.2.5.2 Gamma 333 PC-B .........................................................................1018
10.2.6 Lifting device ..............................................................................................1018
10.2.7 Wire guide gripper ......................................................................................1019
10.2.8 Conveyor belt ..............................................................................................1020
10.2.9 mci 711 options ..........................................................................................1021
10.2.10 Safety cover ..............................................................................................1021
10.3 Electrical settings and adjustments .........................................................................1022
10.3.1 Sensors .......................................................................................................1022
10.3.1.1 Laying sensor cables .....................................................................1022
10.3.1.2 Inductive sensors ...........................................................................1025
10.3.1.3 Hybrid light barriers .......................................................................1025
10.3.2 Electric fuses in control cabinet .................................................................1026
10.3.3 BIO PCB......................................................................................................1027
10.3.4 Output stages of the stepping motors .......................................................1028
10.4 Pneumatic settings and adjustments ......................................................................1030
10.4.1 Operating pressure ....................................................................................1030
10.4.2 Throttle non-return valves ...........................................................................1030
10.5 Setup of processing stations ...................................................................................1031
10.5.1 Crimp module setup ...................................................................................1031
10.5.2 Setup of mci 761 seal module ....................................................................1032
10.5.3 Setting up non MCI modules ......................................................................1033
10.5.4 MRS PCB ....................................................................................................1034

11. Pneumatic and electrical diagrams ............................................................................................


You will nd the diagram for the pneumatic system of the machine here. The electrical diagram is
enclosed separately along with each machine delivery and must be inserted in this chapter of the
operating instructions.

12. I/O list ............................................................................................................................................


The I/O list is enclosed separately along with each machine delivery and must be placed in this
chapter of the operating instructions.

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Version 4

13. Annex .............................................................................................................................................


This chapter is reserved for training materials, technical data sheets, etc.
13.1

_____________________________________________________________________

13.2

_____________________________________________________________________

13.3

_____________________________________________________________________

13.4

_____________________________________________________________________

14. Accessories ..................................................................................................................................


Place the operating instructions for all your accessories in this chapter so you have the instructions for the entire machine conguration together in a single place.
14.1

_____________________________________________________________________

14.2

_____________________________________________________________________

14.3

_____________________________________________________________________

14.4

_____________________________________________________________________

15. Putting the machine out of operation, storage and disposal ..........................................151
15.1 Putting the machine out of operation.........................................................................151
15.2 Storage .......................................................................................................................151
15.3 Disposal .....................................................................................................................151

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1. Produktebeschreibung
1.1 The operating instructions .................................................................................................4
1.1.1 Layout of the instructions ....................................................................................4
1.1.2 Size of the instructions..........................................................................................4
1.1.3 Updating of the instructions .................................................................................5
1.2 Other types of documentation ..........................................................................................5
1.3 Personnel qualications and training ................................................................................6
1.3.1 Personnel qualications ........................................................................................6
1.3.2 Training .................................................................................................................6
1.4 Machine identication ........................................................................................................7
1.5 Technical data / scope of performance .............................................................................8
1.6 Conformity..........................................................................................................................9
1.7 Accessories ......................................................................................................................10

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Product description

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12

Product description

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Version 4

1. Product description
The Komax Gamma 333 PC / 333 PC B is an expandable, fully automatic crimping machine with
up to three individual processing stations.
The Komax Gamma 333 PC / 333 PC B is intended for the following wire processing applications if operated according to the technical specications (see Chapter 1.5):

Application
Cutting wire to size / Stripping
Marking
Crimping
Seal application, one end
Tinning
Length measurement
Seal monitoring (on/off)
Crimp force analysis
Splice monitoring
Conveyor-belt deposition of wire
Good/bad sorting
Sequences
Batch sorting
Split cycle
Double crimping

Sleeves
g 1.1 Scope of application for the Gamma 333 PC

This list assumes that the machine is used to process only the materials (conductors, contacts, etc.) specied in the technical data.
Please take a moment now and read through the operating instructions carefully. They will guide
you step by step through Komax Gamma 333 PC / 333 PC B operations, enabling you to be
running it successfully in no time at all.

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Product description

13

1.1 The operating instructions


These operating instructions are valid for the Komax Gamma 333 PC / Gamma 333 PC B and
are available in German, English, French, Italian, Spanish and Portuguese; other languages are
available on request. The instructions contain all technical specications as well as complete information on the controls, the handling procedures for the entire machine, maintenance and adjustment/setting work.
These operating instructions form an integral part of the Gamma 333 PC / 333 PC B. Always
keep them nearby so you can refer to them readily any time you need this information.
All aspects of these instructions must be thoroughly understood and heeded by anyone responsible for transporting, installing, operating and repairing the machine.

1.1.1 Layout of the instructions


Part A of these instructions, Chapters 1 to 5, contains information you usually need note only
once, except for Chapter 2 on safety notes.
Part B, Chapters 6 to 8, features information on operations and on settings/adjustments. This
section is intended for the individuals actually operating the machine.
Part C, Chapters 9 to 12, covers maintenance, machine settings, diagrams, etc., in other
words, topics of importance to service technicians.
Read through these instructions carefully! Do not begin to work until you understand all the
work steps in the chapters intended for you.
Pay particularly close attention to Chapter 2 on safety notes.

1.1.2 Size of the instructions


These operating instructions have 15 chapters. Below is a list of the valid pages in each chapter:
Chapter 0
Chapter 1
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6
Chapter 7
Chapter 8
Chapter 9
Chapter 10
Chapter 11
Chapter 12
Chapter 13
Chapter 14
Chapter 15

14

8 pages, consecutively numbered from page 0 - 1 to page 0 - 8


12 pages, consecutively numbered from page 1 - 1 to page 1 - 12
8 pages, consecutively numbered from page 2 - 1 to page 2 - 8
Page 3 - 1
Page 4 - 1
8 pages, consecutively numbered from page 5 - 1 to page 5 - 8
18 pages, consecutively numbered from page 6 - 1 to page 6 - 18
10 pages, consecutively numbered from page 7 - 1 to page 7 - 10
Software instructions
The valid pages are listed right in the instructions.
10 pages, consecutively numbered from page 9 - 1 to page 9 - 10
36 pages, consecutively numbered from page 10 - 1 to page 10 - 36
Diagram of compressed air system
Electrical diagram (delivered separately)
I/O list (delivered separately)
Annex: Customer-specic sets of documentation
Accessories: Customer-specic sets of documentation
2 pages, consecutively number from page 15 - 1 to page 15 - 2

Product description

OI Gamma 333 PC / Gamma 333 PC B


Version 4

1.1.3 Updating of the instructions


Each footer in these instructions contains a version number, e.g. Version 1.0.
The number 1.0 designates the rst version of the operating instructions.
Main number
Subordinated number
If individual pages in the instructions change, only the subordinated number on those pages is
increased, e.g. from 1.0 to 1.1.
If the entire operating instructions are newly reissued, the main number also changes, e.g. from
1.3 to 2.0.

1.2 Other types of documentation


The overall documentation for the Komax Gamma 333 PC / 333 PC B is divided into different
types of instructions.
Operating instructions
The following sets of documentation are integrated into the operating instructions:
Software instructions

under Chapter 8

Set of diagrams for compressed air system under Chapter 11


Set of electrical diagrams

under Chapter 11

Input / output lists

under Chapter 12

Operating instructions for accessories

under Chapter 14

The operating instructions for the accessories are enclosed with each device.
Make sure not to mislay these instructions when unpacking and setting up the device; keep them in the main machine documentation.
Training materials
All training materials, personal notes, and customer-specic documents can also be led in these
operating instructions (under Chapter 13).
Spare parts catalog
The spare parts catalog lists all spare and wearing parts for the basic machine. All spare parts lists
for accessories can also be led here.

If you need additional copies of the sets of documentation, just contact your Komax dealer.

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Product description

15

1.3 Personnel qualications and training


1.3.1 Personnel qualications
Machine operators
Machine operators must be sufciently familiar with the machine to be able to operate it and its
accessories and peripheral devices in production without any trouble.
This requires a good technical understanding of the machine and knowledge of the software used
in operating it.
Service technicians
Service technicians must have extensive knowledge of the machine. Aside from machine operations, they must be able to locate errors and take the appropriate steps to remedy them. Service
technicians must also be able to maintain the machine correctly so that its service life and availability is increased. They must also have complete mastery of the software, so that optimum use
can be made of the machine in production.
To carry out these tasks, technicians must have experience in wire processing and crimp technology. They must also have completed formal mechanical or electronics training and be able to
demonstrate a solid understanding of the Komax Gamma 333 PC.

1.3.2 Training
Komax offers individually adapted courses for all, from operators and setup engineers to maintenance and service technicians. You become more familiar with your product, the accessories and
the peripherals and learn how to use them to optimum effect in the production process. Greater
knowledge about maintenance and repairs helps you to increase the availability and service life of
the machine. After successfully completing the training, each participant receives a certicate.
Courses and their contents
The training program is divided into machine-specic and module-specic units. Basically
speaking a training course consists of the following topics:
Tour of Komax
Machine layout
Machine maintenance
Mechanical system
Electrical system
Pneumatic system
Software
Practical exercises
Trouble-shooting
Wrap-up discussion
General information on the way courses are set up
Duration of training: Depends on machine, 1 to 5 days, or as agreed
Venue:
Training center at Komax in Dierikon or at customers premises
Accommodations:
We are happy to make hotel reservations (in downtown Lucerne)
for you.
Training organizer:
Customer Service at Komax in Dierikon
Languages:
German or English
Class size:
The class size is limited to at most three persons.
Training materials:
All materials are distributed on the rst day of training.

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Version 4

1.4 Machine identication


Example of a nameplate
Machine number

Machine type

Voltage version

Power input

A nameplate 1 is located on the frame of the machine.

1
g 1.01 Machine overview of Gamma 333 PC / 333 PC B

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17

1.5 Technical data / scope of performance


Length range

60mm 10000mm, optionally from 30mm

Length accuracy

+/- 1mm or <0.2%, depending on wire length

Length measurement

with measuring encoder

Stripping lengths

0.1 15mm, on side 1, (optionally from 30mm)


0.1 15mm, on side 2

Wire cross section

0.125 5.0mm2
AWG26 AWG10

Piece output

see g 1.02

Feed speed

max. 6m/s (Gamma 333 PC) / max. 10m/s (Gamma 333 PC B)

Electrical connection

3 x 208 480V, N, PE; 50/60Hz; 6000VA


5 4mm2; 25A fuse

Compressed air connection 4 6bar


Noise level

< 75dBA (without presses)

Air consumption

6.5m3/h (without accessories)

Weight

1030kg with two mci 711 crimp presses

Piece number [pcs/h]


4500

mci 721 at 60

mci 721 at 35

4000
3500

mci 721 at 60

3000

2500

mci 721 at 35

2000

mci 721 at 60
1500

mci 761 at 35

1000
0

1000

2000

3000

4000

5000

6000

7000

8000

9000

mci 721 at 90

10000

Wire length (mm)


Conguration of 333 PC
Conductor
Pneumatic pressure
Speed
Acceleration
Quality monitoring
Press optimization
Crimping modules

Conguration of 333 PC-B


FLRY 0.75mm2
6bar (87psi)
6m/s (19.7ft/s)
40m/s (131ft/s2)
active
yes
mci 721

Conductor
Pneumatic pressure
Speed
Acceleration
Quality monitoring
Press optimization
Crimping modules

FLRY 0.75mm2
6bar (87psi)
10m/s (32.8ft/s)
50m/s (164ft/s2)
active
yes
mci 721

g 1.02 Recommended values for piece output on Gamma 333 PC/333 PC B

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Version 4

1.6 Conformity

If used in accordance with the operating documents and specications (operated exclusively with
the stipulated protective, safety, and operating devices), this machine is in conformity with
Directive 89/392/EEC as amended by Directives 91/368/EEC, 93/44/EEC and 93/68/EEC (Machinery Directive).
Directive 89/336/EEC as amended by Directives 91/263/EEC and 92/31/EEC (EMC Directive).
Directive 73/23/EEC as amended by Directive 93/68/EEC (Low Voltage Directive).

In addition, we conrm that the machine complies with the following standards:
EN 50 081-2

Electromagnetic Compatibility (EMC)


Basic Specication on Emitted Interference, Industrial Area

EN 50 082-2

Electromagnetic Compatibility (EMC), Draft


Basic Specication on Emitted Interference, Industrial Area

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Product description

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1.7 Accessories
With the many accessories, the Komax Gamma 333 PC / 333 PC B can be tailored perfectly to
your specic application yet remains open to accommodating future requirements. The following
list gives a quick overview of the possibilities provided by the individual devices.

Blades
Cutting head
Set for stripping lengths up to 30mm on side 1
1
V form stripping blade R 0.1
1
V form stripping blade R 0.5
1
V form stripping blade R 0.75
1
V form stripping blade R 1.0
1
V form stripping blade R 1.5
1
V form stripping blade R 2.0
2
Cutting blade
3 Bad wire cutting blade

1
3

2
g 1.03 Blade head

Wire guides
Various wire guides (arrows) can be used to
ensure optimum wire guidance. Special guides
are available on request.
1 Wire guide
2 Guide hose
3 Wire guide tube, short/long
short

long

1.3
1.5
1.7
2
2.5
3
3.5
4
5
5.5

1
2

g 1.04 Wire guides on the swivel unit, side 1

Grease: Standard

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Version 4

Transport rollers (Gamma 333 PC)


You can use different transport rollers (arrow) to adjust the roller drive to wires with different characteristics.
Elastomer transport rollers
Steel transport rollers, diagonally knurled,
ne (optional)
Steel transport rollers, diagonally knurled,
medium (optional)
Steel transport rollers, diagonally knurled,
coarse (optional)
Plasma-coated transport rollers (optional)

Processing stations

g 1.05 Roller drive

Press accessories
Fixed press positioning
Lever-operated quick clamping system for
mini applicators
Contact feed plates for side 1 and side 2,
side-feed and back-feed
Contact strip cutter, K 455
Paper strip take-up device, K 496

g 1.06

Monitoring
The wire end check is done in the wire drive
with an encoder.
(g 1.07 shows the encoder in the roller
drive for the Gamma 333 PC.)

g 1.07 Monitoring units prior to wire draw-in

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Product description

1 11

Crimp force analysis is integrated in the


mci 711 crimp modules.

g 1.08 Crimp force analysis

Wire deposition
Standard: 1.5m conveyor belt
Optional: 2m extension for conveyor belt, K 419
4m extension for conveyor belt, K 420

g 1.09 Deposit unit, 1.5m

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Version 4

Hinweiserklrung
GEFAHR
Bezeichnet eine Gefahr mit hohem Risiko.
Wenn sie nicht gemieden wird, sind Tod oder schwerste Verletzungen die Folge.

WARNUNG
Bezeichnet eine Gefahr mit mittlerem Risiko.
Wenn sie nicht gemieden wird, knnen Verletzungen die Folge sein.
VORSICHT
Bezeichnet eine Gefahr mit geringem Risiko.
Wenn sie nicht gemieden wird, knnen Sachschden die Folge sein.

HINWEIS
Bezeichnet Anwendertipps und andere ntzliche Informationen.
Es ist kein Signalwort fr Gefahren.

Im Weiteren werden folgende Symbole fr spezische Gefahren der Maschine verwendet:

Gefahr durch Strom

Verbrennungsgefahr durch
heisse Oberchen

Einzugsgefahr fr Finger oder


Hnde

Gefahr durch Laser

Quetschgefahr fr Finger oder


Hnde

Verletzungsgefahr fr Augen
durch Kabel und Litzen

Schnittgefahr fr Finger oder


Hnde

Gefahr durch Zinnspritzer

Gefahr durch ESD


(Elektrostatische Entladung)

Gefahr durch Explosion

Deutsch

Sicherheit

Deutsch

Allgemeine Sicherheitshinweise
Betriebsanleitung
Die Betriebsanleitung ist ein Bestandteil der Maschine. Bevor Sie mit der Maschine arbeiten, muss die Betriebsanleitung gelesen und verstanden werden. Beachten Sie insbesondere die Sicherheits- und Warnhinweise.
Anleitungen Zubehr
Beachten Sie neben den Sicherheitshinweisen in dieser Betriebsanleitung auch die Sicherheitshinweise in den Anleitungen des Zubehrs.
Personensicherheit
Die Personensicherheit ist nur fr einen einzigen Bediener gewhrleistet. Personen die
an der Maschine arbeiten, mssen sich stets vergewissern, dass durch ihr Handeln keine
Personen gefhrdet werden.
Personalqualikation
Die Maschine darf nur von Personen welche die entsprechenden Qualikationen mitbringen
bedient, eingestellt und gewartet werden.

Technischer Zustand der Maschine


Gefahrloser Betrieb
Wenn anzunehmen ist, dass ein gefahrloser Betrieb der Maschine nicht mehr gewhrleistet
ist, muss die Maschine ausgeschaltet und gegen unbeabsichtigtes Einschalten gesichert
werden.
Sicherheitseinrichtungen
Die Maschine darf nur mit funktionierenden Sicherheitseinrichtungen betrieben werden.
Sicherheitseinrichtungen, inbesondere die Schutzhaube, drfen nicht entfernt, berbrckt
oder in irgendwelcher Form manipuliert werden.
Wartung
Die Maschine muss nach den angegebenen Zeitintervallen gewartet werden.
Wird die Maschine nicht regelmssig gewartet, knnen Maschinenschden die Folge sein.
Ersatzteile
Defekte Teile drfen nur durch Originalersatzteile ersetzt werden. Die Originalersatzteile
knnen bei Komax bezogen werden.
Umbauten
Die Maschine darf grundstzlich nicht umgebaut werden. Sollten Umbauten notwendig
sein, drfen diese nur nach Rcksprache mit Komax ausgefhrt werden.
Softwaremodikationen
Jegliche Modikation der Software ist untersagt.

English

Safety
Explanation of notes
DANGER
Indicates a danger involving a high risk.
Not avoiding it results in death or serious injury.

WARNING
Indicates a danger involving a medium risk.
Not avoiding it could result in injuries.
CAUTION
Indicates a danger involving a low risk.
Not avoiding it could result in property damage.

NOTE
Indicates user tips and other useful information.
It is not a word that signals dangers.

The following symbols are used hereafter to indicate the specic dangers posed by the
machine:

Danger from electrical shock

Danger of burns from hot


surfaces

Danger of ngers or hands


being drawn in

Danger from laser

Danger of ngers or hands


being crushed

Risk of injury to eyes from


cables and strand wires

Danger of ngers or hands


being cut

Danger from tin splatters

Danger from ESD


(electrostatic discharge)

Danger from explosion

English

General safety instructions


Operating instructions
The operating instructions are an integral part of the machine. You must read the operating
instructions and make sure you understand them before working with the machine.
Pay especially close attention to the safety and warning instructions.
Instructions for accessories
Besides heeding the safety instructions in these operating instructions, make sure to obey
the safety instructions in the instructions for the modules and accessories.
Safety of persons
Personal safety is guaranteed only for a single machine operator. Anyone working on the
machine must always be careful not to enter a command that puts others in danger.
Personnel qualications
Only individuals with the appropriate qualications are allowed to operate, set up, and
maintain the machine.

Technical condition of the machine


Safe operation
If you have reason to believe the machine can no longer be operated safely, you must put it
out of operation and secure it against being switched on unintentionally.
Safety devices
The machine may only be operated with properly functioning safety devices.
It is not permitted to remove or bridge safety devices or tamper with them in any way.
Maintenance
The machine must be serviced at the indicated time intervals.
Machine damage could occur if the machine is not serviced regularly.
Spare parts
Defective parts must be replaced with original spare parts. These original spare parts are
available for purchase from Komax.
Modications
Basically speaking, the machine is not allowed to be modied. If modications prove
necessary, you may not carry them out without rst consulting Komax.
Software modications
It is forbidden to modify the software in any way.

Explication des remarques


DANGER
Dsigne un danger grand risque.
Si on ne lvite pas, il peut entraner la mort ou de trs graves blessures.

AVERTISSEMENT
Dsigne un danger risque moyen.
Si on ne lvite pas, il peut entraner des blessures.
PRECAUTION
Dsigne un danger faible risque.
Si on ne lvite pas, il peut entraner des dommages matriels.

REMARQUE
Dsigne des conseils pour utilisateurs et autres informations utiles.
Ce nest pas un mot-cl signalant des dangers.

Par ailleurs, les symboles suiants sont utiliss pour dsigner des dangers spciques la
machine:

Danger: courant lectrique

Risque de brlure: surfaces trs


chaudes

Risque de saisisssement des


doigts ou des mains

Danger: laser

Risque dcrasement des doigts


ou des mains

Risque de lsions oculaires


dues aux cbles et aux torons

Risque de se couper les doigts


ou les mains

Danger: projections dtain

Danger: dcharges
lectrostatiques (ESD)

Danger: explosion

Franais

Scurit

Franais

Consignes gnrales de scurit


Instructions de service
Les instructions de service font partie intgrante de la machine. Avant de travailler avec la
machine, les instructions de service doivent avoir t lues et comprises. Observez particulirement les consignes de scurit et davertissement.
Instructions de service des accessoires
Outre les consignes de scurit des prsentes instructions de service, veuillez galement
observer les consignes de scurit des instructions de service des accessoires.
Scurit des personnes
La scurit des personnes nest garantie que pour un seul utilisateur. Les personnes
travaillant sur la machine doivent toujours sassurer quaucune personne nest en danger
du fait dune entre errone.
Qualication du personnel
La commande, le rglage et la maintenance de la machine ne doivent tre raliss que par
des personnes disposant des qualications correspondantes.

Etat technique de la machine


Fonctionnement sans risque
Lorsquon peut supposer quun fonctionnement sans danger de la machine nest plus
garanti, la machine doit tre mise hors circuit et protge contre une mise en circuit involontaire.
Dispositifs de scurit
La machine ne doit tre mise en service que lorsque les dispositifs de scurit fonctionnent
correctement. Les dispositifs de scurit, et notamment le capot de protection, ne doivent
pas tre enlevs, ponts ou manipuls de quelque manire que ce soit.
Maintenance
La maintenance de la machine doit tre ralise aprs les intervalles de temps indiqus.
Lorsque la maintenance de la machine nest pas ralise rgulirement, cela peut entraner
des dommages sur la machine.
Pices de rechange
Les pices dfectueuses ne doivent tre remplaces que par des pices originales.
Les pices de rechange originales peuvent tre achetes chez Komax.
Transformations
Par principe, la machine ne doit pas subir de transformation. Si des transformations
devaient tre ncessaires, elles ne doivent tre excutes quaprs consultation de Komax
ce sujet.
Modications du logiciel
Toute modication du logiciel est interdite.

Spiegazione delle avvertenze


PERICOLO
Contrassegna un pericolo ad alto rischio.
Se non viene evitato, la conseguenza possono essere la morte o gravi ferite.

AVVISO
Contrassegna un pericolo di medio rischio.
Se non viene evitato, come conseguenza si possono subire delle lesioni.
CAUTELA
Contrassegna un pericolo di basso rischio.
Se non viene evitato, possono vericarsi danni materiali.

NOTA
Indica suggerimenti per lutente ed altre utili informazioni.
Non una parola che segnala dei rischi.

Inoltre, vengono impiegati i seguenti simboli per rischi specici della macchina:

Pericolo da corrente elettrica

Rischio di scottarsi contro


superci surriscaldate

Rischio di impigliare dita


o mani

Rischio da laser

Rischio di schiacciare dita


o mani

Rischio di ferirsi gli occhi con


cavi e trefoli

Rischio di tagliare dita o mani

Rischio di schizzi di stagno

Rischio di scariche
elettrostatiche

Rischio di esplosioni

Italiano

Sicurezza

Italiano

Avvertenze generali sulla sicurezza


Istruzioni per luso
Le istruzioni per luso sono parte integrante della macchina. Prima di lavorare con la
macchina, le istruzioni per luso devono essere lette e comprese. Rispettate in particolare le
avvertenze e gli avvisi sulla sicurezza.
Istruzioni degli accessori
Oltre alle avvertenze sulla sicurezza contenute in queste istruzioni per luso, si deve tener
conto anche delle avvertenze sulla sicurezza nelle istruzioni dei moduli e degli accessori.
Sicurezza personale
La sicurezza personale garantita solo per un unico operatore. Le persone che lavorano
sulla macchina devono sempre accertarsi di non mettere in pericolo altre persone con le
loro azioni.
Qualicazione del personale
La macchina pu essere comandata, regolata ed assoggettata a manutenzione solo da
persone dotate di adeguate qualiche.

Stato tecnico della macchina


Funzionamento esente da rischi
Se si ritiene che non sia pi garantito un funzionamento della macchina esente da rischi,
questa deve essere messa fuori servizio ed assicurata contro linserimento accidentale.
Dispositivi di sicurezza
La macchina pu essere fatta funzionare solo con dispositivi di sicurezza operativi.
I dispositivi di sicurezza, in particolare la copertura di protezione, non devono essere
rimossi, messi in derivazione o manipolati in qualsivoglia forma.
Manutenzione
La macchina deve essere assoggettata a manutenzione agli intervalli di tempo indicati.
Se la macchina non viene assoggettata a manutenzione regolarmente, pu subire dei
danni.
Parti di ricambio
I componenti difettosi possono essere sostituiti solo da ricambi originali. I ricambi originali
possono essere acquistati presso la Komax.
Trasformazioni
La macchina in linea di massima non deve essere sottoposta a trasformazioni. Qualora
si rendano necessarie delle trasformazioni, queste si possono eseguire solo dopo aver
consultato la Komax.
Modiche del software
Qualsivoglia modica del software vietata.

Espaol

Seguridad
Explicacin de las indicaciones
PELIGRO
Designa un peligro de elevado riesgo.
Si no se evita, provoca la muerte o heridas graves.

ADVERTENCIA
Designa un peligro de riesgo mediano.
Si no se evita, puede provocar heridas.
CUIDADO
Designa un peligro de riesgo reducido.
Si no se evita, puede provocar daos materiales.

AVISO
Designa avisos para el usuario y otras informaciones provechosas.
No es ningn aviso sobre un peligro.

Por lo dems, se emplean los siguientes smbolos para peligros especcos de la mquina:

Peligro por corriente

Peligro de quemaduras por


supercientes calientes

Peligro de atrapamiento de
dedos o manos

Peligro por lser

Peligro de aplastamiento de
dedos o manos

Peligro de heridas oculares


por cables y cordones

Peligro de corte de dedos o


manos

Peligro por salpicaduras de


estao

Peligro por ESD


(descarga electrosttica)

Peligro por explosin

Espaol

Indicaciones generales de seguridad


Instrucciones de servicio
Las Instrucciones de servicio son parte integrante de la mquina. Antes de trabajar con
la mquina debe haber ledo y entendido las instrucciones de servicio. Observe especialmente los avisos de seguridad y las advertencias.
Instrucciones de accesorios
Observe aparte de los avisos de seguridad en las presentes instrucciones de servicio
tambin los avisos de seguridad en las instrucciones de accesorios.
Seguridad de personas
La seguridad de personas slo viene garantizada para un solo operador. Las personas que
trabajan en la mquina deben cerciorarse siempre que la entrada de un comando no pueda
exponer a peligros a otras personas.
Calicacin del personal
La mquina slo debe ser operada, ajustada y mantenida por personas que satisfagan las
calicaciones correspondientes.

Estado tcnico de la mquina


Operacin exenta de peligros
Cuando es de suponer que ya no est garantizado un funcionamiento de la mquina
exento de peligros, sta debe ponerse fuera de servicio y asegurarse contra la conexin
involuntaria.
Dispositivos de seguridad
La mquina slo debe operarse con los dispositivos de seguridad en funcionamiento.
Los dispositivos de seguridad, especialmente la cubierta de proteccin, no deben quitarse,
puentearse o manipularse de otra manera.
Mantenimiento
La mquina debe ser mantenida conforme a los intervalos de tiempo indicados.
Si la mquina no es mantenida peridicamente, pueden surgir daos de la misma.
Piezas de repuesto
Las piezas defectuosas slo deben ser sustituidas por piezas de repuesto originales.
Las piezas de repuesto originales pueden obtenerse de Komax.
Modicaciones constructivas
En principio, no deben efectuarse modicaciones constructivas de la mquina. Si stas
fueran necesarias, no obstante, debe consultar previamente a Komax.
Modicaciones del software
Se prohbe toda modicacin del software.

Esclarecimentos sobre as instrues


PERIGO
Indica um perigo elevado.
Se no for evitado, a consequncia ser a morte ou ferimentos gravssimos.

ADVERTNCIA
Indica um perigo mdio.
Se no for evitado, pode provocar ferimentos.
CUIDADO
Indica um perigo baixo.
Se no for evitado, pode provocar danos materiais.

NOTA
Indica dicas de aplicao e outras informaes teis.
No um sinal de perigo.

Para alm disso, sero utilizados os seguintes smbolos para perigos especcos da
mquina:
Perigo causado por corrente
elctrica

Perigo de queimadura causado


por superfcies quentes

Perigo de os dedos e as mos


serem puxados

Perigo causado por laser

Perigo de esmagamento para


os dedos ou as mos

Perigo de ferimento aos olhos


por cabos ou condutores
multilares

Perigo de corte aos dedos ou


s mos

Perigo causado por salpicos de


estanho

Perigo causado por DEM


(descarga electromagntica)

Perigo causado por exploso

Portugus

Segurana

Portugus

Instrues gerais de segurana


Manual de instrues
O manual de instrues um componente da mquina. Antes de operar a mquina,
preciso ler e compreender o manual de instrues. Respeite sobretudo as instrues de
segurana e as advertncias.
Manuais de instrues dos acessrios
Observe, para alm das instrues de segurana deste manual de instrues, tambm as
instrues de segurana dos manuais de instrues dos acessrios.
Segurana do pessoal
A segurana do pessoal s est garantida para um nico operador. Pessoas que trabalhem
na mquina devem certicar-se continuamente que as suas aces no pem outras
pessoas em perigo.
Qualicao do pessoal
Apenas pessoal que disponha da respectiva qualicao est autorizado a operar, ajustar
e efectuar trabalhos de manuteno na mquina.

Estado tcnico da mquina


Funcionamento isento de perigo
Se houver justa causa para supor que no se pode garantir um funcionamento da mquina
isento de perigo, preciso pr a mquina fora de servio e proteg-la para que no seja
ligada acidentalmente.
Dispositivos de segurana
S permitido operar a mquina se os dispositivos de segurana estiverem a funcionar
perfeitamente. proibido remover, curto-circuitar ou manipular de qualquer outra forma os
dispositivos de segurana, principalmente a cobertura de proteco.
Manuteno
Os trabalhos de manuteno devem efectuar-se na mquina de acordo com os intervalos
especicados.
Se os trabalhos de manuteno no forem efectuados regularmente na mquina, h perigo
de danos mquina.
Peas sobressalentes
Peas defeituosas s podem ser substitudas por peas sobressalentes originais. As peas
sobressalentes originais podem ser encomendadas rma Komax.
Transformaes
proibido realizar todo e qualquer tipo de transformaes na mquina. Se for necessrio
fazer transformaes na mquina, elas s podem ser realizadas aps consulta prvia
rma Komax.
Modicaes no software
proibido realizar toda e qualquer modicao no software.

Symbolforklaring
FARE
Angiver fare med hj risiko.
Hvis ikke den undgs, er flgen dd eller alvorlige kvstelser.

ADVARSEL
Angiver fare med mellemhj risiko.
Hvis ikke den undgs, kan flgen vre kvstelser.
FORSIGTIGHED PBUDT
Angiver fare med lav risiko.
Hvis ikke den undgs, kan flgen vre skader p ting.

OBS!
Angiver brugerinformationer og andre nyttige oplysninger.
Er ikke en faresignalbetegnelse.

Desuden anvendes flgende symboler for specikke risici ved maskinen:

Fare p grund af strmfrende


dele

Forbrndingsfare p grund af
varme overader

Fare for indtrkning af ngre


eller hnder

Fare p grund af laserstrling

Fare for kvstelser p ngre


eller hnder

Fare for jenkvstelser p


grund af kabler og ledninger

Fare for snitkvstelser p ngre


eller hnder

Sprjterisiko fra tin

Fare for ESD


(elektrostatisk aadning)

Eksplosionsfare

Dansk

Sikkerhed

Dansk

Generelle sikkerhedsanvisninger
Driftsvejledning
Driftsvejledningen er en del af maskinen. Fr der arbejdes med maskinen, skal driftsvejledningen gennemlses og indholdet forsts. Opmrksomheden henledes srligt p
sikkerhedsinstruktioner og advarsler.
Vejledninger for tilbehr
Ud over sikkerhedsinstruktionerne i nrvrende driftsvejledning skal ogs sikkerhedsinstruktionerne i dokumentationerne for tilbehret overholdes.
Personlig sikkerhed
Den personlige sikkerhed kan kun garanteres for en enkelt operatr. Personer, der arbejder
ved maskinen, skal altid overbevise sig om, at deres handlinger ikke indebrer risiko for
andre personer.
Uddannelse
Maskinen m kun betjenes, indstilles og vedligeholdes af personer med den relevante
uddannelse.

Maskinens tekniske tilstand


Risikofri drift
Hvis der opstr tvivl om maskinen kan kre uden sikkerhedsrisiko eller ej, skal maskinen
tages ud af drift og sikres mod utilsigtet genindkobling.
Sikkerhedsanordninger
Maskinen m kun anvendes med fungerende sikkerhedsanordninger.
Sikkerhedsanordninger, specielt sikkerhedshtten, m ikke fjernes, frakobles eller p
nogen mde manipuleres.
Vedligeholdelse
Maskinen skal vedligeholdes iht. de anfrte tidsintervaller.
Vedligeholdes maskinen ikke regelmssigt, kan der opst skader p maskinen.
Reservedele
Defekte dele m kun udskiftes med originale reservedele. Originale reservedele kan bestilles hos Komax.
Modikationer
Maskinen m principielt ikke modiceres. Hvis modikationer skulle vre ndvendige, m
disse kun udfres efter konsultation med Komax.
Softwaremodikationer
Modikation af software er ikke tilladt.

Toelichting op de aanwijzingen
GEVAAR
Betekent een gevaar met groot risico.
Indien dit niet gemeden wordt, zijn de dood of ernstige verwondingen het gevolg.

WAARSCHUWING
Betekent een gevaar met middelgroot risico.
Indien dit niet gemeden wordt, kunnen verwondingen het gevolg zijn.
PAS OP
Betekent een gevaar met gering risico.
Indien dit niet gemeden wordt, kan materile schade het gevolg zijn.

AANWIJZING
Betekent gebruikerstips en andere nuttige informatie.
Het is geen waarschuwing voor gevaar.

Hieronder worden de volgende symbolen voor een speciek gevaarlijke machine gebruikt:

Gevaar door stroom

Verbrandingsgevaar door hete


oppervlakken

Intrekgevaar voor vingers of


handen

Gevaar door laser

Gevaar voor bekneld raken van


vingers of handen

Gevaar voor oogletsel door


kabels en draden

Snijgevaar voor vingers of


handen

Gevaar door spatten tin

Gevaar door ESD


(elektrostatische ontlading)

Gevaar door explosie

Nederlands

Veiligheid

Nederlands

Algemene veiligheidsinstructies
Handleiding
De handleiding vormt een bestanddeel van de machine. Voordat u met de machine werkt,
moet de handleiding gelezen en begrepen worden. Let met name op de veiligheidsinstructies en waarschuwingen.
Handleiding accessoires
Let naast de veiligheidsinstructies in deze handleiding ook op de veiligheidsinstructies in
de handleidingen voor de accessoires.
Veiligheid van personen
De veiligheid van personen is uitsluitend gewaarborgd voor n enkele operator. Personen
die aan de machine werken, moeten zich er steeds van vergewissen, dat door hun handelen geen personen in gevaar worden gebracht.
Kwalicatie van het personeel
De machine mag uitsluitend door hiertoe gekwaliceerde personen bediend, ingesteld en
onderhouden worden.

Technische toestand van de machine


Ongevaarlijke werking
Indien kan worden aangenomen dat een gevaarloze werking van de machine niet meer
gewaarborgd is, moet de machine uitgeschakeld en tegen onopzettelijk opnieuw inschakelen beveiligd worden.
Veiligheidsvoorzieningen
De machine mag uitsluitend met goed functionerende veiligheidsvoorzieningen worden
gebruikt.
Veiligheidsvoorzieningen, met name de beschermkap, mogen niet verwijderd, overbrugd of
in welke vorm dan ook gemanipuleerd worden.
Onderhoud
De machine moet volgens de aangegeven termijnen onderhouden worden.
Indien de machine niet regelmatig onderhouden wordt, kan machineschade het gevolg zijn.
Onderdelen
Defecte onderdelen mogen uitsluitend door originele onderdelen worden vervangen.
De originele onderdelen kunnen bij Komax worden gekocht.
Ombouwen
De machine mag in principe niet worden omgebouwd. Mocht ombouwen noodzakelijk zijn,
dan mag dit uitsluitend in overleg met Komax worden uitgevoerd.
Softwaremodicaties
Iedere modicatie van de software is verboden.

Merkkien selitys
VAARA
Merkitsee suuren riskin vaaraa.
Vaaran seurauksena voi olla kuolema tai vakava tapaturma.

VAROITUS
Merkitsee keskisuuren riskin vaaraa.
Vaaran seurauksena voi olla tapaturma.
HUOMIO
Merkitsee pienen riskin vaaraa.
Vaaran seurauksena voi olla esinevahingot.

OHJE
Merkitsee vinkkej kyttjlle ja muuta hydyllist tietoa.
Ei viittaa mahdolliseen vaaratilanteeseen.

Lisksi koneen mahdolliset vaarapaikat on merkitty seuraavilla symboleilla:

Shkiskun vaara

Palovammojen vaara kuumien


pintojen johdosta

Sormien ja ksien koneeseen


vedetyksi tulemisen vaara

Laserin aiheuttama vaara

Sormien ja ksien
puristumisvaarasormien ja
ksien koneeseen vedetyksi

Silmien vahingoittumisvaara
kaapelien ja johdinten vuoksi

Sormien ja ksien
viiltovammojen vaarasormien
ja ksien koneeseen vedetyksi

Tinaruiskun aiheuttama vaara

Shkstaattisen purkauksen
aiheuttama vaara

Rjhdysvaara

Suomi

Turvallisuus

Suomi

Yleisi turvallisuusohjeita
Kyttohje
Kyttohje on osa konetta. Kyttohje on luettava huolellisesti ja sen sislt ymmrrettv
ennen koneen kyttmist. Perehdy erityisesti turvallisuusohjeisiin ja varoituksiin.
Lisvarusteiden ohjeet
Noudata tmn kyttohjeen turvallisuusohjeiden lisksi mys lisvarusteiden turvallisuusohjeita.
Henkilturvallisuus
Henkilturvallisuus on taattu vain yhdelle ainoalle kyttjlle. Koneella tyskentelevien
henkiliden on varmistettava, ett he eivt vaaranna toiminnallaan muiden henkiliden
turvallisuutta.
Henkilkunnan ptevyys
Konetta saavat kytt, st ja huoltaa vain henkilt, joilla on thn soveltuva ptevyys.

Koneen tekninen kunto


Vaaraton kytt
Kun on epiltviss, ett koneen vaaratonta kytt ei en voida taata, kone on kytkettv
plt ja on varmistettava, ett sit ei voida tahattomasti kytke plle.
Turvalaitteet
Konetta saa kytt vain, kun turvalaitteet toimivat.
Turvalaitteita, erityisesti suojusta, ei saa poistaa, ohittaa eik ksitell milln tavoin.
Huolto
Konetta on huollettava ohjeiden mukaisin aikavlein.
Jos konetta ei huolleta snnllisesti, kone saattaa vioittua.
Varaosat
Vioittuneet osat on vaihdettava alkuperisiin varaosiin. Alkuperisi varaosia voi tilata
Komaxilta.
Muutokset
Konetta ei saa muuttaa. Jos muutoksia tarvitaan, nist on neuvoteltava ensin Komaxin
kanssa.
Ohjelmiston muokkaaminen
Ohjelmiston muokkaaminen on kielletty.

Frklaring
FARA
Indikerar fara med hg risk.
Om varningen inte tas p allvar, kan det leda till att livshotande skador uppstr.

VARNING
Indikerar fara med medelrisk.
Om varningen inte tas p allvar, kan det leda till att skador uppstr.
FRSIKTIGHET
Indikerar fara med lg risk.
Om varningen inte tas p allvar, kan det leda till att sakskador uppstr.

INFORMATION
Indikerar anvndartips och annan vrdefull information.
Detta r inte ett varningstecken.

Nedan visas symboler fr specika faror som kan uppst i samband med att maskinen
anvnds:

Risk fr elchock

Risk fr brnnskada p grund av


heta omrden

Risk fr att ngrar och hnder


fastnar och dras in

Fara p grund av laser

Risk fr att ngrar och hnder


klms fast

Risk fr gonskada p grund av


kablar och trnsar

Risk fr skrskador p ngrar


och hnder

Risk fr tennstnk

Risk fr elektrostatisk urladdning


(ESD)

Fara p grund av explosionsrisk

Svenska

Skerhet

Svenska

Allmnna skerhetsanvisningar
Bruksanvisning
Bruksanvisningen hr till maskinen. Innan arbetet med maskinen pbrjas, r det viktigt
att lsa och frst innehllet i bruksanvisningen. Var extra uppmrksam p skerhets- och
varningsanvisningarna.
Tillbehrsanvisningar
Frutom skerhetsanvisningarna i den hr instruktionsboken ska ven tillbehrens skerhetsanvisningar fljas.
Personskerhet
Personskerheten kan endast garanteras fr en anvndare. Personer som arbetar vid
maskinen mste alltid se till att ingen annan person skadas genom arbetet.
Personalkvalikationer
Maskinen fr endast hanteras, stllas in och underhllas av personer med lmpliga kvalikationer.

Maskinens tekniska skick


Drift utan risk fr fara
Om maskinen inte kan kras utan att det medfr fara, mste maskinen stngas av och
skras mot att ngon rkar starta den av misstag.
Skerhetsanordningar
Maskinen fr endast kras med fungerande skerhetsanordningar.
Skerhetsanordningarna, srskilt skyddskpan, fr inte avlgsnas, frbikopplas eller
manipuleras p ngot stt.
Underhll
Underhll ska utfras p maskinen i enlighet med de angivna tidsintervallen.
Om maskinen inte underhlls regelbundet, kan det leda till att maskinskador uppstr.
Reservdelar
Defekta delar fr endast bytas ut mot originalreservdelar. Originalreservdelarna kan bestllas frn Komax.
Ombyggnad
Maskinen fr aldrig byggas om. Om ombyggnad nd skulle krvas, fr det ske endast
efter verenskommelse med Komax.
Programvarumodieringar
Alla former av modiering av programvaran r frbjudna.

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Vysvtlen pokyn
NEBEZPE
Oznauje nebezpe s vysokm rizikem.
Pokud se nebezpe nezamez, jsou nsledkem smrt nebo nejt porann.
VSTRAHA
Oznauje nebezpe se stednm rizikem.
Pokud se nebezpe nezamez, me zpsobit zrann.
POZOR
Oznauje nebezpe s nzkm rizikem.
Pokud se nebezpe nezamez, me zpsobit vcn kody.

UPOZORNN
Oznauje rady pro uivatele a jin uiten informace.
Nen to vstran text pro ohroen.

V dal sti budou pouity nsledujc symboly pro specick nebezpe stroje:

Nebezpe elektrickm proudem

Nebezpe poplenm horkmi


plochami

Nebezpe vtaen prst nebo


rukou

Nebezpe psobenm laseru

Nebezpe rozdrcen prst nebo


rukou

Nebezpe zrann o kabelem


nebo vodii

Nebezpe poezn prst nebo


rukou

Nebezpe rozstknutm cnem

Nebezpe vlivem
elektrostatickho vybjen

Ohroen vbuchem

esky

Bezpenost

esky

Obecn bezpenostn pokyny


Nvod k provozu
Nvod k provozu je soust stroje. Ped zahjenm prce na stroji si muste nvod
k provozu prost a porozumt mu. Dodrujte zvlt bezpenostn a vstran pokyny.
Nvody psluenstv
Krom bezpenostnch pokyn v tomto nvodu k provozu respektujte rovn bezpenostn
pokyny v nvodech pro psluenstv.
Osobn bezpenost
Osobn bezpenost je zajitna jen pro jedinho opertora. Osoby, kter na stroji pracuj, se
musej vdy pesvdit, zda nejsou jejich jednnm ohroeny dn dal osoby.
Kvalikace personlu
Stroj sm obsluhovat, nastavovat a udrovat jen osoby, kter maj odpovdajc kvalikaci.

Technick stav stroje


Bezpen provoz
Pokud se pedpokld, e ji nen zaruen bezpen provoz stroje, mus se zazen
vypnout a zajistit proti nemyslnmu optovnmu zapnut.
Bezpenostn zazen
Stroj se sm uvst do provozu jen s fungujcm bezpenostnm zazenm.
Bezpenostn zazen, zvlt ochrann kryt, se nesm odstranit, peklenout nebo se s nimi
nesm jakmkoliv zpsobem manipulovat.
drba
Na stroji se mus podle zadanch asovch interval provst drba.
Jestlie se stroj pravideln neudruje, me bt nsledkem jeho pokozen.
Nhradn dly
Vadn dly se smj nahradit vhradn originlnmi nhradnmi dly. Originln nhradn dly
je mono zakoupit u rmy Komax.
pravy
Stroj se zsadn nesm upravovat. Pokud by byly pravy nutn, smj se provst jen po
dohod s rmou Komax.
Modikace softwaru
Jakkoliv modikace softwaru je zakzna.

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Laser



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Komax.

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Komax.

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Megjegyzsek lersa
VESZLY
Nagy kockzat veszlyt jell.
Amennyiben nem kerli el, hallhoz vagy slyos srlsekhez vezethet.

FIGYELMEZTETS
Kzepes kockzat veszlyt jell.
Ha nem kerli el, srlshez vezethet.
VIGYZAT
Kis kockzat veszlyt jell.
Ha nem kerli el, dologi krhoz vezethet.

MEGJEGYZS
Felhasznli tancsokat s egyb hasznos informcikat jell.
Veszlyt nem jell.

Tovbb a kvetkez szimblumok kerlnek hasznlatra a gp specikus veszlyeire:

ram ltali veszly

Forr felletek ltali gsveszly

Ujjak vagy kezek behzsnak


veszlye

Lzer ltali veszly

Ujjak vagy kezek zzdsnak


veszlye

Szem kbelek s pszmk ltali


srlsnek veszlye

Ujjak vagy kezek vgsveszlye

nfrccsens ltali veszly

ESD (elektrosztatikus kisls)


ltali veszly

Robbans ltali veszly

Magyar

Biztonsg

Magyar

ltalnos biztonsgi utastsok


zemeltetsi tmutat
tmutatt, mieltt a gppel dolgozna. Klnsen a biztonsgi s gyelmeztet utastsokat
vegye gyelembe.
Tartozkok tmutati
A jelen zemeltetsi tmutatban szerepl biztonsgi utastsok mellett vegye gyelembe a
tartozkok tmutatiban szerepl biztonsgi utastsokat is.
Szemlyi biztonsg
A szemlyi biztonsg csak egyetlen kezel szmra biztostott. A gpen dolgoz szemlyeknek mindig meg kell gyzdnik arrl, hogy az ltaluk vgzett kezels ms szemlyeket
nem veszlyeztet.
Szemlyzet kpzettsge
A gpet kizrlag a megfelel kpestssel rendelkez szemlyek kezelhetik, llthatjk be
s tarthatjk karban.

A gp mszaki llapota
Veszlytelen mkds
Amennyiben felttelezhet, hogy a gp veszlytelen mkdse tbb nem biztostott, a
gpet ki kell kapcsolni s az akaratlan bekapcsols ellen biztostani kell.
Biztonsgi berendezsek
A gpet kizrlag mkd biztonsgi berendezsekkel szabad zemeltetni.
A biztonsgi berendezseket, klnsen a vdfedelet nem szabad eltvoltani, thidalni
vagy brmilyen egyb formban manipullni.
Karbantarts
A gpet a megadott idintervallumok szerint kell karbantartani.
Ha a gp nem kerl rendszeresen karbantartsra, gy ennek gpkr lehet a kvetkezmnye.
Ptalkatrszek
A hibs alkatrszeket csak eredeti ptalkatrszekkel szabad ptolni. Az eredeti alkatrszek
a Komax cgnl szerezhetk be.
tptsek
A gpet alapveten nem szabad tpteni. Amennyiben mgis szksgesek lennnek
tptsek, gy ezeket csak a Komax vllalattal trtnt egyeztets utn szabad elvgezni.
Szoftvermdostsok
A szoftver mindennem mdostsa tilos.

Mrkuse selgitus
OHT
Thistab krge riskiga ohtu.
Kui seda ra ei hoita, on tagajrjeks surm vi rasked vigastused.

HOIATUS
Thistab keskmise riskiga ohtu.
Kui seda ra ei hoita, vivad tagajrjeks olla vigastused.
HOIATUS
Thistab keskmise riskiga ohtu.
Kui seda ra ei hoita, vib tagajrjeks olla materiaalne kahju.

MRKUS
Thistab npuniteid kasutajale ja muud kasulikku teavet.
Ei mrgista ohte.

Masina spetsiiliste ohtude kohta kasutatakse edaspidi jrgmisi smboleid:

Elektrioht

K madest pindadest tingit d


p let soht

S rmede v i k te sisset mbeoht

Laserioht

S rmede v i k te m lj misoht

Kaablitest ja traatidest tingit d


silmade vigast soht

S rmede v i k te vigast soht

Tinapritsmete oht

Elektrostaatilise laeng oht

Plahvat soht

Eesti

Ohutus

Eesti

ldised oh t sj hised
Kas t sj hend

Tarvik te j hendid

Personali oh t s

Personali kvalikatsioon
Masinat tohivad kasutada, seadistada ja hooldada ainult vastava kvalikatsiooniga isikud.

Masina tehniline seis nd


h t t

Kaitseseadised

Hoold s

Var osad

mberehit sed

Tarkvara modikatsioonid
Tarkvara igasugune moditseerimine on keelatud.

Pastab iaikinimas
PAVO US
ymi pavoj, susijus su didele rizika.
Jeigu jos nevengiama, gali itikti mirtis arba sunkus kno sualojimas.

SPJIMAS
ymi pavoj, susijus su vidutine rizika.
Jeigu jos nevengiama, galite susialoti.
ATSARGIAI
ymi pavoj, susijus su nedidele rizika.
Jeigu jos nevengiama, gali bti padaryta materialin ala.

PASTA A
ymi naudojimo patarimus ir kit nauding informacij.
Tai ne spjimas apie pavoj.

Toliau speciniams mainos keliamiems pavojams ymti naudojami ie simboliai:

Elektros srovs keliamas


pavojus

Karti paviriai galima


nusideginti

Pirt ir rank traukimo pavojus

Lazerio spinduliuots keliamas


pavojus

Pirt ir rank suspaudimo


pavojus

Kabeliai ir laid gyslos kelia aki


sualojimo pavoj

Pirt ir rank sipjovimo


pavojus

Cinko pursl keliamas pavojus

Elektros ikrovos keliamas


pavojus

Sprogimo pavojus

Lietuvi k.

Lietuvi k.

Bendrieji saugos nurodymai


Eksploatavimo instrukcija
Eksploatavimo instrukcija yra neatsiejama mainos dalis. Prie praddami dirbti su maina,
turite perskaityti ir suprasti eksploatavimo instrukcij. Ypating dmes skirkite saugos
nurodymams ir spjimams.
Pried instrukcijos
Be saugos nurodym ioje eksploatavimo instrukcijoje atsivelkite ir saugos nurodymus
pried instrukcijose.
Asmen sauga
Utikrinama tik operatoriaus sauga. Asmenys, dirbantys su maina, visada turi sitikinti, kad
j veikla nekelia pavojaus kitiems asmenims.
Personla kvalikcija
Main valdyti, derinti ir atlikti jos technin prieir gali tik asmenys, turintys atitinkam
kvalikacij.

Technin mainos bkl


Nekeliantis pavojaus eksploatavimas
Jeigu yra prieasi manyti, kad utikrinti nekelianio pavojaus mainos eksploatavimo
nebegalima, main reikia ijungti ir apsaugoti nuo netyinio jungimo.
Apsauginiai renginiai
Main galima eksploatuoti tik su veikianiais apsauginiais renginiais.
Apsaugini rengini, ypa apsauginio gaubto, negalima nuimti, untuoti arba keisti bet

Technin prieira
Technin mainos prieir reikia atlikti prajus nustatytam laikui.
Jeigu reguliariai neatliekama technin mainos prieira, ji gali sugesti.
Atsargins dalys
Sugedusias dalis galima keisti tik originaliomis atsarginmis dalimis. Atsargines dalis galite
sigyti i Komax.
Modikavimas
Main modikuoti grietai draudiama. Jeigu main reikia modikuoti, tai galima atlikti tik
suderinus su Komax.
Programins rangos modikavimas
Grietai draudiamas bet koks programins rangos modikavimas.

Nordjumu skaidrojums
BSTAMI
Apzm bstambu ar augstu riska pakpi.
Ja no ts neizvairs, iestjas nve vai var gt nopietnas traumas.

BRDINJUMS
Apzm bstambu ar vidju riska pakpi.
Ja no ts neizvairs, var gt traumas.
UZMANBU
Apzm bstambu ar zemu riska pakpi.
Ja no ts neizvairs, var rasties materilie zaudjumi.

NORDE
Apzm padomus lietotjam un citu lietdergu informciju.
Tas nav risku signlvrds.

Turpmk nordti simboli, kurus izmanto iekrtas specisko risku apzmanai:

Risks, ko rada elektrisk strva

Apdeguma risks, ko rada karstas


virsmas

Pirkstu vai roku ievilkanas risks

Risks, ko rada lzers

Pirkstu vai roku saspieanas


risks

Acu traumu risks, ko rada kabei


un troses

Pirkstu vai roku sagrieanas


risks

Risks, ko rada alvas


izakstans

Risks, ko rada ESD


(elektrostatisk izlde)

Risks, ko rada eksplozija

Latviski

Droba

Latviski

Visprjie drobas nordjumi


Ekspluatcijas instrukcija
Ekspluatcijas instrukcija ir iekrtas daa. Pirms skt strdt ar iekrtu, jizlasa un jizprot
ekspluatcijas instrukcija. pau vrbu pievrsiet drobas nordjumiem un brdinjuma
nordm.
Piederumu instrukcijas
Ldzs drobas nordjumiem aj instrukcij emiet vr ar drobas nordjumus, kas
sniegti piederumu instrukcijs.
Personu droba
Personu droba ir garantta tikai paam operatoram. Personm, kuras strd ar iekrtu,
vienmr jprliecins, vai viu darbba neapdraud citas personas.
Personla kvalikcija
Iekrtu drkst vadt, iestatt un apkopt tikai personas ar atbilstou kvalikciju.

Iekrtas tehniskais stvoklis


Neapdraudta ekspluatcija
Ja pieem, ka vairs netiek garantta iekrtas neapdraudta ekspluatcija, iekrta ir jizsldz un jnodroina pret nejauu ieslganu.
Drobas mehnismi
Iekrtu drkst izmantot tikai tad, ja darbojas drobas mehnismi.
Drobas mehnismus, sevii aizsargprsegu, nedrkst noemt, untt vai citd veid ar
tiem manipult.
Apkope
Iekrtai jveic apkope pc nordtajiem laika intervliem.
Ja neveic regulru apkopi, iekrtai var rasties bojjumi.
Rezerves daas
Bojts detaas drkst nomaint tikai ar oriinlajm rezerves dam. Oriinls rezerves
daas var iegdties uzmum Komax.
Prbves
Princip iekrtu prbvt nedrkst. Ja nepiecieams veikt prbvi, ts izpilde noteikti
jsaskao ar uzmumu Komax.
Programmatras modikcijas
Jebkda programmatras modicana ir aizliegta.

Objanienie wskazwek
NIEBEZPIECZESTWO
Oznacza zagroenie o wysokim stopniu ryzyka.
Jeli si go nie uniknie, konsekwencj moe by mier lub cikie obraenia.

OSTRZEENIE
Oznacza zagroenie o rednim stopniu ryzyka.
Jeli go si nie uniknie, konsekwencj mog by obraenia ciaa.
OSTRONIE
Oznacza zagroenie o niskim stopniu ryzyka.
Jeli go si nie uniknie, konsekwencj mog by szkody rzeczowe.

WSKAZWKA
Oznacza wskazwki dotyczce uytkowania i inne poyteczne informacje.
Nie oznacza zagroenia.

W instrukcji zastosowano nastpujce symbole specycznych zagroe zwizanych z


eksploatacj maszyny:
Niebezpieczestwo wywoane
przez prd elektryczny

Niebezpieczestwo poparzenia
przez gorce powierzchnie

Niebezpieczestwo wcignicia
palcw lub doni

Niebezpieczestwo wywoane
przez laser

Niebezpieczestwo zmiadenia
palcw lub doni

Niebezpieczestwo skaleczenia
oczu przez kable i druty

Niebezpieczestwo przecicia
palcw lub doni

Niebezpieczestwo wywoane
odpryskami cyny

Niebezpieczestwo
wywoane przez wyadowania
elektrostatyczne

Niebezpieczestwo wywoane
wybuchem

Polski

Bezpieczestwo

Polski

Oglne wskazwki bezpieczestwa


Instrukcja eksploatacji
Instrukcja eksploatacji stanowi cz skadow maszyny. Przed przystpieniem do uyt
kowania maszyny naley ze zrozumieniem przeczyta niniejsz instrukcj eksploatacji. W
szczeglnoci naley przestrzega wskazwek bezpieczestwa i wskazwek ostrzegaw
czych.
Instrukcje wyposaenia dodatkowego
Oprcz wskazwek bezpieczestwa zawartych w niniejszej instrukcji eksploatacji naley
przestrzega rwnie wskazwek bezpieczestwa w instrukcjach wyposaenia dodatko
wego.
Bezpieczestwo osb
Bezpieczestwo osb zagwarantowane jest tylko dla jednego operatora. Osoby pracujce
przy maszynie musz stale pilnowa, aby przez swoje dziaanie nie stwarza zagroenia dla
innych osb.
Kwalikacje personelu
Obsugi, ustawie i konserwacji maszyny mog dokonywa tylko osoby posiadajce odpo
wiednie kwalikacje.

Stan techniczny maszyny


Bezpieczna eksploatacja
W przypadku stwierdzenia, e nie mona duej zapewni bezpiecznego uytkowania
maszyny, maszyn naley wyczy i zabezpieczy przed przypadkowym wczeniem.
Urzdzenia odpowiedzialne za bezpieczestwo
Maszyn naley uytkowa wycznie ze sprawnymi urzdzeniami zabezpieczajcymi.
Nie wolno demontowa i mostkowa urzdze zabezpieczajcych - w szczeglnoci
dotyczy to pokrywy ochronnej - ani manipulowa nimi w jakikolwiek sposb.
Konserwacja
Maszyna wymaga konserwacji w podanych okresach przegldowych.
Jeeli maszyna nie bdzie regularnie konserwowana, konsekwencj moe by jej uszko
dzenie.
Czci zamienne
Uszkodzone czci naley wymienia tylko na oryginalne czci zamienne. Oryginalne
czci zamienne mona naby w rmie Komax.
Przebudowa
Zasadniczo nie zezwala si na przebudow maszyny. Jeeli jednak przebudowa maszyny
jest niezbdna, wolno j wykonywa wycznie po konsultacji z rm Komax.
Modykacje oprogramowania
Jakakolwiek modykacja oprogramowania jest zabroniona.

Explicaia indicaiilor

Legend

PERICOL
Indic un pericol cu risc ridicat.
Dac nu poate evitat, implic vtmri grave sau chiar decesul.

AVERTI ARE
Indic un pericol cu risc mediu.
Dac nu poate evitat, poate s cauzeze vtmri grave.
ATENIE
Indic un pericol cu risc redus.
Dac nu poate evitat, poate s cauzeze pagube materiale.

INDICAIE
Indic recomandri pentru utilizator i alte informaii utile.
Nu reprezint o formul de semnalizare a pericolelor.

n continuare, pentru pericolele specice utilajului se vor utiliza urmtoarele simboluri:

Pericol de natur electric

Pericol de arsuri reprezentat de


suprafeele erbini

Pericol de prindere a degetelor


sau a minilor

Pericol reprezentat de laser

Pericol de strivire a degetelor


sau a minilor

Pericol de vtmare a ochilor


reprezentat de cabluri i lie

Pericol de tiere a degetelor sau


a minilor

Pericol reprezentat de stropii de


cositor

Pericol reprezentat de ESD


(ncrcare electrostatic)

Pericol reprezentat de explozii

Romn

Sigurana

Romn

Instruciuni generale referitoare la siguran


Manualul de exploatare
Manualul de exploatare constituie o parte integrant a utilajului. nainte de a utiliza utilajul,
trebuie s citii i s nelegei manualul de exploatare. Acordai atenie special instruciunilor de siguran i de avertizare.
Instruciuni referitoare la accesorii
Pe lng instruciunile de siguran din cadrul acestui manual de exploatare, inei cont i de
instruciunile de siguran din manualele referitoare la accesorii.
Sigurana persoanelor
Sigurana persoanelor se asigur numai pentru un singur operator. Personalul care exploateaz utilajul trebuie ntotdeauna s se asigure c prin operarea acestuia nu expune la
pericole alte persoane.
Calicarea personalului
Exploatarea, reglarea i ntreinerea utilajului se asigur numai de ctre personal cu calicare corespunztoare.

Starea tehnic a utilajului


Funcionarea n siguran
Dac se consider c nu se mai asigur o funcionare a utilajului n siguran, trebuie s se
opreasc utilajul i s se asigure mpotriva conectrii accidentale.
Dispozitive de siguran
Se permite exploatarea utilajului numai cu dispozitivele de siguran n stare de funcionare.
Dispozitivele de siguran, n special capacul de protecie, nu trebuie ndeprtate, untate
sau manipulate n orice stare.
ntreinere
ntreinerea utilajului trebuie s se efectueze la intervalele de timp specicate.
Dac ntreinerea nu se realizeaz periodic, atunci pot s apar defeciuni ale utilajului.
Piese de schimb
Piesele defecte trebuie nlocuite numai cu piese de schimb originale. Avei posibilitatea s
obinei piese de schimb originale de la Komax.
Modicri constructive
De regul, nu se permit modicri de natur constructiv ale utilajului. Dac modicrile
sunt necesare, atunci efectuarea acestora se permite numai cu acordul Komax.
Modicri referitoare la software
Se interzice orice tip de modicare a software-ului.

V svetlenie pok nov


NEBEZPEENSTVO
Oznauje nebezpeenstvo s vysokm rizikom.
Ak mu nepreddete, me ma za nsledok smr alebo najaie razy.

UPOZORNENIE
Oznauje nebezpeenstvo so strednm rizikom.
Ak mu nepreddete, me ma za nsledok raz.
POZOR
Oznauje nebezpeenstvo s nzkym rizikom.
Ak mu nepreddete, me ma za nsledok raz.

INFORMCIA
Oznauje tipy na pouvanie a in uiton informcie.
Nie je to slovo signalizujce nebezpeenstv.

alej v texte sa bud pouva nasledujce symboly pre pecick nebezpeenstv stroja:

Nebezpeenstvo spsoben
elektrickm prdom

Nebezpeenstvo poplenia na
horcich povrchoch

Nebezpeenstvo vtiahnutia prsta


alebo ruky

Nebezpeenstvo spsoben
laserom

Nebezpeenstvo pomliadenia
prstov alebo rk

Nebezpeenstvo poranenia o
kblom a holm vodiom

Nebezpeenstvo porezania prstu


alebo ruky

Nebezpeenstvo od
odstrekujceho cnu

Nebezpeenstvo ESD
(elektrostatickho vboja)

Nebezpeenstvo vbuchu

Slovensk

Bezpenos

Slovensk

Veobecn bezpenostn pokyny


Nvod na obsluhu
Nvod na obsluhu je sasou stroja. Pred zaatm prce na stroji si nvod na obsluhu
muste najprv pretudova a porozumie mu. Repektujte predovetkm bezpenostn a
varovn pokyny.
Nvody na prsluenstvo
Spolu s bezpenostnmi pokynmi tohto nvodu na obsluhu repektujte aj bezpenostn
pokyny nvodov dodvanch s prsluenstvom.
Osobn bezpenos
Osobn bezpenos je zaruen len pre jednho pracovnka obsluhy. Osoby, ktor na stroji
pracuj, sa vdy musia presvedi, e svojim ponanm neohrozuj iadne osoby.
Kvalikcia personlu
Stroj mu obsluhova, nastavova a udriava iba osoby s potrebnou kvalikciou.

Technick stav stroja


Prevdzka bez nebezpeenstva
Ak mono predpoklada, e prevdzku stroja bez vzniku nebezpeenstva nie je mon
naalej zarui, stroj sa mus vypn a zaisti proti nhodnmu zapnutiu.
Bezpenostn zariadenia
Stroj sa me uvdza do prevdzky iba s fungujcimi bezpenostnmi zariadeniami.
Bezpenostn zariadenia, predovetkm ochrann kryt, sa nesm demontova ani vyradi z
innosti. Nesmie sa s nimi akmkovek spsobom manipulova.
drba
drba stroja sa mus vykonva v tu uvedench asovch intervaloch.
Ak drba stroja nie je pravideln, me to spsobi pokodenie stroja.
Nhradn diely
Chybn diely mono nahradi iba originlnymi nhradnmi dielmi. Originlne nhradn diely
si mono objedna u spolonosti Komax.
Prestavby a pravy
Prestavby stroja s zo zsady zakzan. Ak by boli potrebn akkovek prestavby alebo
pravy, mu sa vykona iba po dohode so spolonosou Komax.
pravy softvru
Akkovek prava softvru je zakzan.

TEHLKE
Yksek risk tayan bir tehlikeye iaret eder.
nlenmedikleri takdirde sonucunda lm ve ar yaralanma meydana gelir.

UYARI
Orta derecede risk tayan bir tehlikeye iaret eder.
nlenmedikleri takdirde sonucunda ar yaralanma meydana gelir.
DKKAT
Dk derecede risk tayan bir tehlikeye iaret eder.
nlenmedikleri takdirde sonucunda maddi hasarlar meydana gelebilir.

UYARI
Kullanc nerilerine ve dier yararl bilgilere iaret eder.
Tehlike sinyali iin kullanlan bir kelime deildir.

Bunlarn dnda aadaki semboller makinenin spesik tehlikeleri iin kullanlr:

Akmn yol at tehlike

Scak yyezlerin neden olduu


yanma tehlikesi

Parmaklarn ve ellerin kaptrlma


tehlikesi

Lazerin neden olduu tehlike

Parmaklarn ve ellerin sktrlma


tehlikesi

Kablolarn ve kordonlarn yol


at gz yaralanmalar tehlikesi

Parmaklarn ve ellerin kesilme


tehlikesi

Kalay enjektrlerinin neden


olduu tehlike

ESD (Elektrostatik Dearj)


sonucunda meydana gelen
tehlike

Patlamann neden olduu tehlike

Trk e

Uyarlara likin Aklamalar

Trk e

Genel Gvenlik Uyarlar


Kullanm Talimat
Kullanm talimat makinenin bir parasdr. Makineyle almaya balamadan nce kullanm
talimatnn okunmas ve anlalmas gerekir. zellikle de gvenlik uyarlarn ve nerilerini
dikkate alnz.
Aksesuar Talimat
Bu kullanm talimatndaki gvenlik uyarlarnn yannda aksesuarlarn talimatlarndaki
gvenlik uyarlarn da dikkate alnz.
Kii Gvenlii
Kii gvenlii sadece tek bir kullanc iin salanmtr. Makine banda alan kiilerin,
almalarndan dolay insanlar tehliye sokmadklarndan emin olmak zorundadrlar.
Personel Vasar
Makine sadece vas kiiler tarafndan kullanlabilir, ayarlanabilir ve bakm yaplabilir.

Makinenin Teknik Durumu


Tehlikesiz Kullanm
Eer makinenin artk tehlikesiz kullanm mmkn grnmyorsa, makinenin kapatlmas ve
kazayla almasna kar gvenliinin salanmas gerekir.
Gvenlik Tertibatlar
Makine sadece fonksiyonunu yerine getirebilen gvenlik tertibatlar ile kullanlabilir. Gvenlik
tertibatlar, zellikle de koruyucu kapak kartlamaz, birletirilemez ya da herhangi bir
biimde deitirilemez.
Bakm
Makinenin belirtilen periyotlarda bakmnn yaplmas gerekir. Eer makinenin bakm dzenli
olarak yaplmazsa sonucunda makine hasarlar meydana gelebilir.
Yedek Paralar
Hasarl paralar sadece orijinal yedekleri ile deitirilebilir. Orijinal yedek paralar Komaxtan
temin edilebilir.
Modikasyon
Makine znde modiye edilemez. Eer modikasyonlar gerekli olacak olursa, bunlar
sadece Komax ile grlerek gerekletirilebilir.
Software Modikasyonlar
Softwarede her trl modikasyonun yaplmas yasaktr.

Razlaga simbolov
EVAR OST
Oznauje nevarnost z visoko stopnjo tveganja.
e se je ne izognete, so njena posledica smrt ali teke pokodbe.

OPO ORILO
Oznauje nevarnost s srednjo stopnjo tveganja.
e se je ne izognete, so njena posledica lahko pokodbe.
PO OR
Oznauje nevarnost z nizko stopnjo tveganja.
e se je ne izognete, so njena posledica lahko pokodbe predmetov.

APOTEK
Oznauje napotke za uporabnika in druge uporabne informacije.
Ni signalna beseda za nevarnost.

V nadaljevanju se za specine nevarnosti strojev uporabljajo naslednji simboli:

Nevarnost toka

Nevarnost opeklin zaradi vroih


povrin

Nevarnost vpotega prstov ali rok

Nevarnost laserske svetlobe

Nevarnost zmekanja prstov ali


rok

Nevarnost pokodb oi zaradi


kablov in jeklenih vrvi

Nevarnost vreza prstov ali rok

Nevarnost brizganja kositra

Nevarnost elektrostatine
razelektritve

Nevarnost eksplozije

Slovenina

Varnost

Slovenina

Sploni varnostni napotki


Navodila za uporabo

Navodila za dopolnilno opremo

Varnost oseb
bljajo, se morajo vedno prepriati, da s svojim ravnanjem ne ogroajo drugih oseb.
Kvalikacija oseb
Stroj lahko upravljajo, nastavljajo in vzdrujejo samo osebe, ki imajo ustrezno kvalikacijo.

Tehnino stanje stroja


Nenevarno delovanje
e domnevate, da varno delovanje stroja ni ve zagotovljeno, morate stroj izklopiti in ga

Varnostna oprema
Stroj lahko obratuje le z delujoimi varnostnimi napravami.
Varnostnih naprav, e posebej zaitnega pokrova, ne smete odstranjevati, premostiti ali na
kakren koli nain z njimi manipulirati.
Vzdrevanje
Stroj morate vzdrevati glede na navedene asovne intervale.
e stroja ne vzdrujete redno, so posledica nevzdrevanja lahko okvare stroja.
Nadomestni deli
-

Predelave
Stroja v osnovi ne smete predelati. e je predelava nujna, se jo lahko izvede le po posvetu

Modikacije programske opreme


Prepovedana je vsakrna modikacija programske opreme.

Spjega

joni tan noti


PERIKLU
Jindika periklu li jinvolvi riskju goli.
Jekk ma tevitax jirriulta fmewt jew ferriment serju.

T ISSIJA
Jindika periklu li jinvolvi riskju medju.
Jekk ma tevitax jirriulta riei.
KA TELA
Jindika periklu li jinvolvi riskju baxx.
Jekk ma tevitax jista jirriulta sara lil proprjet.

N TA
Jindika gajnuniet u informazzjoni utli ora.
Mhux kelma li turi li hemm xi sarat.

Is-simboli li ejjin jintuaw biex jindikaw perikli speii attribwiti mal-magna:

Perikl minn okk elettrik

Periklu ta ruq minn superji


san

Periklu li s-swaba jew l-idejn


jinibdu l ewwa

Perikl minn laser

Periklu li s-swaba jew l-idejn


jitgaffu

Riskju ta sara lil gajnejn minn


kejbils u wajers mibrumin

Periklu li s-swaba jew l-idejn


jistgu jinqatgu

Periklu minn qtug tal-landa

Perikl minn skargar ES


skargar elettrostatik

Periklu minn splujoni

Malti

rt

Malti

Struzzjonijiet ta sigurt enerali


Struzzjonijiet ta taddim
L-istruzzjonijiet ta taddim huma parti integrali tal-magna. Gandek taqra l-istruzzjonijiet ta
taddim u tkun gur li tifhimhom qabel ma tibda tadem fuq il-magna. Oqgod attent bmod
spejali gall-istruzzjonijiet dwar is-sigurt u ta twissija.
Struzzjonijiet gal aessorji
Barra milli gandek timxi mal-istruzzjonijiet dwar is-sigurt fdawn l-istruzzjonijiet ta taddim,
kun gur li ssegwi l-istruzzjonijiet dwar is-sigurt gall-moduli u l-aessorji.
Sigurt ta persuni
Is-sigurt personali hija garantita biss gal operatur wieed tal-magna. Kull persuna li
jadem fuq il-magna gandha tkun gur li ma ddaalx xi kmand li jpoi lil orajn fperiklu.
Kwalii tal-personel
Individwi li gandhom l-kwalii xierqa biss gandhom jitallew joperaw, jimmontaw u
jagmlu manutenzjonijiet fuq il-magna.

K ndizzjoni teknika tal magna


Taddim sikur
Jekk gandek rauni biex taseb li l-magna ma tistax titaddem bmod sikur, mgandekx
talliha tadem u gandek tigura li ma tistax tinxtegel mingajr sieb.
Tagmir ta sigurt
Il-magna gandha titaddem btagmir tas-sigurt li jkun qed jadem sew.
Mhux permess li tnei jew tibbrija t-tagmir tas-sigurt jew tbagbashom bxi mod.
Man tenzjoni
Il-magna gandha tii servisjata -intervalli ta mien indikat.
sara lil magna tista sse jekk il-magna ma tiix servissjata regolarment.
Spare parts
Partijiet difettui gandhom jii mibdula bi spare parts oriinali. Dawn l-ispare parts oriinali
huma disponibbli biex jinxtraw mgand Komax.
Modikazzjonijiet
Bmod enerali, mhux permess li l-magna tii modikata. Jekk modikazzjonijiet huma
metiea, ma tistax taqbad tagmilhom mingajr ma tikkonsulta qabel ma Komax.
Modikazzjonijiet tas-softwer
Huwa pprojbit li timmodika s-softwer bxi mod

.
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. ,
.

,
, .




. .

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- - .

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. Komax.

. Komax.

.

2. Safety
2.1 Explanation of notes ..........................................................................................................3
2.2 Safety notes .......................................................................................................................3
2.2.1 Personal protection ...............................................................................................3
2.2.2 Machine protection ...............................................................................................5
2.2.3 General safety notes ............................................................................................5
2.3 Safety features ...................................................................................................................6
2.4 The RCS safety system ......................................................................................................8

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Safety

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22

Safety

OI Gamma 333 PC / Gamma 333 PC B


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2. Safety
2.1 Explanation of notes
The note boxes in these instructions are marked with three symbols you must understand and
obey. The symbols have the following meanings:

This symbol marks a safety note regarding all work procedures posing a hazard to
you or other persons. Heed these warnings and exercise particular caution in these
situations. Also pass these warnings on to other users.

This symbol is next to all work procedures where special care must be taken to
prevent machine damage. Pass these safety notes on to other machine users.

This symbol signals useful tips and draws your attention to correct procedures and
behavior. Heed these remarks and you will save yourself a lot of time and unnecessary headaches.
Komax AG accepts no liability whatsoever in the event of non-compliance with instructions
marked on the machine or in these notes.

2.2 Safety notes


2.2.1 Personal protection

Danger: High voltage !


Touching live parts is dangerous!
Safety devices may be removed only when the machine is stopped and
the power to it is shut off. Only duly trained persons are allowed to remove housings and covers in particular.

Danger: Wire draw-in !


There is a wire draw-in point where the wire is fed into the machine.
Take care that there are not wire loops that people can trip on or become otherwise tangled up in.

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Safety

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Danger: Moving parts !


Anyone who gets close to the moving parts of the machine could get
pinched. All parts of the machine must be switched off and secured
against unauthorized switch-on before any installation, maintenance and
repair work is carried out.

Danger of injury !
The blades can cause cuts even when not in operation. Prior to working
on the cutting head or blades, ALWAYS turn the main power switch on
the machine to OFF.

Potential sources of danger


Processing stations

Cutting head

Wire draw-in
Control cabinet
Wire drive

Feed belt
and wire deposit tray

Swivel and
pull-off units
g 2.01 Potential sources of danger

24

Safety

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Safety devices
Before starting the machine, ALWAYS check to see that all safety devices, especially covers, are properly attached and functioning.
Safety requirements
The safety requirements are not met unless the safety devices are functioning properly. Moreover, the machine must be operated according to the scope of application described in Chapter 1 and to the technical specications. Make sure it is not
used for any purpose other than the one stipulated.

2.2.2 Machine protection


Training
Thorough training of operating staff is a crucial part of preventing machine damage. Non-compliance with the operating instructions can result in the destruction
of parts of the system. Aside from reading the software instructions, all staff must
read these operating instructions as part of their training.

2.2.3 General safety notes


Authorized personnel
Only authorized and trained personnel familiar with the safety features of the machine are allowed to operate, maintain and repair it.

Danger to other persons


Machine safety is guaranteed only for operators. Machine operators must be very
careful not to enter a command that puts others in danger.

Safe operations not guaranteed


If you have reason to believe that the machine can no longer be operated safely,
disconnect it and secure it from being unintentionally switched back on.

Reading these instructions


Read through these instructions carefully before operating the machine for the rst
time.
General rules of safety and accident prevention
Aside from the advice in these instructions, always observe general rules of safety
and accident prevention.

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Safety

25

2.3 Safety features


The Komax Gamma 333 PC / 333 PC B is built in compliance with the latest safety engineering
standards and has the following safety and protection devices as standard features:

g 2.02 Safety devices

Main power switch for machine


The main switch cuts off the electricity supply for the entire system.

Emergency stop switch


Pressing the emergency stop switches on the front control panel and at wire drawin stops all machine movements and cuts off the power supply to the processing
stations.
Pressing an emergency stop switch shuts off the main air valve.

Approval switch
When entering a command in setup mode that triggers a machine movement, you
must press the approval switch at the same time or the command will not be executed.

Main stopcock for pneumatic system


The pneumatic stopcock interrupts the air feed to the entire pneumatic system.

26

Safety

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Version 4

Safety cover completely closed


The cover which opens upward and the separate safety cover for the Wire drive are each
monitored by two circuit breakers.
Opening a safety cover in production mode
causes the machine to stop immediately and
the on-load voltage to be cut off.
During machine setup, the operating voltage
must be on so that adjustments can be made
inside the machine. However, when entering a
command in setup mode that triggers a machine movement, you must press the approval
switch at the same time. The approval switch is
deactivated in production mode.

g 2.03 Safety covers

When closing the machine cover, make sure no one can reach into the machine
chamber; otherwise, he or she could get pinched.

Accessible operating elements


All operating elements are clearly labeled and readily accessible.
Quiet operation
The noise level without presses is less than 75 dBA.

The machine may be hazardous if operated improperly by untrained persons.

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Safety

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2.4 The RCS safety system


Energy feed

Power
switch-on A
Approval A

Logic safety circuit A


Feedback A

Feedback B
Approval B

Logic safety circuit B


Power
switch-on B

Hazardous components

g 2.04 RCS safety system

The RCS safety system (Redundant Control System) operates with two separate channels. Each
safety cover is tted with two switches. Both channels have to give their approval before certain
actions are carried out, e.g. before a crimp module is triggered.

This machine must NEVER be used with the safety covers bridged.

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Safety

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3. Transport
When transporting the machine, please follow the instructions below and heed
general rules of safety and accident prevention.

The Komax Gamma 333 PC / 333 PC B is prepared for shipping as a single unit.
Dimensions of the packaging (WxHxD): 274 x 184 x 201cm
Weight incl. packaging:
approx. 1130kg (machine alone: approx. 840kg)

Pay close attention to the handling symbols on the packaging:

Up

Keep dry

Keep cool

Delicate
electronic
appliance
Do not load
cover

Delicate
electronic
appliance

Fragile

Weight is not
in balance

Weight is not
in balance
Weight is not
in balance

Corrosion protection
To protect the machine from corrosion, a special mat containing inhibitors is placed in the pakkaging. When the inhibitors vaporize, they protect the metal surfaces. Please note:
Prevent this protective atmosphere from escaping.
Reseal any tears or damage to packaging immediately.
Do not open the package until you use the machine.
For control purposes, the outer covering can be opened briey, but it should be resealed
immediately thereafter. The protective atmosphere is replenished automatically after the pakkaging is sealed.

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Transport

31

Please note the following points when transporting the system:


Transport the system with great care to prevent damage from excessive force or careless loading and unloading.
The delivery documents are attached in a highly visible spot on the outside of the cardboard
packaging in a plastic envelope.
Immediately check the machine for transport damage when it arrives. Report any problems or
shortcomings to us immediately.

32

Transport

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4. Items included in the delivery / incoming inspection

Check the items delivered against the delivery documents to be sure everything
was sent that was supposed to have been.

Please report any missing or defective parts immediately to Komax AG or the nearest Komax dealer.

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Version 4

Items included in the delivery

41

42

Items included in the delivery

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5. Installation
5.1 Installation site ...................................................................................................................3
5.2 Installation ..........................................................................................................................4

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Installation

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52

Installation

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5. Installation
5.1 Installation site
Prior to installing your Komax Gamma 333 PC / 333 PC B, check the following points:
Floor:
Even, solid surface free of vibration
Does the oor have sufcient loading capacity?
Machine weighs approx. 840 kg; with two mci 711 crimp presses, approx. 1030kg
Avoid rooms with high humidity!
Ambient temperature should be neither too high nor too low
Power connection
3x208480V, N, PE; 50 60Hz 6kVA
54mm; 25A fuse

Attention: Heed the connected load!

The machine may be operated only if it has a connected ground conductor.


Compressed air supply
46bar
Space required for basic machine?

Gamma 333 PC 3137 mm (123.5 inch)


Gamma 333 PC-B 3320 mm (130.7 inch)

g 5.01 Space required by Gamma 333 PC / 333 PC B basic machine

Figure in extra space to accommodate wire feed systems, wire deposit system,
pre-processing stations, etc.

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Installation

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5.2 Installation
The machine must be installed and put into operation by an experienced technician.

Observe general rules of safety and accident prevention during installation.

The center of gravity is not in the middle of the machine.

Proceed as follows to install the machine:


Take the machine out of its packaging.
Lay the boxes and unattached machine
parts off to the side.
Make sure the surface on which the machine will be set up is clean. Use a water level
to level the machine.
Adjust the feet of the machine (5 in all) as
required, taking care not to unscrew them
too far.
g 5.02 Leveling the machine

The weight must be distributed equally among each of the ve feet. The less you
unscrew the feet, the more stable the machine will be.

Make sure to tighten the lock nuts on the threaded rods of the feet.

This will ensure that the additional vibrations of the machine do not cause the stepping motors to
malfunction, e.g., to fall out of step.

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Installation

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When laying the compressed air hoses, be careful not to create any kinks in them.
In hazardous areas around moving parts, the hoses must be secured to keep them
from being abraded and pinched. Select hose lengths that do not impair the movements of the components involved.

With the air hose included in the delivery,


hook up the maintenance unit to the compressed air supply (arrow).

g 5.03 Maintenance unit

Power to the machine must be supplied via a power cable with a cross section of at least
54mm2 (25 A fuse on supply side).
Be careful never to switch around the phase and PEN conductors when connecting
the power!

g 5.04 Main power supply X01

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Installation

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Ensure that no wires are pinched in the control cabinet.

Take the monitor, PC, mouse and keyboard


out of their boxes.
Place the PC on the mount provided for it
on the door of the control cabinet and x
into place with the adjustable fastening
brackets.

g 5.05 PC mounted on door of control cabinet

Place the monitor on the control cabinet


and run the two monitor cables through the
opening in the back of the control cabinet.
Connect the cable to the PC.

g 5.06 Control cabinet with monitor, keyboard


and mouse

The PC connections and the terminal assignments are covered in two separate
documents (document Komax PC connection diagram, doc Komax PC hardware
overview). The documents are included in the delivery in a separate package. The
documentations contain the connection diagrams and indicate the assignments of
the PC ports.

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Installation

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Version 4

Mounting the conveyor belt extension


Remove bafe plate 1 from the end of the
basic conveyor belt module and reinstall it
at the end of the extension module.

To ensure better accessibility, remove the


cover plate from the extension module.
Detach the wire ramp from the end of the
extension module and screw ramp 2 to the
end of the basic module.

g 5.07 Bafe plate and wire ramp

Lower the rollers on the extension frame to the position they were in before and move the conveyor belt extension up to the basic module. Align the extension module with the basic module, making sure it is ush in the vertical and the horizontal.
Make sure the ramp does not touch any part of the belt.

Screw the conveyor belts with the two connectors provided and attach the tipping trays as well
as the sections of the deposit trays for the basic and extension modules.

3
4

g 5.08 Conveyor belt for extension module

3 Attachment of tipping trays


4 Attachment of deposit tray section
Now remount the cover plate on the extension module.
Compressed air is supplied at connection 5 (g 5.08).

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Installation

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Power is supplied to the rst extension directly from the control cabinet (connection X07).
Power is supplied to the second extension and any further extensions via the electrical box of
the previous extension.
This completes the installation of the Komax Gamma 333 PC / 333 PC B itself. The installation of the processing stations and the accessories is described in the set of instructions for
each respective device.
The operating and software instructions and the spare parts catalog must be stored in a suitable spot. This also applies to the electrical and mechanical accessories. File away the diagrams
for the compressed air system and the electrical system as well as the I/O list in the operating
instructions under Chapter 11 and Chapter 12.
Dispose of the packaging and pallet in an ecological manner when you nish.

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Installation

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6. Machine overview and functions


6.1 Basic machine ....................................................................................................................3
6.1.1 Straightening unit ..................................................................................................5
6.1.2 Transport unit ........................................................................................................5
6.1.2.1 Gamma 333 PC .......................................................................................5
6.1.2.2 Gamma 333 PC-B ...................................................................................5
6.1.2.3 Encoder ...................................................................................................6
6.1.2 Swivel and pull-off unit on side 1 ..........................................................................6
6.1.3 Cutting head .........................................................................................................8
6.1.4 Swivel and pull-off unit on side 2 ..........................................................................9
6.1.4.1 Good/bad sorting...................................................................................10
6.1.5 Hold-up device ...................................................................................................10
6.1.6 Wire deposit system and conveyor belt .............................................................11
6.1.7 Maintenance unit ................................................................................................11
6.2 Control system .................................................................................................................12
6.2.1 Control cabinet ...................................................................................................12
6.3 Front control panel ..........................................................................................................15
6.4 Sensors ............................................................................................................................16

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Machine overview
and functions

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62

Machine overview
and functions

OI Gamma 333 PC / Gamma 333 PC B


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6. Machine overview and functions


6.1 Basic machine
7

14 15

16

17
18

6
19

10

11 12
1

13

23

22

21

20

5
g 6.01 Machine overview of Gamma 333 PC / 333 PC B basic machine

Straightening unit
Straightens the wire

11

Connector feed side 2, back feed


Feeds connectors from reels

Wire drive
Wire feed, length measurement and wire-end monitoring

12

Processing station side 2


Crimping module conguration

13

Swivel and pull-off unit side 1


Swivels and positions wire on side 1 at the rst processing station

Connector feed side 2, side feed


Feeds connectors from reels

14

Power connection

15

Control cabinet
Contains the power supply and the control
system (PC)

Cutting head
Cuts the wire to the desired length or makes a cut
in the insulation in preparation for stripping; cuts off
bad wire

16

Monitor

Swivel and pull-off unit side 2


Swivels and positions wire on side 2 at the second
processing station

17

Operators station
Machine controls and station for the machine
operator

Machine side 1
Processing of the lead end of the wire

18

Keyboard

Connector feed side 1, side feed


Feeds connectors from reels

19

Mouse

20

Conveyor belt with wire deposit system and


batch separation
Picks up the processed wires and carries them
away them from the machine

21

Machine operator at work

22

Compressed air supply

Processing station, side 1


Crimping module conguration

Connector feed side 1, back feed


Feeds connectors from reels

10

Machine side 2
Processing of the trailing end of the wire

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23 Safety cover

Machine overview
and functions

63

10 11 12 13 14 15 16 17 18
19
20

A
21

22
23

Detail A

Gamma 333 PC B

24
Gamma 333 PC

25

3 5 6

g 6.02 Front view of Gamma 333 PC / 333 PC B

1
2
3
4
5
6
7
8
9
10
11
12

64

Wire advance button


Approval button
Manometer for applied pressure
Control system for applied pressure
Emergency off switch
Button for opening the belt drive
Pressure regulation valve for wire gripper on
side 1
Manometer for pressure regulation valve on
side 1
Manometer for pressure regulation valve on
side 2
Pressure regulation valve for wire gripper on
side 2
Approval button
Start button
(to switch on load voltage)

Machine overview
and functions

13 Stop button
(to switch off load voltage)
14 Monitor
15 Keyboard
16 Start button
17 Stop button
18 Emergency off switch
19 Opening the safety cover
20 Closing the safety cover
21 Mouse
22 Main switch
23 Control cabinet
24 Contact rollers
25 Waste container (at back)

OI Gamma 333 PC / Gamma 333 PC B


Version 4

6.1.1 Straightening unit


1

1 Protection pane
2 Perforated disk
3 Straightening device with quick-action release
4 Installation site for splice detection
(optional)
5 Toolbox
Please consult Chapter 7.5.2 for an explanation
on how to set the straightening units correctly.

5
g 6.03 Straightening unit

6.1.2 Transport unit


6.1.2.1 Gamma 333 PC
1
2
3
4
5
6
7
8

Wire advance button


Approval button
Manometer for applied pressure
Control system for applied pressure in roller
drive
Emergency off switch
Transport rollers
Wire guide
Encoder

5
g 6.04 Roller drive

6.1.2.2 Gamma 333 PC-B


1
2
3
4
5
6
7
8
9
10
11
12

Control system for applied pressure


Manometer for applied pressure
Emergency off switch
Button for opening the belt drive
Wire advance button
Approval button
Wire inlet
Wire drive driven by toothed belt
Pressure cylinder
Encoder pressure wheel
Encoder for length measurement
Wire outlet

OI Gamma 333 PC / Gamma 333 PC B


Version 4

10
11
12

g 6.05 Belt-driven wire drive

Machine overview
and functions

65

6.1.2.3 Encoder
The transport unit has a brushless AC servomotor with length measurement and slip
control.
The ASS automatic slip control compares the
two values of the motor encoder and the length
measurement encoder. The roller drive stops if
the maximum value that can be set in the parameters is exceeded.

g 6.06 ASS automatic slip control

6.1.2 Swivel and pull-off unit on side 1


1 Guide tube
2 Swivel unit
3 Wire guide tube, short/long

The swivel and pull-off unit pulls off the insulation after it has been cut into and then approaches the processing stations.
The gripper on the swivel and pull-off unit on
side 1 is pressed down to the crimp tool during
crimping.

Fig 6.07 Swivel and pull-off unit

66

Machine overview
and functions

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Operating cycle of the swivel and pull-off unit on side 1

After the wire is cut to length and a cut is made


in the insulation, the pull-off unit withdraws,
stripping the wire as it does so.

Side 2
Side 1

The unit then swivels to the processing station.

The pull-off unit moves forward, so the wire can


be fed to processing station 1 for processing.

After processing, the pull-off unit moves the


wire back to the wayback position.

The unit swivels back to the cutting head.

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Machine overview
and functions

67

6.1.3 Cutting head


1
2
3
4
5

Cutting blade, bottom


V stripping blade side 1, top
V stripping blade side 1, bottom
Blow-off air connection
Bad-wire cutting blade

2
3
g 6.05 Cutting head with top and bottom blade block

Operating cycle of cutting head

The cutting blade cuts the


wire.

The pull-off units on side 1


and 2 move the two wire ends
to the stripping position.

The V stripping blades cut the


insulation down to the stranded
conductor.

The V stripping blades withdraw by a pre-programmed


distance so the stranded
conductors are not damaged
during pull-off.

The pull-off units on side 1


and 2 withdraw, pulling off
the insulation. A blow-off unit
clears away any stripping
scraps.

The entire cutting head opens


up, ending the stripping cycle.

68

Machine overview
and functions

OI Gamma 333 PC / Gamma 333 PC B


Version 4

6.1.4 Swivel and pull-off unit on side 2


1
2
3
4

Wire gripper
Pull-off unit
Swivel unit
Drive belt for the swivel unit

g 6.06 Swivel and pull-off unit on side 2

Operating cycle of swivel and pull-off unit on side 2

Side 1

Side 2

The gripper on the pull-off unit


clamps the wire rmly and
pulls it back in preparation for
stripping.

The pull-off unit moves back


to the approach position and
the entire unit swivels to the
processing station.

After processing, the pull-off


unit moves back to the wayback position.

The unit then swivels to the


deposit position, where the
gripper releases the wire,
ending processing on side 2.

OI Gamma 333 PC / Gamma 333 PC B


Version 4

The pull-off unit advances to


the processing position and the
wire is processed on station 2.

Machine overview
and functions

69

6.1.4.1 Good/bad sorting


If the crimp force sensor detects bad processing on wire side 1, the process is stopped, the wire
end is cut off and removed by conveyor belt.
If bad processing is detected on wire side 2, the bad wire end is cut off at the cutting blade (Pos.
1 / g. 6.07) and put in a waste container. The wire is rendered unusable by the cut but is put with
the batch in the wire tray.

Gamma 333 PC

Gamma 333 PC B

6.07 Flow diagram for good/bad sorting

6.1.5 Hold-up device


The hold-up device ensures that the gripper on
side 2 can take over the wire neatly.

g 6.08 Hold-up device

6 10

Machine overview
and functions

OI Gamma 333 PC / Gamma 333 PC B


Version 4

6.1.6 Wire deposit system and conveyor belt


The conveyor belt efciently removes long
wires and disposes of bad wires.

g 6.09 Machine frame with wire deposit system

6.1.7 Maintenance unit


1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Compressed air supply


Stopcock
Manometer for operating pressure
Pressure control for operating pressure
(56 bar)
Water trap, lter
Oiler
Outlet for unoiled air
Setting screw for drip amount
Waste air return
Waste air lter
Drain plug for waste air lter
Main valve
Outlet for oiled air after main valve
Pressure regulator
Outlet for oiled air before main valve

12

15

13
2
1

14

11 10 9 6

g 6.10 Maintenance unit

The blow-off air connection on the blade block is supplied with unoiled compressed air, so the stripped wire ends are not soiled by oil.

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Machine overview
and functions

6 11

6.2 Control system


6.2.1 Control cabinet
Before opening the control cabinet, always switch OFF machines main power
switch.

Open control cabinet

1
Basic layout of the control cabinet

Main switch (turn to OFF)

Rear view of the control cabinet

g 6.11 Overview of control cabinet

1 Main switch
S49
2 Switched-mode power supply 24DC G01
3 Transformer
T01

6 12

Machine overview
and functions

OI Gamma 333 PC / Gamma 333 PC B


Version 4

4
5
6
7
8
9
10
11

Piece counter
P20
RCS PCB (Redundant Control System) A04
BIO PCB (Basic Input Output)
A01
Relay strip
K00-K05
Terminal strip
X02
Stepping motor controller SMC 3003 A10
Output stages for stepping motors A11-A15
Electrolytic capacitor
C01

11

10

9
g 6.12 Large mounting plate

14

15

16

17

12 13 14 15 16 17 18 19 20
g 6.13 Small mounting plate with detailed view

12
13
14
15
16
17
18
19
20

Circuit breaker
F01
230 V switch
X04
Power supply to MCI 711
X05
Conveyor belt
X06
Belt extension
X07
Power supply to non-Komax module X08
Fire station
X09
Country voltage in-feed
X01
Mains lter
Z01

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Machine overview
and functions

6 13

21
22
23
24
25

MRS PCB A65


24VDC power feed
Fuse, 5AT
Connection for PCC card A
Connection for PCC card B

21

25
23

22
24

g 6.14 MRS PCB

6 14

Machine overview
and functions

OI Gamma 333 PC / Gamma 333 PC B


Version 4

6.3 Front control panel

7
g 6.15 Front control panel

1
2
3
4
5
6
7
8

Approval key
Start button for switching on the connected load
Stop button for switching off the connected load
Start button
Stop button
Emergency stop key
Switch for opening the safety cover
Switch for closing the safety cover

The exact functions and uses of the controls are described in the software instructions for this machine.

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Machine overview
and functions

6 15

6.4 Sensors
The movements of the Komax Gamma 333 PC / 333 PC B are monitored by various sensors.

Hybrid light barriers


BM1
BM2
BM3
BM4
BM5

Inductive sensors (Namur)

Cutting head (blade)


Pull-off side 2
Pull-off side 1
Swivel unit side 2
Swivel unit side 1

B10
B11
B12
B13
B14
B16

Lowering gripper side 1


Lowering gripper side 2
Gripper side 2
Hold-up device
Gripper side 1
Wire tray

g 6.16 BM1 sensor cutting head (blade)

6 16

g 6.17 BM2 sensor pull-off side 2

g 6.18 BM3 sensor pull-off side 1

Machine overview
and functions

OI Gamma 333 PC / Gamma 333 PC B


Version 4

B11

BM4
B12
g 6.19 BM4 sensor swiveling side 2
B11 Sensor lowering side 2
B12 Gripper side 2

g 6.20 BM5 sensor swivel unit side 1

g 6.21 B10 sensor lowering side 1

g 6.22 B13 sensor hold-up device

g 6.23 B14 sensor gripper side 1

g 6.24 B16 sensor wire tray

Be aware there is a special allocation of pins. Only the RJ45 from Komax can be
used as a communication cable; other cables can destroy transmitters and receivers.

NEVER plug in or unplug RJ45 cables when the connected load is on.

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Machine overview
and functions

6 17

6 18

Machine overview
and functions

OI Gamma 333 PC / Gamma 333 PC B


Version 4

7. Machine operation
7.1 Checks prior to startup ......................................................................................................3
7.2 Switching the machine ON and OFF .................................................................................4
7.3 Selecting the operating mode ..........................................................................................4
7.4 Safety cover ......................................................................................................................5
7.5 Preparing the machine for production ..............................................................................5
7.5.1 Knot detection .....................................................................................................5
7.5.2 Straightening unit ..................................................................................................5
7.5.3 Wire guide parts ....................................................................................................6
7.5.4 Wire draw-in ..........................................................................................................7
7.5.5 Pull-off unit on side 1 and side 2 ..........................................................................7
7.5.6 Crimping module ..................................................................................................8
7.6 Tool drawer ........................................................................................................................9

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Machine operation

71

72

Machine operation

OI Gamma 333 PC / Gamma 333 PC B


Version 4

7. Machine operation
7.1 Checks prior to startup
To be able to be operated safely and without being damaged, the machine must
be in proper running condition. Check your machine before each startup, taking
special note of the following points:
Electrical connections
Connecting cables

All cables must be correctly plugged in and not damaged, otherwise


replace them!

Compressed air unit


Manometer

Is the correct operating pressure of 56 bar set?

Maintenance unit

Level of pneumatic oil OK? (refer also to Chapter 9; Maintenance)

Compressed air elements


Hose

No visible damage; otherwise replace air hoses!

Connections

Check to be sure there are no leaks; repair/adjust if necessary.

Safety devices
Emergency stop switches
and cover switches

Turn on machine and check to see that these switches are functioning properly. When emergency stop switch is pressed down, the
load voltage must switch off and the pneumatic system must be
pressureless; the Stop key must remain unlit.
Opening the safety covers must trigger a machine stop!

If the safety devices on the Komax Gamma 333 PC / 333 PC B do not work properly, DO NOT operate the machine. DANGER!

DO NOT commence production until you have successfully carried out all of the
above checks. With a properly operating machine, you can avoid production downtime due to machine malfunctions.

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Machine operation

73

7.2 Switching the machine ON and OFF


Once you have carried out all the above checks and determined that the machine is in proper
running condition, you can switch it on:
Turn the red main switch on the control cabinet to ON.
This starts the PC in the control cabinet and loads the user interface.
Shortly thereafter, the log-in window appears on the screen so you can
enter your password. After successful log-in, the connection is established between the PC and the control unit. This also initiates the motor
controllers and the I/O cards.

Switch on the connected voltage with Power On on the control panel.


The loaded voltage cannot be switched on if the emergency stop switch
is pressed and serious machine problems exist.
For setup and production, the machine must be reset from the software,
i.e. the machine is put in a predened state by the software and all functions are checked. Any errors are displayed on the monitor screen. After a
successful reset, the machine is ready for setup or production.

g 7.01

power
on

g 7.02

Switching the machine off


To switch off the load voltage to the machine, press Power Off and then turn the red main switch
to OFF. No production data is deleted when the machine is switched off. It remains stored in the
PC databases.

7.3 Selecting the operating mode


The machine distinguishes between two operating modes, automatic mode for producing and
setup mode for setup.
The two modes differ as follows:
Automatic

Production is controlled in this operating mode. The production window appears on


the screen.
All safety covers must be closed before this operating mode can be run.

Setup

Production is set up in this operating mode. The setup window appears on the
screen.
The safety covers can remain open during setup, but the approval key function must
be taken into account.

You should proceed with special care in setup mode since the machine can execute movements with the safety covers open. Be especially careful that no one else is
working on or around the machine.
When the machine is switched on, the moving parts of the wire tray, the wire guide
gripper, the grippers on side 1 and side 2, and the hold-up device move into their
default positions, posing a PINCHING hazard!!

74

Machine operation

OI Gamma 333 PC / Gamma 333 PC B


Version 4

7.4 Safety cover


The safety cover is opened and closed using
keys on the front operators panel. Opening the
safety cover while the machine is in operation
always triggers an emergency stop. For further
details, read Chapter 2 of these instructions.

Opening the safety cover


Press key 1
Closing the safety cover
Switch on machine load voltage 2
Press close safety cover 3

g 7.03 Front control panel

7.5 Preparing the machine for production


Once you have decided which wire to process, you must make the following adjustments to the
machine to adapt it to this specic wire:

7.5.1 Knot detection


The perforated disk must be turned to the correct diameter.

g 7.04 Knot detection

7.5.2 Straightening unit


The setting shown is ideal for most types of wires. It is important that the wire is straightened
more at the inlet of the straightening station,
so that it merely rolls out straight over the last
straightening roller (x < y).

4
3

Adjustment:
The straightening-roller angle can be set with
screws 1 and 2.
Use eccentric thumb screw 3 to close the
straightening station and scaled dial 4 to set
the wire diameter.

2
g 7.05 Straightening unit

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Machine operation

75

7.5.3 Wire guide parts


Gamma 333 PC
Pull out the wire guide 1 and replace it.
You have two different diameters to choose
from ( 3mm and 6mm).

Detach the two knurled screws 2 and replace the guide tube 3.
You have two different diameters to choose
from ( 3mm and 6mm).

Pull back the collar and replace the guide


tube 4.
Make sure you use the guide tube with the
optimum diameter.

3
g 7.06 Wire guide parts for the Gamma 333 PC

Gamma 333 PC-B


Replace the clamping screw 1 and clamping
lock 2 and replace guide tube 3.
You have two different diameters to choose
from ( 3mm and 6mm).

Pull back the collar and replace the guide


tube 4.
Make sure to use the guide tube with the
optimum diameter.

g 7.07 Wire guide parts for the Gamma 333 PC-B

76

Machine operation

OI Gamma 333 PC / Gamma 333 PC B


Version 4

7.5.4 Wire draw-in


The Gamma 333 PC has basically the same wire draw-in procedure as the Gamma 333 PC-B.

Proceed as follows:
Switch on the machine and reset it.
Open both straightening stations.
Open the cover to the wire drive.
Manually insert the wire up to the transport
rollers or toothed belt.

Reclose the cover to the wire drive.


Push the wire advance button 1 to advance the
wire.
To ensure that the beginning of the wire is tidy,
you can carry out a zero cut.

g 7.08 Wire draw-in

7.5.5 Pull-off unit on side 1 and side 2


The gripper pressure on the pull-off units side
1 and side 2 is set using pressure regulating
valves 1 and 3. Select a pressure at which the
wire is held rmly by the grippers without being
squeezed (indented).
Manometers 2 and 4 indicate the clamping
pressure for each respective gripper.
1
2
3
4

Pressure regulating valve side 1


Manometer side 1
Pressure regulating valve side 2
Manometer side 2

g 7.09 Setting the gripper pressure for the pull-off unit


side 2

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Machine operation

77

7.5.6 Crimping module


The crimping modules have a quick-clamping
system for holding crimping tools. Before
installing the crimping tool, clean the mounting
surface, so the tool can rest rmly on it. Use
lever 1 to open and close the clamping system.
Crimping modules are mounted on continuously height-adjustable crimping module positioning units 2. The height is adjusted by turning
hexagonal screw 3. The bench top has two drilling patterns which can be used to adjust the
crimping module position rearwards to match
the swivel and pull-off units.

2
g 7.10 Crimp module on height-adjustable positioning unit

Adjustment range:
Height:

20mm

Depth:

2 positions

side 1
Side 2

Front position,
Rear position,

The scraps of connector paper strips can be


disposed of by having them drop down through
duct 4 into the waste container. The K 455 connector strip cutter is underneath the crimping
module.
The duct is attached to the bracket and can
be slid in the slotted holes to align it with the
crimping tool. To adapt the duct optimally to
the crimping tool, opening 5 must be further
adjusted manually.

standard position
standard position

5
4

g 7.11 Duct for disposal of strip scraps

78

Machine operation

OI Gamma 333 PC / Gamma 333 PC B


Version 4

7.6 The tool drawer


The tool drawer contains guide parts, tools, gages and other small parts.

The contents of the drawer for the Gamma 333 PC and the Gamma 333 PC B are
identical except for a few items.
The differences are clear from the spare parts catalog.

g 7.12 Tool drawer for the Gamma 333 PC

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Machine operation

79

7 10

Machine operation

OI Gamma 333 PC / Gamma 333 PC B


Version 4

9. Maintenance
9.1 Notes on maintenance .......................................................................................................3
9.2. Maintenance plan ..............................................................................................................4
9.2.1 Daily maintenance.................................................................................................4
9.2.2 Weekly maintenance .............................................................................................4
9.2.3 Monthly maintenance............................................................................................6
9.2.4 Maintenance every six months .............................................................................7
9.3 Explanation of maintenance procedures............................................................................9
9.3.1 Maintenance unit ..................................................................................................9
9.3.2 Cutting head .......................................................................................................10
9.3.3 Grippers on side 1 and side 2 .............................................................................10

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Maintenance

91

92

Maintenance

OI Gamma 333 PC / Gamma 333 PC B


Version 4

9. Maintenance
Before doing any maintenance and repairs, especially in the dangerous areas
around moving machine parts and live electrical components, ALWAYS turn off the
machine at the main switch and secure it against unauthorized switch-on.

The maintenance tasks must be performed regularly at the stipulated intervals to


ensure the operational readiness and long service life of the machine.

The maintenance intervals are geared for single-shift operations. In the event of
heavier use, the machine must be serviced more often!

Any shortcomings and defects arising during daily production must be remedied
immediately to ensure the safety of the machine and the personnel.

9.1 Notes on maintenance


Cleaning
Use only non-fraying, oil-saturated materials to clean the machine (no cleaning wool or the like).

DO NOT USE compressed air to clean. This will blow minuscule bits of insulation
into the guides, increasing wear and impairing accuracy. If you must use compressed air, remove the parts to be cleaned from the machine rst.
Any parts cleaned with solvents must be immediately relubricated or regreased afterwards.
These maintenance tasks apply to the Komax Gamma 333 PC basic machine only. For information on maintaining and cleaning customer-specic processing stations and accessories, check the
operating instructions for these devices.
Lubricants
In principle, you can use standard commercial types of bearing grease for all bearings. Use highpressure paste for points of contact subject to pressure.
Oils
Use a lubricating oil with a viscosity of SAE 25
for all moving parts.

Grease
The grease below is recommended for pull-off
guides, pinions, lubricating nipples and racks.

The following oil is recommended for the pneumatic maintenance unit:


Festo pneumatic oil OFSW-32

Klber Microlube GL 261

Other possible oils


ARAL Vitam GF 32
BP Energol HLP-HM 32
Esso Nuto H 32
Shell Hydrol DO32
Mobil DTE 24
Hydraulic uids complying with DIN51 524 Part
2 with a viscosity of 32mm2/s at 40C (HLP 32)

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Maintenance

93

9.2. Maintenance plan


9.2.1 Daily maintenance
Component

View

Activity

Entire machine

Remove insulation and wire remnants.


Check pneumatic, mechanical and electrical
machine parts for damage.

9.2.2 Weekly maintenance

Weekly maintenance is preceded by daily maintenance.

Component

View

Activity

Maintenance unit

Empty water separator.


Check pneumatic liquid.
Empty water oil separator.
Refer also to Chapter 9.3.

Guide parts

Check for wear and deposits.


Remove wire guides and clean with compressed air.

Transport rollers

Check for wear and deposits of insulation


materials.

(Gamma 333 PC)

Clean encoder wheel with soft copper brush.

94

Maintenance

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Wire drive (belt-driven)


(Gamma 333 PB B)

Check for wear and deposits of insulation


materials.
Check belt tension.
Clean encoder wheel with soft copper brush.

Straightening station

Check free movement of straightening rollers.


Clean straightening station with cloth lightly
soaked in oil.

Scrap container

Empty container.

Conveyor belt

Check lateral running distance.


Refer to Chapter 10.

Blade head

Check blade wear.


Clean blade with cloth saturated in oil.

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Maintenance

95

9.2.3 Monthly maintenance

Monthly maintenance is preceded by daily and weekly maintenance.

Component

View

Activity

Maintenance unit

Remove waste-air lter and clean it.


Clean sight glass when necessary.
Refer also to Chapter 9.3.

Swivel and pull-off unit


on side 1 and side 2

Rub down guides with cloth lightly soaked in


oil.
Lubricate grippers.
Also refer to Chapter 9.3.Also refer also to
Chapter 9.3.

Cutting head

Clean and oil all guides.


Grease rack and pinion.
Refer also to Chapter 9.3.

Wire guide grippers

Clean piston road and rub down with cloth


lightly soaked in oil.
Check free movement.

96

Maintenance

OI Gamma 333 PC / Gamma 333 PC B


Version 4

9.2.4 Maintenance every six months


Maintenance every six month is preceded by daily and weekly and monthly maintenance.

Component

View

Activity

Wire drive
(roller-driven)

Check tension of belt.

Wire drive (belt-driven)

Check tension of toothed belt.

Refer to Chapter 10.

Refer to Chapter 10.

Swivel and

Check tension of toothed belt.

pull-off unit on side 1

Refer to Chapter 10.

Swivel and

Check tension of toothed belt.

pull-off unit on side 2

Refer to Chapter 10.

Cutting head

Check tension of toothed belt.


Refer to Chapter 10.

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Maintenance

97

Control cabinet

Clean the inside of the cabinet.

Conveyor belt

Check belt tension.


Refer to Chapter 10

Safety cover

Clean and grease guides.

Guide parts and bearings

Check for damage, wear and corrosion.

Toothed belts

Check for wear and check setting.


Refer to Chapter 10.

98

Maintenance

OI Gamma 333 PC / Gamma 333 PC B


Version 4

9.3 Explanation of maintenance procedures


9.3.1 Maintenance unit
Emptying the water trap:
Press up valve 1 and drain the water under
pressure.

Emptying the waste air lter:


Loosen drain plug 2 slightly and let the
liquid drain out; then retighten the plug.
Cleaning the waste air lter:
Loosen the drain plug 2, detach shell 6 and
lter 7; clean lter 7 in gasoline and blow
out with compressed air.
To reassemble, reverse the order of the
above steps.
Setting the number of drops on oiler:
Use screw 3 to set the number of drops.
This procedure must be carried out while
the machine is running.
Rule of thumb: 12 drops over a period of 5
minutes.

7
1

6
2

5
g 9.16 Maintenance unit

The maintenance unit must be completely depressurized when the following tasks
are carried out.
This state is reached when compressed air line 4 is disconnected and the dial on the manometer
reads 0 bar.
Replenishing the oil in the oiler:
Remove sight glass 5.
Pour in oil to Max Oil Level.
Remount sight glass; locking lever must snap into place!
Replacing the waste air lter:
Unscrew drain plug 2.
Pull off plastic cover 6 and remove underlying nut and washer.
Replace lter 7.
Reposition washer and nut.
Mount plastic cover; tighten into place with drain plug.

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Maintenance

99

9.3.2 Cutting head


To perform the maintenance tasks on the cutting head correctly, you must rst remove the covers.

Grease rack and pinion (arrows).


Clean and oil linear guides 1.
Check cutting and form blades 2 for wear
and replace if necessary.
Use grease gun to inject grease into lubricating nipples 3.

1
3
2

g 9.17 Cutting head

9.3.3 Grippers on side 1 and side 2

To ensure an optimum distribution of grease everywhere, make sure the grippers


are completely closed before applying the grease gun.

Grippers on side 1:
1 Lubrication nipple, right
2 Lubrication nipple, left

3 Lubrication nipple, front

1
3
g 9.18 Lubrication nipples on grippers on side 1

9 10

Maintenance

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Grippers on side 2:
1 Lubrication nipple, right
2 Lubrication nipple, left

3 Lubrication nipple, front


You have to remove the plate 4 on left lubrication nipple 2 (2 screws) in order to apply the
grease gun to it.

4
3

g 9.19 Lubrication nipples on grippers on side 2

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Maintenance

9 11

9 12

Maintenance

OI Gamma 333 PC / Gamma 333 PC B


Version 4

10. Settings and adjustments


10.1 Blade blocks and blades ..................................................................................................3
10.1.1 Disassembling the blade blocks .........................................................................3
10.1.2 Assembling the blade blocks ..............................................................................3
10.1.3 Changing the blades ...........................................................................................4
10.2 Mechanical settings and adjustments..............................................................................5
10.2.1 Guide parts and bearings ...................................................................................5
10.2.2 Toothed belts ......................................................................................................6
10.2.2.1 Mounting a toothed belt ........................................................................7
10.2.2.1.1 Toothed belt for transport unit on Gamma 333 PC ............................7
10.2.2.1.2 Toothed belt for transport unit on Gamma 333 PC-B.........................8
10.2.2.1.3 Replacing the drive belt for the swivel head on side 1 and side 2 .....9
10.2.2.1.4 Replacing the drive belt for the cutting head....................................10
10.2.2.2 Operating problems associated with toothed belt drives ....................10
10.2.3 Setting the guide for the pull-off unit on side 2 ................................................11
10.2.3.1 Positioning the toothed rack (user side) ..............................................11
10.2.3.2 Positioning the counter guide (at the back) .........................................12
10.2.3.3 Final step and setting-check ..............................................................12
10.2.4 Calibrating the machine ....................................................................................14
10.2.4.1 Calibrating the axes (mechanical) ........................................................14
10.2.4.2 Calibrating the axes under TopWin ......................................................14
10.2.4.3 Calibration procedure .........................................................................15
10.2.5 Wire feed unit ....................................................................................................17
10.2.5.1 Gamma 333 PC ...................................................................................17
10.2.5.2 Gamma 333 PC-B ...............................................................................18
10.2.6 Lifting device ....................................................................................................18
10.2.7 Wire guide gripper ............................................................................................19
10.2.8 Conveyor belt ....................................................................................................20
10.2.9 mci 711 options ................................................................................................21
10.2.10 Safety cover ....................................................................................................21
10.3 Electrical settings and adjustments ...............................................................................22
10.3.1 Sensors .............................................................................................................22
10.3.1.1 Laying sensor cables ...........................................................................22
10.3.1.2 Inductive sensors .................................................................................25
10.3.1.3 Hybrid light barriers .............................................................................25
10.3.2 Electric fuses in control cabinet .......................................................................26
10.3.3 BIO PCB............................................................................................................27
10.3.4 Output stages of the stepping motors .............................................................28

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Settings and adjustments

10 1

10.4 Pneumatic settings and adjustments ............................................................................30


10.4.1 Operating pressure ..........................................................................................30
10.4.2 Throttle non-return valves .................................................................................30
10.5 Setup of processing stations .........................................................................................31
10.5.1 Crimp module setup .........................................................................................31
10.5.2 Setup of mci 761 seal module ..........................................................................32
10.5.3 Setting up non MCI modules ............................................................................33
10.5.4 MRS PCB ..........................................................................................................34

10 2

Settings and adjustments

OI Gamma 333 PC / Gamma 333 PC B


Version 4

10. Settings and adjustments


All setting and adjustment work must be performed with the machine turned off
and by duly authorized personnel only.

10.1 Blade blocks and blades


Before working on the blade blocks or blades, ALWAYS switch off the machine at
the main switch.

10.1.1 Disassembling the blade blocks


Disassembly procedure
Remove the waste container from the unit.
Lower the slideable part of the connection
piece for channeling scraps into the container by loosening the knurled thumb screw.
Move the two blade blocks completely apart
from each other.

Lower blade block


Unscrew threaded pin 1 to loosen and remove the lower blade block.

Upper blade block

1
g 10.01 Blade head

Unscrew threaded pin 2 to loosen and remove the upper blade block..

10.1.2 Assembling the blade blocks


Assemble the blade blocks by reversing the
order of the above steps.
Press up on the upper blade block during assembly.
Press down on the lower blade block during assembly.

To prevent deformation, it is very important that you tighten the threaded pins only
slightly.

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Settings and adjustments

10 3

10.1.3 Changing the blades


You must remove the blade blocks to change the blades.
Remove the corresponding screws to take out the old blades.

Prior to inserting the new blades, make sure the blade blocks are completely clean,
so the blades will sit rmly in the guides.
When tightening the screws, press the blades in the direction of installation to the stop (arrows).

Blade block, up
The grips on the stripping blades point inward.
The grips on the cutting blades point outward
when the blade blocks are held together.

Blade block, down


The grips on the stripping blades point outward.
The grips on the cutting blades point outward
when the blade blocks are held together.

g 10.02 Blade block, up and down

10 4

Settings and adjustments

OI Gamma 333 PC / Gamma 333 PC B


Version 4

10.2 Mechanical settings and adjustments


Several of the machine parts must be readjusted when newly installed to replace defective or
worn parts or if shifted by mechanical loads.

10.2.1 Guide parts and bearings


All guide parts must always have a thin oil lm on them. The bearings must always
be greased and never be allowed to run dry.
All guide parts and bearings must be checked for wear at least every six months.
Damaged guide parts and bearings can cause serious damage to the machine and
must be replaced immediately.

Guide parts
Check guide parts for the following types of
damage:
Corrosion
Scratches or impact damage
Ease of movement
Bearings
Running noise or excessive vibrations or
knocks are an indication of bearing problems.

g 10.03 Example of the guide on the cutting head

Installing and removing the bearings:


In the installation of rolling-contact bearings, expertise and cleanliness are the
two prerequisites for ensuring that the bearings function properly and do not fail
prematurely.
Lubrication of the bearings:
The bearings are sealed on both sides and already lled with grease. Since the useful life of the
lubricant exceeds the expected service life of the bearing, no subsequent lubrication is required or
provided for.

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Settings and adjustments

10 5

10.2.2 Toothed belts


With toothed belts, power is transmitted by positive engagement of belt teeth with pulley grooves.
For this reason, the tension in the toothed belt must not be too high or too low.
Unnecessarily high tension reduces the service life of the drive, increases loading on the bearing
and wear on the teeth, and promotes running noise.
Too little tension causes vibrations and increases abrasion. The belt teeth could also jump if the
load uctuates.

After adjusting the toothed belts, check each to make sure it is running parallel.

To tighten the toothed belts, you must remove the sheet metal covers and loosen the tensioning
device. Refer to the next chapter for details (10.2.2.1).

Frequency measurement
The frequency is measured to determine the
exact tension of the toothed belt.
This procedure involves striking the toothed
belt to set it vibrating and then measuring the
frequency of the vibration. The measuring head
must be centered between the grooved pulleys
and aligned perpendicular to the belt surface.

1
3

1 Measuring head
2 Indicator
3 Striking the belt

g 10.04 Frequency measurement

The rule of thumb is:


The center of the toothed belt must be able to be rotated by 45. If it cannot be, the
toothed belt is too tight.

10 6

Settings and adjustments

OI Gamma 333 PC / Gamma 333 PC B


Version 4

10.2.2.1 Mounting a toothed belt

Toothed belts have relatively rigid tension members in them. Do not force the belt
over the grooved pulley and never force it over a pulley ange.

Check that the pulleys are aligned (ush) and that the axes are absolutely parallel. Avoid any bending, twisting, angling, or buckling of the belt. Make sure the belt does not run out over the faces
of the pulleys. Remember also that once the axis distance is set, it cannot be changed again as
long as the machine is running.

10.2.2.1.1 Toothed belt for transport unit on Gamma 333 PC


Replacing the large toothed belt on the
roller drive:
Remove the entire straightening unit.
Remove the sheet metal cover underneath
the unit.
Loosen the three socket-head cap screws 6
on the motor unit.
Loosen the toothed belt by loosening the
socket-head cap screw 3.
Remove motor unit 4 and set aside in a
suitable place.
Replace the toothed belt 1.
To remount, reverse the order of the above
steps.

1 6 3

4
6

2
5

Initial tension of the toothed belt:


Frequency: 110 +/-10Hz

Replacing the small toothed belt 2 on the


feed unit:

g 10.05 Feed unit, viewed from below

Loosen belt tensioning device 5.


Replace toothed belt 2.
To remount, reverse the order of the above
steps.

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Settings and adjustments

10 7

10.2.2.1.2 Toothed belt for transport unit on Gamma 333 PC-B


Replacing the drive belt in the wire drive:
Detach screws 1.
Measurement point 1
Use the eccentric 3 to slacken the toothed
belt 2.

To reassemble, reverse the order of the above steps.


Pretensioning the drive belt in the wire drive
Measurement point 1:
Measurement point 2:

Replace the toothed belt 2.


When replacing the toothed belt, it might be
useful to remove the rollers 4.

4
2
3

Measurement point 2

Frequency 170 10Hz


Frequency 240 10Hz

1
g 10.06 Belt drive

The toothed belts must be in fully open position during tensioning.

Replacing the drive belt:


Remove the entire transport unit.
Detach screws 1 (4 screws).

Turn the screw 3 to slacken the toothed belt 2.


Remove the motor 4.
Replace the toothed belt 2.

To reassemble, reverse the order of the above steps.


Pretensioning the drive belt
Frequency 130 5Hz

10 8

1
Measurement point 1

4
g 10.07 Transport unit

Settings and adjustments

OI Gamma 333 PC / Gamma 333 PC B


Version 4

10.2.2.1.3 Replacing the drive belt for the swivel head on side 1 and side 2
Side 1
Remove the sheet metal cover from the swivel
unit.
Loosen screwed connections 1 (setting
screws); then loosen socket-head cap screws
2 and move the motor unit to underneath the
cover 3.
Loosen the two socket-head cap screws 4 on
thrust bearing 5 and remove the thrust bearing.
Disconnect the pneumatic hoses from the
gripper.
Remove clamp; lower sensor cables 6 and take
out the pull-off.
Loosen the four socket-head cap screws 7 on
the terminal panel and remove the panel.
Change the belt.
To reassemble, reverse the order of the above
steps.

5
7
2

3
1

Initial stress of the drive belt, side 1


Frequency: 250 +/-10Hz

g 10.08 Toothed belt for swivel unit, side 1

Exercise great care when laying the sensor cable and the pneumatic hoses.

Side 2
Remove sheet metal cover 1 from the swivel
unit on side 2.
Loosen screwed connections 2 (setting
screws); then loosen the socket-head cap
screws 3 and shift the motor unit.
Loosen the two socket-head cap screws 4 on
thrust bearing 5 and remove the thrust bearing.
Disconnect pneumatic hose 6 from the gripper.
Remove clamps 7; lower the sensor cable 8
and take out the pull-off.
Loosen the four socket-head cap screws 3 on
the terminal panel and remove the panel.
Change the belt.
To reassemble, reverse the order of the above
steps.
Initial stress of the drive belt, side 2
Frequency: 250 +/-10Hz

OI Gamma 333 PC / Gamma 333 PC B


Version 4

3
2

5
8

g 10.09 Toothed belt for swivel unit, side 2

Settings and adjustments

10 9

10.2.2.1.4 Replacing the drive belt for the cutting head


Remove the sheet metal cover from the
cutting head.
Detach the pneumatic hose from the valve.
Pull out sensor cables and remove clamp.
Turn socket-head cap screw 1 to loosen
stepping-motor connecting plate.
Release belt tension by detaching sockethead cap screw 2.
Remove thrust bearing 3.
Remove stepping motor unit 4 and set aside
in safe place.
Remove the entire cutting head by detaching socket-head cap screw 5.
Remove both side panels (four socket-head
cap screws on one, eight on the other) 6.
Change belt.
To reassemble, reverse the order of the
above steps.

1
5

6
g 10.10 Drive belt for cutting head

Initial tension of the drive belt for the cutting head


Frequency: 295 +/-10Hz
Be careful of the SM cable when installing the stepping motor.

10.2.2.2 Operating problems associated with toothed belt drives


Type of error

Cause

Remedy

Excessive running noises

Excessive belt tautness

Reduce initial stress

Gear wheels are not aligned

Align gear wheels

Abnormal wear on the loaded tooth


ank of the belt

Incorrect belt tension

Correct tension

Excessively rough surface on toothed


pulleys

Polish or replace the toothed pulleys

Abnormal wear in the gullet of the


belt teeth

Excessively taut belt

Reduce tension

Defective toothed pulleys

Replace the toothed pulleys

Abnormal wear an the lateral anks


of the belt

Shafts are incorrectly aligned

Restore the parallelity and alignment


of the shafts

Flanged wheels ben and / or have


rough surface

Replace the anged wheels

Shaft bearings give

Replace bearing

Belt is broken or belt teeth are


sheared off

Air contains acids or corrosives

Use a suitable belt grade

Apparent elongation of belt

Reduce the distance between shafts


by loosening the shaft bearings or
toothed pulley xture

Reset the distance between shafts


and check the xture

Excessive heating of the toothed belt,


the toothed pulley or the bearings

Check the heat being transferred from


the motor

Initial stress is too high or too low

Adjust the initial stress

Excessive destruction from outside


particles

Use a toothed belt cover

Subject to heavy oil sprays

Shield the belt from oil spray

Premature wear of belt

Bulge in back of belt

10 10

Settings and adjustments

OI Gamma 333 PC / Gamma 333 PC B


Version 4

10.2.3 Setting the guide for the pull-off unit on side 2


The pull-off unit is set and checked at the factory. There is no maintenance cycle for adjusting the
guide.
A collision between the gripper arm and a tool, for example, could cause an undesirable amount
of play between the two guides.

If there is any play in the guides, they must be readjusted immediately!

10.2.3.1 Positioning the toothed rack (user side)


Loosen clamp 1 so that wire 2 is exposed.
Detach the ag (small bracing angle) from
the pull-off sensor.

1
g. 10.11

Loosen the three socket-head cap screws 3


on each side.

3
g. 10.12

The pull-off unit 4 must be mounted level


with the two guides 5.
Center the roller cages 6.
Positioning the rack:
- Press the rack against the pull-off unit
and rack applying steady pressure (see
g. 10.10).
- Distribute any play equally on both sides.
- Apply more pressure to the two ends of
the rack than to the middle.

g. 10.13

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Settings and adjustments

10 11

Slightly tighten screws in the order shown 7,


8 and 9.

g. 10.14

10.2.3.2 Positioning the counter guide (at the back)


The pull-off unit 4 must be positioned level
with the two guides 5. (See Chapter 10.2.3.1
for more information.)
Center the roller cages 6.
Positioning the guide:
Press the guide against the pull-off
unit, apply uniform pressure to it.
Make sure there is no play.
Apply more pressure to the two ends of
the guide than to the middle.
Slightly tighten the screws in the order
shown 10, 11 and 12.

11

10

12
g. 10.15

10.2.3.3 Final step and setting-check


Tighten all six screws to 8 Nm using a torque wrench 13.

13

g. 10.16

10 12

Settings and adjustments

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Check the pull-off unit for ank play, i.e. make


sure there is no play in the rack when it is moved backwards and forwards..

g. 10.17

Check the pull-off unit for lateral play, i.e.


make sure there is no play in the rack when
it is moved from one side to the other.

g. 10.18

At this point all play should be eliminated.

After adjusting the guides, you must recalibrate the machine!


For information on the procedure, see the next chapter.

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Settings and adjustments

10 13

10.2.4 Calibrating the machine


10.2.4.1 Calibrating the axes (mechanical)
If you notice after a reset, for example, that a
swivel unit is no longer perfectly ush with the
cutting head or a sensor or hybrid light barrier is out of position, you must recalibrate the
machine.

1 Calibration bolt for side 1


2 Calibration bolt for side 2

g. 10.19 Calibration gauge

To calibrate the machine, you must remove the


upper and lower blade blocks and install the
calibration gauges in their stead.

g 10.20 Inserted calibration gauge

During the calibration procedure, each motor axis is approached individually and at
a reduced speed; make sure no one can reach into the hazardous area.

10.2.4.2 Calibrating the axes under TopWin


Procedure:
Open cover.
Switch off load voltage.
Switch on load voltage.
Go to Settings/Congurations in TopWin and activate Adjust Machine.
With guidance from the software assistant, carry out the calibration and save all values.

10 14

Settings and adjustments

OI Gamma 333 PC / Gamma 333 PC B


Version 4

10.2.4.3 Calibration procedure

Start calibration
Position pull-off
unit 1

Remove blades
Position swivel unit 2

Insert calibration
gage
Position pull-off
unit 2

Position blade
axis
(Clamped up to
gage)

Draw back pull-off


unit 1+2
(Stop)

Save new calibration data

Remove calibration gage

Position swivel
unit 1
Insert blade
block

End of calibration

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Settings and adjustments

10 15

Check to see if the hybrid light barrier on the cutting head is operating properly:
The light barrier switches on (diode goes out) when the basic position (calibration position) is reached. To see the switching of the diode, you must look underneath the covering. The basic position should be reached when the calibration gauge is clamped in by the upper and lower guide rods
(g 10.20). If this is not the case, it means the sensor on the large pinion is out of position.

Check to see if the inductive sensors are operating properly:


Make sure the sensor is not acting as a stop.

The sensor gap is as follows:


Aluminum: 0.50.7mm or 30 % of nominal switching distance (sn=2mm)
Steel:
0.51.5mm
In general, the sensor must be damped (diode not lit up) before it reaches its end position. This
means there is no contact with the calibration gauge. If there is, the sensor or sensing element
(cutting head) can be shifted accordingly.

The following sensors must be checked in the order listed:


Sensors for the stepping motor axes:
hybrid light barrier
BM1 blade axis
BM2 pull-off axis side 2
BM3 pull-off axis side 1
BM4 swivel axis side 2
BM5 swivel axis side 1

10 16

Settings and adjustments

Other sensors:
inductive sensors (Namur)
B10 lowering side 1
B11 lowering side 2
B12 gripper side 2
B13 lifting device
B14 gripper side 1
B16 wire trough

OI Gamma 333 PC / Gamma 333 PC B


Version 4

10.2.5 Wire feed unit


10.2.5.1 Gamma 333 PC
The distance between the wire transport rollers
should be 0.2mm. You can adjust this distance
by turning screw 1. After making the adjustment, make sure that you retighten counterscrew 2.

0.2mm

g 10.21 Distance between rollers in drive

Roller pressure
Adjust the roller 3 (g 10.21) pressure by
turning screw 4. Lock screw 4 using the lock
screw 5.

4
5

16.5mm

4
5

g 10.22 Adjusting the roller pressure

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Settings and adjustments

10 17

10.2.5.2 Gamma 333 PC-B


Encoder
You must adjust the applied pressure and the
end stop if the encoder makes measurement
errors or if you are processing special wires.

3
4

Adjust the applied pressure by turning screw 1


(tightening = increases pressure, loosening =
lowers pressure).
Adjust the end stop of the encoder by turning
screw 2 so that a gap of 0.2-0.5mm exists between wheel 3 and 4.

2
g 10.23 Adjusting the encoder

Always have the belt-driven wire drive closed when making adjustments.

The height of the unit can be adjusted by turning the two screws 1.
The distance between the gripper jaws, when
closed, and surface 2 must be 1mm.

10.2.6 Lifting device

Final position damping of cylinder


Up 3
Valve open

Down 4
Valve open approx. 1/2 turn

3
4
g 10.24 Lifting device

10 18

Settings and adjustments

OI Gamma 333 PC / Gamma 333 PC B


Version 4

10.2.7 Wire guide gripper

Reset side 1 of machine.


Remove the waste container and detach the
screws on the wire guide gripper.
Adjust the lateral play, making sure the play
on both sides of the wire guide gripper is
the same.
Set the wire guide gripper (gripper jaws 1) at
the same height as the guide tube.
Tighten screws and re-install the waste container.

g 10.25 Wire guide gripper

The jaws of the wire guide gripper can cause injury. Be extremely careful when
handling them.

Closing the wire guide gripper


You close the wire guide gripper from the
software. To do so, go to the Tools menu and
select BIO-Debug. BIO output no. 2 (arrow)
closes the wire guide gripper.

g 10.26 Inputs/outputs on the BIO card

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Settings and adjustments

10 19

10.2.8 Conveyor belt


To prolong the service life of the conveyor belt, make sure the belt tension is correct and that the
belt has minimum contact with the anges of the deection rollers, the end shields, and covers.
Replacing the conveyor belt
Remove lifting device 1.

6
7

Remove cylinder fork head 2 from tipping tray 3.


Remove hand guard 4.
Remove tipping tray 3 along with skirt 5 by unscrewing the three screws 6.

Remove ramp 7.
Remove sheet-metal guard 8.

Loosen the conveyor belt by turning threaded


rods 9.
Remove conveyor belt 10 by pulling it out the
front of the device.
Make sure the axes of the drive and deection
rollers are parallel in terms of alignment and in the
horizontal plane.

g 10.27 Changing the conveyor belt

To reinstall, reverse the order of the above steps.


Pull new conveyor belt onto the rollers.
Adjusting the belt tension

Adjust the tension of conveyor belt 10 with the


two threaded rods 9.

The belt should be touching the section at the


top and virtually touching it at the bottom.
ca. 27mm
Adjusting lateral running distance

g 10.28 Threaded rod on the conveyor belt

Align rollers by turning each threaded rod


individually (the belt is started in the single-step
menu).
Make sure you always retighten the lock nuts.
Switch the machine back on and check the
settings and adjustments while the belt is in
motion.

10

Then turn off the machine and attach the covers.


g 10.29 Conveyor belt touching section

10 20

Settings and adjustments

OI Gamma 333 PC / Gamma 333 PC B


Version 4

10.2.9 mci 711 options


Please refer here to the operating instructions
for the mci 711.

10.2.10 Safety cover

g 10.30 mci 711 crimping module

You must adjust the pressure-operated switch


to prevent machine damage from occurring
when the safety cover is opened and closed.

Unscrew the setting screw on the pressureoperated switch; the pressure-operated switch
does not respond.
Set the cover switches S01, S02 2 with cover
closed; the starting roller (switch) is at the very
top of the column hole.

Adjust pressure-operated switch 1 while cover


is closing; repeat this procedure as often as
necessary until the pressure-operated switch
triggers the reverse function itself when the
limit value is reached.
Unscrew setting screw for the pressure-operated switch by 1/4 turn.

4mm

Adjusting end position dampening 3 in the


cylinder:
Opened 1/2 turn at top
Opened 3/4 turn at bottom

Then check whether the safety cover is functioning properly.


Default setting for the limit switch 4
The basic setting of limit switch four must be
4mm. Adjust whenever a new switch is installed.

10.31 Pneumatic unit on safety cover

When closing the safety cover, make sure no one can reach into the machinery,
otherwise he or she might get pinched!

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Settings and adjustments

10 21

10.3 Electrical settings and adjustments


BEFORE working on any electrical parts throughout the system, ALWAYS turn off
the main switch on the machine and secure it against unauthorized switch-on. It is
hazardous to touch live parts!!

All settings and adjustments must be carried out by persons trained and authorized to do so.

For current country voltages, please refer to annex in the attached I/O list (Article
Number 0025246).

10.3.1 Sensors
Be very careful when wiring the sensors; incorrect handling is a frequent cause of sensor cable
failure. Observe the following points to avoid problems:
Lay the wires carefully along the hose, i.e.
make sure cables are not squeezed by sharp objects;
when changing the direction of cable, do so using a U-shaped loop.
Do not pull or strike the cable and protect it from being pulled or struck.
Make sure nothing is rubbing against any part of the cable.

10.3.1.1 Laying sensor cables


Side 1

The sensor cable for the lowering sensor 1


must have a strain-relief device on it.
The sensor-cable and air tubes 2 must run
parallel to each other at the base. Do not
allow them to cross each other.

10.32 Overview of side 1

10 22

Settings and adjustments

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Side 1 in pull-off position


The sensor cable for the pull-off sensor 3
must not be allowed to touch the safety
cover in any position.
Check the angle of the fastening clip 4. The
sensor cable should only touch the stationary sheet-metal part.

10.33 Side 1 in pull-off position

Side 1 in 90 position
The sensor cables for the sensor lowering/
sensor gripper and air hoses form a uniform
arc 5 and are laid parallel to each other.
Make sure the sensor cable 6 touches
nothing when lowered.

6
5

10.34 Side 1 in 90 position

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Settings and adjustments

10 23

Side 2

7
8

Make sure the sensor cables 7 do not touch


the air hoses 8.

9
g 10.35 Side 2 from above

The side sensor cable 9 for the pull-off sensor must be strain-relieved. Make sure it is
strain-relieved in all positions.

g 10.36 Side 2, side view 1

Make sure the sensor cables 10 do not


touch each other when they are being lowered.

10

g 10.37 Side 2, side view 2

Side 2 lower sensor


The position of the sensor cable shown here
10 is an optimum one for relieving strain on
the connector plug.

11
10.37 Side 2 in 90 position

10 24

Settings and adjustments

OI Gamma 333 PC / Gamma 333 PC B


Version 4

10.3.1.2 Inductive sensors

Inductive sensors are sensitive, non-contact


electronic switches.
To ensure that sensor 1 works properly, the
distance to switching plate 2 must be exactly
right. If it is too small, i.e. if it touches the switching plate, the sensor will be destroyed. If it is
too large, switching errors will occur.
x
Setting

Detach the sensor and replace if necessary.


Use a screw-pitch gauge to set switching distance x. Then retighten the sensor.
The sensor distance is as follows:
Aluminum: 0.5 -0.7mm or 30% of nominal
switching distance (sn=2mm)
Steel:
0.5 - 1.5mm

g 10.38 Inductive sensor

10.3.1.3 Hybrid light barriers


The Komax Gamma 333PC / 333 PC B has several photoelectric, or light, barriers (see pages 6 12) and an encoder. Do not allow dust or foreign objects to cover the slits for the transmitting and
receiving diodes.
The photoelectric barriers are factory set.

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Settings and adjustments

10 25

10.3.2 Electric fuses in control cabinet


If the current in an electrical circuit exceeds the admissible value, the power supply is cut off by a
fuse to ensure the safety of humans and the machine.
The Komax Gamma 333 PC / 333 PC B has the following fusing:
Circuit breaker (g 6.40, Item 12)
The circuit breaker can be reused after being tripped. It has two trip devices, a magnetic tripper
which responds to a short circuit and a bimetal tripper which responds to an overload. If the circuit
breaker is tripped by a power overload, it cannot be reactivated until the bimetal trip device has
cooled off. To reactivate, push the lever up. This is the main fusing device for the machine.
1 Fine-wire fuses (g 10.39)
These fuses melt in the event of an overload
and must be replaced.
Remove the fuse from its holder, check to see
if the wire is melted and replace with a fuse of
exactly the same type and rating.

g 10.39 Miniature circuit breakers and ne-wire fuses

Be very careful never to install a stronger fuse or to switch around slow and
fast fuses. Otherwise, the safety of the machine and its operators can no longer
be guaranteed!

Fuses must never be repaired or bridged.

Fuse list
Designation Fuse for
F01
F02
F03
F06
F07
F08
F09
F18
A65/F1
A01/F1
A01/F2
A04/F1
10 26

Type

Installation site

Circuit breaker
316A
Delta drive 3210 VAC (333 PC)
33.15AT
Delta drive 3210 VAC (333 PC B) 35AT
Stepping motors 392 VAC
35AT
Power supply 230 VAC
6.3AT
SM power supply cards 130 VDC 5AT
Control circuit contactors 120VAC 0.5AT (220V)
Power supply 24V
8AT
Conveyor-belt motor protecting- 1.6-2.5A
switches
2.5-4.0A
MRS card
5AT
Input BIO card
2AT
Output BIO card
6.3AT
RCS card
1.6AT
Settings and adjustments

Small mounting plate


Large mounting plate (X02)
Large mounting plate (X02)
Large mounting plate (X02)
Large mounting plate (X02)
Large mounting plate (X02)
Large mounting plate (X02)
Large mounting plate (X03)
Large mounting plate (X02)
MRS
BIO
BIO
RCS

(A03)
(A01)
(A01)
(A04)

OI Gamma 333 PC / Gamma 333 PC B


Version 4

10.3.3 BIO PCB


The BIO card has dynamic inputs/outputs for use in various applications and options. During
input/output conguration, either the MRS PCB window or the BIO PCB window will appear, depending on whether an MCI module or some other processing station was selected.

1
9

10

12
11
17

16

15 14

13

g 10.40 Layout of the BIO PCB

1
2
3
4
5
6
7
8
9
10

Inputs
Connection to RCS PCB
Connection to MRS PCB
Never plug in
Analog inputs
Pressure regulator output
Splice detection 2
Connection pneumatic valves
Outputs
Relay outputs

OI Gamma 333 PC / Gamma 333 PC B


Version 4

11
12
13
14
15
16
17

Fuse F1 IN
Fuse F2 OUT
Power feed to BIO PCB (X25)
Power feed to RCS PCB (X27)
Power feed to expanded BIO PCB
Connection for expanded BIO PCB
Jumper for optional splice detection
unit (Depicted: splice detection not
activated)

Settings and adjustments

10 27

18

g 10.41

Select the menu item marked with an arrow in


g 10.38 and window opens with an illustration
of the BIO PCB (g 10.41).
If an input/output is functioning correctly, a dot
lights up at terminal panel 18. This can occur
manually or by entering a prescribed repetition
interval.
You can activate the pneumatic valves at their
connector 19 by clicking on the corresponding
output.

19

g 10.42 BIO PCB as depicted in TopWin software

10.3.4 Output stages of the stepping motors

LED 1
LED 2
LED 3
LED 4
LED 5

green
red
red
red
red

indicates correct operation


indicates short-circuit between two motor phases
indicates excess temperature on heat sink (>75C)
indicates excess voltage in braking mode (>140V)
indicates undervoltage (<80V)

DIP switches
The DIP switches must be OFF!
Selection dial for motor phase current (refer also to I/O list)
M01
M02
M03
M04
M05

blade axis
pull-off axis side 2
pull-off axis side 1
swivel drive side 2
swivel drive side 1

position D
position D
position D
position D
position D

g 10.43 Components of output stage

10 28

Settings and adjustments

OI Gamma 333 PC / Gamma 333 PC B


Version 4

The output stages are all interchangeable.


Installation location of the output stages:
1
2
3
4
5
6

blade axis
pull-off axis side 2
pull-off axis side 1
swivel drive side 2
swivel drive side 1
stepping motor controller

g 10.44 Output stages in the control cabinet

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Settings and adjustments

10 29

10.4 Pneumatic settings and


adjustments

10.4.1 Operating pressure


The operating pressure of the machine is set
with the pressure regulating valve 1 to p=6 bar.

g 10.45 Maintenance unit with pressure regulating valve

10.4.2 Throttle non-return valves


These valves are utilized to regulate the ow of
exit air with double-action cylinders. Changing
the amount of air changes the piston speed.
Throttle screw 1 regulates the air quantity.

2 Lock nut

g 10.46 Throttle non-return valve

Please note that both throttle non-return valves


1 must be closed on side 2.

Direction of
installation

g 10.47 Direction of installation for throttle non-return valve

The throttle non-return valves integrated in the pressure regulating valve for the
wire grippers on side 1 and side 2 must be closed.

10 30

Settings and adjustments

OI Gamma 333 PC / Gamma 333 PC B


Version 4

10.5 Setup of processing stations


You can position the processing stations from the TopWin user interface using setup gages.

10.5.1 Crimp module setup


To align the wire with the station, go to the conguration menu and click there on the station
you wish to set up. Then follow the wizards
instructions.

g 10.48 Selecting a module

The gage 1 is put directly on the tool mount 2.


After the setting is correct and the gripper is
pressed down, the wire must sit neatly in the
notch and lie at the gage stop.

2
g 10.49 Crimping press

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Settings and adjustments

10 31

10.5.2 Setup of mci 761 seal module


To align the wire with the station, go to the conguration menu and click there on the station
you wish to set up. Then follow the wizards
instructions.

g 10.50 Selecting a module

Move the loading head forward and remove the


lower expanding sleeve. Mount the setup gage
for the seal module in its place and move the
loading head back.

g 10.51 Mounting the setup gage

The seal module is correctly positioned if the


wire is neatly in the notch and lies at the rear
gage stop.

g 10.52 Aligning a module

10 32

Settings and adjustments

OI Gamma 333 PC / Gamma 333 PC B


Version 4

10.5.3 Setting up non MCI modules


Non-MCI modules can be set up from the software, just like MCI modules. Go once again to the
conguration menu and select the desired station. Align the wire to the applicator in the positioning window, just as you would for an MCI module.
When you click inputs/outputs, however, the
BIO card appears instead of the MRS PCB.
You must now activate the corresponding
connections on the BIO card based on whether
or not you want the processing stations wired
in the control cabinet (for module wiring, see
electrical diagrams). Non available connections
are crossed out.

g 10.59 Example: installing a Komax 106 wire feed system

OI Gamma 333 PC / Gamma 333 PC B


Version 4

Settings and adjustments

10 33

10.5.4 MRS PCB

Due to the special pin assignment, you must use RJ45 cables with yellow caps
from Komax. Incorrect cables will destroy the transmitter and receiver!

NEVER plug RJ45 cables in or out while the load voltage is on. If you do so, the
software will crash immediately and you will have to restart the PCC card in the PC
by pressing the reset button.

The MRS PCB offers an easy means of connecting the various MCI modules.
Standard assignment of channels:
CH0
Motor controller Delta drive
CH1
SMC
CH2
Seals module mci 761 side 1
CH3
Crimping module mci 711 side 1.1
CH4
Reserved
CH5
Crimping module mci 711 side 1.2
CH6
Reserved
CH7
Crimping module mci 711 side 2
CH8
Reserved
CH9
mci 781 side 1
CH10 mci 781 side 2
CH11 Double gripper module
CH12 Reserved
CH13 BIO PCB
CH14 RCS connection
The channels 0, 1, 12, 13 and 14 have preassigned uses and may not be used for MCI
modules.
1
2
3
4

Power feed 24VDC


Fuse 5AT
Connection PCC card A
Connection PCC card B

Standard mci 711


side 2

2
Standard mci
711 side 1

1
Standard mci
761 side 1

g 10.60 MRS PCB

10 34

Settings and adjustments

OI Gamma 333 PC / Gamma 333 PC B


Version 4

15. Putting the machine out of operation, storage and disposal


15.1 Putting the machine out of operation
Proceed as follows to put the machine out of operation:
Switch off the main power switch to the machine.
Close the safety covers.
Disconnect the machine from the power supply.
Disconnect the machine from the compressed air supply.
Make sure that no liquids can escape from the machine (e.g. ux).

15.2 Storage
When putting the machine into storage for an extended length of time, keep the following points in
mind:
Put the machine out of operation as described in Chapter 15.1.
The criteria for the storage location are the same as those for the installation site (oor properties, space requirements, ambient conditions, see Chapter 5.1).
Protect the machine from dirt.
Protect the machine from corrosion (dry rooms, no direct sunlight).

15.3 Disposal
Most materials from which the machine is made (metals, plastics) can be recycled. To dispose of
the machine, proceed as follows:
Put the machine out of operation as described in Chapter 15.1.
Disassemble the machine, sorting the parts by material; have these materials transported to
the appropriate recycling centers.
Electrical and electronic components, particularly PCBs, monitors, etc. must be properly disposed of.
It is recommended that you involve companies specializing in this type of waste in the disposal
process.

The machine operator is responsible for ensuring that the machine and the materials used
in its operations are disposed of in a proper and environmentally friendly manner. Make sure
you comply with the national and local legal regulations regarding waste disposal.

OI Gamma 333 PC / Gamma 333 PC B


Version 4

15 1

15 2

OI Gamma 333 PC / Gamma 333 PC B


Version 4