USER'S MANUAL “PRIMA”
Contents
1. USER 5 MANUAL PRIMA Release 4 8 October 01 2012 WARNING WARNING This machine has been built according to the appropriate safety rules as required by law The user must fulfil all safety requirements concerning the use and maintenance of the machine LCM shall not be considered responsible for damages to people or things caused by incorrect or inappropriate use of the machine The user must also ascertain that the pressing operation is performed adequately and its results correspond to the expected technical and esthetical requirements It remains the user s responsibility to verify that the product of the pressing operation is according to the standards requested LCM may cooperate with the user who needs specific parts to enhance the quality of the operation for example by manufacturing if requested specific tools and frames to carry out particular operations LCM may modify the software or the manual of this machine without giving prior communication PREFACE PREFACE The scope of this manual is to teach the operator about the use of this machine regarding its transport handling installation setting operation and maintenance This manual must be kept for reference near the machine or in a place easily retrievable It must be kept in a proper place avoiding humid environments and2. Now the display shows the word INIT To operate the machine it is necessary to press the RESET button Pressure adjustment Choosing the position of the pin can vary the pressure by turning clockwise or counter clockwise the knob of the pressure regulator rotating clockwise the pressure increases Pressure Regulator 5 ERS 1 5 3 Figure 12 29 PART 2 INSTALLATION SETTING AND OPERATION Replacing the anvil Switch off the machine pressing power button by checking the display off Pull forward the anvil holding carriage and remove the screw under the anvil Anvil Screw Carriage Figure 13 Take off the anvil from its seating and replace it with the new one Fix the anvil onto the carriage by its screw Switch on the machine pressing power button Replacing the punch Repeat steps fulcrum pin adjustment Figures 8 9 10 internal part of the machine is now exposed Remove the fulcrum pin Slide the press lever backward Push the piston of the sheet blocking device backward by lifting the small lever located behind the piston Pressing Lever Figure 14 Lever Sheet Blocking Device 30 PART 2 INSTALLATION SETTING AND OPERATION Figure 15 5 3 Remove the punch by seizing it from the top while pushing it from the bottom at the same
3. Figure 20 This accessory works at a lower height if compared to the standard configuration and has a shaft which acts as an extension of the punch It is through the shaft that the punch exerts the pressure on the fastener The accessory No 2 also includes two types of frames Frame cod 001 figure 21 Frame cod 002 figure 22 Figure 21 Figure 22 35 PART 2 INSTALLATION SETTING AND OPERATION To install the accessory No 2 proceed as follows Switch off the machine pressing power button by checking the display off Insert selected frame Figure 21 or Figure 22 in the accessory n 2 lower support and lock it by tightening the bolt at the left end of the guide then place the anvil chosen on the frame ge Te a RYE YS S Anvil Holder Carriage Figure 23 Accessory 22 Lower Support Pull the carriage forward and remove the anvil holder screw Remove the anvil and the anvil holder Insert the accessory onto the carriage by lowering it from above The pin at the front end of the carriage must engage the slot inside the accessory Slide the accessory forward along the appropriate guides Once at stroke end block the accessory by its quick action fastener Quick Action Fastener Figure 24 36 PART 2 INSTALLATION SETTING AND OPERATION Insert the connector of the accessory cable into the socket of the e
4. Upon completion of the pressing release the FOOTSWITCH to allow the accessory to go back to its original position and remove the sheet The machine is ready for a new pressing cycl 37 970 740 ACCESSORY 2 Figure 26 38 Dimension in mm PART 3 MAINTENANCE 39 PART THREE MAINTENANCE CHAPTER 6 MAINTENANCE 61 OVERVIEW The maintenance program consists of daily and periodical operations Daily operations must be done at the start and at the end of the work session and do not require the use of special tools Periodical maintenance operations instead may require the dismantling of some parts of the machine including the removal of some safety device 6 2 DAILY MAINTENANCE Check ups to be done before starting the production cycle Visual inspection of the whole machine to find out whether there are damages or broken parts Inspection of the mains plug and cable and of the air piping Start up and test to verify abnormal operation or noises Warning If breaking damaging abnormal operation or any other irregularity is found switch off the machine and disconnect it from the mains and the compressed air Call for qualified servicing personnel authorized by the manufacturers Operations to be done at the end of each work session Clean the machine thoroughly using only compressed air to remove dust and any other foreign materi
5. along its full length that the electrical lead is not damaged 3 4 STORING BEFORE UNPACKING The machine may be stored in its original packaging for a maximum period of six months provided that the packaging does not show evidence of damaging as described in the previous paragraph If damage is found remove the machine from the packaging check that the machine itself has not been damaged and store it again in a new adequate packaging The storing place must be a closed room clean with temperature between 5 C and 40 C 23 F and 104 F Relative Humidity less than 80 The machine must never be subjected to bumps vibrations or loads 18 PART 2 INSTALLATION SETTING AND OPERATION 3 5 STORING AFTER UNPACKING If the machine has to be stored again after use it may be stored for a maximum period of three months provided that it has been previously cleaned lubricated and maintained as described ahead in the chapter on maintenance The storing place must have the characteristics described in paragraph 3 4 3 6 DISPOSAL OF PACKAGING Unpack the machine by removing the hood without breaking the base take out the transportation documents and ensure that the content of the packaging corresponds to what described in the papers The packaging is made of materials which may be disposed of with no particular restrictions However you should always comply with the relevant laws and regulations of your country on this matte
6. 58 means that the Force currently set up is of 2 58 tons If the force is gt 4 00 tons the F flashes to alert you that a HIGH force is currently in use To modify the force adjust the air pressure regulator and or change the position of the fulcrum of the pressing lever The force shown on the display always represents the current value thanks to an electronic sensor that takes into account also the current fulcrum position The pressing cycle is the following 1 Pull out the anvil holding carriage 2 Put the self clinching fastener in the anvil 3 Place the metal sheet on the fastener 4 Push back the carriage up to the stroke end position a micro switch automatically allows the sheet blocking device to operate 5 Push RIGHT COMMAND or LEFT COMMAND to perform the actual pressing of the insert into the metal sheet 6 Pull out the anvil holding carriage 7 Remove the metal sheet The press is ready to start a new cycle Do not release the workpiece during and after the pressing operation The operator must to wear clothes that do not have flapping parts at the wrists and avoid to wearing necklaces or bracelets to avoid risks of dragging in the danger zone Operational errors If a wrong operation is done during the pressing cycle an error message is displayed EROI means that the RIGHT COMMAND or the LEFT COMMAND has been pushed when the carriage was not in the proper position yet 2 means that the carriage has been p
7. base reaches its stroke end Remove the control key As we have seen a key controls this command In this way the manufacturer wants to avoid the accidental activation of the raising lowering of the machine Without the control of a key under particular conditions which are difficult to foresee an accidental activation might take place and result into dangerous situations for the safety of the operators Servicing must be done only by properly qualified personnel 42 APPENDIX TO THE MANUAL Figure 2 Figure 3 43 APPENDIX TO THE MANUAL APPENDIX TO THE MANUAL Autt minimum pressing time for the automatic mode A value between 0 10 and 3 00 seconds can be entered With release 0 05 and higher of the software the function automatic can be utilized If you select this function there is no need for you to press any command to start the pressing operation which is commanded directly by the carriage stroke end switch To activate this function you have to follow these instructions Press the RESET and the LEFT COMMAND buttons at the same time for at least 3 seconds The word AUto will appear on the display which means that the press is now ready to work in the automatic mode You can adjust the time elapsing between the sheet blocking device activation and the actual pressing operation To perform the said adjustment follow the instructions given in the Functions Menu Possibl
8. display must show the current force eg F0 45 Pull the carriage and place the fastener in the anvil 31 PART 2 INSTALLATION SETTING AND OPERATION Place the sheet in position centre the hole into the part of the fastener projecting out The anvil holding the fastener can be rotated to ease this operation Push the carriage up to stroke end while holding the sheet in the correct position the sheet holder will automatically start working and help the operator keep the piece in the required position Push either the RIGTH COMMAND or the LEFT COMMAND to complete the inserting operation As an alternative the FOOTSWITCH may be used instead of the RIGTH COMMAND and of the LEFT COMMAND Atthe end the pressing cycle the punch goes up automatically Pull the carriage forward and finally remove the sheet The machine is now ready for a new cycle 5 4 INSERTING OF FASTENERS THAN CANNOT BE CLINCHED WITH THE MACHINE IN ITS STANDARD CONFIGURATION The PRIMA even in its standard configuration can insert fasteners into a wide variety of shaped parts However there exist pieces shaped in such ways that cannot be worked at with the machine in its standard configuration To solve this problem special accessories have been designed Currently two accessories are already available which will be described in the next paragraphs New accessories may be designed in future The accessories also have replaceable parts which great
9. good care must be taken to avoid its deterioration For other copies updated copies or further information please contact LCM Via Martino 54100 MASSA ITALIA email prima Figure 1 shows CE markings as reported on the machine tag LCM DIVISIONE MACCHINE Via Martino Ferraro 3 54100 Massa ITALY TIPO PRIMA N SERIE 00 ANNO 2000 Figure 1 INDEX PART 1 DESCRIPTION OF THE MACHINE CHAPTER 1 TECHNICAL FEATURES 1 1 Overview 1 2 How it works NENNEN 1 3 Field of application____ M 1 4 Materials which may be used 1 5 Power requirements__ 1 6 Operating environment __ D 1 7 5 workplace MEE CN 1 8 5 requirements o 1 9 Description of commands 1 10 Noise__ EEE N 1 11 Technical data CHAPTER 2 SAFETY 2 1 Compressed air switch off device 2 2 Hazards 2 3 Misuse _ 2 4 Max sheet dimensions and weight PART 2 INSTALLATION SETTING AND OPERATION CHAPTER 3 INSTALLATION 3 1 Packaging 3 2 Handling M e 3 3 Preliminary checking 3 4 Storing before unpacking 3 5 Storing after unpacking 3 6 Disposal of packaging i 3 7 Checking after unpacking 3 8 Installation of the machine on its standard 3 9 Installation of the machine without its standard base INDEX CHAPTER4 SETTING 4 1 Connection to mains and to compresse
10. the ergonomics of the machine by enabling the user to work at two different heights The higher level is usually meant for the use of the accessories In order to raise the base follow this procedure Remove the safety pivot Figure 1 Make sure the area above is clear of obstacles so that the machine can be raised 160mm Ascertain that nobody else is in contact with the machine Verify your position while remaining outside the area where the raising takes place Insert the control key and turn it clockwise until you hear the click figure 2 Wait up to the end of the piston stroke approx 5 seconds Insert the two blocking pins into the body of the machine by moving the two black side knobs figure 3 Insert the control key and turn it anticlockwise until you hear the click figure 2 Remove the control key To lower the base of the machine do the opposite of what above described Make sure the area below is clear of obstacles so that the machine can be lowered Ascertain that nobody else is in contact with the machine Verify your position while remaining outside the area where the lowering takes place Insert the control key and turn it clockwise until you hear the click figure 2 Wait up to the end of the piston stroke approx 5 seconds Take the two blocking pins out of the body of the machine by moving the two black side knobs figure 3 Turn the control key anticlockwise until you hear the click figure 2 Wait till the
11. time and substitute it Place the press lever in its original position a screw pressing lever stroke on the right hand side of the machine will allow doing this operation Screw Pressing Lever Stroke Place the fulcrum pin into position Close the casing and lock the casing fastener and turn on the air valve Now the display shows the word INIT To operate the machine it is necessary to press the RESET button INSERTING OF SELF CLINCHING FASTENERS WITH THE MACHINE IN ITS STANDARD CONFIGURATION The machine in its standard configuration allows the clinching of fasteners in a wide range of parts included shaped ones There are however some limitations due to the shapes and dimensions of these parts in this case special accessories must be used as described in the following paragraphs For example if the fastener has to be clinched on a part with a rim bent downward the operation is possible on a machine in its standard configuration only if the bent rim is less than 30 mm wide If the same insert must be clinched on the same part but with the rim bent upward the operation is not possible in the standard configuration Before starting the first clinching cycle the operator must Choose the most suitable punch and anvil choose the position of the fulcrum pin of the pressing lever set the pressure of air and stand in the correct position in front of the machine Push the RESET button to get the machine ready the
12. 0 860 2 Atm tons 0 570 2 Atm tons 1 720 3 Atm tons 0 860 3 Atm tons 2 580 4 Atm tons 1 150 4 Atm tons 3 450 5 Atm tons 1 440 5 Atm tons 4 310 6 Atm tons 1 790 6 Atm tons 5 180 7 Atm tons 2 010 7 Atm tons 6 040 Changing the fulcrum pin position of the press lever Unlock the casing fastener located on the left hand side of the machine and turn off the air valve to depressurise the machine Check the pressure gauge to verify that there is no pressure Casing Fastener gt gt Y o 3 Compressed O Air Valve Pressure Gauge Figure 8 27 PART 2 INSTALLATION SETTING AND OPERATION Pull the casing forward and then lift it upward When in vertical position it slides into a blocking pin the internal part of the machine is now exposed Figure 9 Remove the fulcrum pin from the hole where it is fitted and place it into the other hole Before inserting the pin make sure that the pinhole and the lever hole inside are well aligned Fulcrum Pin Fulcrum Pin Position 1 Position 2 Pin Figure 10 28 PART 2 INSTALLATION SETTING AND OPERATION Lift the casing vertically to free it from the blocking pin and then lower it to its original position Lock the casing fastener and turn on the air valve Figure 11
13. Functions button light blue FUNCTION Footswitch connector FOOTSWITCH Accessories connector ACCESSORIES The power switch POWER turns the PRIMA on and off 10 PART1 DESCRIPTION OF THE MACHINE The four digit display DISPLAY shows the value of the pressing force or other data depending on which function is currently selected The reset button RESET has the following uses When you switch on the press the display flashes showing the word This button must be pushed to have the press operative When you press this button during normal operation the work cycle is interrupted and the sheet blocking lever is released allowing the operator to start the cycle from the beginning for instance in the case he wants to re position the piece he is working at The function button FUNCTION has the following functions Counting the number of fasteners clinched Adjusting the timing of the work cycle of the machine Testing the machine The footswitch connector FOOTSWITCH enables you to use a FOOTSWITCH to operate the sheet blocking device Pushing one of the two green buttons at the sides of the machine as described previously performs the actual pressing When the machine is used in its standard configuration without Accessories the pressing operation can be done indifferently either by the FOOTSWITCH or by pressing the RIGHT or LEFT COMMAND The accessories connector ACCESSORIES c
14. HE MANUAL WARNING No user serviceable parts inside Servicing must be done only by properly qualified personnel ATTACHMENT No 2 PNEUMATIC DIAGRAM 51 APPENDIX TO THE MANUAL gt 5 271 dp ea 8 15 H PREMI LAMIERA g8x1 5 g8x15 4 0 15 25x0 15 1V1 ANTE 221 272 Nis i 1 bo PRESSORE i xm 1 25 15 28117 PRIMA INSERTER SCHEMA Ne 52
15. NOT ALLOWED The use of products sheets or materials that for their properties or structural characteristics are subject to breakage thus throwing fragments and splinters is not allowed The use of products that may deflagrate or explode when subjected to pressure is not allowed Servicing by unauthorised personnel is not allowed It is strictly prohibited to service PRIMA before disconnecting it from the mains and from the air pressure 1 4 MATERIALS WHICH MAY BE USED The materials for which the press may be employed are those with yield strength lower than the pressure locally developed by the press itself Within these limits plastic or metallic materials like steel aluminium bronze and the like may be employed The maximum thickness of the piece under work must be 3 mm considering that in the gap between punch and anvil there must be space enough for the self clinching fastener 1 5 POWER REQUIREMENTS To work correctly the machine needs to be connected to these power sources Mains connection Connect the lead of the machine to a 230 Volts 50 Hz 16 Amps mains socket PART1 DESCRIPTION OF THE MACHINE Compressed air connection Connect the machine to a compressed air outlet supplying a pressure of 6 to 8 bars 1 6 OPERATING ENVIRONMENT The environment where the machine will be operated must have the following characteristics Temperature 5 40 23 104 F Max relative humidity 80 The machine mus
16. UNCTION DECREASING COUNT FUNCTION PART 2 INSTALLATION SETTING AND OPERATION Modifying the minimum pressing time It is possible to modify the minimum pressing time for each of the positions of the fulcrum Enter into the value set mode by pressing for at least three seconds the FUNCTION button when the word INIT flashes on the display or press the RESET button to have this the display shows the word CNT Keep on pressing the RIGHT COMMAND until FUIT for fulcrum 1 or FU2T for fulcrum 2 appear on the display Pressing the FUNCTION button once again you enter into the function required to modify the minimum pressing time By pressing the RIGHT COMMAND you increase the time by pressing the LEFT COMMAND you decrease it Press FUNCTION to confirm the value or RESET to keep the old value After modifying the minimum pressing time press the RESET button to have the word INIT flash on the display At this point press RESET again to continue with your work The functions menu Possible selections Besides the functions already mentioned other selections are possible By pressing the FUNCTION button for at least three seconds when the word INIT flashes as explained above the function menu is entered To move up and down the same menu and select the required function press the RIGHT COMMAND or the LEFT COMMAND After you get the required function proceed as for the above described Modifying the minimum pressing time The follow
17. al Use safety goggles to protect your eyes Clean the air filter and remove the moisture that might have been collected inside the pressure regulator Always keep the fulcrum pin the punch and their seats clean and lubricated Lubricate also other parts subjected to movement Check that no part is rusty any rusty part must be immediately substituted 40 PART THREE MAINTENANCE 6 3 USE OF THE TEST MENU Only the service technician must use this function When you select TEST in the functions menu see on page 26 how to access it it is possible to select one of the following functions State of the inputs Four hexadecimal digits are shown representing the status of the 16 inputs of the machine Analogue input The status of the analogue digital converter is shown in hexadecimal digits Anxx Pressure The current value as read by the pressure sensor is shown PRx xx Debug status It shows the debug status of the machine d E 0 means no debug Test status It shows the test status of the machine t PO means no test 41 APPENDIX TO THE MANUAL HOW TO USE THE RAISABLE STAND After unpacking and positioning the machine remove the safety pivot figurel The said pivot blocks the sliding of the base and is mounted in order to allow the transport of the machine and for repairs that may be necessary if the raising system is not working properly The raisable stand improves
18. ase contact the manufacturer at the following address LCM S r l Via Martino Ferraro 3 54100 Massa MS ITALY email prima lcmmac it PART1 DESCRIPTION OF THE MACHINE 1 2 HOW IT WORKS PRIMA LCM is a press for self clinching fasteners which must be employed on products obtained from metal or plastic sheets Being cost effective flexible compact easy to use and to maintain this machine is very attractive to anyone working with metal sheets A sturdy metal frame containing inside all the leverage to operate the pressing constitutes the main body It also accommodates a carriage that supports the anvil holder The anvil can be replaced according to the type of fastener to be fitted Movements are obtained by a double effect pneumatic cylinder operating a lever which presses the punch inserting the fastener A device that blocks the piece between punch and anvil with a force of 15 Kg makes inserting easier more accurate and safer The body of the machine which support also the electronics cabinet is placed on a sturdy steel structure that can be fixed either on the original base optional or on a adequately strong and stable bench figure 2 1 3 FIELD OF APPLICATION The machine is intended exclusively for the insertion of self clinching fasteners on materials having the requisites specified in the next paragraph The manufacturer disclaims any liability for uses of the machine not specified in this manual USES
19. d air 2 4 2 Preliminary checking E CHAPTER5 HOW TO OPERATE THE MACHINE 5 1 Electronic functions _ 5 2 Adjustments and settings 5 3 Inserting of self clinching fasteners with the machine in its standard configuration 2 5 4 Inserting of self clinching fasteners in other configurations Accessory 1 and Accessory 2 PART 3 MAINTENANCE CHAPTER 6 MAINTENANCE 6 1 Overview _ 6 2 Daily maintenance _ 2 6 3 Use of the TEST menu ATTACHMENT No I ELECTRIC DIAGRAM ATTACHMENT No 2 PNEUMATIC DIAGRAM PART 1 DESCRIPTION OF THE MACHINE CHAPTER 1 TECHNICAL FEATURES 1 1 OVERVIEW This manual contains instructions for installation use and maintenance of the PRIMA press The manual is intended both for the operators and for the trainers of the operators The original of this publication written in Italian is a unique reference for the resolution of any disputes related to the interpretive translations in European languages This publication is also an integral part of the machine and therefore must be preserved for future reference until the final demolition of the machine SCOPE OF THE MANUAL The scope of this manual is to teach operators how to safely use the machine Uses of PRIMA that differ from those herein specified are prohibited The user must also comply with work legislation in force in the country where the machine is operated HOW TO KEEP THE MANUAL This manual must be kept in a protect
20. e Lighting The machine is not equipped with a lighting system The lighting of the work place therefore must be enough for the operator to use the machine safely During operations of maintenance to parts of the machine which are not sufficiently lighted it is mandatory to use a portable lighting system in order to avoid that the parts the operator is working at will be in the shade 22 PART 2 INSTALLATION SETTING AND OPERATION CHAPTER 5 HOW TO OPERATE THE MACHINE 5 1 ELECTRONIC FUNCTIONS Press the POWER switch on For a few seconds the display shows the software release installed in the machine then the flashing word INIT appears If other messages are displayed some incorrect condition has been diagnosed One of the following errors may be displayed CArt The upper casing is open see section 5 2 HIPr The pressure is gt 7 5 bar maximum operating pressure Action to take lower the pressure acting on the pressure regulator present on the machine see section 5 2 HIFo The force is too high for the accessory currently installed on the machine Action to take lower the pressure acting on the pressure regulator present on the machine or change position of the fulcrum pin on the lever see section 5 2 To execute the pressing operations press the RESET button Pressing this button the letter F force followed by three digits is displayed to show you what is the Force currently set on the press E g F2
21. e Selections page 26 of this Manual When the machine remains idle for a longer time than the value set in the Tout function it goes back automatically to the manual mode and the selection procedure must be repeated if you wish to access the automatic mode again WARNING If you see that after the activation of the sheet blocking device there is something wrong with the position of the metal sheet or even a risk of crushing your or someone else s fingers In the manual mode you can decide not to push the command that starts the pressing operation In the automatic mode the cycle can only be interrupted by removing the carriage or if one of the accessories is being used by removing your foot from the foot switch or in any case by pressing the RESET button The default value for the time elapsing between the activation of the sheet blocking device and the pressing operation is 0 75 second and it can vary from 0 10 to 3 00 seconds It is up to the user to decide what the most appropriate time will be after assessing his particular work situation and his reaction time in order to avoid damages to himself and to the piece he is working at As far as the risk of crushing one s fingers hands is concerned it is clear that there is hardly any risk at all if the machine is used according to the instructions given in this Manual Unfortunately though it frequently happens that users do tamper with safety protections
22. ed and dry place near the machine to allow quick consultation It is also advisable to make a copy of this manual as a back up When consulting the manufacturer for any question about the machine always quote model and serial number of the machine you own use This manual must be kept for all the life of the machine should it deteriorate ask the manufacturer for a new copy UPDATING OF THE MANUAL The instructions contained here have been prepared according to the laws in force at the date of release of the machine on the market The current manual cannot be considered inadequate because of later updating determined by new rules or by other needs Possible modifications adaptations enhancements and the like that should be made on machines sold afterward do not oblige the manufacturer to modify machines formerly sold nor justify considering the machine or the manual lacking or inadequate Possible additions to this User s Manual that the manufacturer would send to users are to be considered integral part of the manual itself and shall be kept together with the original manual PART1 DESCRIPTION OF THE MACHINE COOPERATION WITH THE USER The manufacturer may be contacted for further information and will consider proposals and hints to improve this manual If the machine is sold or given to a third party this manual must accompany it In this case the original owner user is required to send the new owner s user s address to the
23. eration inside the machine check that the pressure indicated by the pressure gauge is zero How to close the upper casing 1 2 3 4 5 release the casing from the blocking pin by pulling it upward lower it and let it rest in its seat push the casing backwards up to the end lock the casing fastener on the left hand side of the machine give pressure by switching on the air valve Casing Pressure Upper Fastener Regulator Casing 4 Compressed P Air Valvs ressure Gauge Figure 3 13 PART 1 DESCRIPTION OF THE MACHINE 2 2 HAZARDS Replacing the anvil represents a hazard if the operator forgets to turn off the air by pushing the carriage he might unintentionally switch on the micro switch and activate the sheet blocking device As a matter of fact when the anvil has been removed which forms an integral part of the safety system there is space enough to interpose a hand or an arm between punch and carriage Under this circumstance the press might be operated by mistake causing the crushing of the operator s hand or arm To avoid this hazard it is absolutely necessary to turn off air and power supply before you replace the anvil 2 3 MISUSE Using the machine for operations not allowed may constitute a risk for the user besides jeopardising the machine s reliability and safety The following list includes a series of improper operations not allowed under any circumstances The list is not exha
24. ersonnel to repair the machine Do not drop the piece under work during and after the pressing operation 14 PART 1 DESCRIPTION OF THE MACHINE 2 4 MAXIMUM SHEET DIMENSIONS AND WEIGHT Maximum sheet dimensions allowed There are no particular restrictions related to the dimensions of the pieces to be worked except for the thickness of the sheet which is limited by the space between punch and anvil The operator must be careful with the possible movements of the piece when subjected to pressing The machine has optional accessories that allow inserting fasteners also in complex parts not workable with the machine in its standard configuration Maximum weight allowed The maximum weight of the part to be worked depends mainly on the capability of the user If the piece is very heavy the sheet blocking device may not have sufficient force to keep it in position In this case the operator must support the piece in such a way to keep it flat and horizontal between punch and anvil If this condition cannot be obtained the operation is not safe and the piece cannot be worked 15 PART 2 INSTALLATION SETTING AND OPERATION PART2 INSTALLATION SETTING AND OPERATION CHAPTER 3 INSTALLATION 3 1 PACKAGING Machines are shipped in standard packaging not waterproof as required for transport by land in covered vehicles Special packaging may be designed upon request in this case particular instructions on the packaging will be
25. given If requested by the customer each packaging is marked with the following indications Machine model and identification data Gross weight Instructions for handling Standard packaging The standard packaging is a wooden crate made of two parts a base and a hood When you receive it the packaging must be intact that is it must show no evidence of damage or breaking having been subjected to water heat sources or to other factors that could damage it in any Way tampering To remove the packaging it is necessary to detach the hood from the base by removing the nails in the lower part of the crate and lifting off the hood 3 2 HANDLING When the machine is packed in its crate it must be handled by forklift or similar Be very careful to avoid bumps and abrupt manoeuvres which could cause the machine to fall and hurt people nearby Once the machine has been removed from its crate it must be lifted by the appropriate rings like shown in figure 4 17 PART 2 INSTALLATION SETTING AND OPERATION Lift Lifting Ring Power rl2lola Telameccantequs Figure 4 3 3 PRELIMINARY CHECKING Immediately after unpacking it check that the machine and the accessories are not damaged there must be no evidence of rust moisture dents and so on and check
26. he right hand side of the electronics cabinet and turn the tap on Before starting the first clinching cycle the operator must Choose the most suitable anvil and the position of the fulcrum pin of the pressing lever set the pressure of air and stand in the correct position in front of the machine Push the RESET button to get the machine ready the display must show the current force eg F0 45 Lift the handle of the manual sheet blocking device of the accessory Place the fastener into the anvil Place the sheet in position centre the hole into the part of the fastener projecting out The anvil holding the fastener can be rotated to ease this operation Lower the handle of the manual sheet blocking device Press the FOOTSWITCH the accessory moves forward under the punch and the sheet blocking device is activated Push either the RIGTH COMMAND or the LEFT COMMAND to complete the inserting operation 34 PART 2 INSTALLATION SETTING AND OPERATION Upon completion of the pressing release the FOOTSWITCH to allow the accessory to go back to its original position lift the lever of the sheet blocking device and remove the sheet The machine is ready for a new pressing cycle INSTALLATION INSERTS WITH PIECES OF BOX SHAPED To insert fasteners in box shaped parts and in many other bent sheets the accessory no 2 is needed figure 20 ACCESSORY No 2 SEN
27. ing is the complete sequence of the functions available with the release 0 03 of the software CNT Decrement insert counter A value between 0 and 99 may be chosen Zero means no count FUIT minimum pressing time with fulcrum in position 1 A value between 0 05 and 3 00 seconds may be chosen The default value is 1 00 second FU2T minimum pressing time for fulcrum in position 2 A value between 0 05 and 3 00 may be chosen The default value is 1 30 seconds AOIT time for accessory on I O 1 A value between 0 05 and 3 00 may be chosen The default value is 0 50 seconds AO2T time for accessory on Input 2 A value between 0 05 and 3 00 may be chosen The default value is 0 25 seconds 2 time for accessory on Output 2 A value between 0 05 and 3 00 may be chosen The default value is 0 50 seconds TOUT reset time after idle A value between 10 and 250 seconds may be chosen The default value is 60 seconds If the machine stays idle for a period longer than the selected time the machine returns to the INIT state that is no pressing allowed TEST test function of the machine This function must be used by the service technician and will be described separately CTOT total counter This function shows the total number of inserting operations performed up to tens of thousands To show the number in millions press the FUNCTION button Press RESET to exit the function CPAr Insert incremental counter It shows
28. lectronics cabinet of the machine Insert the connector of the footswitch cable into the socket of the electronics cabinet of the machine Insert the compressed air pipe of the accessory into the tap situated at the right hand side of the electronics cabinet and turn the tap on Figure 25 Compressed Air Tap Accessories Warning For safety reasons it is mandatory to always fit an anvil onto the frame in order to have the correct gap between punch and anvil Otherwise there will be enough space left to insert a hand or an arm in the gap between punch and anvil possibly causing serious injury in case of accidental pressing Before starting the first clinching cycle the operator must Choose the most suitable anvil and the position of the fulcrum pin of the pressing lever set the pressure of air and stand in the correct position in front of the machine Push the RESET button to get the machine ready the display must show the current force eg F0 45 Place the fastener into the anvil Place the sheet in position centre the hole into the part of the fastener projecting out The anvil holding the fastener can be rotated to ease this operation Press the FOOTSWITCH the accessory moves forward under the punch and the sheet blocking device is activated Push either the RIGTH COMMAND or the LEFT COMMAND to complete the inserting operation
29. ly enhance their flexibility of use For example to clinch fasteners in C like pieces the accessory N 1 may be most suitable one Figure 16 ACCESSORY No 1 Figure 16 32 PART 2 INSTALLATION SETTING AND OPERATION To install the accessory N 1 proceed as follows Switch off the machine pressing power button by checking the display off Pull the carriage forward and remove the anvil holder screw Remove the anvil and the anvil holder Sy Anvil Holder Figure 17 Insert the accessory onto the carriage by lowering it from above The pin at the front end of the carriage must engage the slot inside the accessory Slide the accessory forward along the appropriate guides Once at stroke end block the accessory by its quick action fastener Quick Action Fastener Figure 18 33 PART 2 INSTALLATION SETTING AND OPERATION m 2 An 7 9 T 9 9 ve 9 e 6 1 gt Accessory Figure 19 pans Footswitch Compressed Air Tap Accessory Accessories Connector 0 Insert the connector of the accessory cable into the socket of the electronics cabinet of the machine Insert the connector of the footswitch cable into the socket of the electronics cabinet of the machine Insert the compressed air pipe of the accessory into the tap situated at t
30. manufacturer in this way the manufacturer shall be able to contact the new user for any updating or communications needed WARRANTY The warranty duration is 1 year The user must strictly follow the indications given in this manual to avoid invalidating the warranty In particular he shall always the machine within the specified limits a careful daily maintenance Employ people adequately trained and who have proven skill and attitude for this kind of job The manufacturer disclaims any liability deriving from Failure to observe the instructions Uses of the machine different from those specified in this manual Use ofthe machine by people who have not read and understood this manual Uses of the machine that go against the relevant laws of the country where the machine is operated Modifications on the machine not authorized by the manufacturer Repairs by unauthorised people Use of spare parts and accessories that are not original The warranty is invalidated if when selling the machine to a third party one omits furnishing the new user with this manual as well Should the new user be from a country where a different language is spoken it will be the original owner s responsibility to give him an accurate and faithful translation of this manual in the user s language TECHNICAL ASSISTANCE For any kind of repair and servicing not described in the manual ple
31. of machines or utilize parts that are not original Should that happen with users of our press then additional risks may arise and they will become even more dangerous with the automatic mode It is FORBIDDEN to use PRIMA INSERTER without its safety protections as it can cause crushing related injuries to the operator 44 APPENDIX TO THE MANUAL WARNING No user serviceable parts inside Servicing must be done only by properly qualified personnel ATTACHMENT No I ELECTRIC DIAGRAM 45 APPENDIX TO THE MANUAL TO PRIMA02 PWR PCB TO AUXILIARY VO PCB 26 PIN FLAT CABLE PRIMA02 CPU PRIMAU C PU APPENDIX TO THE MANUAL FROM PRIMAU2 CPU PROSSIMITY SENSOR RIGHT COMMAND KEY FA 26 PIN FLAT CABLE PROSSIMITY SENSOR CABLE LEFT KEY E 2 POWER SUPPLY CABLE POWER SUPPLY 22 av BROWN EARTH GREEN YELLOW FRONT PANEL POWER KEY PRESSURE SENSOR PRESSURE SENSOR CABLE CYLINDER VALVE SHEET BLOCKING VALVE UPPER CASE SWITCH PRIMA 2 PWR APPENDIX TO THE MANUAL FROM PRIMA CPU PCB AUXILIARY TOOL ACCESSORIES FOOT SWITCH CONNECTOR AUXILIARY CONNECTOR CONXT FOOT swrrch AUXILIARY APPENDIX TO THE MANUAL PRIMA INTOLA PCB VACUUM DOWN SOLENOID FORWARD BACKW ARD SOLENOID UP SOLENOID P4 VACUUM SOLENOID 12 AUXILIARY TOOL APPENDIX TO THE MANUAL APPENDIX TO T
32. ommands the electric and pneumatic devices mounted on the accessories POWER Command L Command R Q Pow er C L C R Display Reset Function F Foor SWITCH Accessos Foot Sw itch Figure 2 11 PART1 DESCRIPTION OF THE MACHINE 1 10 NOISE The machine has been tested for the level of noise emitted The level of noise results Max 76 4 decibels 1 11 Technical data The PRIMA may exert forces in the range from 280 KGs to 6 tons and above ELECTRICAL SPECIFICATION VOLTAGE ABSORPTION MAXIMUM POWER 230 VOLTS 0 1 AMPERES 20 WATTS 115 VOLTS 0 2 AMPERES 20 WATTS PART 1 DESCRIPTION OF THE MACHINE CHAPTER 2 SAFETY AND WARNINGS 2 1 COMPRESSED AIR SWITCH OFF DEVICE Some operations like changing the position of the fulcrum pin or replacing the punch can only be carried out after opening the upper casing of the machine However a safety device prevents its opening unless the air valve has been switched off which makes the machine mechanically inoperative How to open the upper casing 1 2 3 4 5 unlock the casing fastener on the left hand side of the machine switch off the air valve check that the pressure gauge indicates absence of pressure pull the casing forward lift it upwards to the vertical position until it slides downward into a blocking pin fig 3 Before doing any op
33. play and memorised If for any reason while already working you need to start again from the set value push the FUNCTION button for at least three seconds the count mode will go back to the set value b Increasing count function Push the FUNCTION button for at least three seconds when the display shows the word INIT or else press the RESET button to have INIT shown After pressing FUNCTION the word CNT count is displayed Pressing the FUNCTION button again a flashing two digit number is shown the default value is 05 Press the RIGHT and the LEFT COMMANDS at the same time to zero the value The display shows 00 flashing Press FUNCTION the display shows CNT Push the LEFT COMMAND CPAr partial count appears on the display Press FUNCTION the display shows the previous count in four digits which we shall call XXXX Press FUNCTION again the new set value 0 is confirmed and memorised the display shows CPAr Push RESET to get INIT and RESET once again to have the actual force shows on the display During the pressing operation the display normally shows the pressing force If you want to see the count value just press the FUNCTION button By pushing again the FUNCTION button the pressing force is shown again 24 PART 2 INSTALLATION SETTING AND OPERATION EE 215 51 81 085 8090000927272 ARE INCREASING COUNT F
34. r It is advisable to separate the different materials for correct recycling according to local laws ENSURE THAT NO ENVIRONMENT POLLUTION IS CAUSED BY THE DISPOSAL OF THE PACKAGING MATERIALS 3 7 CHECKING AFTER UNPACKING Before their shipment the machine and its accessories have been carefully inspected Nevertheless it is advisable to carry out a complete inspection of the machine as soon as you receive it If defective or missing items are found immediately call the manufacturers and wait for their instructions before operating the machine The machine is equipped with this User s Manual and of a set of anvils 3 8 INSTALLATION OF THE MACHINE WITHOUT ITS STANDARD BASE Before installing the machine please ensure that the electric plant is in conformity with your country s relevant laws To ensure a optimal stability of the press is required anchoring to the ground with suitable fastening systems In Figure 5 are represented the fixing holes present on the press Figure 5 Fixing Holes on 2 sides 19 PART 2 INSTALLATION SETTING AND OPERATION 3 9 INSTALLATION OF THE MACHINE ON ITS STANDARD BASE Before installing the PRIMA please ensure that the electric plant is in conformity with your country s relevant laws To ensure a optimal stability of the press is required anchoring to the ground with suitable fastening systems In Figure 6 are represented the fixing holes present on the p
35. ress Front Stabilization Stirrup Fixing Holes Back Stabilization Stirrup Figure 6 20 PART 2 INSTALLATION SETTING AND OPERATION CHAPTER4 SETTING 4 1 CONNECTION TO MAINS AND TO COMPRESSED AIR Mains connections The user must ensure that the electric plant be suitable put to earth and in conformity with his country s relevant laws The machine needs a 16 Amps 230 Volts 50 Hz socket compliant to CE or other local norms The fuse of electrical circuit must be 200 mA delayed for replacement see chapter 6 maintenance Compressed air connection The machine must be connected to a source of compressed air at a pressure of 6 8 bars For the connection remove the left side cover insert the male connector into the female connection compressed air and refit the cover Left Side Case Male Connection Female Connection Compressed Air Compressed Air Figure 7 The machine is also equipped with a pressure gauge that allows at any time to check the actual pressure in the press 21 PART 2 INSTALLATION SETTING AND OPERATION 4 2 PRELIMINARY CHECKING Before carrying out the function test of the machine check the following Function tests Press the POWER button the display must showing the INIT written intermittently Operator During normal use the position of the operator is in front of the machin
36. t not be operated outdoors or wherever exposed to atmospheric agents vapours corrosive or abrasive fumes or dust It must not be operated in areas with fire or explosion hazard and wherever the use of anti deflagrating components is required 1 7 OPERATOR S WORKPLACE The machine is to be operated by only one person who must stand in front of the machine at the most convenient distance facing the electronics cabinet The lighting must be strong enough to allow a good vision of the work area and must not generate shadows disturbing the sight in the work area 1 8 OPERATOR S REQUIREMENTS The operator must be adequately trained on safety issues in general and on specific safety issues related to the machine He must also have sufficient experience on how to operate the machine and on the characteristics of the materials employed 1 9 DESCRIPTION OF THE COMMANDS The machine has a simple set of commands On the two sides of the machine s body there are two green buttons Either of them commands the pressing provided the carriage holding the anvil is at stroke end The two green buttons are situated one on the left of the machine LEFT COMMAND and one on the right RIGHT COMMAND they may be used indifferently depending upon the operator s convenience The electronics cabinet on the right side of the machine has the following commands Power switch green POWER Four digit display DISPLAY Reset button yellow RESET
37. the partial count of the insertions you are doing To start the count again from zero press the RIGHT and LEFT COMMANDS at the same time To restore all the default values switch on the machine while keeping RESET and FUNCTION pressed at the same time for a few seconds When the display shows the word EEIN release the two buttons and operate the press as usual The total counter is not affected by this operation Note When you access the function menu buttons C D and 5 do not command pressing but changing the software parameters 26 PART 2 INSTALLATION SETTING AND OPERATION 5 2 ADJUSTMENTS AND SETTINGS Before operating the machine some adjustments and settings are needed for best performance Adjustment of pressing force The pressing force must be varied according to the type and size of fastener and to the materialin use By changing the air pressure and the position of the fulcrum of the pressing lever the pressing force may be varied in a very wide range The force corresponding to the combination of air pressure and fulcrum position is shown on the machine s display Compressed air pressure adjustment The air pressure may be varied by adjusting the knob of the pressure regulator by turning it clockwise the pressure increases by turning it anti clockwise the pressure decreases Force exerted Force exerted With fulcrum pin in hole 1 With fulcrum pin in hole 2 1 Atm tons 0 280 1 Atm tons
38. ulled out when the pressing cycle had not been completed To exit an error condition press the RESET button To switch off the machine press the POWER button the display switches off after a few seconds 23 PART 2 INSTALLATION SETTING AND OPERATION Insert count mode see page 27 for a graphic demonstration While inserting fasteners you can activate a function that counts the number of fasteners clinched You can choose either the Decreasing or the Increasing Count Function a Decreasing count function The count starts from a set value and is decremented each time a pressing operation is performed When the count reaches zero it starts again from the set value To set the initial count value push the FUNCTION button for at least three seconds when the display shows the word INIT or else press the RESET button to have INIT shown After pressing FUNCTION the word CNT count is displayed Pressing the FUNCTION button again a flashing two digit number is shown the default value is 05 By pushing the RIGHT COMMAND you increase the value By pushing the LEFT COMMAND you decrease the value Use either command until the desired value is displayed Push the FUNCTION button the word CNT appears Press RESET to have INIT shown on the display Press RESET again the current Force X appears on the display X XX stands for Force in tons Press FUNCTION for three seconds at least the new set value is shown on the dis
39. ustive but only indicates some of the possible situations reasonably foreseeable The operator must pay attention to the movements made by the sheet during pressing For example a long piece pressed at one end may lift at the opposite end during pressing This represents a risk for the operator or for people passing by in that moment During the down stroke of the sheet blocking device the operator may already assess which movements the piece will do when subjected to pressing The user must not modify the machine to enlarge the gap between punch and anvil to work sheets of higher thickness The gap between punch and anvil must not exceed 4 mm Do not operate the machine when the working environment characteristics are not those specified in this manual Do not allow unqualified personnel to operate the machine Do not modify or tamper with the safety devices or any other part of the machine Do not use the machine for operations not specified in this manual Do not use materials having characteristics different from those specified in this manual Do not use the machine without the upper casing on Do not operate the machine or make servicing operations when lighting is insufficient Do not inspect repair or maintain the machine without removing the mains plug and switching off the air Strictly use only original spare parts designed by the manufacturer Do not allow unqualified p
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