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MANUAL KPS 515 Serial No. 2008.01.14564

KPS SERIES Contents

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0 General Safety Instructions ........................................................... 7

0.1 Remaining dangers ............................................................................ 9 0.2 Safety regulations ............................................................................ 10

1 Machine Information ................................................................. 12

1.1 Preface and working possibilities ....................................................... 12 1.2 Features & technical specifications ..................................................... 13 1.2.1 Vertical punch unit ........................................................................... 13 1.2.2 Features KPS501 ............................................................................. 14 1.2.3 Features KPS503 ............................................................................. 15 1.2.4 Features KPS 506 ............................................................................ 16 1.2.5 Features KPS 515 ............................................................................ 17 1.2.6 Flat shear unit.................................................................................. 18 1.2.7 Horizontal Punch Unit ....................................................................... 19 1.2.8 Angle shear (DC Type 160*160*15)................................................ 20 1.2.9 Angle shear (SC Type 200*200*20) ................................................. 21 1.2.10 Angle shear (SC Type 200*200*25) ................................................. 21 1.2.11 Material pusher M100P.................................................................... 22 1.2.12 Transport T10.................................................................................. 23 1.2.13 Cross transport ................................................................................ 24 1.2.14 Product output table ......................................................................... 26 1.2.15 Product push-off device ..................................................................... 26 1.2.16 Marking unit ................................................................................... 27 1.2.17 General.......................................................................................... 28 1.3 Machine Layout ............................................................................... 29 1.4 Safety provisions.............................................................................. 30

2 Setup Environment..................................................................... 31

2.1 Machine Layout and main dimensions ................................................ 31 2.1.1 Main Dimensions ............................................................................. 32 2.2 Fundament ...................................................................................... 33 2.3 Enviroments..................................................................................... 34 2.4 Installation safetys ............................................................................ 35

3 Installation ............................................................................... 36

3.1 Package and Stocking ...................................................................... 36 3.2 Transport ........................................................................................ 37 3.2.1 Lifting instructions............................................................................. 37 3.3 Preparation for setup ........................................................................ 38 3.3.1 Preperations .................................................................................... 38 3.4 Setup ............................................................................................. 39

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3.4.1 Setup the safety fences and safety light guards .................................... 39 3.4.2 Anchoring and levelling.................................................................... 40 3.4.3 Electrical connections ....................................................................... 41 3.4.4 Pneumatic connections...................................................................... 42 3.5 Initial Commissioning ....................................................................... 43 3.6 Safety............................................................................................. 44

4 Operation................................................................................ 45

4.1 Switching on the machine ................................................................. 45 4.2 Switching Off The Machine ............................................................... 45 4.3 Lock out procedure........................................................................... 46 4.4 Stop procedure................................................................................ 47 4.5 Operation controls ........................................................................... 48 4.5.1 Operation controls Functions ............................................................. 48 4.5.2 Touchscreen Button Functions............................................................. 49 4.6 Fitting Tools and equipment............................................................... 53 4.6.1 Fixing Punch Tools ........................................................................... 53 4.6.2 Removing Punch Tools ...................................................................... 53 4.6.3 Fixing the knife in the shear unit......................................................... 53 4.6.4 Removing the knife of the shear unit ................................................... 53 4.6.5 Tensiontorque knife bolts................................................................... 54 4.6.6 Drill changing.................................................................................. 55 4.6.7 Fitting the Toolholder magazine ......................................................... 56 4.7 Adjustment ...................................................................................... 57 4.7.1 Feed and drill speed ........................................................................ 57 4.8 Pusher mounting adapter .................................................................. 59 4.9 Start Operation............................................................................... 60 4.9.1 Initializing sequence......................................................................... 60 4.10 Software description......................................................................... 61 4.10.1 Introduction..................................................................................... 61 4.10.2 System requirements......................................................................... 62 4.10.3 Installing the software ....................................................................... 63 4.10.4 Order manager ............................................................................... 65 4.10.5 Pattern manager .............................................................................. 72 4.10.6 Nesting manager............................................................................. 73 4.10.7 Optimize manager........................................................................... 75 4.10.8 Output manager .............................................................................. 80 4.10.9 Profile library .................................................................................. 83 4.10.10 Adding new profiles and changing data ............................................. 84 4.10.11 Tool manager.................................................................................. 85 4.10.12 Operator menu................................................................................ 87 4.10.13 Extern file import.............................................................................. 92

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5 Maintenance ............................................................................ 93

5.1 Maintenance ................................................................................... 93 5.1.1 Tool lubrication system...................................................................... 94 5.1.2 Lubrication ...................................................................................... 95 5.1.3 Lubrication points............................................................................. 96 5.1.4 Hydraulic system............................................................................ 107 5.1.5 Lubrication table ............................................................................ 107

6 Technical Documentation.......................................................... 108

6.1 General Instructions........................................................................ 108 6.2 Tools ............................................................................................ 109 6.2.1 Punch and Dies General Information................................................. 109 6.2.2 Punch-Die Clearance ...................................................................... 111 6.2.3 Correct tool order KPS503 .............................................................. 112 6.2.4 Minimum punch position KPS 501 (Peddinghaus type) ........................ 113 6.2.5 Minimum punch position KPS 503 (Peddinghaus type) ........................ 113 6.2.6 Minimum punch position KPS 506 (Peddinghaus type) ........................ 113 6.2.7 Minimum puns position KPS 515 (Peddinghaus type).......................... 113 6.2.8 Flat Shear Unit............................................................................... 114 6.2.9 Angle Shear Unit ........................................................................... 116 6.2.10 Grinding requirements knives .......................................................... 117 6.2.11 Knife Block Guiding System............................................................. 119 6.2.12 Drills General Information ............................................................... 120 6.2.13 Drill Types and qualities.................................................................. 120 6.2.14 Recommended drill Suppliers........................................................... 121 6.2.15 Grinding the drills .......................................................................... 122 6.2.16 Grinding instructions ...................................................................... 122 6.2.17 Drill Cooling.................................................................................. 124 6.2.18 Solving drill problems ..................................................................... 125 6.3 Spare Parts ................................................................................... 126 6.3.1 Spare parts punch KPS503 ............................................................. 126 6.3.2 Spare parts punch KPS506 ............................................................. 127 6.3.3 Spare parts punch KPS515 ............................................................. 128 6.3.4 Flat shear knives ............................................................................ 129 6.3.5 Spare parts angle knives................................................................. 130 6.3.6 Spare parts ball bearing spindle ...................................................... 131 6.3.7 Spare parts drill unit ....................................................................... 132 6.3.8 Spare parts Tool Changer ............................................................... 133 6.3.9 Suggested Spare part kit................................................................. 134 6.4 Pneumatic drawings ....................................................................... 135 6.5 Hydraulic drawings........................................................................ 136 6.6 Electric drawings ........................................................................... 137

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7 Appendix .............................................................................. 138

KPS SERIES General Safety Instructions

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0 General Safety Instructions The punching-shearing machine is built according to the current safety regulations. The necessary provisions are made for a safe way of working for the operator. In spite of all taken precautions, dangers may occur however while working with the machine. A total safety does not exist ! Therefore it is requested that, while working with or at the machine, the necessary attention should be taken in consideration.

-

WARNING

Read and understand manual before set up, operate or servicing this machine. Failure to follow instructions could result in personal injury or damage to equipment.


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The following conventions are used to indicate and classify precautions in this manual. Always follow the information provide with them. Failure to follow precautions could result in personal injury or damage to equipment. The conventions meets the ANSI Z535.5-1997 Designs and Definitions: SIGN DESCRIPTION

indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.

indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

indicates a potentially hazardous situation which, if not avoided, may result in minor or major injury."

signs used to indicate a statement of company policy directly or indirectly related to the safety of personnel or protection of property. This signal word shall not be associated directly with a hazard or hazardous situation and shall not be used in place of DANGER, WARNING or CAUTION.

signs used to indicate general instructions relative to safe work

The signs DANGER, WARNING and CAUTION are preceed by the

logo

DANGER

WARNING

CAUTION

NOTICE

SAFETY FIRST


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0.1 Remaining dangers When persons are in danger zones when the machine is switched on (what is not allowed), the following dangers can arise: • Moving parts of the machine can inflict grievous bodily harm. • Moving parts of the machine and tools can grab in clothes by which these

persons can be seriously injured. • The carriage can inflict grievous bodily harm by moving. • The products, waste or trim pieces can inflict grievous bodily harm to persons

which are in danger areas like on or in the input and output conveyors or at the ends of the machine.


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0.2 Safety regulations In order to minimize the chance on possible remaining dangers the following instructions have to be followed: • The machine may only be operated by fully instructed staff. • The machine may only be operated by staff who has read and understood the

manual. • The competence to operate the machine has to be put down in writing and

followed. • The machine may only be operated by staff which are commissioned by there

authority. • Outsiders are not allowed to operate the machine without commission and

instruction. • It is not allowed to make alterations or to carry out repairs to the machine

without the written permission of KALTENBACH in advance. • Irregularities of the machine during operation have to be reported immediately

to the supplier. • The operator has to take the responsibility that there are no persons in the

reach of the moving parts of the machine when the machine is turned on. • It is not allowed to reach, to sit, or to enter in the reach of the moving parts of

the machine. • Maintenance or repair activities are only allowed when the machine is

switched off according the LOCKOUT procedure, so that thoughtless switch on is not possible.

• Check or adjust activities are only allowed when the machine is switched off

(emergency stop activated). • Be sure that the machine is without pressure while disconnecting the pneumatic

or hydraulic pipes. • Electrical activities must only be done by certified electricians!


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• The use of the machine without the safety provisions or without taking in consideration the safety regulations is not allowed.

• It is not allowed to enter inside the safety protection while the machine is

turned on. • The machine may only be used for the purposes and materials for which it has

been designed. • It is important to check the function of the operation mechanism and safety

provisions regularly (1.4). Replace damaged parts immediately. • Use the personal protective means, safety shoes, Eye protection, ear

protection. • In connection with the possibility to hurt hands to sharp sides of the material or

burn by heated chips it is required to ware gloves.

KPS SERIES Machine Information

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1 Machine Information 1.1 Preface and working possibilities The KPS machine is designed for the special market requirements of steel fabricators and steel service centres and is appropriate for punching, shearing, drilling and centre marking of structural steel like, angle steel, U-profiles and flat-bar steel

For the possibilities in other working areas you can contact the sales department of KALTENBACH.


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1.2 Features & technical specifications 1.2.1 Vertical punch unit Features general • The sideward positioning of the punch unit running on linear bearings by

means of ball screw spindle with servo motor. • To prevent undesired process blockings the machine is standard equipped with

a automatic material lifter, which pulls the material out of the carriage at burring.

• Program controlled pop-marking function via automatic punch force reduction. • Automatic horizontal and vertical material clamping device within the

automatic cycle. Hardened clamping rollers running on linear bearings.

• Initial bar length control at the front edge of the bar via light scanner, integrated in the infeed roller conveyor.

• Automatic program controlled tool lubrication system via spray oil mist system.


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1.2.2 Features KPS501 • Massive steel C-frame construction, designed to carry one vertical punch unit

with totally 1 tool. • Hydraulic down holding device, arranged on the in- and outfeed side of the

material. • Standard tool set of 3 Peddinghaus punch / dies for 16, 18 and 20 mm for a

plate thickness of 12 mm. Specifications Working range min Flat mm ......................... 50 x 5 max Flat mm ..................... 500 x 25 min Angle Steel mm ..................50 x 50 x 5 max Angle Steel mm ............160 x 160 x 15 min U-profiles mm ...............65 x 42 x 5.5 max U-profiles mm ............320 x 100 x 14 Automatic tool change Tool carriage piece...............................1 Punch diameter min. - max mm .......................... 5 - 40 Punch force kN ............................1250 Drive performance Positioning drive punch unit kW ..............................2.2


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1.2.3 Features KPS503 • Massive steel C-frame construction, designed to carry one vertical punch unit

with totally 3 tools. • The punch tools are set up in line and can, due to the heavy punch guiding

construction with each of the three tools, the maximum punch power be utilized.

• Hydraulic down holding device, arranged on the in- and outfeed side of the

material. • Standard tool set of 3 Peddinghaus punch / dies for 16, 18 and 20 mm for a

plate thickness of 12 mm. Specifications Working range min Flat mm ......................... 50 x 5 max Flat mm ..................... 500 x 25 min Angle Steel mm ..................50 x 50 x 5 max Angle Steel mm ............160 x 160 x 15 min U-profiles mm ...............65 x 42 x 5.5 max U-profiles mm ............320 x 100 x 14 Automatic tool change Tool carriage piece...............................3 Punch diameter min. - max mm .......................... 5 - 40 Punch force kN ............................1250 Punch force distribution %.................. 70 - 100 - 70 Drive performance Positioning drive punch unit kW ..............................2.2


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1.2.4 Features KPS 506 • Massive steel C-frame construction, designed to carry one vertical punch unit

with totally 6 tools. • The twisting of the 6-station tool changer and the die carousel via servomotor

and rotary encoder. • The punch revolver and the die carousel are aligned with each other

mechanically. Both devices are additionally locked at every position to prevent them from turning.

• Hydraulic double down holding device arranged on the in- and outfeed side to

fix the material on the die carousel.

• Standard tool set of punch / dies for 16, 18, 20, 22, 26 and 32 mm for a plate thickness of 12 mm.

Specifications Working range min Flat mm ......................... 50 x 5 max Flat mm ..................... 500 x 25 min Angle Steel mm ..................50 x 50 x 5 max Angle Steel mm ............160 x 160 x 15 min U-profiles mm ...............65 x 42 x 5.5 max U-profiles mm ............320 x 100 x 14 Automatic tool change Tool carriage piece...............................6 Punch diameter min. - max mm .......................... 5 - 70 Punch force kN ..............................900 Drive performance Positioning drive punch unit kW ..............................2.2 Positioning drive rotary automatic tool changer and matrix plate kW ..............................2.2


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1.2.5 Features KPS 515 • Massive steel Portal-frame, with totally 15 punch- and 24 die tools. • The punch- and die tools are set up independent on a under- and upper

carousel. Servo motor and a mechanical blocking system bring and hold the carousel on the exact and guaranteed position.

• Hydraulic down holding and material correction device (4 t), arranged on the

in- and outfeed side of the material. • Standard tool set of 3 Peddinghaus punch / dies for 16, 18 and 20 mm for a

plate thickness of 12 mm.

Specifications Working range min Flat ...................................mm 50 x 5 max Flat ...................................mm 500 x 25 min Angle Steel ........................mm 50 x 50 x 5 max Angle Steel ........................mm 160 x 160 x 15 min U-profiles ...........................mm 65 x 42 x 5.5 max U-profiles ...........................mm 320 x 100 x 14 Automatic tool change Tool carriage .................. piece 15 tool die carousel .......................... piece 24 Punch diameter min. - max ........................................mm 5 - 40 Punch force .........................................kN 1250 positioning drive punch- and die carousel ......................... kW 2 x 2.2 Drive performance Positioning drive punch unit ................ kW 2.2


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1.2.6 Flat shear unit

Features • Massive steel portal frame construction • The sideward positioning of the complete shear unit running on linear bearings

by means of ball screw spindle with servo motor. To uniformly take up the shear forces the flat shear unit always positions centric to the material width.

• The blades are, before grinding, multiple turnable. • In the shear unit integrated hydraulic down holder to clamp the workpiece. • Extreme short rest piece length: 2 x the material thickness to be processed

(min. 20 mm).

• A process without remnant is also possible by optimizing the bar configuration (no remnant cut).

Specifications Working range min ......................................mm 50 x 5 max ......................................mm 500 x 25

Shear force ......................................................... kN 2200 Drive performance .........................................................kW 2.2 Blade inclination 2 positions degrees 1,25/ 2,5

NC controlled flat shear indexing: Swivelling range ................................degrees ± 60 Drive performance ......................................kW 2.2 Working range 90° ......................................mm 500 x 25 ± 60° ......................................mm 400 x 25 ± 45° ......................................mm 350 x 25 ± 30° ......................................mm 245 x 25


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1.2.7 Horizontal Punch Unit Features • For angle steel profiles.

• The rigid construction is designed to carry two punch tools.

• The punch unit is located between the vertical punch unit and the flat shear

unit.

• Height positioning via ball screw spindle with servo-motor.

• Floating mounted punch carriage running on linear bearings.

• Punch wastes are being conveyed into a container via a stripping device and an ejection channel.

• Automatic program controlled tool lubrication via spray oil mist system. Specifications

Working range min Angle steel ..................... mm 50x50x5 max Angle steel...................... mm 160x160x15

min U-steel ............................ mm 65x42x5,5 max U-steel ............................ mm 320x100x14

Punch diameter min - max ..................................... mm 5 - 26 Punch force kN 2x550 Punch force in combination with angle steel shear unit,

200*200*25 single cut kN 2x750


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1.2.8 Angle shear (DC Type 160*160*15) Feautures • With the two-edges cutting method the material is being supported on two

sides of the cutting line. This cutting action requires less force and prevents deforming of the material.

• Multiple utilization of the tool by simply turning the lower blade. • Shortest product: 2 x the material thickness to be processed (min. 20 mm). • Rest piece: not smaller than the flange width. • A process without remnant is also possible by optimising the bar configuration

(no remnant cut). • A blade for angle steel for 50x50x5 to 160x160x15 mm is included in the

standard scope of supply. • Automatic program controlled tool lubrication via spray oil mist system. Specifications Working range min Angle steel ..................... mm 50x50x5

max Angle steel...................... mm 160x160x15 Shear force ..................................... kN 750 Drive performance positioning drive shear unit ................. kW 2.2


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1.2.9 Angle shear (SC Type 200*200*20) Specifications Working range min Angle steel ..................... mm 50x50x5

max Angle steel...................... mm 200x200x20 Shear force ..................................... kN 4000 Drive performance positioning drive shear unit ................. kW 2.2 1.2.10 Angle shear (SC Type 200*200*25) Specifications Working range min Angle steel ..................... mm 50x50x5

max Angle steel...................... mm 200x200x25 Shear force ..................................... kN 5000 Drive performance positioning drive shear unit ................. kW 2.2


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1.2.11 Material pusher M100P Feautures • Data input via the software program of the punch / shear. • Pusher-type measuring system running on linear bearings. • Positioning via servo motor, rack and pinion and rotary encoder • Automatic approach to profile end. • Positioning Length measuring at the front edge of the profile via light sensor. Specifications Measuring range ......................................................................... m 6.1 Drive performance, positioning drive ........................................... kW 2.2 Positioning speed measuring carriage min. - max. ..................... m/min 0 - 35 Feed force of the pusher type measuring carriage for material weight up to max. kN 20


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1.2.12 Transport T10 Features Roller conveyor sections in modular system, executed in solid steel construction with non-powered tubular transport rollers with ball bearings. In the roller integrated solid steel vertical alignment blocks on the datum line. Specifications Working height .......................................................................... mm 1050 Roller diameter .......................................................................... mm 50 Roller width ............................................................................... mm 415 Maximum material width ............................................................. mm 500 Infeed roller conveyor for material lengths put on infeed material stillages from - to ............................................................m 1.7 - 6.1 from - to ............................................................m 1.0 - 6.1 Material stillages: Features • Material stillages in rigid steel construction. • Infeed and aligning of material against the vertical alignment blocks of the

infeed roller conveyor through the operator (manually). Specifitcations Material stillages depth ...................................................................................... m 0.5 Infeed material stillage number of material stillages ...................................... piece 4 carrying capacity ....................................................... kN 10


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1.2.13 Cross transport Features • as well as automatic material separation system by means of flat carrying

chain type cross conveyor Chain type cross conveyor, 1st section: • Material supports in solid steel construction. • Cross transports in solid steel construction. • Chain type conveyor working in two directions. • No gaps required between stock material, resulting in maximum utilization of

cross conveyor width. • Drive system with gear motor. • Alignment of material on the chain conveyor by means of pneumatically

activated stop pins. Automatic material separation system by means of carrying and lifting chain type cross conveyor, 2nd section: • Cross transports in solid steel construction. • Carrying and lifting chain type conveyor working in both directions. • Drive system with gear motor. • Automatic take over and segregation of a material bar from the 1st section to

the 2nd section cross transport onto the overlapping chain conveyor of the infeed rollerway.

• Conveying, automatic lifting and aligning of the material bar against the

vertical alignment blocks of the infeed rollerway. • Suitable for flat, angle, channel and U-steel


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Specification Chain type cross conveyor, 1st section Transport speed c.c. ................................. m/min 0/5 Cross conveyor drive ......................................kW 1.1 Cross conveyor width ........................................ m 1.5 Infeed cross transport number of chain conveyors ............. pieces 4

number of motors ........................... pieces 1 Carrying capacity .......................................kN 20

Automatic material separation system by means of carrying and lifting chain type cross conveyor, 2nd section Transport speed c.c. ................................. m/min 0/7.5 Cross conveyor drive ......................................kW 1.1 Infeed cross transport number of chain conveyor ............... pieces 4

number of motors ........................... pieces 1 lifting capacity, per support .................. kN 150

Compressed air connection (by customer) .................................. bar 6 – 8 Air consumption at 6 bar .................................. l/min 250


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1.2.14 Product output table Features • Because of tumbling of the material at last product with minimal desired rest

length, it is necessary to put in this output table. • Output table executed in solid steel construction. • Program controlled movement of the table in X-direction via servo motor to

pick-up good pieces. The table remains in the home position when cutting trim or remnant pieces which fall via a chute into a container after the shearing process.

• Pneumatically controlled lowering of the output table during the shearing

process to assure optimum pick-up of good pieces. Specifications Working height .......................................................................... mm 1050 Maximum material width ............................................................. mm 500 Table length .............................................................................mm 4000 1.2.15 Product push-off device • The product output table will be equipped with a push-off mechanism to push-

off longer material lengths onto material stillages (to be provided by customer). • This function is automatically or manually controlled by the operator from the

operating panel.


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1.2.16 Marking unit Features • Marking device for flat angle and U-steel, for installation directly adjacent to

the portal frame of the vertical punch unit. • The marking process is program controlled by the machine software

MULTILINE 2. • Each character can be exchanged separately. Marking unit with single marking wheel Specification Drive performance marking wheel servo motor .............................. kW 0.75 Height and width of characters .................................................... mm 10 Position character height ..............................................................mm 20 Number of characters in the marking wheel ............................... pieces 39 Figures from 0-9 Letters from A-Z plus 3 additional free places Max. number of characters in one line ...................................... pieces 15 Marking depth ........................................................mm 1 Marking unit with four marking wheels Specification Drive performance marking wheel servo-motor .............................. kW 2.2 Height and width of characters .................................................... mm 10 Number of marking wheels ..................................................... pieces 4 Number of characters per marking wheel .................................. pieces 39 Figures from 0-9 Letters from A-Z plus 3 additional free places Max. number of characters in one line (3x4) ............................. pieces 12 Marking depth ........................................................................... mm 1


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1.2.17 General Specifications Working height above floor.......................................................mm 1050 Compressed air connectionby customer ............................................ bar 6 – 8 Air consumption at 6 bar ........................................................ l/min 250 Weight Machine without accessories ................... approx. kg 14.000 Machine dimensions............................................. L x W x H (meter) 1.8 x 2.7 x 2.8 Electric equipmentaccording to EN 60204, with integrated switchboard cabinet Operating voltage.................................................................V/Hz 400/50 Connection .................................................................. phases 3 +0+ Earth Protection of external lead........................................................... A 63 (slow) Power consumption maximal ....................................................kVA 32 Power consumption nominal ................................................kVA/A 26/50


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1.3 Machine Layout Refer to the Enclosed Layout drawing.


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1.4 Safety provisions The KALTENBACH machines has been built according to the current safety provisions, which regular have to checked on function. Safety provisions Function Emergency stop switches all the movements of the machine are

stopped Electrical thermal safety when a motor is overheated the

emergency stop will be switched on Safety switches on the moveable safety fences or lightguards

when a safety fence or guard is activated the automatically mode will be stopped

WARNING

Operating the machine without safety provisions may cause grievous bodily harm. The machine may only be operated when all the safety provisions are functioning and are mounted on there place.

The machine will be delivered with a manufacturer's declaration according to enclosure IIB of Guideline 98/37/EG. The user has to guarantee that the complete machine complies with the EC-Machine Guideline No. 89/392. Depending on the conditions on site, additional safety equipment, e.g. fences, light barriers, etc., may be required. A CE-declaration of conformity may be issued after additional safety equipment is provided and the machine provided with a CE-decal. Any additional safety measure required by local Health and Safety regulations are not included in our scope of delivery. In spite of all taken precautions, dangers may occur however while working with the machine. A total safety does not exist ! Therefore it is requested that, while working with or at the machine, the necessary attention should be taken in consideration.

KPS SERIES Setup Environment

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2 Setup Environment 2.1 Machine Layout and main dimensions • For the type of machine and the accessories and the repetition of the machine

data we refer to the confirmation of the order. • When setting up the machine, it has to be taken in consideration that the

required passages to the machine must be kept free, in particular:

- the free working space of the operator

- the space for the removal of curls

- the space the punching units need to make their stroke

- the space a carriage needs to be able to move


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2.1.1 Main Dimensions Refer to the Enclosed Layout drawing.


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2.2 Fundament For a good functioning the machine must be placed on a stable, flat (concrete) floor. In the use of stay bolts the regulations of the manufacturer must be followed. The foundation must at least have sufficient portative power to carry the individual weight of the total machine.


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2.3 Enviroments Temperature Operation : +5 ºC ….. +40ºC Storage : -40ºC ….. +70ºC Variation of temperature Operation : max 10 ºC/h Storage / Transport : max 20ºC/h Relative Humidity (according to DIN 40040)

:15% ..... 95% (indoor no condensation) Pollutants SO2 : ≤ 0,5 ppm ≤ 60% (no condensation) H2S : ≤ 0.1 ppm (relative humidity) ≤ 60% (no condensation) Floor vibrations Floor vibrations can disturb the functioning of the machine and electronically components. Therefore make sure that there are no strong floor vibrations near the machine Magnetic Fields Strong Magnetic Fields can disturb the functions of electronically components. Therefore make sure that there are no strong Magnetic Fields near the machine.


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2.4 Installation safetys For general safety considerations attention must be paid to the following points, both in choosing the place for the machine and in the set up and the transport: - Adequate lighting of the working area of the machine - Protection against bumping of carriages or cranes - The required power supplies (electricity, pneumatics etc.) must be provided

together with the possibility to uncouple the machine. These facilities must be adjustable.

- Take the actual situation in the plant in good account so that by setting up the

new machine no new dangerous situations can occur.

KPS SERIES Installation

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3 Installation 3.1 Package and Stocking Packing Standard packing - in upright position - bright parts treated with rust preventive Seaworthy packing See Standard packing Storage - in upright position - bright parts treated with rust preventive - dry storage


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3.2 Transport 3.2.1 Lifting instructions KPS

DANGER

NEVER WALK OR STAND UNDER A HOISTED LOAD. THIS CAN LEAD TO DEAD OR SERIOUS INJURY, IN CASE THE LOAD WILL BREAKE LOOSE! NEVER ENTER A HOISTED LOAD!

NOTICE To lift use two synchronised cranes or a lifting beam.

NOTICE A--> Two lenght of minimal massive ∅ 50mm x 250mm (L)

The machine has to be transported in accordance with the hoisting instructions delivered with the machine and in the appendix of this manual.


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3.3 Preparation for setup 3.3.1 Preperations - Checking the delivery for completeness - Checking the delivery for damage due to transport - Transporting the machine parts to the place of set up - Checking whether all conditions for connection have been provided - Remove rust preventive from bright parts with a cloth. When in this check up no deficiencies have been found, the set up of the machine in accordance with the Layout drawing can start.


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3.4 Setup Order of setting up: - Set up the punching-shearing machine at the right height and level in a straight

line - Set up the marking unit at the right height and level in a straight line. (option) - Set up the input roller conveyor with rail in a straight line and level at the right

height - Set up the column punching machine at the right height and level in a straight

line with the input roller conveyor - Set up the sawing machine (option) at the right height and level in a straight

line with the input roller conveyor - Set up the output table way in a straight line and level at the right height - Place the operation desk and fixed it to the floor by means of 4 stay bolts. - Place the safety fences and/or safety light guards - Fix and connect the electrical cable work according to the electrical diagrams

which are delivered with the machine. - Fix and connect the pneumatic tubes according to the diagrams which are

delivered with the machine. 3.4.1 Setup the safety fences and safety light guards For the protection against moving parts a safety protection is provided. The safety protection can consists of safety fences, safety light guards and/or emergency switch buttons. The safety fences and light guards must be fixed to the floor by means of stay bolts. The position of the safety protections must be in accordance with the construction Layout drawing which is delivered prior to the shipment of the machine


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3.4.2 Anchoring and levelling Machine parts must be anchored to a concrete floor by means of stay bolts. Leveling by means of the leveling screws, adjust the height of the machine to a working level of 1020 mm. Fine-tune the machine parts in height according the height level diagram.

Operating cabinet and switchboard cabinet with 4x stay bolts M12x113, no level adjustment.

Puns-shear machine, stays on place by its own weight.

Level adjustment by 8x feetbolts (±25 mm).

Infeed and outfeed table with 4x M12x113 stay bolts for each leg. Level adjustment by thread ends.

Cross conveyors with 4x M12x113 stay bolts for each transport. Level adjustment by thread ends. MWA404 with 4x M12x113 stay bolts. Level adjustment by thread ends.


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3.4.3 Electrical connections

NOTICE Electrical connections must only be made by certified electricians. The machine must be connected totally according to the enclosed electrical diagrams.


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3.4.4 Pneumatic connections The main connection for the pneumatic provision is located at the back side of the machine and indicated with following label.

Air supply conditions:

* Air supply: 6- 8 Bar * Air consumption: 250 l/min * Dew point: < 3ºC * Relative humidity: <10%


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3.5 Initial Commissioning

CAUTION

Observe the safety regulations.

- Read this manual thoroughly

NOTICE Execute the initial tests, for safety reason, without material and tools.

- Remove the transport Bar and other transport utilities if available - Fill up the reservoir for Tool Lubrication - Check the hydraulic Oil level


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3.6 Safety • Set up - Only qualified skilled persons may setup , assemble, install electric and

hydraulic and commission the machine and periphery systems - Use qualified lifting and hoisting equipment - drill and periphery systems to be lifted through the suspension points only, if

provided. With forklift or hand truck only the supporting parts may be used for hoisting.

DANGER

NEVER WALK OR STAND UNDER A HOISTED LOAD. THIS CAN LEAD TO DEAD OR SERIOUS INJURY, IN CASE THE LOAD WILL BREAKE LOOSE! NEVER ENTER A HOISTED LOAD!

- mechanical setup must be completed before the electric and hydraulic

connections can be made • Disassemble - Disconnect the machine from the electric main supply and air supply - Pump out the cooling fluid and discharge. - Clean the machine free of punch waste, chips, Dirt and cooling fluid. - Disconnect the electric, hydraulic and air connections from the periphery

systems. - Label these points before disconnection. - Blind stop the hydraulic tubes and connections. - Mount the transport bar and, if removed, mount the two transport supports on

the drill machine. - Unscrew the nuts from the anchor bolts.

KPS SERIES Operation

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4 Operation 4.1 Switching on the machine

CAUTION

Before switching on, Observe the safety regulations!

- Close all covers and entries - Turn Mainswitch in position 1 - Unlock the Emergency Switch - The Computer Control System will power up automatically - Wait until the Mainscreen is displayed on the screen

- Activate the output manager by pressing the button

- Power on the machine by pressing the button - Follow the instructions on the screen for running the initialising program

→ Chapter 4.9.1 4.2 Switching Off The Machine

- Stop Auto Cycle by pressing the button - Follow the instructions on the screen for putting the machine in safe position

mode → Chapter

- Activate the Exit mode by pressing the button Follow the instructions on the screen for exiting the program

- Turn Mainswitch in position 0

NOTICE Switch off the machine according the above instructions. Improper computer shut-off can result in data loss, startup problems, network failures x.


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4.3 Lock out procedure

SAFETY Follow lockout procedures before servicing. Lock out procedure - Announce lockout to other personnel - Switch off the machine according the instructions → Chapter 4.2 - Lockout the Mainswitch in OFF position - Put key in pocket - Clear machine of all personnel - Block, chain or release stored energy sources - Clear machine of personnel before restarting machine - Take key from pocket - Unlock the lockout device - Switch off the machine according the instructions → Chapter 4.1 - Announce machine is ON to other personnel. Follow Lock out procedure before: - Servicing - Maintenance - Cleaning


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4.4 Stop procedure

SAFETY Follow Stop procedures before inserting Tools. - Announce Stop to other personnel

- Stop Auto Cycle by pressing the button - Follow the instructions on the screen for putting the machine in safe position

mode → Chapter - Activate the EMERGENCY STOP by pressing the Emergency switch - Lock the emergency switch Button - Put key in pocket - Announce machine is STOPPED to other personnel.


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4.5 Operation controls

4.5.1 Operation controls Functions Key Description Function 1 Mainswitch Horizontal:

- Pos 1: Main power switched on Vertical: - Pos 2: Main power switched off

2 Emergency switch Pressed: - Machine stopped all movement immediately - Switch is locked Release: - Pull the switch in upwards direction

3 Touch screen Controlling the machine functions and software

1. Mainswitch 2. Emergency switch

3. Touch screen


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4.5.2 Touchscreen Button Functions

Button Description Function

Order Manager Input and for orders and posnumbers

Nesting Manager To divide a profile into different posnumbers

Optimize Manager In this menu it is possible to optimize several orders in a profile, with a minimum of rest

Tool Manager A survey of the data of the tools, such as diameter of the tools and the lubrication frequency

Feed Manager A survey of the tools and the matching feeding and rotation speed

Operator menu Select the different functions of the machine

Start cycle To start a cycle

Restart cycle To continue the cycle after a stop

Stop cycle To stop the machine

Toggle buttons Other function buttons will appear

Keyboard To enter characters with the touch screen

Profile library A survey of the different profile types

Manual mode

To control the machine manually

Program info Shows information about the program, for example the version number.


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Extern file import To import and convert DSTV files generated by CAD software

Delete The selected field will be deleted

Delete all line All the lines in the posnumber will be deleted

Copy Duplicates the selected field and places it on the clipboard

Paste Inserts text from the clipboard into the field where the cursor is located

Output manager Display machine status, axis positions and operator messages

Rule up Cursor one rule up

Rule down Cursor one rule down

Page up One page up

Page down One page down

Insert lin Insert a new line

Pattern Manager Input and storage for hole patterns

Turn product 180° The product of the cursor location will be turned around the longitudinal axis.

Mirror the product The product of the cursor location will be mirrored

Mirror flange of an U beam

Mirror the flange holes along the y-axis


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Escape To go back to the main screen

Program Exit The program will control all the axis to their rest positions and asks if the program has to be ended.

Calibrate the index shear

For service engineers only

Tool change position The punch unit will be controlled to the tool change position

Quick punch menu Opening a menu, to control some functions manually, while in the automatic mode

Manual mode Activate the manual mode The following Buttons are only activated in the manual mode >

The following Function Buttons shown and activated in the manual mode only.

Transport 1 forwards The first transport will be controlled forwards

Transport 1 backwards

The first transport will be controlled backwards

Transport 2 forwards The second transport will be controlled forwards

Transport 2 backwards

The second transport will be controlled backwards

Cam up / down The cam will be controlled up / down

Transport up / down The transport will be controlled up / down

Flat shear position The flat shear unit will be controlled in a straight line with the installation

L shear position The angle shear unit will be controlled in a straight line with the installation


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U profile position The shear units will be controlled to the position for U profile between the two shear units

Ejector cycle The output ejector will be controlled

Drill up The drill will be controlled upwards

Drill down The drill will be controlled down


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4.6 Fitting Tools and equipment

CAUTION

Fitting Tools while the machine is ON can inflict grievous bodily harm to persons. Fitting Tools is only allowed when the machine is Stopped or Switched OFF. Follow the STOP or LOCKOUT procedure before fitting or removing Tools.

NOTICE In connection with the possibility to hurt hands to sharp sides of the material or Tools it is required to ware hand gloves.

4.6.1 Fixing Punch Tools - Follow the STOP procedure, Chapter → 4.4 - Screw on the punch holder with the punch tool as firm as possible by hand - Fasten the punch holder with the special ring spanner - Check if the right mould for the punch tools is fixed - Check the correct position of the punch tools 4.6.2 Removing Punch Tools - Follow the STOP procedure, Chapter → 4.4 - Release the punch holder with the special delivered ring spanner - Screw the punch holder off by hand completely and take it out of the machine

to change the punch tool 4.6.3 Fixing the knife in the shear unit - Follow the STOP procedure, Chapter → 4.4 - Fix the top- or bottom-knife by means of the fixing bolts - Check the cutting tolerance 4.6.4 Removing the knife of the shear unit - Follow the STOP procedure, Chapter → 4.4 - Make sure that the shear unit is in the right position - Release the top- or bottom-knife by taking of the fixing bolts


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4.6.5 Tensiontorque knife bolts

ATENCIÓN Check the Tensiontorque of the bolts again after 5 cut cycles.

ATENCIÓN Do not use LOCTITE.

• KPS503/506/515 flatshear : upperknive: 120 Nm (± 5 Nm) (M12x50 8.8 bolts) lowerknive: 120 Nm (± 5 Nm) (M12x50 8.8 bolts)


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4.6.6 Drill changing - Bring / put the machine in safe mode, Chapter → - Activate the emergency stop by pressing the emergency stop switch - Put on hand gloves - Hold the drill in one hand - Push back the ring (A) of the drill unit with the other hand - Take out the chuck with tool - Put in new chuck with tool - Check and enter the drill length and diameter in the Toolmanager Chapter →

A


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4.6.7 Fitting the Toolholder magazine Due to an misallignment or operation failure the Toolholder can be reject out of is position. In this case the emergency stop circuit will automatically be activated. The toolholder is catched and absorbed by two rubber bands. Follow the next procedur for re-inserting the Toolholder magazine: - Lock the emergency stop by pressing the emergency stop switch. - Put on hand gloves - Remove all Tools out of the magazine, and keep them in right-order. - Place the handle in open position as shown in the figure, this will relieve the

dish-springs - Reposition the magazine into his original place - Be sure that the two alignments bolts at the back and the alignment bolt at the

front side are in correct position - Place the handle in locked position as shown in the figure - Place back the Tools in their original positions.

2

3

4

1

OPEN

5 LOCKED


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4.7 Adjustment 4.7.1 Feed and drill speed The Feed – penetration speed of a drill unit is provided by a ball circulation spindle which is controlled by a servo motor. The speed of the drill spindle is controlled directly from the computer program, dependant on the entered drill diameter according to the list below. The rotation speed of a drill spindle is determined by a frequency controlled drill motor. The drill motor is controlled digitally from the computer program by means of a frequency regulator. The default factory settings for Speed and Feed Penetration are set as follows:

Drill diameter Feed/ Penetration Feed Rate Speed mm mm/min mm/rev RPM M/min

7 / 8 180 0.18 1000 25,1 9 / 10 180 0.21 800 25,1 11 / 12 170 0.24 700 26,4 13 / 14 160 0.26 600 26,3 15 / 16 160 0.32 500 25,1 17 / 18 160 0.32 500 28,2 19 / 20 150 0.37 400 25,1 21 / 22 140 0.35 400 27,1 23 / 24 120 0.34 350 26,4 25 / 26 110 0.36 300 24,5 27 / 28 110 0.36 300 26,4 29 / 30 90 0.36 250 23,5 31/32 90 0.36 250 25,2 33/34 90 0.36 250 26,7 35/36 80 0.32 250 28,2 37/38 70 0.35 200 23,8 39/40 60 0.3 200 25,1

The above data to be used when drilling Steel 37A Grade Material (<30mm deep), HSS Endfeed drill with air/oil microlubricated cooling and KALTENBACH grinding method. For harder materials (50 Grades)or >30 mm deep, reduce the drilling speed (RPM) but maintain the FEED RATE (mm/rev).


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NOTICE

To further reduce production time, increase the feed rate only ! Pay careful attention to the stresses that may be imposed on the machine. Too high RPM against an inappropriate Feed Rate will burn out the drill !

Settings are recommended, but can be changed depending on Grinding quality, cooling method, Tooling quality, Steel quality, Drill manufacture etc. The factory settings above are based on a maximum speed of about 30 m/min at the outside of the drill head. Refer to the Technical documentation of your drill supplier (manufacture) for guideline settings for other drill types.


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4.8 Pusher mounting adapter Depending of the width of the material, the right mounting adapter has to be fixed on the pusher. Use the table to select the right adapter. Material direction width left >right right >left 50-279 mm Order nr 101769 Order nr 101770 280-500 mm Order nr 101772 Order nr 101771

NOTICE Don’t use the wide mounting adapter by angle steel profiles !


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4.9 Start Operation 4.9.1 Initializing sequence

NOTICE Startup the machine without Material! The material which are still in the machine must be removed before starting the machine. After switching and powering on the machine, the punch units, clamping units and the pusher-carriage will be initialized by the control program. All axis will move to a fixed cam, after reaching the fixed cam the axis get his reference point. The control program asks for a confirmation of the correct performing of the above-mentioned points. Confirmation is given by means of the button "RESTART" on the operation desk. Starting order of the initializing sequence: - Clamping units are opened - Shear unit and punching unit are controlled upwards - Flange punch unit initialised - Drilling unit initialised - Carriage initialised - Punching unit initialised - Marking unit initialised - Shear unit initialised

NOTICE Correct performing of the initialising sequence must be checked visually by the operator.


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4.10 Software description 4.10.1 Introduction The software program MULTILINE has been developed by KALTENBACH BV specifically for the PUNCHING_SHEARING series machines in close co-operation with a number of large steel construction firms. The program is written in the programming language C++ and Delphi and runs on a IBM compatible PC under WINDOWS. The information for the machine can be entered in three different ways: - Directly on the control computer of the machine - On a computer for work preparation in an office environment. - From a CAD/drawing program. Input directly on the computer of the column punch shear machine. Because of a simple input screen with three dimensional graphical display it is possible at any time to enter and to process a work piece quickly and easily on the work floor. The input of data can take place during the punch shear process. The punch shear data which are entered can be saved under a Order/Pos. number in order to be processed in a later stage. Input on a computer for work preparation. Installing the software on a computer for work preparation makes it possible to put in data in a "quiet" environment. The input is done in the same way as on the work floor. The data can be saved under an Order/Pos. number. In case of a network connection data entered on the Workprepration can directly be executed and made visible on the machine control computer. Input from a CAD / drawing program. This method of working can be divided into a number of working methods, dependent on the possibilities of the type of CAD program. One example: - The CAD program generates a DSTV file directly from the drawing. The method is the most common way of work preparation. The mentioned DSTV is a international standard which is specially developed for the steel construction. The DSTV is a description of different steel construction profiles. Here is also described in which way the punch shear data are recorded in a DSTV file.


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4.10.2 System requirements Minimum and recommended Office Computer Hardware - Pentium IV 950Mhz or higher - 256 Mb internal memory - Disk station 3½ inch, 1.44 Mb - Hard disk with 2GB free space for the program files and data - Display color screen with a resolution 800x600 or higher - LPT printer port (for hardware key protection) - CD-ROM drive - Microsoft Windows 95 (osr2) or, - Microsoft Windows 98 (98 or Second edition) or, - Microsoft Windows NT 4.0 (service pack 5) or, - Microsoft Windows 2000 - Microsoft Windows XP Requirements network connection Installed network adaptor for the machine control computer Make : 3COM Type : Ether-Link 10/100 PCI Adapter Order nr. : 3C905C-TX IEEE 802.3 10 BASE-T IEEE 802.3u 100 BASE-TX Requirements network cable Preferred type of network cable Foiled shielded twisted-pair FTP CAT.5 cable. Complete cable connections conform EIA/TIA-568, Category 5. Maximum distance 100 m, extendable up to 500 m with use of repeaters or Hubs Optional cable types Fiber Optics, duplex Multimode zip cord, 62.5/125 fiber, orange jacket, with use of fiber optic Transceivers with AUI connections and ST, SC, SMA or FDDI connectors. Maximum distance 2000m


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4.10.3 Installing the software This section describes how to install MULTILINE on a standalone computer or on a network. Follow this procedure to install MULTILINE. - If you have an earlier version of MULTILINE, ensure that it is not running - Close all other Windows applications - Place the Installation CD with the MUL:TILINE software - Run the SETUP.EXE program

After the initial setup is complete, you will see the Welcome window. - Click the next' button. The Choose Destination Location dialog box displays:

If you want to install MULTILINE in a different directory than the one shown in the Destination Directory box, click the Browse button and choose a different directory.


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- Click Next to continue to the Select Program Folder dialog box: If you want to change the name of the program folder, enter a new one or select one from the Existing Folders list. - Click Next.

The Copying program files screen displays indicating that program files are being installed:

- Click Finish. Before you can run MULTILINE, you must restart Windows or your computer.


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4.10.4 Order manager

In this menu the different products with the matching dimensions and the punching coordinates have to be entered.

4.10.4.1 Input fields for general profile and pos information • Order Enter a new [Order] name, in the field order. When this character is in front of a line, first press the key [Insert] When this character * is in front of a line, enter the new order • Posnummer Enter in the field [Posnumber] a posnumber. When importing DStV files this field is the combination of the fields Drawing/Mark and Posnumber • Profile Type Select the right Profile type from the profile library • Length Here the length of the profile must be entered in [mm]. The length, which is entered here, is always an "outside dimension", also when saw angles are entered. • Quantity need


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When several profiles with the same drill patterns and dimensions have to be processed the number of pieces can be entered in this field. After the processing of one profile the processing of the next profile can start immediately after. • Quantity done Immediately after processing a profile the program will increase this field with one automatically. When the quantity done is equal to the quantity need the program will give a message automatically. The starting of a next cycle will not be possible any more. The values in this field can be adjusted manually. This field is also displayed in the order manager. • Direction The profiles can be transported through the punch shear machine in several ways. After selecting this field the profile can be turned around the longitudinal axis each time 90 degrees C.W. or 90 degrees C.C.W. For assistance the position is shown graphically in red. For each profile type the rule is, that only the positions can be selected which are possible to process. A profile of the type steel flats can not be entered standing up. - Click the arrow to the right of the Direction text box to display the drop-down list - Select one of the following directions by checking the graphical view:

1 2 3 4

• Input y-direction There are three input modes for the input of the y-direction positions: - (ABS) Absolute: For the absolute input the measuring is counted from the fixed

side of the clamping, and the value filled in from the fixed side of the clamping.

- (SYM) Symetrical: For the symmetrical input the rule is, that the measuring is counted from the middle of the profile.

- (TOP) (NOT USED) For the top input the measuring is counted from the moving side of the clamping, but the value is filled in from the fixed side of the clamping


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• Input ZW-axis There are three input modes for the input of the Z- and W-positions: - (ABS) Absolute; the measuring has to be filled in from the bottom side of the

profile and the program will measure the distance from the bottom side of the profile to get a constant distance to the bottom.

- (SYM FLANGE) Symmetrical-flange; the measuring is counted from the middle of the profile, in which the middle of the profile is determined by the height of the flange.

- (SYM-WEB) Symmetrical-web; The measuring is counted from the middle of the profile, in which the middle of the profile is determined by the height of the web.

- (TOP) Top; (NOT USED) The measuring has to be filled in from the bottom side of the profile but the machine will calculate this and measures the distance from the top to get a constant distance to the top.

• Steel type Select the type of steel from the summary which are filled in the Feed Manager A correction factor to the standard supply speed is filled in for each type of steel. During the processing the supply speed of the drills will be adjusted to the values from the list. - Select the field Steel type - In a second window shows a survey of the steel types • Shearing angle

Enter the X position of the left upper corner Enter the Y position of the left upper corner Enter the X position of the left lower corner Enter the Y position of the left lower corner

An angle on the right side of the product will only be cut when this is a full angle. This means that the angle has to overlap the whole width of the material. When not a full angle entered, the installation will center on two positions so it is possible to cut the angle later manually.


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Enter the X position of the right upper corner Enter the Y position of the right upper corner Enter the X position of the right lower corner Enter the Y position of the right lower corner

• Arranged Here the program displays the number of plates witch are already arranged. • Height Here the program displays the height of the selected profile type [mm]. • Width Here the program displays the width of the selected profile type [mm]. • End piece The end piece from the x-position of the last process.


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4.10.4.2 Input fields for punch or drill co-ordinates • Punch/Drill co-ordinates • Nr This column displays the line number and can not be filled in. In a list a maximal of 400 different punch/drill co-ordinates can be entered. • X In this column the X-position of the drill holes must be entered. The position of the drill hole is measured from the zero-position of the profile or in reference to the previous position, dependent on the input mode. • Mode There are two input modes for the input of the X-positions: - Absolute - Relative

Absolute input means that all positions are related to the zero point of the material. This means the beginning of the material. Relative input means that the entered X-position is related to the previously entered absolute X-position. The absolute mode can be selected by entering a [A] or [a] in this column, followed by pressing the [ENTER] key. The relative mode can be selected by entering a [R] or [r] in this column, followed by pressing the [ENTER] key. • y Dependent on the setting in the material data the y-position of the drill hole must be entered and measured from the bottom side of the profile or from the middle of the material. See the description input mode Yy-axis and Zy- Wy-axis in the chapter Material Data. • Unit Here the unit must be entered with which must be punched or drilled. The machine knows three units Y, Z and W. The Y-unit is indicated by typing a 'Y', the Z-unit by a 'Z' and the W-unit by typing a 'W'. - The Y-unit is the unit above the material. - The Z-unit is the unit which is located on the fixed side of the machine. - The W-unit is not used.


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- The U-unit is not used. • Process Depending on the options, the machine is able to do several processes. By entering a [1], [2], [3] [4], [5] or a [6] it is determined which proces will be activated.

- 1 = drilling - 2 = dot marking - 3 = drilling - 4 = marking text - 5 = special punching

• Diameter In this column the requested drill diameter must be entered. When the output program is started at the machine, the program will check whether the correct tools diameters have been placed in the tool change storage places. The TOOL MANAGER gives a survey which tools are selected. When the machine is not equipped with a automatic tool change a message "TOOL CHANGE" will be generated. • Marking Text Enter in this field the text you want to mark on the material


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4.10.4.3 Functions in the order manager • Check the list - Press the right mouse button in a field - select 'Check the list'

the next window displays the error and number of the line #: on line # 1 must be the Y position between 32 and 141.


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4.10.5 Pattern manager

• Pattern Enter a name of the pattern • Row # Enter the number of rows for this pattern • Column # Enter the number of columns for this pattern • X Enter the distance between the columns • Y Enter the distance between the first rows • Diameter Enter the diameter of the holes • Process Select the process • Y-unit, Z-unit, W-unit Select the right axle for the process • x-position Enter the x position for the first hole of the pattern • y position Enter the y position for the first hole of the pattern • Centered The whole pattern will be centered in the x or y direction

To insert the Pattern into the posnumber press the Button:


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4.10.6 Nesting manager

In the nesting manager it is possible to divide a stocklength into several posnumbers

• Batch Enter a new [Batch] name, in the field order When this character is in front of a line, first press the key [Insert] When this character * is in front of a line, enter the new Batch • Run Enter a new 'Run #'. • ID Enter the 'machine ID' of the machine. • Profile type Select the Profile type to be processed. • Length Enter the length of the material to be processed. • Qt. need Enter the number of profile types to be processed.


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• Qt. done Shows the number of already processed profile types. • End piece Enter an end piece. • Steel type Select the Steel type to be processed. • Order Select the order of the products to be divided. Only orders with the same profile type will been displayed. • Posnumber Select a posnumber. Only the posnumbers which have not yet been divided will be displayed on the screen. When all posnumbers have already been divided, this list will be empty. • Number Enter the needed number. This field will turn red when there are too many divided. Length The program shows the length of the selected posnumber

Press this button to leave the nesting manager.


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4.10.7 Optimize manager

In this menu it is possible to divide an order, which consists of different posnumbers, as optimally as possible with a minimum waste. An 'optimized' order will be saved as a 'Batch'. Before a stock length can be optimized in different posnumbers of an order, the order must first be made and entered in the order manager. Optimize = to divide stock lengths into posnumbers of an order.


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Page 1 of 3, Select the orders to be optimized The Optimize Manager consists off three pages. The number of the current page is shown on the top of the page. Page 1 = select the orders which has to be optimized, from the field Order Survey.

- Select the order, which has to be optimized - Press the right mouse button in a field - Select the order, which has to be optimized - Press the button [>] to insert this order in the right column 'Order to optimize' - Press on the button [>>] to insert all orders in the right colomn 'Order to

optimize' - Press on the button next to go to the next page


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Page 2 of 3, Select profiles from stock and batch info The second page consists off three parts

Profiles to be processed (left part) The program shows in the left part a survey of what is needed to realize the selected orders, such as: - the profile types - the total profile lengths - the number of posnumbers per profile type • Batch - Enter a new Batch name • Machine ID - Indicates which machine has to process this Batch • Rest piece - Enter a rest piece for this batch. The program will stick to this rest piece during

the optimizing.


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Stock (lower right part) • Active - Indicates which stock lengths can be used for this order. • Length - Enter the lengths of the stock profiles. • # - Enter the number of the stock profiles. • Qt. Used - The program displays the number of divided lengths. After an acceptance of

an optimized will this number will be subtracted from the stock.


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Page 3 of 3, Optimizing result

Pressing the button will start the optimizing The result will be displayed in the following screen.

Run # The parts and profiles are nested in Run Numbers. When a run is selected, the division is displayed. The divided posnumbers and matching orders will be displayed well-organized displayed and graphical. When the result is not acceptable, it is possible to go back to the previous page to edit some data by means of the button [Previous]. When the result is acceptable, the batch will be made active by pressing the button [Accept].


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4.10.8 Output manager

The Output Manager shows a survey of the processes of the machine.

1= Mentions for the operator 2= The second part of the screen shows the errors and warnings 3= Manual input fields 4= the actual process of the machine

1

2 3

4


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4.10.8.1 Manual mode

By pressing the button the manual mode screen appears. In this mode it is possible to control the machine manual. X-position Enter the X-position [mm] of the process Y-position Enter the Y-position [mm] of the process

Enter the diameter [mm] of the punching- or drilling process Marking text Enter the text, which has to be marked on the material by the marking unit X-shear

Enter the x-position of the shearing angle Y-shear Enter the y-position of the shearing angle Profile width Enter the width of the profile [mm]

Process Select the process (unit) for the entered coordinates:

Flange punch Drilling Index shearing Center


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4.10.8.2 Quick punch manager

In this menu it is possible to control some functions manually, while in the automatic mode


punching with unit 4




punching with flange unit 1

Activate Drilling unit

Move carriage backwards

Move carriage forwards

punching unit backwards

punching unit forwards

slide table open

slide table closed


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4.10.9 Profile library

Displays and stores a survey of profile types. Common profile types are pre-programmed. • Profile Name and dimensions Enter the data of the profile in the columns. The graphical display in the lower right corner shows the matching dimensions. • Type Click the arrow to the right of the Type text box to display the drop-down list, select one the following profile types: - I = H profile - U = U profile - L = Angle profile - M = Square profile - B = Flat profile - T = T profile • Weight Weight per meter of the profile (kg’s) • Profile type filter options Profile types with a mark will be displayed, others are filtered out and not displayed


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4.10.10 Adding new profiles and changing data - Select the field Profile name - Press the keyboard button on the screen - Enter a new profile name and press [Accept]. The new name will appear in the column - Enter all information and dimensions fields for the new profile name.


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4.10.11 Tool manager

This menu displays the data for the available tools for the machine.

• Punch diameter - The diameter of the punch for each Tool position. • Flange punch - The diameter of the punch for the flange punch units. • Lubrication frequency - Enter the amount of lubrication for each tool position.

For Example 5 means, each Fifth punch stroke there will be a small amount of lubrication mist blown on the punch tool

• Lubrication type

Only applied for the drill unit(s). Select the lubrication type for each drill unit. N = none I = intern cooling E = extern cooling


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• Drill diameter - Diameter of the drill. • Drill length - The length of the drill in millimeters according to the drawing below.

• Drill point (X) - The length X (Grinding point/grinding angle) in mm. • Pulse time - Lubrication amount (numbers of mist spays per minute).


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4.10.12 Operator menu

In this menu it is possible to activate or deactivate several functions of the installation.


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4.10.12.1 General

• Default stock length - The default length for new run entries. • Min. front piece - The minimum front piece [mm]. • Min. end piece - The minimum end piece [mm]. • Shear correction - Enter a correction to shift the whole pattern to adjust inaccuracy caused by

deforming of the material during shearing. • Length correction - Due to deforming of the material during shearing it is possible that the

products become longer. By filling in this correction the products will be sheared shorter.

• Punch time up - Punch stroke time (upwards) • Punch time down - Punch stroke time (downwards) • Flange punch time - Flange Punch stroke time (forward + backward). • Min. waste length at optimize - Enter a minimum waste length for the program to take into account during

optimizing, for example the minimum length that can be used afterwards. • Shear waste for L - Blade thickness of the angle shear. • L Shear uptime in cycle - Upstroke time for angle shear during cycle


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4.10.12.2 Options

• Marking unit present

ON activate the automatic control for the marking unit. OFF deactivate the automatic control for the marking unit.

• Cross transport

ON activate the automatic control for the cross transport. OFF deactivate the automatic control for the cross transport.

• Length check (option)

ON the length of the material will be checked before processing (option). OFF the length of the material won't be checked, but the program will assume the

entered length. • Width measuring (option)

ON the width of the material will be checked before processing (option). OFF the width of the material won't be checked, but the program will assume the

entered width.

• Open slide for front piece ON opens the output table during shearing front pieces. OFF the output table will remain closed during shearing front pieces.

• Pushing through

ON the carriage will automatic push an end piece through onto the output table. OFF the carriage won't push an end piece through onto the output table.

• Automatic order run

ON the machine processes the runs in the order in which they are shown on screen, the order (sequence) can be edited.

OFF the machine processes one selected run only.


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Editing the order of the runs:

- Press the profile type figure (lower right corner) in the nesting manager - Select the run number to be moved

- Press the button to move the run one position lower

- Press the button to move the run one position higher

- Press the button to confirm the new position of the run.

• Restart after shearing

ON the cycle stops after a shear cut, confirm with RESTART to continue. OFF the cycle continues automatically after a shear cut.

• Out feed table open

ON the outfeed table is always open. OFF activate the automatic control of the outfeed table.

• Outfeed table closed

ON the outfeed table is always closed. OFF activate the automatic control of the outfeed table.

• Pusher out feed table

ON activate the automatic control of the pusher out feed table. OFF deactivate the automatic control of the pusher out feed table.


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4.10.12.3 Corrections If the machine is not equipped with the automatic straightening system, use this menu to set the correction pressure for each unit after a punch process

4.10.12.4 Totals The program counts the number of processes for each unit and shows the totals in this screen.


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4.10.13 Extern file import

• Filter Enter a filter so the program will only show these kinds of files. • Search directory Enter the search directory from where the program has to import the DSTV files Importing DSTV files Select and import DSTV files following the next possibilities: - Select one file in a folder - Select multiple files in a folder - Select a folder, all the files in this folder will be imported

Use the import button to import the selected files. • DSTV viewer Show the contents of the selected DSTV file. By using the right mouse button it is possible to edit a DSTV file.

KPS SERIES Maintenance

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5 Maintenance

WARNING

Maintenance or repair activities are only allowed when the machine is switched OFF. Follow the LOCKOUT procedure before servicing the machine. Read and understand all maintenance instruction before servicing the machine

5.1 Maintenance • Daily maintenance - Keep the workplace clean and tidy - Remove chips and waste from the machine - Keep the controlling desk clean with an none aggressive cleaning agent. - Check Tool lubrication Level • Yearly maintenance KALTENBACH BV offers you the opportunity to have the machine inspected every year and to do all the required (preventive) maintenance. We will make you an offer upon request.


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5.1.1 Tool lubrication system Recommended Tool Lubrication type: Pos. No Quantity Designation Order-

No 1 1 ltr CUTOL MS (ferro) 900060 2 5 ltr CUTOL MS (ferro) 900065

Lubrication units for shear blade and punch tools are mounted on the machine. A reservoir is mounted on each unit. The contents of this reservoir is about 1/4 liter. The pulsing time (amount of lubrication) for the punch tools can be adjusted by the operator trough the software. No mechanical adjustments are necessary in the cooling unit. For visual inspection the unit cans easily be lifted out (C).

A

C

NOTICE Do not exceed the maximum level at refilling (D). Check Oil Level every 8 hours.

D


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5.1.2 Lubrication • Linear guiding The linear guidings are factory prepared. The linear bearings are lubricated with grease, and is equipped with a lubrication cassette, filled with oil. Timing interval for lubrication is 3 to 5 year depending on usage The cassettes can be greased by the lubrication-nipple, see picture lubrication. The lubrication cassettes need to be replaced after 3 to 5 years .This must be done by a qualified engineer • Ball screw The Ball screw units are equipped 2 two lubrication blocks, see picture lubrication Timing interval for lubrication is 6 months. • Knife and punch unit guiding Timing interval for lubrication is 0,5 to 1 year depending on usage • Lubrication Points The lubrication points are marked with yellow labels. The following table shows the labels and matching description: Label Description

Bring an Oil or Grease Gun on the lubrication nipple

Use a Brush to bring Grease onto the lubricate point

Use an Oilcan to lubricate


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5.1.3 Lubrication points Material transport and position system

2X 2X

Blocking unit

2x

each year,four shots



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Flange punch

8X

2X



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KPS 501 punch

Each year, four shots

4x

Each year, four shots

1x


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each year, four shots

KPS 503 punch

each month, one shoteach year, four shots

1x

1x 4x


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KPS 506 punch with Tool Changer

3x

1x

4x

1x

each week, one shot each month, 4 shots each month, 1 shot



each year,one shot



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KPS 515 punch with Tool Changer



each month, one shot

each month, one shots each year, four shots

4x

3x

15x

1x

1x


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Angle shear SC

each month, one shoteach month, one shot Each year, one

shot

4x

2x

4x


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Angle shear DC

No grease points


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Flat shear

4x

1x 4x


each year,four shotseach year,four shots


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Drill-Unit

1x

1x



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1x

2x

2x



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Hydraulic system - Factory set, the hydraulic oil tank is filled - Check oil level by means of the gauge glass - If the level is below 25 check for any leakage. - Replace oil after 2.000 hours - Contents of the tank is 300 liter

NOTICE Replace the filter when the Oil is replaced. 5.1.4 Lubrication table Hydraulic oil

H-LP 32 Lubricating Oil

CGL 68 Lubricating Grease

CASTROL Magnaglide D68 Spheerol AP 2

ESSO NUTO H 32 Febis K Multi purpose gr

SHELL Tellus T 32 Tonna T Alvania R 2

ELF Elf olna 32 Movixa Multi Multi 2

KLUBER Lamora HLP 32 Lamora D68 Isoflex NCA 15

MOBIL SHC 639

ARAL Vitan D E 32

B.P. Energol H.L.P 32

KPS SERIES Technical Documentation

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6 Technical Documentation 6.1 General Instructions In addition to our standard guarantee conditions as described in the general conditions for sale and delivery, it is not allowed: - to make alterations to sealed machine settings without our written permission in

advance. - to make alterations to the machine without our written permission in advance. - to install accessories or parts of third parties without our written permission in

advance. KALTENBACH BV can not be held responsible when one or more of the above-mentioned points are not taken in consideration. For possible supplementary guarantee conditions as agreed, we refer to the confirmation of the order.

CAUTION Use of Non-original parts can influence the safe operation of the

machine. It is urgently to use only exclusively original KALTENBACH spare parts.

Provide us following information when ordering spare parts: - Machine type (KPS) - Machine Nr. (123.456) - Number Spare part page (M-UK-KPS-xx) - Position number of spare part (3) - Description of spare part (Bearing) - Order number of spare part (D123456) - Shipment method (express)


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6.2 Tools 6.2.1 Punch and Dies General Information

CAUTION

Wrong Punch Tool Settings can inflict grievous bodily harm to persons. The diameter of the punch hole should always be bigger than the material thickness to be processed !

• With all types of punch units, except the triple-unit (KPS503/ KPSA206), an

hole-in-hole can be punched, only if ¾ of the punch punches in full material. For the triple-unit only the punch in the middle is allowed to punch hole-in-hole. The outer most punches are not allowed to punch hole-in-hole.

• To reduce deforming of the material, a distance of at least 1 hole diameter of

the edge should be observed.

• To reduce deforming of the material, a distance of at least 1 hole diameter should be observed between each hole.

• Use the right ‘family’ of punching tools for the vertical and flange punch. See

the supplies: Drawing # 700055 Tool information & min punch position KPS503

• Pay attention to using the right (special) tools for the flange punch if processing

angle steel and/or U-profile. Consult your dealer or tool supplier.


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• Make sure of using the filling ring of the inner side of the mould at the flange punch and check if they are correct installed in the right position.

• Always mount the filling pieces enclosed to the punch holder and check

whether the tools are really secured after tightening. • Before using check whether the mould are well secured against turning. • Reduction rings for dies are delivered with all triple-punch units (KPS503 /

KPSA206). These rings may only be used when the punch-force rises up to maximal 25 tonnes. When bigger is needed, the large die (Ø63,5) must be applied.


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6.2.2 Punch-Die Clearance Next to the important fact of having a suitable machine, it is even more important to have the right tools with the correct cutting clearance.

NOTICE Use sharp Punches and Dies with correct Clearance Only A correct cutting clearance results in - a long usage-time of the tools - is preventing deformation of the material and bending of the products - the thicker the material the bigger the cutting tolerance should be. The cutting tolerance is difference between punch and die diameters. The cutting tolerance is determined by 8-10% of the material thickness to be processed. Example: Material thickness 20 mm Punch (1) diameter 26 mm Cutting tolerance 10% 2,0 mm Die (2) diameter 28 mm


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6.2.3 Correct tool order KPS503

Punch 1 Punch 2 Punch 3 Max. punch load Max. punch load Max. punch load

60 % 100 % 60 %

Punch 1 Punch 2 Punch 3 Hole in hole punching

(slotholes) Hole in hole punching

(slotholes) Hole in hole punching

(slotholes)

Not allowed! Allowed; Overlap max. 25%

(2nd hole must pierce min. 75% of material)

Not allowed!

1 32


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6.2.4 Minimum punch position KPS 501 (Peddinghaus type) Refer to the appendix for the minimum punch positions: Drawing 700056 6.2.5 Minimum punch position KPS 503 (Peddinghaus type) Refer to the appendix for the minimum punch positions: Drawing 700055 6.2.6 Minimum punch position KPS 506 (Peddinghaus type) Refer to the appendix for the minimum punch positions: Drawing 700054 6.2.7 Minimum punch position KPS 515 (Peddinghaus type) Refer to the appendix for the minimum punch positions: Drawing 7000xx


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6.2.8 Flat Shear Unit 6.2.8.1 Cutting Tolerance Flat Shear To obtain the best cutting results, a correct cutting tolerance should be observed. The average cutting tolerance between the upper knife and the bottom knife should be approx. 0,9 mm. After some time the cutting tolerance can increase. By means of the adjustable knife block guiding it can be set again. The upper knife that is supplied with the machine, can be used for the 2 different cutting angles (1,5 and 3,0°). The 4 cutting edge of the knife can be used. The lower knife can be also used on the 4 cutting edges. 1= right cutting surface (approx. 0,9 mm) 2= wrong cutting surface (<0,8 mm)

With the option ‘automatic cutting tolerance’ tolerance will be adjust automatically at 10% of the materialthickness.


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6.2.8.2 Grinding requirements flat shear knives The knives of the shearing unit need to be grinded if the quality of the sheared surface decreases. The knife needs to be grinded at the cut surface with a roughness (Ra) of max. 1,6 µm.

NOTICE

Without ‘autmatic cutting clearance’: Measure the cutting clearance set previous to demounting of the knives. (During the cutting movement in hand operation, when the shears are next to each other, press emergency stop and measure the tolerance with a feeler gauge)

Grind the knives according to under-mentioned drawing. It is recommended to grind the knives in steps of 0,5 mm until both sides of the knife are sharp again. Have your grinder measure the hardness of the knife after grinding. This should be approx. 57-58 Hrc. When replacing the knives, justify the loss from grinding by filling plates of 0,5 or 1,0mm. In this way the correct tolerance is set again.


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6.2.9 Angle Shear Unit 6.2.9.1 Cutting tolerance angle shear (SC type) To obtain the best cutting results, a correct cutting tolerance should be observed.

Blade Clearance (X) Material range Cutting qualityRadius [mm]

[mm] … X … X … -- / - / + / ++

8 0.7 50 x 50 x 5 - 100 x 100 x 10 ++ 11 1.0 100 x 100 x 10 - 160 x 160 x 15 ++ 18 2.0 160 x 160 x 15 - 200 x 200 x 20 (25) +

6.2.9.2 Cutting tolerance angle shear (DC type) To obtain the best cutting results, a correct cutting tolerance should be observed. Use following guideline: * factory settings ** optional extra knife

Blade Clearance (X) Material range Cutting qualitythickness

Mm Mm … X … X … -- / - / + / ++

12 0.8 (*) 50 x 50 x 5 - 160 x 160 x 15 + 13.5 ** 0.8 50 x 50 x 5 - 100 x 100 x 10 ++

12 1.4 100 x 100 x 10 - 160 x 160 x 15 ++

X

X X


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6.2.10 Grinding requirements knives General instruction: The knives of the shearing unit need to be grinded if the quality of the sheared surface decreases. The knife needs to be grinded at the cut surface with a roughness (Ra) of max. 1,6 µm. Measure the cutting clearance set previous to demounting of the knives. (During the cutting movement in hand operation, when the shears are next to each other, press emergency stop and measure the tolerance with a feeler gauge) Have your grinder measure the hardness of the knife after grinding. This should be approx. 57-58 Hrc. It is recommended to grind the knives in steps of 0,5 mm until both sides of the knife are sharp again. When replacing the knives, justify the loss from grinding by filling plates of 0,5 or 1,0mm. In this way the correct tolerance is set again. Grind the knives according to under-mentioned drawing. Grinding angle shear (SC type)


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Grinding angle shear (DC type) Grinding angle shear, fixed bottom knives (SC +DCtype) Dismount the in- and output table, so the fixed knives can be taken out. Possible filling plates should be put back in the same place when replacing the knives.


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6.2.11 Knife Block Guiding System A knife block, that is tilting too much, decreases the life of the knife block guiding. In the end these will be damaged too much resulting in breaking out. Check whether the knife block is tilting during shearing of narrow material. If this is the case, it is necessary to reset the guiding on the side of the shear. While resetting, make sure the knife block is in the centre of the cylinder bar as much as possible. By setting a minimum tolerance on one or two sides, unnecessary wear is prevented. If desired our service department can carry out these activities.


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6.2.12 Drills General Information Next to the important fact of having a suitable drilling machine, it is even more important to have the right drills with the correct method of grinding. A high-quality drill, which has been grinded in the correct way, possesses / brings the following features: - a nice and clean surface of the hole - a round- shaped hole (not triangular) - minimum amounts of (small) chips - long usage-time - optimum feed rates possible (gain in the production) - optimum cutting speed (gain in the production)no drill-resonance - Short chips 6.2.13 Drill Types and qualities The best drills to purchase for drilling steel profiles are normal spiral drills; these should have the quality HSS or better. For the optimum lubrication and cooling of the drills, it is recommended to use drills with internal cooling channels. When using this type of drill, it has to be made sure that the drilling machine is suitable and has a facility for these tools, e.g. a micro dosage system. Advantages of using the drills with cooling channels are: - longer usage-time of the drill - better holes in the profiles - no pollution of work or environment (because of mist cooling)

NOTICE When the drills with cooling channels are not used, the dosage system should be switched off.


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6.2.14 Recommended drill Suppliers Fab. Type Order No.

Gühring HSS coolchannel drill with axial cooling acc. DIN341

270

G.C.D.C Chipbreaker twist drills morse taper shank end feed

Titex HSS coolchannel drill with axial cooling acc. DIN341

A4426 MC2, MC3, MC4


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6.2.15 Grinding the drills A new grinding geometry has been developed for drills that are used for drilling into steel profiles. This geometry of the drill makes that all advantages mentioned above are realized. The main points of the grinding are: - The grinding of the top with an angle of app. 10° - The taking out or grinding away of the web of the drill This can be done by the user provided that a suitable grinding machine is available; good results are achieved with a KALTENBACH grinding machine type BSG 60. 6.2.16 Grinding instructions

A B C D

mm mm Clearance Drill point

10 3,4 2,5° 2,5

15 4,0 2,5° 2,5

18 4,5 2,5° 2,5

20 5,2 3° 3

24 6,0 3° 3

28 6,5 3° 4

30 7,0 3,5° 4


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The re grinding of the head of the drill from app. 30° to app. 10° gives the following advantages: - better drilling results; - better countermarking; - fewer chips during drilling; - longer usage-time - shorter drilling distance (gain in production time); - an optimum feed rate (gain in production time); - optimum cutting speed (gain in production time); - less drill-resonance. - shorter chips The web of the drill of a normal drill does not cut, but only presses away the material during the rotation of the drill. Because of this, an enormous drilling pressure is required (up to 1,000 kg) for drills with a large diameter (> 25 mm). This causes problems among which: - unnecessary fast wear of the drills; - maximum burrs caused by the coming through of the drill; - no optimum feeding rate (loss of production time); - disturbing drill-resonance; - distortion of flanges of small profiles. When grinding out the web, it should be made certain that on the place of the web two cutting fields are created. The making of the cutting area to 16 ensures short, small chips and a even longer usage-time of the drill. The level of burrs is further reduced by the 45 inclining of the outer side of the drill. Refer to the Manual of the Grinding machine BSGB60 for guideline settings for grinding.


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6.2.17 Drill Cooling 6.2.17.1 Micro lubrication system Principle of working The cooling of the drill is in mainly obtained by heat transfer to the drill-chips (for this reason, the drill feed should therefore never be too low). The compressed air flowing through the drill will cool the drill tool, the oil is mainly added to get a lubrication and much less for a cooling effect. The life of the drill tool is not effected if it is not directly foreseen with oil, of course under the condition that the drill is correctly sharpened and the tool is used with the correct feed and rpm. Experiences - When activating the micro-lubrication system after a new drill has been

inserted in the machine, it takes time before it is visual that the oil is coming out of the drill

- If the drill is taken out, the customer experiences that accumulated oil comes out of the drill holder

- It is thought that the micro-lubrication system is a mist-spray system Answers - In the standard drill adapters which are available on the market, both for

automatic tool change and for manual change (ISO40), openings have been incorporated in order to release the drill from the adapter with a tool. These openings, which are of course necessary, will fill with oil due to the centrifugal force of the revolving drill. Only after this opening has been filled completely with oil, does the full flow-through of oil to the drill follow. Once the drill is released, this accumulated oil escapes.

- There will never be a situation that there is a mist spray out of the end of the drill, even if there is a direct connection of the oil feed tube to the drill.

- A micro-lubrication system is a system producing drops of oil, which will give only a oily air flow out of the drill, if the unit is correctly adjusted (minimal oil volume and maximal air pressure).


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6.2.18 Solving drill problems Below a survey is given of possible situations concerning the drills. Problem Caused Solution

The head of the drill will burn after several holes.

A cutting speed which is too high gives the problem that the head of the drill will burn after several holes.

Select a lower cutting speed, check grinding quality of the drill.

The drills break. Cutting speed too low or feeding speed too high.

Select a higher cutting speed or a lower feeding speed.

Te chips are thick. Feeding speed too high. Select a lower feeding speed.

Te chips are thin. Feeding speed too low. Select a higher feeding speed.

The drill oscillates. Due to feeding speed too low , it is possible that the drill has not enough pressure loads against the material.

Select a higher feeding speed.


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KALTENBACH

6.3 Spare Parts 6.3.1 Spare parts punch KPS503

Pos.No Designation Fabrikat, Type OrderNo 1 Cylinder 3V-punch complete IMAC S.R.L. 854-01-07 2 Sealing set cylinder 3V-punch Kaltenbach B.V. 854-01-02N 3 Blocking cylinder punch selection Kaltenbach B.V. 854-01-17N 4 Punch bar IMAC S.R.L. 854-01-02 5 Refer to the appendix, drawing 700055_X 6 Refer to the appendix, drawing 700055_X 7 Down pusher IMAC S.R.L. 854-01-39X 8 Die holder IMAC S.R.L. 854-01-19


M-UK-KPS--06 11/02/03 of 138

KALTENBACH

6.3.2 Spare parts punch KPS506

Pos.No Designation Fabrikat, Type OrderNo 1 Punch information Refer to the appendix, 700054_X 2 Die information, refer to the appendix, 700054_X

1

2


M-UK-KPS--06 11/02/03 of 138

KALTENBACH

6.3.3 Spare parts punch KPS515

Pos.No Designation Fabrikat, Type OrderNo

1 Punch information Refer to the appendix, 700054_X 2 Die information, refer to the appendix, 700054_X

1

2


M-UK-KPS--06 11/02/03 of 138

KALTENBACH

6.3.4 Flat shear knives

M12 (6x)

44q

O

44q

(6x)13,5

x44

42

(6x)M12

550

530

3

2

0,74° 48,9x

44

1


1 Upperknive flat shear IMAC S.R.L. 22870 2 Lower knive (autom cuttingclearance) 102169 3 Lower knive (fixed cuttingclearance) IMAC S.R.L. 22871


M-UK-KPS--06 11/02/03 of 138

KALTENBACH

6.3.5 Spare parts angle knives DC type


1 Upper knive angle shear DC 160 – 12 mm Kaltenbach B.V. 22872 2 Upper knive angle shear DC 160 – 13,5 mm Kaltenbach B.V. 22874

3+4 Lower knive angle shear DC 160 – set IMAC S.R.L. 22873

SC type:


5 Upper knive angle shear SC 200 – r=8 IMAC S.R.L. 107098 6 Upper knive angle shear SC 200 – r=11 IMAC S.R.L. 107099 7 Lower knive angle shear SC 200 – piece IMAC S.R.L. 107097


M-UK-KPS--06 11/02/03 of 138

KALTENBACH

6.3.6 Spare parts ball bearing spindle

23

22

14 13

3 87

6

10

12141516

17

2021

2

5

9

Pos. Designation Fabrikat, Type OrderNo 1 Lockring Kaltenbach D25799 2 Bearing INA, Ø20x Ø47x14 400718 3 Bearing case Kaltenbach D25790 4 ring Kaltenbach D25798 5 Bearing DIN912, M8x30 400781 6 Nutcase Kaltenbach D25789 7 Ball rotation nut Rexroth, 32x5 400054 8 Coupling right insert M6x4 400110 9 Bolt MBZ Kaltenbach D25810 10 Ball bearing spindle Rexroth, KGT 32x5 Table A 12 Spline 6x6x32 400107 13 Nutcase Kaltenbach D25786 14 Brake flange Kaltenbach D25788 15 Ring INA, ZKLN 2557-2RS 400051 16 Lockring Kaltenbach 400111 17 Locknut M25x1.5 400052 20 Pulley Kaltenbach Table A 21 Closingplate Kaltenbach D25803 22 Gearbelt Contitech, HTD 8M 720 B20 400090 23 Pulley Kaltenbach Table A


M-UK-KPS--06 11/02/03 of 138

KALTENBACH

6.3.7 Spare parts drill unit

1

3

45

6

7

8

9

10

11

1213

14

16

15

17

18


1 Runner block Rexroth, 1651-314-20 400059 3 Block Kaltenbach 400757 4 Plate Kaltenbach D25809 5 Rail Kaltenbach D25801 6 Locknut Kaltenbach D27262 7 Retraction plate Kaltenbach D103153 8 Pulley Contitech, HTD Ref.Table A 9 Servomotor 8MSA4L.R0-31 B&R, 8MSA4L.R0-31 760296 10 Flange plate Kaltenbach D102933 11 Cover Kaltenbach D25782 12 Connection plate Kaltenbach D27260 13 Mounting plate Kaltenbach D101248 14 Pneumatic Cilinder Vesta, ADM 40-020 400726 15 Rotation joint 8mm 400946 16 Drilling unit complete Kaltenbach 400728 17 Plate Kaltenbach D25804 18 Cover Kaltenbach D25780


M-UK-KPS--06 11/02/03 of 138

KALTENBACH

6.3.8 Spare parts Tool Changer

13

12

98

6

5

7

1

2

10

3

11

19

17

18

1516

14


1 Mounting plate for cilinder Kaltenbach 400775 2 Pneumatic cilinder ISO6431 PMY 32-250 400928 3 Runner block Rexroth, 1651-314-20 400059 5 Base plate Kaltenbach D27217 6 Bolt Kaltenbach D100287 7 Toolholder plate Kaltenbach D26760 8 Ring Kaltenbach D27250 9 Clamp spring Kaltenbach 27123 10 Proximity switch Omron, E2EG-X1R5B1-M1 400919 11 Mounting plate for switch Kaltenbach D100285 12 Handle Kaltenbach D101066 13 Handle clamp Kaltenbach D101093 14a Cilinder cover Kaltenbach D27259 14b Cilinder cover (mirrored) Kaltenbach D27259M 15 Dish springs 20x10,2x0.8 400963 16 Bolt Kaltenbach 101069 17 Ring M8 401008 18 Toolholder plate Kaltenbach 27216 19 Strip Kaltenbach 27251


M-UK-KPS--06 11/02/03 of 138

KALTENBACH

6.3.9 Suggested Spare part kit Pos.No Designation Fabrikat, Type OrderNo

Synchronic motor B&R 760300 Synchronic motor B&R 760304 Servo drive Acopos 1022 B&R, 1022 760312 Servo drive Acopos 1045 B&R, 1045 760314 Industrial Controler B&R, IPC5000 3330 2003 digital mixed module, 16in/16out. B&R, 7DM465.7 760320 Noodstop relais- DOLD-BH5928 DOLD, BH5928 720215 Safety relay G& S 4A2B 24VDC Omron, G&S 4A2B 24VDC 720220 Relay base P7S- 14F Omron, P7S- 14F 720221 Fuses 10x 5A Standard 750100 Relay 24 V dc MY2N Omron, MY2N 720020 Timer H3YN- 2 24VDC Omron, H3YN- 2 24VDC 720062 Timer H3DR- A Omron, H3DR- A 720067 Magnetic switch 4kW, 1NO, 24Vdc GEC, 100216 710361 Contact 1x nc EK 01 Moeller, 216385 711130 Socket BE 3 Moeller, 216374 711140 Emergency switch locked RPV Moeller, M22-PV 216876 711200 Lineair encoder mix Elgo, LMIX2-000-08-1-01 810508 Lineair measurement tape Elgo, MB20.50 810514 Frequency converter Lenze, E82EV552K4C040 710945 Gearbelt Contitech, HTD 8M 720 B20 110527 Front Lubrication Unit Rexroth D400084 Runner block Short Size 35 Rexroth D400226 Gearbox MVF63/FC I=30 Bonfiglioli 700165 Hydraulic Cylinder Horizontal Kavee 200632 Hydraulic Cylinder Vertical Kavee 200625 Hydraulic unit UNTKHY015002 Kavee 200620


M-UK-KPS--06 11/02/03 of 138

KALTENBACH

6.4 Pneumatic drawings


M-UK-KPS--06 11/02/03 Page 136 of 138

KALTENBACH

6.5 Hydraulic drawings

Scale:Title: KALTENBACH

Checked by

Designed by Project No.

Date Remarks:

Drawing #:

P.O. Box 30, 2290 AA, Wateringen, Holland Mail: [email protected]

© OBSERVE COPYRIGHT DIN34No part of this drawing may be reproduced or submitted to third parties in any form, by any means, without the written permission of KALTENBACH BV. If no order follows drawing and enclosure must be returned.

A3Size:


Checked by


Date Remarks:

Drawing #:



A3Size:

POS NB. PART NUMBER CODE

1 2400159C S07 OILRESERVOIR

1 FRI-250 BAF1 A25N 1402.5006 RETURN FILTER

1 SP-E6 1490.1007 VISUAL ELEC. INDICATOR

1 Pi-0126 mic I01 FILLER / BREATHER

3 HCX.127/T-M12 D04 LEVEL GAUGE INDICATOR

1 LME-350F/NC 1807.0001 LEVEL SWITCH

1 090-1" T02 VALVE

1 SKG180 M-4 B5 K02 E-MOTOR

1 PK 350/6/5-00 K08 BELL HOUSING

1 Bowex 48/40H7/48H7 K08 FLEXIBLE COUPLING

1 QX52-063/43-032R B17 DOUBLE PUMP

1 AFS 112 G E05 FLANGE (S) 3" SAE

1 AFS 102 G E05 FLANGE (P) 1" SAE

1 AFS 104 G E05 FLANGE (S) 1 1/4" SAE

18,5kW-1500rpm-400/680V-50Hz-IP55

92,1/46,8 LTR/MIN.

16

15

17

DESCRIPTION

ELEMENT: SP-CU-250 A25N

06

V = 400 LITER

ELEMENT: 852519 Mic

13

14

08

09

10

11

12

07

01

02

04

03

REMARKS

05

POS NB. PART NUMBER CODE

1 7110397 F03 MANIFOLD

1 AGMZO-A-20/315 1024.0020 PROP. PRESS.RELIEF VALVE

1 FMP-03/10-E 1309.0001 MODULAR FILTER

1 AGIU-20/10/210/5-IX 24DC H15 UNLOADING VALVE

1 LIDA-2 1039.0003 COVER

1 SC LI-25322 1036.0102 CARTRIDGE

2 2103-01-18.00 R05 TEST CONNECTION

3 SP-667/09T/C3/24 4018.0004 CONNECTOR

1 PG-63B315B 1509.0308 PRESSURE GAUGE

1 2105-05-11.00 R05 PRESSURE GAUGE CONNECTOR

2 S100-AC-AC-0100 R05 TEST HOSE

1 3200223 S07 PRESSURE GAUGE SUPPORT

1 96004 OIL COOLER LOC-011-4-D-B

DESCRIPTION REMARKS

20

19

21

22

23

24

25

26

27

28

29

30

31

32

ELEMENT: SP-CMP-03/10

LOC-011-4-D-B

Scale:

Title:

KA

LT

EN

BA

CH

Checked by

Designed by

Project No.

Date

Rem

arks:

Draw

ing #:

P.O. Box 30, 2290 AA, Wateringen, Holland

Mail: [email protected]

© OBSERVE COPYRIGHT DIN34

No part of this drawing may be reproduced or submitted to third parties in any form, by any means, without the written permission of KALTENBACH BV. If no order follows drawing and enclosure must be returned.

A3S

ize:


Checked by


Date Remarks:

Drawing #:



A3Size:


M-UK-KPS--06 11/02/03 Page 137 of 138

KALTENBACH

6.6 Electric drawings

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Coverpage

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E1018301-DKPS515

8

=+

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2a

1

Main-voltage:

Control-voltage:

All wiring 1 mm² (exceptions displayed)

L1, L2, L3 = blackN = l.bluePE = yellow/green

24V dc = d blue

˜24V ac = red

Project:

Customer:

KPS515

Machine:

Turfschipper 22292 JA WateringenTel.:+31 174 272727email: [email protected]

Samaras

Gecontroleerd:

Uitgegeven:

Terug:

29-01-2008

Index-pagePage Header Extra field Modification

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PAGINDEX pagina-overzicht (interactief)

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2a.a

2a

1 Coverpage 13-01-2006

2a PAGINDEX pagina-overzicht (interactief) 29-01-2008

2a.a PAGINDEX pagina-overzicht (interactief) 29-01-2008

2a.b PAGINDEX pagina-overzicht (interactief) 29-01-2008

2a.c PAGINDEX pagina-overzicht (interactief) 29-01-2008

2a.d PAGINDEX pagina-overzicht (interactief) 29-01-2008

3a Material-overview 29-01-2008

3b Material-overview 29-01-2008

3c Material-overview 29-01-2008

3d Material-overview 29-01-2008

3e Material-overview 29-01-2008

3f Material-overview 29-01-2008

3g Material-overview 29-01-2008

3h Material-overview 29-01-2008

3i Material-overview 29-01-2008

3j Material-overview 29-01-2008

4 Modification 13-01-2006

5.1 Options 19-04-2007

5.2 Options 19-04-2007

6 Control panel 29-01-2008

8 connections APC620 29-01-2008

9 operation desk 29-01-2008

10 Voltage 400V ac 29-01-2008

11 Main-voltage 29-01-2008

12.U dwars invoer 29-01-2008


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2a.a

15 Voltage 240V 29-01-2008

15.G Airco control cabinet 20-04-2007

15.M Operation desk airco 20-04-2007

16 Voltage 24V dc 29-01-2008

20 Servocontroller M120P 29-01-2008

21 Servocontroller punch unit 29-01-2008

21.F Servocontroller punch table 29-01-2008

22.F Servocontroller dies table 29-01-2008

24 Servocontroller shear 29-01-2008

25.W Servocontroller turningtabel shear 29-01-2008

26.E Servocontroller marking wheel 29-01-2008

27.K Servocontroller outputtable 29-01-2008

29.L Servocontroller cuttingclearance 29-01-2008

30 entrance safety 1LSG1 29-01-2008

31 Emergency stop circuit 29-01-2008

32 Star- delta circuit 29-01-2008

33.V safety lightcurtain input 1LA1 (option) 29-01-2008

34.Z safety lightcurtain output 1LA2 (option) 29-01-2008

40 Inputs 29-01-2008

41 Inputs 20-04-2007

42 Inputs in 1S1 29-01-2008

43 Inputs 29-01-2008

44 Uitgangen 29-01-2008

45 Uitgangen analoog 29-01-2008

46 Outputs 29-01-2008


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2a.b

47.U Outputs 29-01-2008

100 X67 voltage connection 29-01-2008





110 Outputs 29-01-2008

111 Outputs 29-01-2008

112 Outputs 29-01-2008

113 Outputs 29-01-2008

114 Outputs 29-01-2008

115 Outputs 29-01-2008

116 Outputs punch unit 29-01-2008

117.F Outputs KPS515 punch 29-01-2008

118.F Inputs KPS515 punch 29-01-2008

119.F Inputs KPS515 punch 29-01-2008

120.F 29-01-2008

121 20-04-2007

122 Outputs shearunit 29-01-2008


124 Inputs shearunit 29-01-2008

125 Inputs shearunit 20-04-2007

126.K Outputs outfeedtable 29-01-2008

127.K Outputs outfeedtable 29-01-2008

128.K inputs outfeedtable 29-01-2008


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2a.c

129.K inputs outfeedtable 29-01-2008

130.E Outputs markingunit 29-01-2008

131.E Outputs markingunit 29-01-2008



134 Outputs Drillunit 29-01-2008

135 Inputs Drillunit 29-01-2008

136.E Outputs fourfold marking wheel 29-01-2008

137.E Outputs fourfold marking wheel 29-01-2008

151 X67 bus connection 20-04-2007





170 Terminal diagram












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210 12-06-2007

400 PLC card overview : U410 - U420 29-01-2008










Material-overviewDevice Part number Description Type Page

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Material-overview

5 6 7

E1018301-DKPS515

8

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3b

3a

F151 710332 EP62 2P C16 15.1

F151 710346 CA H 15.1

F160 750054 16.0

F160 750055 16.0

F160 750087 16.0

F161 750054 16.1

F161 750055 16.1

F161 750087 16.1

F162 750054 16.2

F162 750055 16.2

F162 750070 16.2

F163 750054 16.3

F163 750055 16.3

F163 750070 16.3

F164 750054 16.4

F164 750055 16.4

F164 750070 16.4

F165 750054 16.5

F165 750055 16.5

F165 750070 16.5

F166 750054 16.6

F166 750055 16.6

F166 750070 16.6

F167 750054 16.7

F167 750055 16.7

F167 750070 16.7

F454 750078 45.4

F454 750054 45.4

F454 750055 45.4

H1299 710054 2371.020 129.K.9

H1299 710057 2368.010 129.K.9

H1299 710058 2372.110 129.K.9

J9 730242 COB24BC 40.7

J9 730304 COBTSF 40.7

J9 730355 CNF 24 40.7


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E1018301-DKPS515

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3c

3b

J9 730360 CNM 24 40.7

J10 730244 COB16BC 10.4

J10 730304 COBTSF 10.4

J10 730340 CPF 06 10.4

J10 730345 CPM 06 10.4

J11 730242 COB24BC 11.7

J11 730304 COBTSF 11.7

J11 730355 CNF 24 11.7

J11 730360 CNM 24 11.7

J12 730242 COB24BC 12.U.1

J12 730304 COBTSF 12.U.1

J12 730355 CNF 24 12.U.1

J12 730360 CNM 24 12.U.1

J14 730242 COB24BC 100.0

J14 730304 COBTSF 100.0

J14 730355 CNF 24 100.0

J14 730360 CNM 24 100.0

J15 730242 COB24BC 103.0

J15 730304 COBTSF 103.0

J15 730355 CNF 24 103.0

J15 730360 CNM 24 103.0

J35 730242 COB24BC 15.1

J35 730355 CNF 24 15.1

J35 730304 COBTSF 15.1

J35 730360 CNM 24 15.1

J36 730303 15.1

J36 730355 15.1

J42 730242 COB24BC 42.5

J42 730304 COBTSF 42.5

J42 730355 CNF 24 42.5

J42 730360 CNM 24 42.5

J43 730242 COB24BC 40.7

J43 730304 COBTSF 40.7

J43 730355 CNF 24 40.7

J43 730360 CNM 24 40.7

CNF 24


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3d

3c

J46 730242 COB24BC 46.1

J46 730304 COBTSF 46.1

J46 730355 CNF 24 46.1

J46 730360 CNM 24 46.1

J101 730242 COB24BC 30.3

J101 730304 30.3

J101 730355 CNF 24 30.3

J101 730360 CNM 24 30.3

K300 720045 MY4N 30.0

K300 720092 PYF14S 30.0

K300 720093 PYF-CM-14-S 30.0

K314 720220 G&S 4A2B 24VDC 31.4

K314 720221 P7S-14F 31.4

K315 720220 G&S 4A2B 24VDC 31.5

K315 720221 P7S-14F 31.5

K316 720020 MY2N 24V DC 31.6

K316 720082 PYF08S 31.6

K316 720083 PYCM08S 31.6

K321 720062 H3YN-2 24VDC 32.1

K321 720082 PYF08S 32.1

K322 710363 32.2

K323 710363 CL25D300TD 32.3

K323 710369 32.3

K323 710358 32.3

K324 710363 CL25D300TD 32.4

K324 710369 32.4

K325 710361 MC1C301AT 32.5

K325 710369 32.5

K327 710361 MC1C301AT 32.7

K327 710369 32.7

K327 710358 MMH0 32.7

K424 720045 MY4N 42.4

K424 720092 PYF14S 42.4

K424 720093 PYF-CM-14-S 42.4

K425 720045 MY4N 42.5

COBTSF

CL25D300TD

MMH0


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3d

K425 720092 PYF14S 42.5

K425 720093 42.5

K426 720170 38.61.7.024.0050 42.6

K426 720172 42.6

K427 720170 38.61.7.024.0050 42.7

K441 720170 38.61.7.024.0050 44.1

K442 720170 38.61.7.024.0050 44.2

K443 720170 38.61.7.024.0050 44.3

K444 720170 38.61.7.024.0050 44.4

K446 720170 44.6

K475 710361 MC1C301AT 47.U.5

K475 710369 47.U.5

K475 710358 47.U.5

K476 710361 MC1C301AT 47.U.6

K476 710369 47.U.6

K477 710361 MC1C301AT 47.U.7

K477 710369 47.U.7

K477 710358 47.U.7

K478 710361 MC1C301AT 47.U.8

K478 710369 47.U.8

1LA1/A 370100 RRT42.6 33.V.3

1LA1/B 370024 AMI 33.V.4

1LA2/A 370100 RRT42.6 34.Z.3

1LA2/B 370028 PM-2V 34.Z.4

LSG1/A 370100 30.3

LSG1/B 370024 30.5

M290 760303 29.L.0

PE 810545 12.U.1

Q100 710404 63A ML 10.0

Q108 710315 GPS2BSAS 10.4

Q108 710316 10.4

Q108 710318 10.4

Q108 710320 10.4

Q108 710323 10.4

Q112 710312 GPS1BSAN 11.2

PYF-CM-14-S

38.61.7.024.0050

MMH0

MMH0

RRT42.6

AMI

GPAC10FBA

GPB1FA


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3e

Q112 710316 GPAC10FBA 11.2

Q114 710306 GPS1BSAH 11.4

Q114 710316 GPAC10FBA 11.4

Q117 710304 GPS1BSAG 11.7

Q117 710316 GPAC10FBA 11.7

Q121 710306 GPS1BSAH 12.U.1

Q121 710316 GPAC10FBA 12.U.1

Q122 710302 GPS1BSAF 12.U.1

Q122 710316 GPAC10FBA 12.U.1

Q123 710302 GPS1BSAF 12.U.3

Q123 710316 GPAC10FBA 12.U.3

Q127 710302 GPS1BSAF 12.U.6

Q127 710316 GPAC10FBA 12.U.6

Q128 710302 12.U.8

Q128 710316 GPAC10FBA 12.U.8

Q160 710304 GPS1BSAG 16.1

S130 711200 M22-PV 31.2

S130 711130 M22-CK01 31.2

S130 711140 M22-A 31.2

S151 810535 PS4127000 15.M.5

S154 810535 15.G.4

S300A 711095 30.0

S300A 711110 M22-CK10 30.0

S300A 711140 M22-A 30.0

S310 610415 D4DS-15FS 31.1

S310 610417 D4DS-K3 31.1

S403B 710519 40.5

S405 610155 40.7

S425 610140 42.5

S426 610140 42.6

S436 610155 43.6

S1182 710512 118.F.2

S1182 766001 118.F.2

S1184 710512 118.F.4

S1184 766001 118.F.4

GPS1BSAF

PS4127000

E3S-BT-81

E2EG-X2B1-M1

E2EG-X2B1-M1


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Projekt:

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19-04-2007

29-01-2008

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2 3 4

Material-overview

5 6 7

E1018301-DKPS515

8

=+

9

409

3g

3f

S1184 610155 118.F.4

S1186 710512 118.F.6

S1186 766001 118.F.6

S1186 610155 118.F.6

S1199 810488 119.F.9

S1199 766102 119.F.9

S1242 710521 124.2

S1242 766001 124.2

S1284 610155 128.K.4

S1286 610155 128.K.6

2S1 770660 10.0

2S1 810530 10.0

2S1 750010 10.0

2S1 810560 10.0

2S1 810580 10.0

2S1 810539 10.0

2S1 770655 10.0

2S1 810579 10.0

2S1 770665 BA 6 60080 10.0

2S1 770650 BA 6 40025 10.0

U100 3334 5P62:KALTENBACH-03 8.3

U101 761684 5AP920.1505-1+5DLSDL.1000-00+09.2

U151 810586 15.M.3

U154 810586 15.G.4

U154 810581 15.G.4

U160 760611 MCS 40 16.0

U200 760307 ACOPOS 1045 20.0

U210 760307 ACOPOS 1045 21.0

U210 760316 8AC123.60-1 21.0

U220 760307 ACOPOS 1045 21.F.0

U222 760307 ACOPOS 1045 22.F.0

U240 760307 ACOPOS 1045 24.0

U250 760307 ACOPOS 1045 25.W.0

U260 760307 ACOPOS 1045 26.E.0

U270 760307 ACOPOS 1045 27.K.0

E2EG-X2B1-M1

E2A-M18LS08-M1-B1

BA 6 60060

DIN-3TS35


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Material-overview

5 6 7

E1018301-DKPS515

8

=+

9

409

3h

3g

U290 760307 ACOPOS 1045 29.L.0

U310 720215 BH-5928 31.0

U315 720215 BH-5928 30.2

U330 8-4330-100225 33.V.1

U330 720215 BH-5928 33.V.1

U340 8-4330-100225 34.Z.1

U340 720215 BH-5928 34.Z.1

U400 760318 40.0

U400 760327 40.0

U410 710340 7CM211.7 44.0

U410 760322 44.0

U420 760320 7MD465.7 46.0

U420 760322 7TB718:91-02 46.0

U451 909993 E-BM-AC-01F 45.1

U1000 760392 DM1321 100.0

U1002 760392 DM1321 100.2

U1005 760392 DM1321 100.5

U1007 760396 PS1300 100.7

U1010 760394 DO1332 101.0

U1012 760392 DM1321 101.2

U1015 760392 DM1321 101.5

U1017 760396 PS1300 101.7

U1020 760394 DO1332 102.0

U1022 760392 DM1321 102.2

U1025 760396 PS1300 102.5

U1027 760392 DM1321 102.7

U1030 760392 DM1321 103.0

U1032 760394 DO1332 103.2

U1035 760396 PS1300 103.5

U1037 760394 DO1332 103.7

U1040 760392 DM1321 104.0

U1042 760392 DM1321 104.2

W1LA1-1 766430 33.V.3

W1LA2-1 766430 34.Z.3

W210-PL 765402 20.6

7EX484.50-1

7TB718:91-02


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29-01-2008

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2 3 4

Material-overview

5 6 7

E1018301-DKPS515

8

=+

9

409

3i

3h

W220-PL 765405 21.F.6

W222-PL 765405 22.F.6

W240-PL 765405 24.6

W250-PL 765405 25.W.6

W260-PL 765405 26.E.6

W270-PL 765405 27.K.6

W290-PL 765405 29.L.6

WLSG-1 766430 30.3

WMODEM 761536 8.2

WSDL 761686 8.2

WU400/PL 765402 8.2

WU1000-A 765700 151.0

WU1000-A 760311 151.0

WU1000-C 765810 100.0

WU1002-A 765702 151.4

WU1002-C 765810 100.2

WU1005-A 765703 151.0

WU1005-A 765705 151.0

WU1005-C 765810 100.5

WU1007-A 765702 151.4

WU1007-C 765810 100.7

WU1010-A 765702 152.0

WU1010-C 765810 101.0

WU1012-A 765702 152.4

WU1012-C 765810 101.2

WU1015-A 765702 152.0

WU1015-C 765810 101.5

WU1017-A 765702 152.4

WU1017-C 765810 101.7

WU1020-A 765705 153.0

WU1020-C 765810 102.0

WU1022-A 765702 153.4

WU1022-C 765810 102.2

WU1025-A 765702 153.0

WU1025-C 765810 102.5

394-2454

5CASDL.0200-00

X67CA0X01.0020


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29-01-2008

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2 3 4

Material-overview

5 6 7

E1018301-DKPS515

8

=+

9

409

3j

3i

WU1027-A 765703 153.4

WU1027-A 765710 153.4

WU1027-C 765810 102.7

WU1030-A 765710 154.0

WU1030-C 765810 103.0

WU1032-A 765703 154.4

WU1032-A 765705 154.4

WU1032-C 765810 103.2

WU1035-A 765702 154.0

WU1035-C 765810 103.5

WU1037-A 765703 154.4

WU1037-A 765705 154.4

WU1037-C 765810 103.7

WU1040-A 765700 155.1

WU1040-A 760311 155.1

WU1040-C 765810 104.0

WU1042-A 765702 155.4

WU1042-C 765810 104.2

1X0 770598 10.0

1X0 770571 10.0

1X0 770586 10.0

Y461 810438 45A/SC1/DDDJ/1KF 46.1

Y461 810439 46.1

Y461 800510 46.1

Y461 15271 46.1

Y462 810438 46.2

Y463 810438 46.3

Y463 810439 M/450001/01P 46.3

Y464 810438 45A/SC1/DDDJ/1KF 46.4

Y464 810439 M/450001/01P 46.4

Y465 810438 45A/SC1/DDDJ/1KF 46.5

Y465 810439 M/450001/01P 46.5

Y1102A 766301 110.2

Y1102B 766301 110.4

Y1106A 766301 110.6

X67CA0X01.0020

X67CA0X01.0020

X67CA0X01.0020

UK16

M/450001/01P

45A/SC1/DDDJ/1KF

45A/SC1/DDDJ/1KF


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29-01-2008

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Material-overview

5 6 7

E1018301-DKPS515

8

=+

9

409

4

3j

Y1106B 766301 110.9

Y1112A 766301 111.2

Y1112B 766301 111.4

Y1116A 766301 111.6

Y1116B 766301 111.9

Y1122A 766202 112.2

Y1122B 766202 112.4

Y1132A 766202 113.2

Y1132B 766202 113.4

Y1142 766202 114.2

Y1162A 766201 116.2

Y1162B 766201 116.4

Y1166A 766201 116.6

Y1166B 766201 116.9

Y1222A 766202 122.2

Y1222B 766202 122.4

Y1226A 766202 122.6

Y1226B 766202 122.9

Y1262 766202 126.K.2

Y1264 766202 126.K.4

Y1309A 766202 130.E.9

Y1309B 766202 131.E.2

Y1362A 766202 136.E.2

Y1362B 766202 136.E.4

Y1366A 766202 136.E.6

Y1366B 766202 136.E.9

Y1372 766202 137.E.2

Y1374 766202 137.E.4

Y1376 766202 137.E.6

Y1379 766202 137.E.9

keyboard 1403 9.7

keyboard 14031 9.7

mouse 761595 9.7

mouse 761598 9.7

CHERRY G83-6104

FELL001

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8

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5.1

4

Name:

modificationDescription: :

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2 3 4

Options

5 6 7

E1018301-DKPS515

8

=+

9

409

5.2

5.1

Name:

L: option cuttingclearance- servo

M: option operation desk- airco

N: option switchcabinet- heating

R: option slidetable- servo outputbelt + ejector

Q> option hydraulic heating

O: option operation desk- heating

P> option voltagestabilizer

K: option slidetable- servo + ejector

G: option airco switchcabinet

H: option drill unit

I: option KPS 503

J: option slidetable- servo

D: option single marking wheel

A: option flange unit

B: option angle shear

C: option width measuring

E: option fourfold marking wheel

F: option KPS 515

OptionsDescription: Yes

ExistNo

XX

X

X

X

XX

X

X

X

X

XX

X

X

X

XX

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Options

5 6 7

E1018301-DKPS515

8

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6

5.2

Name:

X: option lightcurtain 1LSG1 < 10m.

Y: option lightcurtain 1LA1 < 10m.

Z: option lightcurtain 1LA2 < 10m.

T: option KKS saw

U: option cross supports

S: option lightcurtain output conveyor 1LA2 > 10m.

V: option safety lightcurtain input 1LA1 > 10m.

W: option turningtabel shear

OptionsDescription: Yes

ExistNo

XX

XX

X

XX

X

X

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2 3 4

Control panel

5 6 7

E1018301-DKPS515

8

=+

9

409

8

6

Q108 GPS2BSAS 710315U200 ACOPOS 1045 760307U210 ACOPOS 1045 760307U222 ACOPOS 1045 760307U220 ACOPOS 1045 760307U240 ACOPOS 1045 760307U250 ACOPOS 1045 760307U260 ACOPOS 1045 760307U270 ACOPOS 1045 760307U290 ACOPOS 1045 760307U451 E-BM-AC-01F 909993F162 750054F163 750054F164 750054F165 750054F166 750054F167 750054F454 750054F160 750054F161 750054U410 7CM211.7 710340U420 7MD465.7 760320U400 7EX484.50-1 760318K426 38.61.7.024.0050 720170K427 38.61.7.024.0050 720170K441 38.61.7.024.0050 720170K442 38.61.7.024.0050 720170K443 38.61.7.024.0050 720170K444 38.61.7.024.0050 720170K446 38.61.7.024.0050 720170K314 P7S-14F 720221K315 P7S-14F 720221U310 BH-5928 720215K425 PYF14S 720092K316 PYF08S 720082K300 PYF14S 720092K321 PYF08S 720082K424 PYF14S 720092K327 MC1C301AT 710361K478 MC1C301AT 710361K477 MC1C301AT 710361K325 MC1C301AT 710361K475 MC1C301AT 710361K476 MC1C301AT 710361Q127 GPS1BSAF 710302Q128 GPS1BSAF 710302Q112 GPS1BSAN 710312Q117 GPS1BSAG 710304Q121 GPS1BSAH 710306Q122 GPS1BSAF 710302

Q123 GPS1BSAF 710302F151 EP62 2P C16 710332K324 CL25D300TD 710363K322 CL25D300TD 710363K323 CL25D300TD 710363K323 MMH0 710358U160 MCS 40 760611Q160 GPS1BSAG 710304U100 5P62:KALTENBACH-03 3334U315 BH-5928 720215U330 BH-5928 720215U340 BH-5928 720215Q114 GPS1BSAH 710306

DT Type designation Partnumber DT Part

numberType designation

side left

65x6

6

65x6

6

65x66x670

65x66x670

65x66x670

65x66x670

30x66x670

85x66x670

1X3

PE

1X2

85x6

6x18

95

30x40

tracefor side rightin de kabinet

1X0

sideright

AIRCO

Let op, aansluit kabel naar onderen niet afknippen!

*B=option kabinet heating

main switch

8105

82

555

605

855

955

1060

1160

1265

1365

1470

1570

1675

1785 185

265

360

460

1100

1260

20

30x6

6X40

0

T/M

J10

Q16

0

Auto

mat

ion

PC

U10

0

30x6

6X40

0

35 106

177

248

319

390

461

532

603

674

755

U31

5

U33

0

U34

0

Q11

4

1S1

U20

0

U21

0

U400

K325

Q10

8

U22

2K4

75

Q11

2

U410

K476

Q11

7

K477

Q12

1

U420

U24

0

K478

Q12

2

Q12

3U

250

K300

Q12

7

K316

K321

K426

U26

0Q

128

K427

K441

K424

K444

K425

U27

0

K314

K315

F151

U31

0K3

22U

290

K323

K324

F160

F167

F454

U45

1

U160

J9J11 J12J14J15J35J42 J46J101

U22

0

J43

K327

K446

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29-01-2008

1

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2 3 4

connections APC620

5 6 7

E1018301-DKPS515

8

=+

9

409

9

8

MODEM

isoleren ( niet gebruikt )

MO

DEM

LICENSE

POW

ER 24VD

C+

-m

onitor/panelCO

M1

COM

2

POW

ERLIN

KX2X LIN

K

CAN D

RILL

CAN SAW

W1000-A765700 4x0,34mm²

rdwtbkbl

WU400/PL 765402

WMODEM 761536

WSDL 761686

PE 27

U100

+pe

.

123

4

X2X+/

X2X/

X2XGND/

X2X\/

U400-2/PL/40.1

L+/APC/9.0

L-/9.0

U101/SDL/9.5

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Projekt:

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29-01-2008

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2 3 4

operation desk

5 6 7

E1018301-DKPS515

8

=+

9

409

10

9

POWER 24VDC+ - panel IN USB 1 USB 2

AARDEN AAN LESSENAAR

1P1

U101

W1P1-57700233x1,5mm²

J35 10

J36 10

+ PE

11

11

.

keyboard

mouse

L+/APC/8.1

L-/8.1

U101/SDL/8.1

L+/APC/ 16.0

L- / 16.3

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2 3 4

Voltage 400V ac

5 6 7

E1018301-DKPS515

8

=+

9

409

11

10

3 x 400V L1/L2/L3/N/PE50Hz 63AP=15,5KVA

voltage

paneel

Hydro motor Delta Starcircuit

2S1

10mm²

2

1

4

3

6

5

Q100

6mm²

1X0 L1 L2 L3 N

PE 1

6mm²

PE PL

2

6mm²

PE

3

6mm²

WJ1-M063 770022 7x6mm²

10mm²

1

2

3

4

5

6Q10834,7A

6mm²

6mm²

1

2K322

32.2

6mm²

J10 1

3

4

2

5

6

3

W2U2V2

W1V1U1

PE

M10418,5 KW 400V

Hydropomp

3~M

3

431.6

1

2K323

32.3

6mm²

4

3

4

5

5

6

6 R

1

2K324

32.4

PE 4

3

4

5

6

L1 / 11.0

L2 / 11.0

L3 / 11.0

N / 11.0

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2 3 4

Main-voltage

5 6 7

E1018301-DKPS515

8

=+

9

409

12.U

11

Servocontrollers Hydro coolingMotor debur unit aboveMotor debur unit down

10mm²

1

2

3

4

5

6Q112

18A

2,5mm²

3

431.6

W1b 770015 4x0,75mm²

10mm²

1

2

3

4

5

6Q1171,86A

1

2K325

32.5

J11 1

U V W

PE

M1170,75kW-1,86A-Y

3

4

2

5

6

3

PE 5

4

3

431.6

W114 770015 4x0,75mm²

10mm²

1

2

3

4

5

6Q114

1

2K327

32.7

J11 5

U V W

PE

M1140,75kW-Y

3

4

6

5

6

7

PE 28

8

3

431.6

W115 770015 4x0,75mm²

9

U V W

PE

M1150,75kW-Y

10 11

PE 29

12

L1/10.9

L2/10.9

L3/10.9

N/10.9

2L1

/20

.1

2L2

/20

.1

2L3

/20

.1

L1 / 12.U.0

L2 / 12.U.0

L3 / 12.U.0

N / 12.U.0

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2 3 4

dwars invoer

5 6 7

E1018301-DKPS515

8

=+

9

409

15

12.U

Transport 1 cross Transport 2 cross

W12a 770015 4x0.75mm²

10mm²1

2

3

4

5

6Q121

4A

1

2K47547.U.5

1

2

3

4

5

6Q122

1A

J12 1

U V W

PE

M1210,37kW-1A-Y 3~

M

3

4

2

5

6

3

PE 6

4

3

431.6

3

431.6

1

2K47647.U.6

3

4

5

6

W12b 770015 4x0.75mm²

1

2

3

4

5

6Q123

1A

J12 5

U V W

PE

M1230,37kW-1A-Y 3~

M

6 7

5

8

3

431.6

W12c 770015 4x0.75mm²

1

2K47747.U.7

1

2

3

4

5

6Q127

1A

13

U V W

PE

M1270,37kW-1A-Y 3~

M

3

4

14

5

6

15

PE 7

16

3

431.6

1

2K47847.U.8

3

4

5

6

W12d 770015 4x0.75mm²

1

2

3

4

5

6Q128

1A

17

U V W

PE

M1280,37kW-1A-Y 3~

M

18 19

PE 6

20

3

431.6

L1/11.9

L2/11.9

L3/11.9

N/11.9

L1 / 15.0

L2 / 15.0

L3 / 15.0

N / 15.0

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0

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1

Samaras

2 3 4

Voltage 240V

5 6 7

E1018301-DKPS515

8

=+

9

409

15.G

15

Operation desk

1P1

W1P1-1 770011 2x0,75mm²

1

2

3

4F15116A

1,5mm²

1X2 1

J35 1

J36 1

10X1 1

1X2 2

J35 2

2

2

L1/12.U.9

L2/12.U.9

L3/12.U.9

N/12.U.9

10X1:2/ 15.M.2

10X1:1/ 15.M.2

1X2:1/ 15.G.3

1X2:2/ 15.G.3

L1 / 16.0

L2 / 16.0

L3 / 16.0

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15

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2 3 4

Airco control cabinet

5 6 7

E1018301-DKPS515

8

=+

9

409

15.M

15.G

aircoswitchcabinet

U154

L1 N

1X2 PE

PE

121

22S154Door

PE 9

2

1X2:1/15.4

1X2:2/15.4

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2 3 4

Operation desk airco

5 6 7

E1018301-DKPS515

8

=+

9

409

16

15.M

operation desk airco

U151

10X1 1

L1

2

N PE

PE

PE 9

1

21

22S151Door

2

W10X1/U151

10X1:2/15.1

10X1:1/15.1

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15.M

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29-01-2008

1

Samaras

2 3 4

Voltage 24V dc

5 6 7

E1018301-DKPS515

8

=+

9

409

20

16

24V dc L+ 24V dc NA1 24V dc NA2 24V dc NA3 24V dc NA4

2,5mm²

24V DC outsidecontrol cabinet

24V DC NA5

U16024dcV-40A

2,5mm²

F16010A

1,5mm²

10mm²1

2

3

4

5

6

Q1601,63A

4/L1

8/DC+

3/L2

7/DC+

2/L3

6/DC-

2,5mm²

1X3 2

6mm²

PE 11

1/PE

5/DC-

2

2,5mm²

F16110A

1,5mm²

1X3 1

4mm²

PE 10

2,5mm²

F1625A t

1,5mm²

47

48U310

31.01,5mm²

1X3 3

2,5mm²

F1635A t

1,5mm²

13

14K314

31.41,5mm²

4

2,5mm²

F1645A t

1,5mm²

23

24K314

31.41,5mm²

5

2,5mm²

F1655A

1,5mm²

33

34K314

31.41,5mm²

6

F1665A

1,5mm²

13

14K315

31.51,5mm²

7

F1675A

1,5mm²

1X3 20

L1/15.9

L2/15.9

L3/15.9

L+/APC9.8

L+20.1

L-9.8

NA1V20.1

NA232.0

NA3101.0

NA4102.0

NA5103.2

L+/X67100.7

Bl.

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Create date:

Modification:

HS

Projekt:

16

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Servocontroller M120P

5 6 7

E1018301-DKPS515

8

=+

9

409

21

20

L1 L2

ACTUATOR MOTOR M100P

L3 PE

W PE

Tempature sensor

0V

ACO

M(8

/9)

COM

(5-7

)(1

3-15

)B D

02

U2001045

M200

2,5mm²

U200/X3 1 2

W20

0a 8

CM0X

X.12

-1 8

x1,5

mm

²

U200/X5 1

bw

U1 V1 W1

PE

3

4

bn

PE 11

2,5mm²

4

3

zt

2

gl/gn

PE 12

2,5mm²

PE

U200/X4 4

wt/bw

B+

U200/X1 1 2

3

wt/gn

B-

3 4

2

wt

1

2Θ

5

1

wt/rd

6 7 8

3X3 3

9

AC120

2

18

W20

0-b

8CE0

xx.1

2-1

12x0

,14m

m²

U200/X6 2

wt/

gn10

1

14

4

wt/

rd

7

15

1

gn

15

10

9

bn

16

17

3

gr

12

11

gl

13

5

wt

14

13

vi

17

8

zw

8

AC112

15

rd

9

W210-PL 765402

10

ro

4

12

bl

1

U200/X2 1 2 3 4

47

48U33033.V.1

L+/16.1

L-/20.8

NA1V/16.2

2L1/11.2

2L2/11.2

2L3/11.2

U200/PL40.1

U210/PL21.6

L+/ 21.0

L- / 20.1

NA1V / 21.0

2L1 / 21.0

2L2 / 21.0

2L3 / 21.0

Bl.

Created by:

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Create date:

Modification:

HS

Projekt:

20

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Servocontroller punch unit

5 6 7

E1018301-DKPS515

8

=+

9

409

21.F

21

Actuator motor punch unit

L1 L2

W

L3

PE

PE

Tempature sensor

A B D

0V

04

1045U210

M210

W21

0a 8

CM0X

X.12

-1 8

x1,5

mm

²

U210/X5 1

bw

U1 V1 W1

PE

2,5mm²

U210/X3 1

4

bn

2

3

zt

3

2

gl/gn

PE 13

4

PE 14

2,5mm²

PE

U210X4B 4

wt/bw

3

wt/gn

2

wt

1

2Θ

1

wt/rd

U210/X1 1 2

AC120

W21

0-b

8CE0

xx.1

2-1

12x0

,14m

m²

3

U210/X6 2

wt/

gn

10

4

4

wt/

rd

7

5

1

gn

15

6

9

bn

16

7

3

gr

12

8

11

gl

13

1X3 3

9

5

wt

14

2

18

13

vi17

1

14

8

zw8

15

15

rd

9

10

10

ro

4

17

12

bl

1

AC112

W210-PL 765402

U210/X2 1 2 3 4

B+ B-

L+/20.8

L-/21.9

NA1V/20.8

2L1/20.8

2L2/20.8

2L3/20.8

U210/PL20.7

U220/PL21.F.6

L+/ 21.F.1

L- / 21.0

NA1V / 21.F.1

2L1 / 21.F.0

2L2 / 21.F.0

2L3 / 21.F.0

Bl.

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Create date:

Modification:

HS

Projekt:

21

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Servocontroller punch table

5 6 7

E1018301-DKPS515

8

=+

9

409

22.F

21.F

L1 L2 L3

Actuator motor punch changer

PE

W PE

Tempature sensor

0V

COM

(8/9

)

COM

(5-7

)(1

3-15

)A B D

06

U2201045

M220

2,5mm²

U220/X3 1 2 3

W22

0a 8

CM0X

X.12

-1 8

x1,5

mm

²

U220/X5 1

bw

U1 V1 W1

PE

PE 17

4

4

bn

3

zt

PE 18

2,5mm²

PE

2

gl/gn

U220/X1 1

U220/X4 4

wt/bw

B+

2 3

3

wt/gn

B-

4 5

2

wt

1

2Θ

6

1

wt/rd

7 8

1X3 3

9

2

18

1

14

AC120

15

W22

0-b

8CE0

xx.1

2-1

12x0

,14m

m²

U220/X6 2

wt/

gn

10

10

4

wt/

rd

7

17

1

gn

15

9

bn

16

3

gr

12

AC112

11

gl

13

W220-PL 765405

5

wt

14

13

vi

17

8

zw

8

15

rd

9

10

ro

4

12

bl

1

U220/X2 1 2 3 4

2L1/21.9

2L2/21.9

2L3/21.9

L+/21.9

L-/21.F.9

NA1V/21.9

U220/PL21.7

U222/PL22.F.6

L+/ 22.F.1

L- / 21.F.1

NA1V / 22.F.1

2L1 / 22.F.0

2L2 / 22.F.0

2L3 / 22.F.0

Bl.

Created by:

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Create date:

Modification:

HS

Projekt:

21.F

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Servocontroller dies table

5 6 7

E1018301-DKPS515

8

=+

9

409

24

22.F

L1 L2 L3

Servocontroller punch changer

PE

W PE

Tempature sensor

0V

COM

(8/9

)

COM

(5-7

)(1

3-15

)A B D

08

U2221045

M222

2,5mm²

U222/X3 1 2 3

W22

2a 8

CM0X

X.12

-1 8

x1,5

mm

²

U222/X5 1

bw

U1 V1 W1

PE

PE 17

4

4

bn

3

zt

PE 18

2,5mm²

PE

2

gl/gn

U222/X1 1

U222/X4 4

wt/bw

B+

2 3

3

wt/gn

B-

4 5

2

wt

1

2Θ

6

1

wt/rd

7 8

1X3 3

9

2

18

1

14

AC120

15

W22

2-b

8CE0

xx.1

2-1

12x0

,14m

m²

U222/X6 2

wt/

gn

10

10

4

wt/

rd

7

17

1

gn

15

9

bn

16

3

gr

12

AC112

11

gl

13

W222-PL 765405

5

wt

14

13

vi

17

8

zw

8

15

rd

9

10

ro

4

12

bl

1

U222/X2 1 2 3 4

2L1/21.F.9

2L2/21.F.9

2L3/21.F.9

L+/21.F.9

L-/22.F.9

NA1V/21.F.9

U222/PL21.F.7

U240/PL24.6

L+/ 24.0

L- / 22.F.1

NA1V / 24.0

2L1 / 24.0

2L2 / 24.0

2L3 / 24.0

Bl.

Created by:

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Create date:

Modification:

HS

Projekt:

22.F

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Servocontroller shear

5 6 7

E1018301-DKPS515

8

=+

9

409

25.W

24

L1 L2 L3 PE

W PE

Tempature sensor

0V

COM

(8/9

)A

COM

(5-7

)(1

3-15

)

B D

0C

1045U240

2,5mm²

U240/X3 1

M240

2 3

PE 19

4

W24

0a 8

CM0X

X.12

-1 8

x1,5

mm

²

U240/X5 1

bw

U1 V1 W1

PE

4

bn

PE 20

2,5mm²

PE

3

zt

2

gl/gn

U240/X4 4

wt/bw

3

wt/gn

U240/X1 1 2

2

wt

1

2Θ

3

1

wt/rd

4 5 6 7 8

1X3 3

9

2

18

AC120

1

14

W24

0-b

8CE0

xx.1

2-1

12x0

,14m

m²

U240/X6 2

wt/

gn

10

15

4

wt/

rd

7

10

1

gn

15

17

9

bn

16

3

gr

12

11

gl

13

AC112

5

wt

14

W240-PL 765405

13

vi

17

8

zw

8

15

rd

9

10

ro

4

12

bl

1

U240/X2 1 2 3 4

B+ B-

L+/22.F.9

L-/24.9

NA1V/22.F.9

2L1/22.F.9

2L2/22.F.9

2L3/22.F.9

U240/PL22.F.7

U250/PL25.W.6

L+/ 25.W.1

L- / 24.0

NA1V / 25.W.1

2L1 / 25.W.0

2L2 / 25.W.0

2L3 / 25.W.0

Bl.

Created by:

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Create date:

Modification:

HS

Projekt:

24

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Servocontroller turningtabel shear

5 6 7

E1018301-DKPS515

8

=+

9

409

26.E

25.W

L1 L2 L3 PE

W PE

Tempature sensor

0V

COM

(8/9

)

COM

(5-7

)(1

3-15

)A B D

0

U2501045

M250

2,5mm²

U250/X3 1 2 3

W25

0a 8

CM0X

X.12

-1 8

x1,5

mm

²

U250/X5 1

bw

U1 V1 W1

PE

PE 21

4

4

bn

3

zt

PE 22

PE

2

gl/gn

U250/X1 1

U250/X4 4

wt/bw

B+

2 3

3

wt/gn

B-

4 5

2

wt

1

2Θ

6

1

wt/rd

7 8

1X3 3

9

2

18

1

14

AC120

15

W25

0-b

8CE0

xx.1

2-1

12x0

,14m

m²

10

U250/X6 2

wt/

gn

10

4

wt/

rd

7

17

1

gn

15

9

bn

16

AC112

3

gr

12

W250-PL 765405

11

gl

13

5

wt

14

13

vi

17

8

zw

8

15

rd

9

10

ro

4

12

bl

1

U250/X2 1 2 3 4

2L1/24.9

2L2/24.9

2L3/24.9

L+/24.9

L-/25.W.9

NA1V/24.9

U250/PL24.7

U260/PL26.E.6

L+/ 26.E.0

L- / 25.W.1

NA1V / 26.E.0

2L1 / 26.E.0

2L2 / 26.E.0

2L3 / 26.E.0

Bl.

Created by:

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Create date:

Modification:

HS

Projekt:

25.W

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Servocontroller marking wheel

5 6 7

E1018301-DKPS515

8

=+

9

409

27.K

26.E

L1 L2 L3 PE

W PE

Tempature sensor

0V

COM

(8/9

)A

COM

(5-7

)(1

3-15

)B D

10

1045U260

2,5mm²

U260/X3 1 2

M260

3

W26

0a 8

CM0X

X.12

-1 8

x1,5

mm

²

U260/X5 1

bw

U1 V1 W1

PE

PE 23

4

4

bn

PE 24

2,5mm²

PE

3

zt

2

gl/gn

U260/X4 4

wt/bw

3

wt/gn

U260/X1 1

2

wt

1

2Θ

2

1

wt/rd

3 4 5 6 7 8

1X3 3

9

AC120

2

18

W26

0-b

8CE0

xx.1

2-1

12x0

,14m

m²

1

14

U260/X6 2

wt/

gn

10

15

4

wt/

rd

7

10

1

gn

15

9

bn

16

17

3

gr

12

11

gl

13

AC112

5

wt

14

W260-PL 765405

13

vi

17

8

zw

8

15

rd

9

10

ro

4

12

bl

1

U260/X2 1 2 3 4

B+ B-

L+/25.W.9

L-/26.E.9

NA1V/25.W.9

2L1/25.W.9

2L2/25.W.9

2L3/25.W.9

U260/PL25.W.7

U270/PL27.K.6

L+/ 27.K.1

L- / 26.E.0

NA1V / 27.K.1

2L1 / 27.K.0

2L2 / 27.K.0

2L3 / 27.K.0

Bl.

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Modification:

HS

Projekt:

26.E

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Servocontroller outputtable

5 6 7

E1018301-DKPS515

8

=+

9

409

29.L

27.K

L1 L2 L3 PE

W PE

Tempature sensor

0V

COM

(8/9

)

COM

(5-7

)(1

3-15

)A B D

12

U2701045

M270

2,5mm²

U270/X3 1 2 3

W27

0a 8

CM0X

X.12

-1 8

x1,5

mm

²

U270/X5 1

bw

U1 V1 W1

PE

PE 25

4

4

bn

3

zt

PE 26

PE

2

gl/gn

U270/X1 1

U270/X4 4

wt/bw

B+

2 3

3

wt/gn

B-

4 5

2

wt

1

2Θ

6

1

wt/rd

7 8

1X3 3

9

2

18

1

14

AC120

15

W27

0-b

8CE0

xx.1

2-1

12x0

,14m

m²

U270/X6 2

wt/

gn

10

10

4

wt/

rd

7

17

1

gn

15

9

bn

16

3

gr

12

AC112

11

gl

13

W270-PL 765405

5

wt

14

13

vi

17

8

zw

8

15

rd

9

10

ro

4

12

bl

1

U270/X2 1 2 3 4

29

30U34034.Z.1

2L1/26.E.9

2L2/26.E.9

2L3/26.E.9

L+/26.E.9

L-/27.K.9

NA1V/26.E.9

U270/PL26.E.7

U290/PL29.L.6

L+/ 29.L.1

L- / 27.K.1

NA1V / 29.L.1

2L1 / 29.L.1

2L2 / 29.L.1

2L3 / 29.L.1

Bl.

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Modification:

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Projekt:

27.K

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Servocontroller cuttingclearance

5 6 7

E1018301-DKPS515

8

=+

9

409

30

29.L

L1 L2 L3 PE

W PE

Tempature sensor

0V

COM

(8/9

)A

COM

(5-7

)(1

3-15

)

B D

16

U2901045

M290

2,5mm²

U290/X3 1 2

W29

0a 7

6037

0 8x

1,5

mm

²

U290/X5 1

bw

U1 V1 W1

PE

3

4

bn

PE 11

4

3

zt

2

gl/gn

PE 12

2,5mm²

PE

U290/X4 4

wt/bw

B+

U290/X1 1 2

3

wt/gn

B-

3 4

2

wt

1

2Θ

5

1

wt/rd

6 7 8

3X3 3

9

2

18

AC120

1

14

W29

0-b

8CE0

xx.1

2-1

12x0

,14m

m²

U290/X6 2

wt/

gn

10

15

4

wt/

rd

7

10

1

gn

15

17

9

bn

16

3

gr

12

11

gl

13

5

wt

14

AC112

13

vi

17

W290-PL 765405

8

zw

8

15

rd

9

10

ro

4

12

bl

1

U290/X2 1 2 3 4

L+/27.K.9

L-/29.L.9

NA1V/27.K.9

2L1/27.K.9

2L2/27.K.9

2L3/27.K.9

U290/PL27.K.7

L+/ 30.0

L- / 29.L.1

NA1V / 104.2

Bl.

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Projekt:

29.L

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

entrance safety 1LSG1

5 6 7

E1018301-DKPS515

8

=+

9

409

31

30

reset monitoringunit

Leuze lumiflexROBUST RRT42

+24

VD

C 0V + gnd

1P1

1X3 1

J35 4

J36 4

3

4S300A

5J36

5J35

A2

A1K300

.334.Z.233.V.2

PYF14SMY4N

VM

1X3 2

U315

A1

A2

S31 S32

S21

S13

S22

S14 Y39

S11 S12

Y40S33 S34

14

11K300

.0

LSG1/A1 2

2

3

3

4

4

5

5

6

6

PE

AMI 42LSG1/B

J101 7

1

8

3

J101 1

WLSG-1766430 8x0,5mm²

wt bn gn gl gsWLSG-2770011 2x0,75mm²

1 2rs

3X3 16

3X3 16

PE

rd

PE 25

31.242.1

VM

L+/29.L.9

L-/30.9

L+/ 31.0

L- / 30.0

Bl.

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Projekt:

30

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Emergency stop circuit

5 6 7

E1018301-DKPS515

8

=+

9

409

32

31

Emergency stop

Operation desk

t=2 sec

Failure

U310DOLD-BH5928

1X3 1

A1

.4

.516.2

VM

S33

51

52K314

.4

51

52K315

.5

1X3 15

1X3 141X3 14

21

22S310

Fence1X3 13

11

12K443

44.3

14

11K316

.6

S11

1P1

S34

11

14K442

44.2

S21

J35 12

J36 12

11

12S130

24J36

24J35

13

14U315

30.2

S12

S22

S31 S32

Y39 Y40 A2

1X3 2

13

14U310

.0

0

1K314

16.316.416.540.4

.1

P7S-14FG&S 4A2B 24VDC

VM

23

24U310

.0

0

1K315

16.6 .1

P7S-14FG&S 4A2B 24VDC

VM

3

4Q108

10.5

3

4Q112

11.2

3

4Q117

11.8

4

3Q12112.U.2

3

4Q12212.U.2

3

4Q12312.U.4

3

4Q12712.U.6

3

4Q12812.U.8

95

96F151

A2

A1K316

.140.3

PYF08SMY2N 24V DC

VM

3

4Q114

11.4

L+/30.9

L-/31.9

L+/ 32.0

L- / 31.0

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

31

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Star- delta circuit

5 6 7

E1018301-DKPS515

8

=+

9

409

33.V

32

Star-delta Hydro motor Hydrauliccooling

1X3 4

11

14K441

44.1

A1

A2

K321vertr.opk.

4 sec

M

.3 .4

PYF08SH3YN-2 24VDC

VM

1X3 2

A1

A2K322

10.410.410.4

CL25D300TDVM

11

14K321

.1

21

22K324

.4

A1

A2K323

10.510.510.6

.4

CL25D300TDVM

11

12K321

.1

21

22K323

.3

A1

A2K324

10.610.610.7

.3

CL25D300TDVM

11

14K444

44.4

A1

A2K325

11.711.711.7

MC1C301ATVM

A1

A2K327

11.411.411.4

MC1C301ATVM

1X3 1 1X3 4

11

14K446

44.6

NA2/16.3

L-/32.9

NA2 / 46.0

IN 4 / 40.6

L+/31.9 L+/ 33.V.0

L- / 32.0

Bl.

Created by:

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Create date:

Modification:

HS

Projekt:

32

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

safety lightcurtaininput 1LA1 (option)

5 6 7

E1018301-DKPS515

8

=+

9

409

34.Z

33.V

Safety LightcurtainInput

Leuze lumiflexROBUST RRT42

+24

VD

C 0V + gnd

DOLDBH 5928.93

13

14U330

.1

3X3 2

1LA1/A1

J101 9

2

10

3

11

4

12

5

13

6

14

PE

AMI 421LA1/B

J101 15

1

16

3

U330t=1sec A1

24dcV

20.4.6

VM

A2

S33

41

44K300

30.0

S34 S31

S21

S32

S22

Y39

S11

Y40

S12

W1LA1-1766430 8x0,5mm²

wt bn gn gl gsW1LA1-2770011 2x0,75mm²

1 2rs

PEPE 26

rd

L+/32.9

L-/33.V.5

L+/ 34.Z.0

L- / 33.V.0

U330/13 / 42.3

U330/14 / 42.3

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

33.V

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

safety lightcurtainoutput 1LA2 (option)

5 6 7

E1018301-DKPS515

8

=+

9

409

40

34.Z

BH 5928.93DOLD

0V

+24

VD

C

ROBUST RRT42Leuze lumiflex

Safety LightcurtainInput

31

34K300

30.0

rsgsglgnbnwtW1LA2-1766430 8x0,5mm²

S12

Y40

S11

Y39

S22

S32

S21

S31S34S33

A2

24dcV

.627.K.3

VM

A1U340

t=1sec

24J101 23

PE

22

6

21

5

20

4

19

3

18

2

J101 17

11LA2/A

3X3 2

13

14U340

.1

receiverPM-2V1LA2/B

PEPE 27

rd

L+/33.V.5

L-/34.Z.5

L+/ 40.0

L- / 34.Z.0

U340/14 / 42.4

U340/13 / 42.4

Bl.

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Modification:

HS

Projekt:

34.Z

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Inputs

5 6 7

E1018301-DKPS515

8

=+

9

409

41

40

ThermicalFailure

Emergency stop Lengthmeasuring

Oil level Oil returnfilter

Oilproportionalvalve filter

1 7

Upper cilinderdeburing unit

is up

hydraulicsstarted

1X3 1 2

44

41K316

31.6

43

44K314

31.4

bn

S403A

1

J42 9

bn

zt

bw

S403B710519

-+

11J42

2

10

J9 1

S406

2J9

J9 3

4J9

J9 5

6J9

U400

PE

PE2 20

+ .

1 2 3 4 U41044.0

IN1

X1:5

IN2

X1:6

IN3

X1:7

IN5

X1:9

IN6

X1:10

IN7

X1:11

IN8

X1:12X1:2X1:1; X1:3

J43 1

2J43

1

2S405

IN4

X1:8

S408S407

L+/34.Z.5

L-/40.9L+/ 42.0

L- / 40.0

U200/PL/20.6

U400-2/PL/8.1

IN 4/32.3

Bl.

Created by:

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Create date:

Modification:

HS

Projekt:

40

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Inputs

5 6 7

E1018301-DKPS515

8

=+

9

409

42

41

Oil tempature

S411

770055 4x0,34 mm²

3

wt

J9 14

1

bn

15 13

U41044.0

X1:14 X1:3 X1:13 X1:17 X1:18 X1:16

Bl.

Created by:

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Create date:

Modification:

HS

Projekt:

41

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Inputs in 1S1

5 6 7

E1018301-DKPS515

8

=+

9

409

43

42

entrance safety1LSG1

entrance safety1LSG2

*T

entrance safetyinput conveyor 1LA1

(option)

*S

entrance safetyoutput conveyor 1LA2

(option)

Up changerlocked

Down changerlocked

Marking wheelpos 1

(forward)

Marking wheelpos 2

(backward)

23

24U315

30.2

1X3 1

1X3 10

1X3 1

1X3 11

A2

A1K424

47.U.547.U.647.U.747.U.8

PYF14SMY4N

VM

1X3 2

1X3 1

1X3 12

A2

A1K425

102.7

PYF14SMY4N

VM

J42 1

1

2S425

2J42

A1

A2K426

101.0

38.61.7.024.0050VM

1X3 2

J42 3

1

2S426

4J42

A1

A2K427

101.0

38.61.7.024.0050VM

J42 5

6J42

J42 7

8J42

U42046.0

IN9

X1:3

IN10

X1:4

IN11

X1:5

IN12

X1:6

IN13

X1:7

IN14

X1:8

IN15

X1:9

IN16

X1:10

L+/40.9

L-/42.9

U330/1333.V.6

U330/1433.V.6

U340/1334.Z.6

U340/1434.Z.6

L+/ 43.0

L- / 42.0

Bl.

Created by:

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Create date:

Modification:

HS

Projekt:

42

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Inputs

5 6 7

E1018301-DKPS515

8

=+

9

409

44

43

Bottom cylinderdeburing unit

is down

SpareSpareSpareSpareSpare Spare Spare

U42046.0

IN17

X1:11

IN18

X1:12

IN19

X1:13

IN20

X1:14

IN21

X1:15

IN22

X1:16

IN23

X1:17

IN24

X1:18

J43 3

1

2S436

4J43

L+/42.9 L+/ 45.0

Bl.

Created by:

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Modification:

HS

Projekt:

43

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Uitgangen

5 6 7

E1018301-DKPS515

8

=+

9

409

45

44

Hydraulicmotor on

Installationon

Installationoff

Hydrauliccooler on

High capacitypump

Start deburingunit

SPARE SPARE

1X3 2

A1

A2K441

32.1

38.61.7.024.0050VM

A1

A2K442

31.1

38.61.7.024.0050VM

A1

A2K443

31.1

38.61.7.024.0050VM

A1

A2K444

32.5

38.61.7.024.0050VM

J9 7

+

-Y445

8J9

U41040.241.045.045.5

X2:1;

OUT1

X2:5X2:2

OUT2

X2:6

OUT3

X2:7

OUT4

X2:8

OUT5

X2:9

OUT6

X2:10

OUT7

X2:11

OUT8

X2:12X2:3

A1

A2K446

32.7

38.61.7.024.0050VM

1X3:244.9

1X3:2/ 44.0

Bl.

Created by:

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Create date:

Modification:

HS

Projekt:

44

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Uitgangen analoog

5 6 7

E1018301-DKPS515

8

=+

9

409

46

45

proportional valveoil pressure

U451E-BM-AC-01F

770055 4x0,34 mm²gn

3

gl

2

1X3 1

F4543,15AT

11

770055 4x0,34 mm²

770055 4x0,34 mm²

1X3 2

1

9

gn

J9 9

gn

+

-Y348

PE

10

bn

10

bn

11

PE2 19

PE2 20

U41044.0

X2:14 X2:15 X2:13 X2:17 X2:18 X2:16

U41044.0

L+/43.9

L-/45.9L+/ 46.0

L- / 45.0

Bl.

Created by:

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Create date:

Modification:

HS

Projekt:

45

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs

5 6 7

E1018301-DKPS515

8

=+

9

409

47.U

46

Cam transport 1up

Support 1up

Support 2up

Support 3up

Support 4up

Support 5up

Support 6up

Support 7up

1X3 1

1X3 4

J46 1

+

-Y461

2J46

J46 3

+

-Y462

4J46

J46 5

+

-Y463

6J46

J46 7

+

-Y464

8J46

J46 9

+

-Y465

10J46

J46 11

12J46

J46 13

14J46

J46 15

16J46

U42042.043.0

47.U.0X1:1 X2:1

OUT9

X2:3

X2:2X1:2OUT10

X2:4

OUT11

X2:5

OUT12

X2:6

OUT13

X2:7

OUT14

X2:8

OUT15

X2:9

OUT16

X2:10

L+/45.9

NA2/32.9

L-/46.9 L- / 46.0

NA2/100.0

Bl.

Created by:

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Create date:

Modification:

HS

Projekt:

46

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs

5 6 7

E1018301-DKPS515

8

=+

9

409

100

47.U

Transport 1 forwards Transport 1 backwards Transport 2 forwards Transport 2 backwardsRetract lowerdeburing cylinder

Eject lowerdeburinig cylinder

Retract upperdeburing cylinder

Eject upperdeburinig cylinder

11

14K424

42.4

21

22K476

.6

A1

A2K475

12.U.112.U.112.U.1

.6

MC1C301ATVM

21

24K424

42.4

21

22K475

.5

A1

A2K476

12.U.212.U.212.U.2

.5

MC1C301ATVM

1X3 2

31

34K424

42.4

21

22K478

.8

A1

A2K477

12.U.612.U.612.U.6

.8

MC1C301ATVM

41

44K424

42.4

21

22K477

.7

A1

A2K478

12.U.712.U.712.U.7

.7

MC1C301ATVM

1X3 2

U42046.0

OUT17

X2:11

OUT18

X2:12

OUT19

X2:13

OUT20

X2:14

OUT21

X2:15

OUT22

X2:16

OUT23

X2:17

OUT24

X2:18

J43 10

+

-Y471A

11J43

J43 12

+

-Y471B

13J43

J43 14

+

-Y473A

15J43

J43 16

+

-Y473B

17J43

L-/47.U.8 L- / 47.U.0

Bl.

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Modification:

HS

Projekt:

47.U

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

X67 voltage connection

5 6 7

E1018301-DKPS515

8

=+

9

409

101

100

X67 DM1321 Spannungsanschluß X67 DM1321 Spannungsanschluß X67 DM1321 Spannungsanschluß X67 PS1300 Spannungsanschluß

U1000

110.0110.2110.5110.7111.0111.2111.5111.7151.0

WU1000-C

1X3 4

J14 1

bn

1-C

2J14

1X3 2

wt

U1002

112.0112.2112.5112.7113.0113.2113.5113.7151.4

U1005

114.0114.2114.5114.7115.0115.2115.5115.7151.0

U1007

151.4

1X3 20

J14 7

8J14

1X3 2

WU1002-Cbn wt

WU1005-Cbn wt

WU1007-Cbn wt

WU1000-Cbw zt

WU1002-Cbw zt

WU1005-Cbw zt

WU1007-Cbw zt

2 1-D 2

-C 3 4 -D 3 4

1-C 2 1-D 2

-C 3 4 -D 3 4

1-C 2 1-D 2

-C 3 4 -D 3 4

1-C 2 1-D 2

-C 3 4 -D 3 4

NA246.1

L-100.9

L+/X6716.7

L+/X67101.2

L-100.0

Bl.

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Modification:

HS

Projekt:

100

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4


5 6 7

E1018301-DKPS515

8

=+

9

409

102

101

X67 DM1321 Spannungsanschluß X67 DM1321 Spannungsanschluß X67 PS1300 SpannungsanschlußX67 DO1332 Spannungsanschluß

U1010

116.0116.2116.5116.7

117.F.0117.F.2117.F.5117.F.7152.0

WU1010-Cbn

1-C

wt

U1012

118.F.0118.F.2118.F.5118.F.7119.F.0119.F.2119.F.5119.F.7152.4

U1015

120.F.0120.F.2120.F.5120.F.7121.0121.2121.5121.7152.0

U1017

152.4

WU1012-Cbn wt

WU1015-Cbn wt

WU1017-Cbn wt

WU1010-Cbw zt

WU1012-Cbw zt

WU1015-Cbw zt

WU1017-Cbw zt

2 1-D 2

-C 3 4 -D 3 4

1-C 2 1-D 2

-C 3 4 -D 3 4

1-C 2 1-D 2

-C 3 4 -D 3 4

1-C 2 1-D 2

-C 3 4 -D 3 4

1X3 5

J14 9

1X3 20

J14 11

1X3 20

J14 15

10J14

1X3 2

12J14

1X3 2

16J14

1X3 2

11

14K427

42.7

11

14K426

42.6

NA316.4

L+/X67100.9

L+/X67102.2

L-101.9

L-101.0

Bl.

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Modification:

HS

Projekt:

101

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4


5 6 7

E1018301-DKPS515

8

=+

9

409

103

102

X67 DM1321 Spannungsanschluß X67 DM1321 SpannungsanschlußX67 PS1300 SpannungsanschlußX67 DO1332 Spannungsanschluß

U1020

122.0122.2122.5122.7123.0123.2123.5123.7153.0

WU1020-Cbn

1-C

wt

U1022

124.0124.2124.5124.7125.0125.2125.5125.7153.4

U1027

126.K.0126.K.2126.K.5126.K.7127.K.0127.K.2127.K.5127.K.7153.4

U1025

153.0

WU1022-Cbn wt

WU1025-Cbn wt

WU1027-Cbn wt

WU1020-Cbw zt

WU1022-Cbw zt

WU1025-Cbw zt

WU1027-Cbw zt

2 1-D 2

-C 3 4 -D 3 4

1-C 2 1-D 2

-C 3 4 -D 3 4

1-C 2 1-D 2

-C 3 4 -D 3 4

1-C 2 1-D 2

-C 3 4 -D 3 4

1X3 6

J14 17

1X3 20

J14 19

1X3 20

J14 21

1X3 6

14

11K425

42.5

J14 23

18J14

1X3 2

20J14

1X3 2

22J14

1X3 2

24J14

1X3 2

NA416.5

L+/X67101.8

L+/X67103.0

L-102.9

L-102.0

Bl.

Created by:

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Create date:

Modification:

HS

Projekt:

102

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4


5 6 7

E1018301-DKPS515

8

=+

9

409

104

103

X67 DM1321 Spannungsanschluß X67 PS1300 SpannungsanschlußX67 DO1332 Spannungsanschluß X67 DO1332 Spannungsanschluß

U1032

130.E.0130.E.2130.E.5130.E.7131.E.0131.E.2131.E.5131.E.7154.4

WU1030-Cbn

1-C

wt

U1030

128.K.0128.K.2128.K.5128.K.7129.K.0129.K.2129.K.5129.K.7154.0

U1035

154.0

WU1032-Cbn wt

WU1035-Cbn wt

WU1037-Cbn wt

WU1030-Cbw zt

WU1032-Cbw zt

WU1035-Cbw zt

WU1037-Cbw zt

2 1-D 2

-C 3 4 -D 3 4

1-C 2 1-D 2

-C 3 4 -D 3 4

1-C 2 1-D 2

-C 3 4 -D 3 4

1-C 2 1-D 2

-C 3 4 -D 3 4

1X3 20

J15 1

1X3 7

J15 3

1X3 20

J15 5

1X3 7

J15 7

U1037

132.0132.2132.5132.7133.0133.2133.5133.7154.4

2J15

1X3 2

4J15

1X3 2

6J15

1X3 2

8J15

1X3 2

L+/X67102.5

NA516.6

L+/X67104.0

L-103.0

L-103.9

Bl.

Created by:

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Create date:

Modification:

HS

Projekt:

103

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4


5 6 7

E1018301-DKPS515

8

=+

9

409

110

104

X67 DM1321 Spannungsanschluß X67 DM1321 Spannungsanschluß

U1040

134.0134.2134.5134.7135.0135.2135.5135.7155.0

WU1040-Cbn

1-C

wt

U1042

136.E.0136.E.2136.E.5136.E.7137.E.0137.E.2137.E.5137.E.7155.4

WU1042-Cbn wt

WU1040-Cbw zt

WU1042-Cbw zt

2 1-D 2

-C 3 4 -D 3 4

1-C 2 1-D 2

-C 3 4 -D 3 4

1X3 20

J15 9

1X3 3

J15 11

10J15

1X3 2

12J15

1X3 2

L+/X67103.9

NA1V29.L.9

L-

Bl.

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Create date:

Modification:

HS

Projekt:

104

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs

5 6 7

E1018301-DKPS515

8

=+

9

409

111

110

X67 DM1321 Digital Output X67 DM1321 Digital Output X67 DM1321 Digital Output X67 DM1321 Digital Output

+

-Y1102A

p

+

-Y1102B

P

+

-Y1106A

P

+

-Y1106B

P

100.0U1000

100.0U1000

100.0U1000

100.0U1000

1

24VDC-1:1

3

-1:3

4

OUT25

Closehorizontalclamp 1

-1:4Q0.1

1

24VDC-2:1

3

-2:3

4

OUT26

Openhorizontalclamp 1

-2:4Q0.2

1

24VDC-3:1

3

-3:3

4

OUT27


-3:4Q0.3

1

24VDC-4:1

3

-4:3

4

OUT28


-4:4Q0.4

Bl.

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HS

Projekt:

110

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs

5 6 7

E1018301-DKPS515

8

=+

9

409

112

111

X67 X67 X67 X67

+

-Y1112A

P

+

-Y1112B

P

+

-Y1116A

P

+

-Y1116B

P

100.0U1000

100.0U1000

100.0U1000

100.0U1000

1

24VDC-5:1

3

-5:3

4

OUT29

Closevertical clamp

1

-5:4Q0.5

1

24VDC-6:1

3

-6:3

4

OUT30

Openvertical clamp

1

-6:4Q0.6

1

24VDC-7:1

3

-7:3

4

OUT31

Closevertical clamp

2

-7:4Q0.7

1

24VDC-8:1

3

-8:3

4

OUT32

Openvertical clamp

2

-8:4Q0.8

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Bl.Checked by:

Create date:

Modification:

HS

Projekt:

111

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs

5 6 7

E1018301-DKPS515

8

=+

9

409

113

112

X67 X67 X67 X67

+

-Y1122A

P

+

-Y1122B

P

100.2U1002

100.2U1002

100.2U1002

100.2U1002

1

24VDC-1:1

3

-1:3

4

OUT33


-1:4Q0.1

1

24VDC-2:1

3

-2:3

4

OUT34


-2:4Q0.2

1

24VDC-3:1

3

-3:3

4

OUT35


-3:4Q0.3

1

24VDC-4:1

3

-4:3

4

OUT36


-4:4Q0.4

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

112

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs

5 6 7

E1018301-DKPS515

8

=+

9

409

114

113

X67 X67 X67 X67

+

-Y1132A

P

+

-Y1132B

P

100.2U1002

100.2U1002

100.2U1002

100.2U1002

1

24VDC-5:1

3

-5:3

4

OUT37

Closevertical clamp

3

-5:4Q0.5

1

24VDC-6:1

3

-6:3

4

OUT38

Openvertical clamp

3

-6:4Q0.6

1

24VDC-7:1

3

-7:3

4

OUT39

Closevertical clamp

4

-7:4Q0.7

1

24VDC-8:1

3

-8:3

4

OUT40

Openvertical clamp

4

-8:4Q0.8

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

113

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs

5 6 7

E1018301-DKPS515

8

=+

9

409

115

114

X67 X67 X67 X67

+

-Y1142

P

100.5U1005

100.5U1005

100.5U1005

100.5U1005

1

24VDC-1:1

3

-1:3

4

OUT41

Lubricationpunch 1

-1:4Q0.1

1

24VDC-2:1

3

-2:3

4

OUT42

-2:4Q0.2

1

24VDC-3:1

3

-3:3

4

OUT43

-3:4Q0.3

1

24VDC-4:1

3

-4:3

4

OUT44

Option ALubrication

flange punch

-4:4Q0.4

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

114

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs

5 6 7

E1018301-DKPS515

8

=+

9

409

116

115

X67 X67 X67 X67

100.5U1005

100.5U1005

100.5U1005

100.5U1005

1

24VDC-5:1

3

-5:3

4

OUT45

Optionlubricationangle shear

-5:4Q0.5

1

24VDC-6:1

3

-6:3

4

OUT46

Option Hdrill

cooling

-6:4Q0.6

1

24VDC-7:1

3

-7:3

4

OUT47

Option Hexternal

drill cooling

-7:4Q0.7

1

24VDC-8:1

3

-8:3

4

OUT48

Option Hexternal

drill cooling

-8:4Q0.8

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

115

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs punch unit

5 6 7

E1018301-DKPS515

8

=+

9

409

117.F

116

X67 DO1332 Digital Output X67 DO1332 Digital Output X67 DO1332 Digital Output X67 DO1332 Digital Output

+

-Y1162A

H

+

-Y1162B

H

+

-Y1166A

H

+

-Y1166B

H

101.0U1010

101.0U1010

101.0U1010

101.0U1010

1

24VDC-1:1

3

-1:3

4

OUT49

Punch tomaterial

-1:4Q0.

1

24VDC-2:1

3

-2:3

4

OUT50

Punch frommaterial

-2:4Q0.2

1

24VDC-3:1

3

-3:3

4

OUT51

Punchdownpusher

down

-3:4Q0.3

1

24VDC-4:1

3

-4:3

4

OUT52

Punchdownpusher

up

-4:4Q0.4

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

116

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs KPS515 punch

5 6 7

E1018301-DKPS515

8

=+

9

409

118.F

117.F


101.0U1010

101.0U1010

101.0U1010

101.0U1010

1

24VDC-5:1

3

-5:3

4

OUT53

-5:4Q0.5

1

24VDC-6:1

3

-6:3

4

OUT54

-6:4Q0.6

1

24VDC-7:1

3

-7:3

4

OUT55

Spare

-7:4Q0.7

1

24VDC-8:1

3

-8:3

4

OUT56

Spare

-8:4Q0.8

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

117.F

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Inputs KPS515 punch

5 6 7

E1018301-DKPS515

8

=+

9

409

119.F

118.F

X67 X67 X67 X67

1

4

3

S1182

1

4

3

S1184

1

4

3

S1186

U1012101.2

1

-1:124VDC

4

IN25

-1:4I0.1

Punchis high

U1012101.2

U1012101.2

3

-1:3

U1012101.2

1

-2:124VDC

3

-2 :3

4

IN26

-2:4I0.2

Punchis in center position

1

-3:124VDC

3

-3:3

4

IN27

-3:4I0.3

Punchis low

1

-4:124VDC

3

-4:3

4

IN28

-4:4I0.4

Spare

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

118.F

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Inputs KPS515 punch

5 6 7

E1018301-DKPS515

8

=+

9

409

120.F

119.F

X67

X67 X67 X67

+

-Y1192

P

+

-Y1194

P

+

-Y1196

P

S1199

U1012101.2

1

-8:124VDC

3

-8:3

4

IN29

-8:4I0.8

Air pressurepresent

101.2U1012

101.2U1012

101.2U1012

1

24VDC-5:1

3

-5:3

4

OUT57

Lock die table

-5:4Q0.5

1

24VDC-6:1

3

-6:3

4

OUT58

Lock punch table

-6:4Q0.6

1

24VDC-7:1

3

-7:3

4

OUT59

Air pillow

-7:4Q0.7

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

119.F

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4 5 6 7

E1018301-DKPS515

8

=+

9

409

121

120.F

X67 X67 X67 X67

U1015101.5

1

-1:124VDC

4

IN30

-1:4I0.1

Spare

U1015101.5

U1015101.5

3

-1:3

U1015101.5

1

-2:124VDC

3

-2 :3

4

IN31

-2:4I0.2

Spare

1

-3:124VDC

3

-3:3

4

IN32

-3:4I0.3

Spare

1

-4:124VDC

3

-4:3

4

IN33

-4:4I0.4

Spare

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

120.F

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4 5 6 7

E1018301-DKPS515

8

=+

9

409

122

121

X67 X67 X67 X67

U1015101.5

U1015101.5

U1015101.5

U1015101.5

1

-5:124VDC

3

-5:3

4

IN34

-5:4I0.5

Spare

1

-6:124VDC

3

-6:3

4

IN35

-6:4I0.6

Spare

1

-7:124VDC

3

-7:3

4

IN36

-7:4I0.7

Spare

1

-8:124VDC

3

-8:3

4

IN37

-8:4I0.8

Spare

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

121

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs shearunit

5 6 7

E1018301-DKPS515

8

=+

9

409

123

122


+

-Y1222A

H

+

-Y1222B

H

+

-Y1226A

H

+

-Y1226B

H

102.0U1020

102.0U1020

102.0U1020

102.0U1020

1

24VDC-1:1

3

-1:3

4

OUT60

Flat shearto material

-1:4Q0.1

1

24VDC-2:1

3

-2:3

4

OUT61

Flat shearfrom material

-2:4Q0.2

1

24VDC-3:1

3

-3:3

4

OUT62

vertical downpusher flat shear down

-3:4Q0.3

1

24VDC-4:1

3

-4:3

4

OUT63

vertical downpusher flat shear up

-4:4Q0.4

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

122

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs shearunit

5 6 7

E1018301-DKPS515

8

=+

9

409

124

123


102.0U1020

102.0U1020

102.0U1020

102.0U1020

1

24VDC-5:1

3

-5:3

4

OUT64

Angle shear tomaterial

-5:4Q0.5

1

24VDC-6:1

3

-6:3

4

OUT65

Angle shearfrom material

-6:4Q0.6

1

24VDC-7:1

3

-7:3

4

OUT66

Downpusherangle shear

tomaterial

-7:4Q0.7

1

24VDC-8:1

3

-8:3

4

OUT67

Downpusherangle shear

frommaterial

-8:4Q0.8

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

123

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Inputs shearunit

5 6 7

E1018301-DKPS515

8

=+

9

409

125

124

X67 X67 X67 X67

1

4

3

S1242

U1022102.2

1

-1:124VDC

4

IN38

-1:4I0.1

Flat shearis high/low

U1022102.2

U1022102.2

3

-1:3

U1022102.2

1

-2:124VDC

3

-2 :3

4

IN39

-2:4I0.2

Angle shearis high/low

1

-3:124VDC

3

-3:3

4

IN40

-3:4I0.3

Spare

1

-4:124VDC

3

-4:3

4

IN41

-4:4I0.4

Spare

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

124

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Inputs shearunit

5 6 7

E1018301-DKPS515

8

=+

9

409

126.K

125

X67 X67 X67 X67

U1022102.2

U1022102.2

U1022102.2

U1022102.2

1

-5:124VDC

3

-5:3

4

IN42

-5:4I0.5

Spare

1

-6:124VDC

3

-6:3

4

IN43

-6:4I0.6

Spare

1

-7:124VDC

3

-7:3

4

IN44

-7:4I0.7

Spare

1

-8:124VDC

3

-8:3

4

IN45

-8:4I0.8

Spare

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

125

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs outfeedtable

5 6 7

E1018301-DKPS515

8

=+

9

409

127.K

126.K

X67 X67 X67 X67

+

-Y1262

P

+

-Y1264

P

102.7U1027

102.7U1027

102.7U1027

102.7U1027

1

24VDC-1:1

3

-1:3

4

OUT68

Push-off device 1

-1:4Q0.1

1

24VDC-2:1

3

-2:3

4

OUT69

Push-off device 2

-2:4Q0.2

1

24VDC-3:1

3

-3:3

4

OUT70

Optionpush-off device 3

-3:4Q0.3

1

24VDC-4:1

3

-4:3

4

OUT71

Optionclose

slidetable

-4:4Q0.4

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

126.K

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs outfeedtable

5 6 7

E1018301-DKPS515

8

=+

9

409

128.K

127.K

X67 X67 X67 X67

1

24VDC-5:1

3

-5:3

1

24VDC-6:1

3

-6:3

4

OUT73

OptionStopper up

-6:4Q0.6

1

24VDC-7:1

3

-7:3

4

OUT74

Optionstopper down

-7:4Q0.7

1

24VDC-8:1

3

-8:3

4

OUT75

Optiondatumline

down

-8:4Q0.8

102.7U1027

102.7U1027

102.7U1027

102.7U1027

4

OUT72

Optionopen

slidetable

-5:4Q0.5

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

127.K

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

inputs outfeedtable

5 6 7

E1018301-DKPS515

8

=+

9

409

129.K

128.K

X67 X67 X67 X67

13

14S1282

1

2S1284

1

2S1286

U1030103.0

1

-1:124VDC

4

IN46

-1:4I0.1

Slidetable to low

U1030103.0

U1030103.0

3

-1:3

U1030103.0

1

-2:124VDC

3

-2 :3

4

IN47

-2:4I0.2

Push-offdevice is in front

1

-3:124VDC

3

-3:3

4

IN48

-3:4I0.3

Push-offdevice is in back

1

-4:124VDC

3

-4:3

4

IN49

-4:4I0.4

Optionslidetable

from shear

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

128.K

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

inputs outfeedtable

5 6 7

E1018301-DKPS515

8

=+

9

409

130.E

129.K

X67 X67 X67

X67

H1299

U1030103.0

U1030103.0

U1030103.0

1

-5:124VDC

3

-5:3

4

IN50

-5:4I0.5

Optionslidetablein shear

1

-6:124VDC

3

-6:3

4

IN51

-6:4I0.6

OptionStopper

is up

1

-7:124VDC

3

-7:3

4

IN52

-7:4I0.7

Spare

1

24VDC-8:1

3

-8:3

4

OUT76

Cariage active

-8:4Q0.8

103.0U1030

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

129.K

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs markingunit

5 6 7

E1018301-DKPS515

8

=+

9

409

131.E

130.E


+

-Y1309A

H

103.2U1032

103.2U1032

103.2U1032

103.2U1032

1

24VDC-1:1

3

-1:3

4

OUT77

-1:4Q0.1

1

24VDC-2:1

3

-2:3

4

OUT78

Extra positonmarking unitbackwards

-2:4Q0.2

1

24VDC-3:1

3

-3:3

4

OUT79

Refrence cammarking weel

-3:4Q0.3

1

24VDC-4:1

3

-4:3

4

OUT80

Markingcylinder on

-4:4Q0.4

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

130.E

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs markingunit

5 6 7

E1018301-DKPS515

8

=+

9

409

132

131.E


+

-Y1309B

H

103.2U1032

103.2U1032

103.2U1032

103.2U1032

1

24VDC-5:1

3

-5:3

4

OUT81

Markingcylinder backwards

-5:4Q0.5

1

24VDC-6:1

3

-6:3

4

OUT82

Close horizontal clamp 5

-6:4Q0.6

1

24VDC-7:1

3

-7:3

4

OUT83

Open horizontal clamp 5

-7:4Q0.7

1

24VDC-8:1

3

-8:3

4

OUT84

Spare

-8:4Q0.8

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

131.E

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs shearunit

5 6 7

E1018301-DKPS515

8

=+

9

409

133

132


103.7U1037

103.7U1037

103.7U1037

103.7U1037

1

24VDC-1:1

3

-1:3

4

OUT85

Flange punch1 to material

-1:4Q0.1

1

24VDC-2:1

3

-2:3

4

OUT86

Flange punch1 from material

-2:4Q0.2

1

24VDC-3:1

3

-3:3

4

OUT87

Flange punch2 to material

-3:4Q0.3

1

24VDC-4:1

3

-4:3

4

OUT88

Flange punch2 from material

-4:4Q0.4

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

132

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs shearunit

5 6 7

E1018301-DKPS515

8

=+

9

409

134

133


103.7U1037

1

24VDC-5:1

3

-5:3

103.7U1037

1

24VDC-6:1

3

-6:3

103.7U1037

1

24VDC-7:1

3

-7:3

103.7U1037

1

24VDC-8:1

3

-8:3

4

OUT92

Spare

-8:4Q0.8

4

OUT89

Flange bufferbackwards

-5:4Q0.5

4

OUT90

Spare

-6:4Q0.6

4

OUT91

Spare

-7:4Q0.7

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

133

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs Drillunit

5 6 7

E1018301-DKPS515

8

=+

9

409

135

134

X67 X67 X67 X67

104.0U1040

104.0U1040

104.0U1040

104.0U1040

1

24VDC-1:1

3

-1:3

4

OUT93

Tool changerforwards

-1:4Q0.1

1

24VDC-2:1

3

-2:3

4

OUT94

Tool changerbackwards

-2:4Q0.2

1

24VDC-3:1

3

-3:3

4

OUT95

Release tool

-3:4Q0.3

1

24VDC-4:1

3

-4:3

4

OUT96

-4:4Q0.4

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

134

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Inputs Drillunit

5 6 7

E1018301-DKPS515

8

=+

9

409

136.E

135

X67 X67 X67 X67

U1040104.0

U1040104.0

U1040104.0

U1040104.0

1

-5:124VDC

3

-5:3

4

IN53

-5:4I0.5

Error toolchanger

1

-6:124VDC

3

-6:3

4

IN54

-6:4I0.6

1

-7:124VDC

3

-7:3

4

IN55

-7:4I0.7

Tool changer is infront

1

-8:124VDC

3

-8:3

4

IN56

-8:4I0.8

Spare

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

135

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs fourfold marking wheel

5 6 7

E1018301-DKPS515

8

=+

9

409

137.E

136.E

X67 X67 X67 X67

+

-Y1362A

P

+

-Y1362B

P

+

-Y1366A

P

+

-Y1366B

P

104.2U1042

104.2U1042

104.2U1042

104.2U1042

1

24VDC-1:1

3

-1:3

4

OUT97

Changecylinder 1 forwards

-1:4Q0.1

1

24VDC-2:1

3

-2:3

4

OUT98

Change cylinder 1backwards

-2:4Q0.2

1

24VDC-3:1

3

-3:3

4

OUT99

Changecylinder 2 forwards

-3:4Q0.3

1

24VDC-4:1

3

-4:3

4

OUT100

Change cylinder 2backwards

-4:4Q0.4

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

136.E

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Outputs fourfold marking wheel

5 6 7

E1018301-DKPS515

8

=+

9

409

151

137.E

X67 X67 X67 X67

+

-Y1372

P

+

-Y1374

P

+

-Y1376

P

+

-Y1379

P

104.2U1042

104.2U1042

104.2U1042

104.2U1042

1

24VDC-5:1

3

-5:3

4

OUT101

Unlock wheel1

-5:4Q0.5

1

24VDC-6:1

3

-6:3

4

OUT102

Unlock wheel2

-6:4Q0.6

1

24VDC-7:1

3

-7:3

4

OUT103

Unlock wheel3

-7:4Q0.7

1

24VDC-8:1

3

-8:3

4

OUT104

Unlock wheel4

-8:4Q0.8

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

137.E

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

X67 bus connection

5 6 7

E1018301-DKPS515

8

=+

9

409

152

151

X67 DM1321 Busanschluß



X67 PS1300 Busanschluß

U1000100.0

U1005100.5

WU1000-A

WU1005-A

-A 1

X2X+

-A 1

X2X+

2

X2X

2

X2X

3

X2XGND

3

X2XGND

4

X2X\

4

X2X\

X2X+

X2X+

X2X

X2X

X2XGND

X2XGND

X2X\

X2X\

U1002100.2

U1007100.7

WU1002-A

WU1007-A

-A 1

X2X+

-A 1

X2X+

2

X2X

2

X2X

3

X2XGND

3

X2XGND

4

X2X\

4

X2X\

X2X+

X2X+

X2X

X2X

X2XGND

X2XGND

X2X\

X2X\

U1010A-1 / 152.0

U1010A-2 / 152.0

U1010A-3 / 152.0

U1010A-4 / 152.0

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

151

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

X67 bus connection

5 6 7

E1018301-DKPS515

8

=+

9

409

153

152

X67 DO1332 Busanschluß




U1010101.0

U1015101.5

WU1010-A

WU1015-A

-A 1

X2X+

-A 1

X2X+

2

X2X

2

X2X

3

X2XGND

3

X2XGND

4

X2X\

4

X2X\

X2X+

X2X+

X2X

X2X

X2XGND

X2XGND

X2X\

X2X\

U1012101.2

U1017101.7

WU1012-A

WU1017-A

-A 1

X2X+

-A 1

X2X+

2

X2X

2

X2X

3

X2XGND

3

X2XGND

4

X2X\

4

X2X\

X2X+

X2X+

X2X

X2X

X2XGND

X2XGND

X2X\

X2X\

U1010A-1/151.8

U1010A-2/151.8

U1010A-3/151.8

U1010A-4/151.8

U1020A-1 / 153.0

U1020A-2 / 153.0

U1020A-3 / 153.0

U1020A-4 / 153.0

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

152

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

X67 bus connection

5 6 7

E1018301-DKPS515

8

=+

9

409

154

153





U1020102.0

U1025102.5

WU1020-A

WU1025-A

-A 1

X2X+

-A 1

X2X+

2

X2X

2

X2X

3

X2XGND

3

X2XGND

4

X2X\

4

X2X\

X2X+

X2X+

X2X

X2X

X2XGND

X2XGND

X2X\

X2X\

U1022102.2

U1027102.7

WU1022-A

WU1027-A

-A 1

X2X+

-A 1

X2X+

2

X2X

2

X2X

3

X2XGND

3

X2XGND

4

X2X\

4

X2X\

X2X+

X2X+

X2X

X2X

X2XGND

X2XGND

X2X\

X2X\

U1020A-1/152.8

U1020A-2/152.8

U1020A-3/152.8

U1020A-4/152.8

U1030A-1 / 154.0

U1030A-2 / 154.0

U1030A-3 / 154.0

U1030A-4 / 154.0

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

153

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

X67 bus connection

5 6 7

E1018301-DKPS515

8

=+

9

409

155

154





U1030103.0

U1035103.5

WU1030-A

WU1035-A

-A 1

X2X+

-A 1

X2X+

2

X2X

2

X2X

3

X2XGND

3

X2XGND

4

X2X\

4

X2X\

X2X+

X2X+

X2X

X2X

X2XGND

X2XGND

X2X\

X2X\

U1032103.2

U1037103.7

WU1032-A

WU1037-A

-A 1

X2X+

-A 1

X2X+

2

X2X

2

X2X

3

X2XGND

3

X2XGND

4

X2X\

4

X2X\

X2X+

X2X+

X2X

X2X

X2XGND

X2XGND

X2X\

X2X\

U1030A-1/153.8

U1030A-2/153.8

U1030A-3/153.8

U1030A-4/153.8

U1040A-1 / 155.0

U1040A-2 / 155.0

U1040A-3 / 155.0

U1040A-4 / 155.0

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

154

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

X67 bus connection

5 6 7

E1018301-DKPS515

8

=+

9

409

170

155

X67 DM1321 Busanschluß X67 DM1321 Busanschluß

U1040104.0

WU1040-A

-A 1

X2X+

2

X2X

3

X2XGND

4

X2X\ X2X+ X2X X2XGND X2X\U1042

104.2

WU1042-A

-A 1

X2X+

2

X2X

3

X2XGND

4

X2X\ X2X+ X2X X2XGND X2X\

U1040A-1/154.8

U1040A-2/154.8

U1040A-3/154.8

U1040A-4/154.8

kabelkodering

kabelkodering

klem

men

stro

okko

derin

g

kabeltype

aansluiting

PLC-kodering

b

klem-kodering

aansluiting

kabeltype

r

onde

r-de

elko

dein

tern

onde

r-de

elko

deex

tern

u

g

pagi

na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

155

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

171

170

J9

40.7

3J4

31

S406

40.7

10U

410

IN6

2S4

06

40.8

3S4

07

40.8

11U

410

IN7

4S4

07

40.9

23U

315

5S4

08

40.9

12U

410

IN8

6S4

08

44.5

9U

410

OU

T57

+Y4

45

44.5

A2K4

448

-Y4

45

45.4

9U

451

9+

Y348

45.5

10U

451

10-

Y348

45.5

SH11

SH

41.1

SH13

SH

41.1

14U

410

AI1+

143

S411

41.1

3U

410

24VD

C+15

1S4

11

kabelkodering

kabelkodering

klem

men

stro

okko

derin

g

kabeltype

aansluiting

PLC-kodering

b

klem-kodering

aansluiting

kabeltype

r

onde

r-de

elko

dein

tern

onde

r-de

elko

deex

tern

u

g

pagi

na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

170

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

172

171

J10

10.4

2K3

221

U1

M10

4

WJ1-M063 770022

10.4

4K3

222

V1M

104

10.4

6K3

223

W1

M10

4

10.5

2K3

234

W2

M10

4

10.5

4K3

235

U2

M10

4

10.6

6K3

236

V2M

104

10.6

4PE

RPE

M10

4

kabelkodering

kabelkodering

klem

men

stro

okko

derin

g

kabeltype

aansluiting

PLC-kodering

b

klem-kodering

aansluiting

kabeltype

r

onde

r-de

elko

dein

tern

onde

r-de

elko

deex

tern

u

g

pagi

na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

171

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

173

172

J11

11.7

2K3

251

UM

117

W1b 770015W114 770015W115 770015

11.7

4K3

252

VM

117

11.7

6K3

253

WM

117

11.7

5PE

4PE

M11

7

11.4

2K3

275

UM

114

11.4

4K3

276

VM

114

11.4

6K3

277

WM

114

11.4

28PE

8PE

M11

4

11.5

2K3

279

UM

115

11.5

4K3

2710

VM

115

11.5

6K3

2711

WM

115

11.6

29PE

12PE

M11

5

kabelkodering

kabelkodering

klem

men

stro

okko

derin

g

kabeltype

aansluiting

PLC-kodering

b

klem-kodering

aansluiting

kabeltype

r

onde

r-de

elko

dein

tern

onde

r-de

elko

deex

tern

u

g

pagi

na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

172

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

174

173

J12

12.U

.12

Q12

21

UM

121

W12a 770015W12c 770015W12d 770015

12.U

.14

Q12

22

VM

121

12.U

.16

Q12

23

WM

121

12.U

.16

PE4

PEM

121

12.U

.32

Q12

35

UM

123

12.U

.34

Q12

36

VM

123

12.U

.36

Q12

37

WM

123

12.U

.35

8PE

M12

3

12.U

.62

Q12

713

UM

127

12.U

.64

Q12

714

VM

127

12.U

.66

Q12

715

WM

127

12.U

.67

PE16

PEM

127

12.U

.82

Q12

817

UM

128

12.U

.84

Q12

818

VM

128

12.U

.86

Q12

819

WM

128

12.U

.86

PE20

PEM

128

kabelkodering

kabelkodering

klem

men

stro

okko

derin

g

kabeltype

aansluiting

PLC-kodering

b

klem-kodering

aansluiting

kabeltype

r

onde

r-de

elko

dein

tern

onde

r-de

elko

deex

tern

u

g

pagi

na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

173

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

175

174

J14

100.

04

1X3

11

U10

00

WU1000-C bn

WU1007-CWU1010-CWU1012-CWU1017-CWU1020-CWU1022-CWU1025-CWU1027-C

100.

02

1X3

23

U10

00bw

100.

720

1X3

71

U10

07bn

100.

72

1X3

83

U10

07bw

101.

014

K426

91

U10

10bn

101.

02

1X3

103

U10

10bw

101.

220

1X3

111

U10

12bn

101.

22

1X3

123

U10

12bw

101.

720

1X3

151

U10

17bn

101.

72

1X3

163

U10

17bw

102.

06

1X3

171

U10

20bn

102.

02

1X3

183

U10

20bw

102.

220

1X3

191

U10

22bn

102.

22

1X3

203

U10

22bw

102.

520

1X3

211

U10

25bn

102.

52

1X3

223

U10

25bw

102.

711

K425

231

U10

27bn

102.

72

1X3

243

U10

27bw

kabelkodering

kabelkodering

klem

men

stro

okko

derin

g

kabeltype

aansluiting

PLC-kodering

b

klem-kodering

aansluiting

kabeltype

r

onde

r-de

elko

dein

tern

onde

r-de

elko

deex

tern

u

g

pagi

na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

174

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

176

175

J15

103.

020

1X3

11

U10

30

WU1030-C bn

WU1032-CWU1035-CWU1037-CWU1040-CWU1042-C

103.

02

1X3

23

U10

30bw

103.

27

1X3

31

U10

32bn

103.

22

1X3

43

U10

32bw

103.

520

1X3

51

U10

35bn

103.

52

1X3

63

U10

35bw

103.

77

1X3

71

U10

37bn

103.

72

1X3

83

U10

37bw

104.

020

1X3

91

U10

40bn

104.

02

1X3

103

U10

40bw

104.

23

1X3

111

U10

42bn

104.

22

1X3

123

U10

42bw

kabelkodering

kabelkodering

klem

men

stro

okko

derin

g

kabeltype

aansluiting

PLC-kodering

b

klem-kodering

aansluiting

kabeltype

r

onde

r-de

elko

dein

tern

onde

r-de

elko

deex

tern

u

g

pagi

na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

175

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

177

176

J35

15.1

11X

21

1J3

6

W1P1-1 770011W1P1-3 770050W1P1-5 770023

15.1

21X

22

2J3

6

30.0

11X

34

4J3

64

30.0

A2K3

005

5J3

65

9.4

+10

10J3

6

9.4

.11

11J3

6

31.2

151X

312

12J3

612

31.2

13U

315

2424

J36

24

kabelkodering

kabelkodering

klem

men

stro

okko

derin

g

kabeltype

aansluiting

PLC-kodering

b

klem-kodering

aansluiting

kabeltype

r

onde

r-de

elko

dein

tern

onde

r-de

elko

deex

tern

u

g

pagi

na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

176

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

178

177

J36

15.1

110

X11

1J3

5

W1P1-1 770011W1P1-3 770050W1P1-5 770023

15.1

210

X12

2J3

5

30.0

3S3

00A

44

J35

4

30.0

4S3

00A

55

J35

5

9.4

+1P

110

10J3

5

9.4

.1P

111

11J3

5

31.2

11S1

3012

12J3

512

31.2

12S1

3024

24J3

524

kabelkodering

kabelkodering

klem

men

stro

okko

derin

g

kabeltype

aansluiting

PLC-kodering

b

klem-kodering

aansluiting

kabeltype

r

onde

r-de

elko

dein

tern

onde

r-de

elko

deex

tern

u

g

pagi

na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

177

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

179

178

J42

42.5

11X

3IN

101

1S4

25

42.5

7U

420

IN13

22

S425

42.6

31

S426

42.6

8U

420

IN14

42

S426

42.7

5

42.7

9U

420

IN15

6

42.8

3J4

37

42.8

10U

420

IN16

8

40.5

11X

39

bnS4

03B

40.5

21X

310

bwS4

03B

40.5

7U

410

IN3

11zt

S403

B

kabelkodering

kabelkodering

klem

men

stro

okko

derin

g

kabeltype

aansluiting

PLC-kodering

b

klem-kodering

aansluiting

kabeltype

r

onde

r-de

elko

dein

tern

onde

r-de

elko

deex

tern

u

g

pagi

na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

178

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

180

179

J43

40.7

11X

33

1S4

05

43.T

.67

J42

IN10

31

S436

40.7

9U

410

IN5

42

S405

43.T

.616

U42

0IN

224

2S4

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kabelkodering

klem

men

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kabeltype

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PLC-kodering

b

klem-kodering

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kabeltype

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onde

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na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

179

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

181

180

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16

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b

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kabeltype

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tern

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pagi

na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

180

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

182

181

J101

30.3

11

LSG

1/A

WLSG-1 766430 wt

WLSG-2 770011W1LA1-2 770011W1LA2-1 766430

30.3

A2U

315

22

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1/A

bn

30.3

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53

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36

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71

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1/B

1

30.5

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38

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G1/

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33.V

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11L

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33.V

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11L

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1

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163

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kabelkodering

klem

men

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kabeltype

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PLC-kodering

b

klem-kodering

aansluiting

kabeltype

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Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

181

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

183

182

1X0

10.0

1Q

100

L1

10.0

3Q

100

L2

10.1

5Q

100

L3

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3F1

51N

10.1

1PE

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kabelkodering

klem

men

stro

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kabeltype

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na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

182

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

184

183

1X2

15.1

2F1

511

1J3

5

15.1

4F1

512

2J3

5

15.G

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154

kabelkodering

kabelkodering

klem

men

stro

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PLC-kodering

b

klem-kodering

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kabeltype

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pagi

na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

183

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

185

184

1X3

16.1

F161

11

3X3

21.5

14U

210/

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3

21.F

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1

22.F

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1

24.5

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1

26.E

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0/X1

1

27.K

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11

3X3

30.0

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31

4J3

5

31.0

A1U

310

17

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3Q

108

111

K444

40.0

+U

400

123

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40.5

43K3

141

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2

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123

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5

42.3

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330

1

42.4

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340

11

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21

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1

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78

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kabelkodering

kabelkodering

klem

men

stro

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kabeltype

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PLC-kodering

b

klem-kodering

aansluiting

kabeltype

r

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tern

onde

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pagi

na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

184

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

186

185

1X3

101.

010

J14

2

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212

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33

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3

21.F

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3

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3

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3

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kabelkodering

kabelkodering

klem

men

stro

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na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

185

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

187

186

1X3

31.1

1421

S310

31.1

12J3

515

16.7

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20

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211

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kabelkodering

kabelkodering

klem

men

stro

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kabeltype

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PLC-kodering

b

klem-kodering

aansluiting

kabeltype

r

onde

r-de

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dein

tern

onde

r-de

elko

deex

tern

u

g

pagi

na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

186

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

188

187

3X3

20.5

14U

200/

X11

11X

3

29.L

.514

U29

0/X1

11

1X3

20.4

18U

200/

X12

29.L

.418

U29

0/X1

2

33.V

.1A2

U33

02

16J1

01

34.Z

.1A2

U34

02

24J1

01

20.4

47U

330

33

1X3

29.L

.49

U29

0/X1

33

1X3

30.4

S12

U31

514

30.4

146

J101

kabelkodering

kabelkodering

klem

men

stro

okko

derin

g

kabeltype

aansluiting

PLC-kodering

b

klem-kodering

aansluiting

kabeltype

r

onde

r-de

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dein

tern

onde

r-de

elko

deex

tern

u

g

pagi

na /

pad

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

187

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

Terminal diagram

5 6 7

E1018301-DKPS515

8

=+

9

409

210

188

10X1

15.1

1J3

61

W10X1/U151

15.M

.31

L1U

151

15.1

2J3

62

15.M

.32

NU

151

15.M

.49

PEPE

PEU

151

Device Designation Length Description Part number Quantity

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

188

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4 5 6 7

E1018301-DKPS515

8

=+

9

409

400

210

W200-a

MOTORZIJDE

W200a-b 1m.

1

Helft lengte baan + 1,5mtr

2

2m.

3

ZIJDEKAST

4

5

6

W200-b

W200-aW200-b12

345

6

2m

8CM0xx 12-1 8x1,5mm²8CE0xx 12-1 12x0.14mm²Rupsketting 25 cupskabelrups bevestiging

M5 x 14Borgmoer M5

Beschermslang NW21

Sluitring

760374760444610170610160

400504401096

770380

400481

2

2

26

Assignment list

F20_004

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

210

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4

PLC card overview : U410 - U420

5 6 7

E1018301-DKPS515

8

=+

9

409

401

400

U410

1; 40.22 40.23+24VDC 40.3324VDC+ 41.15IN1 40.3 Thermical Failure6IN2 40.4 Emergency stop7 40.5 Length measuring8 40.6 hydraulics started9 40.7 Upper cilinder deburing unit is up

S406 10IN6 40.7 Oil levelS407 11IN7 40.8 Oil return filterS408 12IN8 40.9 Oil proportional valve filter:SH 13SHLD 41.2

14AI1+ 41.116SHLD 41.5 SHIELD17AI2+ 41.418 41.51; 44.02 44.03 44.05OUT1 44.1 Hydraulic motor on6OUT2 44.2 Installation on7OUT3 44.3 Installation off

7CM211.7X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X2

X2

X2

X2

X2

X2

U420

1 46.02 46.0

S408 3IN9 42.1 entrance safety 1LSG1U420:3 4IN10 42.2 entrance safety 1LSG2U420:4 5IN11 42.3 entrance safety input conveyor 1LA1 (option)U420:5 6IN12 42.4 entrance safety output conveyor 1LA2 (option)S425:2 7IN13 42.5 Up changer lockedS426:2 8IN14 42.6 Down changer lockedJ42:6 9IN15 42.7 Marking wheel pos 1 (forward)J42:8 10IN16 42.8 Marking wheel pos 2 (backward)

11IN17 43.1 Spare12IN18 43.2 Spare13IN19 43.3 Spare14IN20 43.4 Spare15IN21 43.5 Spare

S436:2 16IN22 43.6 Bottom cylinder deburing unit is down17IN23 43.7 Spare18IN24 43.8 Spare1 46.02 46.0

Y461:+ 3OUT9 46.1 Cam transport 1 upY462:+ 4OUT10 46.2 Support 1 upY463:+ 5OUT11 46.3 Support 2 upY464:+ 6OUT12 46.4 Support 3 upY465:+ 7OUT13 46.5 Support 4 upJ46:11 8OUT14 46.6 Support 5 upJ46:13 9OUT15 46.7 Support 6 upJ46:15 10OUT16 46.8 Support 7 upY471A:+ 11OUT17 47.U.1 Retract lower deburing cylinderY471B:+ 12OUT18 47.U.2 Eject lower deburinig cylinderY473A:+ 13OUT19 47.U.3 Retract upper deburing cylinderY473B:+ 14OUT20 47.U.4 Eject upper deburinig cylinderY473B:- 15OUT21 47.U.5 Transport 1 forwardsU420:15 16OUT22 47.U.6 Transport 1 backwardsU420:16 17OUT23 47.U.7 Transport 2 forwardsU420:17 18OUT24 47.U.8 Transport 2 backwards

7MD465.7X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X1

X2

X2

X2

X2

X2

X2

X2

X2

X2

X2

X2

X2

X2

X2

X2

X2

X2

X2

S411:1U410:1U410:5U410:6 IN31X3:2 IN4S405:2 IN5

U410:1U410:5U410:6U410:7 8OUT4 44.4 Hydraulic cooler onY445:+ 9OUT5 44.5 High capacity pump

10OUT6 44.611OUT7 44.712OUT8 44.8

:SH 13SHLD 45.2 SHIELDU451:3 14AO1 45.1

15AGND 45.216SHLD 45.7 SHIELD17AO2 45.7

X2

X2

X2

X2

X2

X2

X2

X2

X2

X2

S411:3

AGND

Y445:- Start deburing unit

U451:2

18AGND 45.7X2

SPARESPARE

Assignment list

F20_004

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

400

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4


5 6 7

E1018301-DKPS515

8

=+

9

409

402

401

U1000

X2X 151.1U1002:X2X X2X 151.3

X2X+ 151.0U1002:X2X+ X2X+ 151.2

X2XGND 151.1U1002:X2XGND X2XGND 151.3

X2X\ 151.1U1002:X2X\ X2X\ 151.3

1 110.0 24VDC3 110.1

U1000:1 4OUT25 110.2 Close horizontal clamp 11 110.2 24VDC3 110.3

U1000:2 4OUT26 110.4 Open horizontal clamp 11 110.5 24VDC3 110.6



U1000:5 4OUT29 111.2 Close vertical clamp 11 111.2 24VDC3 111.3

U1000:6 4OUT30 111.4 Open vertical clamp 11 111.5 24VDC3 111.6


U1000:8 4OUT32 111.9 Open vertical clamp 21 100.02 100.03 100.04 100.0

DM1321

-1

-1

-1

-2

-2

-2

-3

-3

-3

-4

-4

-4

-5

-5

-5

-6

-6

-6

-7

-7

-7

-8

-8

-8

-C

-C

-C

-C

U1002

X2X 151.5U1000:X2XU1005:X2X X2X 151.6U1000:X2X+ X2X+ 151.4U1005:X2X+ X2X+ 151.6U1000:X2XGND X2XGND 151.5U1005:X2XGND X2XGND 151.7U1000:X2X\ X2X\ 151.5U1005:X2X\ X2X\ 151.7

1 112.0 24VDC3 112.1






U1002:6 4OUT38 113.4 Open vertical clamp 31 113.5 24VDC3 113.6


U1002:8 4OUT40 113.9 Open vertical clamp 41 100.22 100.33 100.24 100.3

DM1321

-1

-1

-1

-2

-2

-2

-3

-3

-3

-4

-4

-4

-5

-5

-5

-6

-6

-6

-7

-7

-7

-8

-8

-8

-C

-C

-C

-C

Assignment list

F20_004

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

401

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4


5 6 7

E1018301-DKPS515

8

=+

9

409

403

402

U1005


1 114.0 24VDC3 114.1

U1005:1 4OUT41 114.2 Lubrication punch 11 114.2 24VDC3 114.3

U1005:2 4OUT42 114.41 114.5 24VDC3 114.6

U1005:3 4OUT43 114.61 114.7 24VDC3 114.8

U1005:4 4OUT44 114.9 Option A Lubrication flange punch1 115.0 24VDC3 115.1

U1005:5 4OUT45 115.2 Option lubrication angle shear1 115.2 24VDC3 115.3

U1005:6 4OUT46 115.4 Option H drill cooling1 115.5 24VDC3 115.6

U1005:7 4OUT47 115.6 Option H external drill cooling1 115.7 24VDC3 115.8

U1005:8 4OUT48 115.9 Option H external drill cooling1 100.52 100.53 100.54 100.5

DM1321

-1

-1

-1

-2

-2

-2

-3

-3

-3

-4

-4

-4

-5

-5

-5

-6

-6

-6

-7

-7

-7

-8

-8

-8

-C

-C

-C

-C

U1007

X2X 151.5U1005:X2XX2X 151.6

U1005:X2X+ X2X+ 151.4X2X+ 151.6

U1005:X2XGND X2XGND 151.5X2XGND 151.7

U1005:X2X\ X2X\ 151.5X2X\ 151.7

1 100.72 100.83 100.74 100.81 100.92 100.93 100.94 100.9

PS1300

-C

-C

-C

-C

-D

-D

-D

-D

Assignment list

F20_004

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

402

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4


5 6 7

E1018301-DKPS515

8

=+

9

409

404

403

U1010


1 116.0 24VDC3 116.1

U1010:1 4OUT49 116.2 Punch to material1 116.2 24VDC3 116.34 116.4 Punch from material1 116.5 24VDC3 116.6

U1010:3 4OUT51 116.6 Punch downpusher down1 116.7 24VDC3 116.84 116.9 Punch downpusher up1 117.F.0 24VDC3 117.F.14 117.F.21 117.F.2 24VDC3 117.F.34 117.F.41 117.F.5 24VDC3 117.F.64 117.F.6 Spare1 117.F.7 24VDC3 117.F.8

U1010:8 4OUT56 117.F.9 Spare1 101.02 101.03 101.04 101.0

DO1332

-1

-1

-1

-2

-2

-2

-3

-3

-3

-4

-4

-4

-5

-5

-5

-6

-6

-6

-7

-7

-7

-8

-8

-8

-C

-C

-C

-C

U1012


1 118.F.0 24VDC3 118.F.1

U1012:1 4IN25 118.F.2 Punch is high1 118.F.2 24VDC

U1012:2 4IN26 118.F.4 Punch is in center position3 118.F.31 118.F.5 24VDC3 118.F.6

U1012:3 4IN27 118.F.6 Punch is low1 118.F.7 24VDC3 118.F.8

U1012:4 4IN28 118.F.9 Spare1 119.F.0 24VDC3 119.F.1

U1012:5 4OUT57 119.F.2 Lock die table1 119.F.2 24VDC3 119.F.3

U1012:6 4OUT58 119.F.4 Lock punch table1 119.F.5 24VDC3 119.F.6

U1012:7 4OUT59 119.F.6 Air pillow1 119.F.7 24VDC3 119.F.8

U1012:8 4IN29 119.F.9 Air pressure present1 101.22 101.33 101.24 101.3

DM1321

-1

-1

-1

-2

-2

-2

-3

-3

-3

-4

-4

-4

-5

-5

-5

-6

-6

-6

-7

-7

-7

-8

-8

-8

-C

-C

-C

-C

U1010:2 OUT50

U1010:4 OUT52

U1010:5 OUT53

U1010:6 OUT54

U1010:7 OUT55

Assignment list

F20_004

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

403

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4


5 6 7

E1018301-DKPS515

8

=+

9

409

405

404

U1015


1 120.F.0 24VDC3 120.F.1

U1015:1 4IN30 120.F.2 Spare1 120.F.2 24VDC

U1015:2 4IN31 120.F.4 Spare3 120.F.31 120.F.5 24VDC3 120.F.6

U1015:3 4IN32 120.F.6 Spare1 120.F.7 24VDC3 120.F.8

U1015:4 4IN33 120.F.9 Spare1 121.0 24VDC3 121.1

U1015:5 4IN34 121.2 Spare1 121.2 24VDC3 121.3

U1015:6 4IN35 121.4 Spare1 121.5 24VDC3 121.6

U1015:7 4IN36 121.6 Spare1 121.7 24VDC3 121.8

U1015:8 4IN37 121.9 Spare1 101.52 101.53 101.54 101.5

DM1321

-1

-1

-1

-2

-2

-2

-3

-3

-3

-4

-4

-4

-5

-5

-5

-6

-6

-6

-7

-7

-7

-8

-8

-8

-C

-C

-C

-C

U1017

X2X 152.5U1015:X2XX2X 152.7

U1015:X2X+ X2X+ 152.4X2X+ 152.6


U1015:X2X\ X2X\ 152.5X2X\ 152.7

1 101.72 101.83 101.74 101.81 101.92 101.93 101.94 101.9

PS1300

-C

-C

-C

-C

-D

-D

-D

-D

Assignment list

F20_004

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

404

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4


5 6 7

E1018301-DKPS515

8

=+

9

409

406

405

U1020

X2X 153.1U1017:X2XU1022:X2X X2X 153.3

X2X+ 153.1U1022:X2X+ X2X+ 153.2U1017:X2XGND X2XGND 153.1U1022:X2XGND X2XGND 153.3U1017:X2X\ X2X\ 153.1U1022:X2X\ X2X\ 153.3

1 122.0 24VDC3 122.1

U1020:1 4OUT60 122.2 Flat shear to material1 122.2 24VDC3 122.34 122.4 Flat shear from material1 122.5 24VDC3 122.6

U1020:3 4OUT62 122.6 vertical downpusher flat shear down1 122.7 24VDC3 122.84 122.9 vertical downpusher flat shear up1 123.0 24VDC3 123.14 123.2 Angle shear to material1 123.2 24VDC3 123.34 123.4 Angle shear from material1 123.5 24VDC3 123.64 123.6 Downpusher angle shear to material1 123.7 24VDC3 123.8

U1020:8 4OUT67 123.9 Downpusher angle shear from material1 102.02 102.03 102.04 102.0

DO1332

-1

-1

-1

-2

-2

-2

-3

-3

-3

-4

-4

-4

-5

-5

-5

-6

-6

-6

-7

-7

-7

-8

-8

-8

-C

-C

-C

-C

U1022


1 124.0 24VDC3 124.1

U1022:1 4IN38 124.2 Flat shear is high/low1 124.2 24VDC

U1022:2 4IN39 124.4 Angle shear is high/low3 124.31 124.5 24VDC3 124.6

U1022:3 4IN40 124.6 Spare1 124.7 24VDC3 124.8

U1022:4 4IN41 124.9 Spare1 125.0 24VDC3 125.1

U1022:5 4IN42 125.2 Spare1 125.2 24VDC3 125.3

U1022:6 4IN43 125.4 Spare1 125.5 24VDC3 125.6

U1022:7 4IN44 125.6 Spare1 125.7 24VDC3 125.8

U1022:8 4IN45 125.9 Spare1 102.22 102.33 102.24 102.3

DM1321

-1

-1

-1

-2

-2

-2

-3

-3

-3

-4

-4

-4

-5

-5

-5

-6

-6

-6

-7

-7

-7

-8

-8

-8

-C

-C

-C

-C

U1020:2 OUT61

U1020:4 OUT63

U1020:5 OUT64

U1020:6 OUT65

U1020:7 OUT66

Assignment list

F20_004

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

405

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4


5 6 7

E1018301-DKPS515

8

=+

9

409

407

406

U1025


1 102.52 102.53 102.54 102.51 102.62 102.73 102.64 102.7

PS1300

-C

-C

-C

-C

-D

-D

-D

-D

U1027

X2X 153.5U1025:X2XX2X 153.7

U1025:X2X+ X2X+ 153.4X2X+ 153.6


U1025:X2X\ X2X\ 153.5X2X\ 153.7

1 126.K.0 24VDC3 126.K.1

U1027:1 4OUT68 126.K.2 Push-off device 11 126.K.2 24VDC3 126.K.3

U1027:2 4OUT69 126.K.4 Push-off device 21 126.K.5 24VDC3 126.K.6

U1027:3 4OUT70 126.K.6 Option push-off device 31 126.K.7 24VDC3 126.K.8

U1027:4 4OUT71 126.K.9 Option close slidetable1 127.K.0 24VDC3 127.K.1

U1027:5 4OUT72 127.K.2 Option open slidetable1 127.K.2 24VDC3 127.K.3

U1027:6 4OUT73 127.K.4 Option Stopper up1 127.K.5 24VDC3 127.K.6

U1027:7 4OUT74 127.K.6 Option stopper down1 127.K.7 24VDC3 127.K.8

U1027:8 4OUT75 127.K.9 Option datumline down1 102.72 102.83 102.74 102.8

DM1321

-1

-1

-1

-2

-2

-2

-3

-3

-3

-4

-4

-4

-5

-5

-5

-6

-6

-6

-7

-7

-7

-8

-8

-8

-C

-C

-C

-C

Assignment list

F20_004

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

406

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4


5 6 7

E1018301-DKPS515

8

=+

9

409

408

407

U1030


1 128.K.0 24VDC3 128.K.1

U1030:1 4IN46 128.K.2 Slidetable to low1 128.K.2 24VDC

U1030:2 4IN47 128.K.4 Push-off device is in front3 128.K.31 128.K.5 24VDC3 128.K.6

U1030:3 4IN48 128.K.6 Push-off device is in back1 128.K.7 24VDC3 128.K.8

U1030:4 4IN49 128.K.9 Option slidetable from shear1 129.K.0 24VDC3 129.K.1

U1030:5 4IN50 129.K.2 Option slidetable in shear1 129.K.2 24VDC3 129.K.3

U1030:6 4IN51 129.K.4 Option Stopper is up1 129.K.5 24VDC3 129.K.6

U1030:7 4IN52 129.K.6 Spare1 129.K.7 24VDC3 129.K.8

U1030:8 4OUT76 129.K.9 Cariage active1 103.02 103.03 103.04 103.0

DM1321

-1

-1

-1

-2

-2

-2

-3

-3

-3

-4

-4

-4

-5

-5

-5

-6

-6

-6

-7

-7

-7

-8

-8

-8

-C

-C

-C

-C

U1032


1 130.E.0 24VDC3 130.E.1

U1032:1 4OUT77 130.E.21 130.E.2 24VDC3 130.E.34 130.E.4 Extra positon marking unit backwards1 130.E.5 24VDC3 130.E.6

U1032:3 4OUT79 130.E.6 Refrence cam marking weel1 130.E.7 24VDC3 130.E.84 130.E.9 Marking cylinder on1 131.E.0 24VDC3 131.E.14 131.E.2 Marking cylinder backwards1 131.E.2 24VDC3 131.E.34 131.E.4 Close horizontal clamp 51 131.E.5 24VDC3 131.E.64 131.E.6 Open horizontal clamp 51 131.E.7 24VDC3 131.E.8

U1032:8 4OUT84 131.E.9 Spare1 103.22 103.33 103.24 103.3

DO1332

-1

-1

-1

-2

-2

-2

-3

-3

-3

-4

-4

-4

-5

-5

-5

-6

-6

-6

-7

-7

-7

-8

-8

-8

-C

-C

-C

-C

U1032:2 OUT78

U1032:4 OUT80

U1032:5 OUT81

U1032:6 OUT82

U1032:7 OUT83

Assignment list

F20_004

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

407

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4


5 6 7

E1018301-DKPS515

8

=+

9

409

409

408

U1035


1 103.52 103.53 103.54 103.51 103.62 103.73 103.64 103.7

PS1300

-C

-C

-C

-C

-D

-D

-D

-D

U1037


1 132.0 24VDC3 132.1

U1037:1 4OUT85 132.2 Flange punch 1 to material1 132.2 24VDC3 132.34 132.4 Flange punch 1 from material1 132.5 24VDC3 132.6

U1037:3 4OUT87 132.6 Flange punch 2 to material1 132.7 24VDC3 132.84 132.9 Flange punch 2 from material1 133.0 24VDC3 133.14 133.2 Flange buffer backwards1 133.2 24VDC3 133.34 133.4 Spare1 133.5 24VDC3 133.64 133.6 Spare1 133.7 24VDC3 133.8

U1037:8 4OUT92 133.9 Spare1 103.72 103.83 103.74 103.8

DO1332

-1

-1

-1

-2

-2

-2

-3

-3

-3

-4

-4

-4

-5

-5

-5

-6

-6

-6

-7

-7

-7

-8

-8

-8

-C

-C

-C

-C

U1037:2 OUT86

U1037:4 OUT88

U1037:5 OUT89

U1037:6 OUT90

U1037:7 OUT91

Assignment list

F20_004

Bl.

Created by:

Bl.Checked by:

Create date:

Modification:

HS

Projekt:

408

0

CS15

19-04-2007

29-01-2008

1

Samaras

2 3 4


5 6 7

E1018301-DKPS515

8

=+

9

409409

U1040

X2X 155.1U1037:X2XU1042:X2X X2X 155.3U1037:X2X+ X2X+ 155.1U1042:X2X+ X2X+ 155.3U1037:X2XGND X2XGND 155.1U1042:X2XGND X2XGND 155.3

X2X\ 155.2U1042:X2X\ X2X\ 155.3

1 134.0 24VDC3 134.1

U1040:1 4OUT93 134.2 Tool changer forwards1 134.2 24VDC3 134.3

U1040:2 4OUT94 134.4 Tool changer backwards1 134.5 24VDC3 134.6

U1040:3 4OUT95 134.6 Release tool1 134.7 24VDC3 134.8

U1040:4 4OUT96 134.91 135.0 24VDC3 135.1

U1040:5 4IN53 135.2 Error tool changer1 135.2 24VDC3 135.3

U1040:6 4IN54 135.41 135.5 24VDC3 135.6

U1040:7 4IN55 135.6 Tool changer is in front1 135.7 24VDC3 135.8

U1040:8 4IN56 135.9 Spare1 104.02 104.03 104.04 104.0

DM1321

-1

-1

-1

-2

-2

-2

-3

-3

-3

-4

-4

-4

-5

-5

-5

-6

-6

-6

-7

-7

-7

-8

-8

-8

-C

-C

-C

-C

U1042

X2X 155.5U1040:X2XX2X 155.7

U1040:X2X+ X2X+ 155.4X2X+ 155.6


U1040:X2X\ X2X\ 155.5X2X\ 155.7

1 136.E.0 24VDC3 136.E.1

U1042:1 4OUT97 136.E.2 Change cylinder 1 forwards1 136.E.2 24VDC3 136.E.3

U1042:2 4OUT98 136.E.4 Change cylinder 1 backwards1 136.E.5 24VDC3 136.E.6

U1042:3 4OUT99 136.E.6 Change cylinder 2 forwards1 136.E.7 24VDC3 136.E.8

U1042:4 4OUT100 136.E.9 Change cylinder 2 backwards1 137.E.0 24VDC3 137.E.1

U1042:5 4OUT101 137.E.2 Unlock wheel 11 137.E.2 24VDC3 137.E.3



U1042:8 4OUT104 137.E.9 Unlock wheel 41 104.22 104.33 104.24 104.3

DM1321

-1

-1

-1

-2

-2

-2

-3

-3

-3

-4

-4

-4

-5

-5

-5

-6

-6

-6

-7

-7

-7

-8

-8

-8

-C

-C

-C

-C


M-UK-KPS--06 11/02/03 Page 138 of 138

KALTENBACH

7 Appendix Layout KPS 501 Hoisting instructions 700025_* KPS 503 Hoisting instructions 700081_* KPS 506 Hoisting instructions 700022_* KPS 506 Hoisting instructions 700023_* KPS 501 Tool information & min. punch positions 700056_* KPS 503 Tool information & min. punch positions 700055_* KPS 506/515 Tool information & min. punch positions 700054_* Flange Punch Tool information & min. punch positions 700058_*

Manufacturer’s Declaration

in accordance with the EC Machine Directive 98/37/EG, Appendix IIB

The manufacturer KALTENBACH B.V. Turfschipper 2 2292 JA Wateringen - Nederland hereby declares that the machine Make : KALTENBACH Year of construction : 2008 Equipment number : 2008.01.14564 consists of : KPS515 T10 equipped as delivered is designed to be mounted to or installed in another device. It is illegal to operate the machine until it has been certified that the device itself complies with the regulations of the EC-Machine Directive 98/37/EC. The following harmonised standards were applied: EN ISO 12100-1 EN ISO 12100-2 EN 954-1 EN 60204-1 Wateringen d.d. : 29.01.2008 ……………………………………. ……….…………………………..

manual kps 515 - smsales.com.au€¦ · the kps machine is designed for the special market...

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