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MBO Delivery KAS 30ME Translation Of The Original Operating Manual

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Translation of the original operating manual
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KAS 30ME
MC-Control

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Summary of Contents for MBO Delivery KAS 30ME

  • Page 1 Delivery Translation of the original operating manual KAS 30ME MC-Control Keep for future use!
  • Page 2 Author: 29.10.2012 Status as Machine no.: U.S. English BA_KAS30ME__MC_V Language: File name: 1.2_us MBO Maschinenbau Oppenweiler Binder GmbH & Co. KG PO box 1169 71567 Oppenweiler GERMANY Manufacturer: Tel.: +49 7191 46 0 Fax:+49 7191 46 34 http://www.mbo-folder.com info@mbo-folder.com Subject to alterations! Copyright: This documentation is subject to copyright law.
  • Page 3 Label and CE Mark: For all questions relating to your machine, please contact your MBO agen- You can find the address on our home page: www.mbo-folder.com. Please gather the significant data for identification of the machine from the label on the machine.
  • Page 4 EC Declaration of Conformity according to the EC Machinery Directive (2006/42/EC), Appendix IIA. The manufacturer MBO Maschinenbau Oppenweiler Binder GmbH & Co. KG Grabenstraße 4-6 71570 Oppenweiler GERMANY hereby declares that the machine described below Order no. Designation Delivery Type...
  • Page 5 Work on electrical equipment ......... . . 23 Delivery KAS 30ME MC-Control...
  • Page 6 Main control console ..........43 Delivery KAS 30ME MC-Control...
  • Page 7 Setting multiple-up production ......... . 63 Delivery KAS 30ME MC-Control...
  • Page 8 10.1.2 Property damage messages ......... . . 87 Delivery KAS 30ME MC-Control...
  • Page 9 Disposal/recycling ..........88 Delivery KAS 30ME MC-Control...
  • Page 10 List of contents Delivery KAS 30ME MC-Control...
  • Page 11 General remarks Important notes about the operating manual General remarks With this MBO product, you have acquired a high-quality industrial product with which you, if you follow the operating manual carefully, can achieve the highest reliability and productivity. Important notes about the operating manual This operating manual must be read by everybody who transports, sets up, connects, operates, maintains, repairs or dismantles this machine.
  • Page 12 Shutdown,storage and Shutdown, storage condi- Owner/operator putting the machine tions Operating personnel back into operation Maintenance personnel Service technicians Disposal Dismantlement, environ- Owner/operato mentally-friendly disposal Maintenance personnel Service technicians Tabelle 1: Structure of the operating manual Delivery KAS 30ME MC-Control...
  • Page 13 Numbered instruction for action; adhere to sequence. < STOP > Pushbutton with the label that is between the brackets (e.g. Stop). Additional information for use of the machine. Important notice, please observe. Tabelle 2: Symbols, terms, and abbreviations Delivery KAS 30ME MC-Control...
  • Page 14 CAUTION indicates a hazardous situation which, Avoidance of personal if not avoided, could result in minor or moderate injury. injury. NOTICE indicates a property damage message. Avoidance of property damage. Tabelle 3: Definition of signal words Delivery KAS 30ME MC-Control...
  • Page 15 • Signal word. • Type of hazard. • Potential consequences of the hazard. • Evasive/avoidance actions to be taken. Example: Property damage message: Type of hazard. Potential consequences of the hazard. Evasive/avoidance actions to be taken. Delivery KAS 30ME MC-Control...
  • Page 16 Fire protection symbol Red background, white symbol. Safety symbol that identifies the location of fire alarm or fire extinguishing equipment and/or the path to this equipment in case of an emer- gency. Tabelle 4: Safety symbols Delivery KAS 30ME MC-Control...
  • Page 17 Warning of hand injuries due to moving rollers. Warning of crushing of hand. Warning of crushing injuries due to noise dam- ping hoods. Warning of rotating machine parts. Warning of lifting heavy machine parts. Tabelle 5: Warning triangle Delivery KAS 30ME MC-Control...
  • Page 18 Warning of hot surface. Warning of tripping hazards. Tabelle 5: Warning triangle User assessment of the operating manual Our operating manuals are updated regularly. You are kindly requested to recommend any improvements to make the instructions user-friendly. Delivery KAS 30ME MC-Control...
  • Page 19 • Adhere to the inspection and maintenance intervals. • Use only original wearing parts and spare parts. Use the machine only as intended and with the safety system in a flawless state. This is the only way to guarantee the machine's operating safety. Delivery KAS 30ME MC-Control...
  • Page 20 The use of spare parts and wearing parts from third-party manufacturers parts: can cause risks. Use only original parts or parts approved by the manufacturer. The manufacturer assumes no liability for damage from the use of spare parts and wearing parts not approved by the manufacturer. Delivery KAS 30ME MC-Control...
  • Page 21 • not or improperly maintained or serviced. The machine must only be used: • For the intended use. • If it is in perfect condition with respect to safety. Faults that can compromise safety must be remedied immediately. Delivery KAS 30ME MC-Control...
  • Page 22 • Improper monitoring of machine parts that are subject to wear, such as belts, brushes, and couplings. • Installation of spare and wearing parts that were not ordered from the manufacturer. • Cases of catastrophe and acts of God. Delivery KAS 30ME MC-Control...
  • Page 23 • Dismounting, bridging or working around safety devices and equipment. • Operation without protective covers. • Rotating machine parts. • Infeed points • Stumbling points due to cables lying around. 2.5.4 Maintenance Operational maintenance: • Rotating machine parts. • Operation without protective covers. Delivery KAS 30ME MC-Control...
  • Page 24 • Incorrect/poor maintenance tools. • Improper maintenance. • Improper maintenance intervals, lubrication intervals, and cleaning in- tervals with multi-shift operation. Repair: • Improper repair. 2.5.5 Removing from operation, storage • Incorrect storage. 2.5.6 Disposal • Improper disposal. Delivery KAS 30ME MC-Control...
  • Page 25 Life time of the machine The life time of this machine is designed for 20 years. 2.6.2 Life span of the safety-technical components All components of the control-technical safety circuits have a life span of more than 20 years. Delivery KAS 30ME MC-Control...
  • Page 26 Secure components or parts so that they present no danger. Do not linger or work under hanging loads. • After completion of the work, do not leave any tools or other loose ob- jects lying on the machine. Delivery KAS 30ME MC-Control...
  • Page 27 DIN VDE 0105-100 / DIN EN 50110-1 and BGV A3. • In case of faults in the electrical power supply, the machine must be switched off immediately. • Only use original fuses with the prescribed amperage. Delivery KAS 30ME MC-Control...
  • Page 28 • have understood and can implement practically the operating manual with respect to responsibilities, tasks, and activities for the machine. 2.8.1 Qualification of the personnel This table lists the necessary qualification of the personnel related to the various activities at or on the machine. Delivery KAS 30ME MC-Control...
  • Page 29 Personnel, qualification, and duties Transportation Interim storage Set-up Electrical connec- tions Network connection Start-up Troubleshooting (mechanical/electri- Setting up, equip- ping Operating Cleaning Maintenance Repair Shutdown Bearing assembly Disposal Table 6: Qualification of personnel Legend: X authorized, - not authorized Delivery KAS 30ME MC-Control...
  • Page 30 • identified defects or abnormal operating states/malfunctions being rem- edied immediately, • operation of the machine being ceased during troubleshooting. The requirements of the EC Directive for use of equipment 2007/30/EC must be complied with. Delivery KAS 30ME MC-Control...
  • Page 31 • use the machine as intended, • wear the necessary personal protective equipment. The maintenance personnel is responsible for • protecting the machine against unauthorized use, • the maintenance being carried out according to the maintenance sched- ule. Delivery KAS 30ME MC-Control...
  • Page 32 • Safety shoes 2.9.2 Operational maintenance (cleaning) This personal protective kit must be provided and worn for the proper main- tenance (cleaning) of the machine: • Safety glasses • Suitable safety gloves • Safety shoes Delivery KAS 30ME MC-Control...
  • Page 33 100 cm. • The service area is highlighted shaded. • The possible work places are marked with an "X." Measurement in 1 Work place Figure 2: Work area and work place Delivery KAS 30ME MC-Control...
  • Page 34 Markings on the machine These markings must be on the machine and in an easily legible condition. If the markings are damaged or illegible, they must be replaced. For the corresponding MBO part number, please see the chapter “2.11.2 Position and meaning”. 2.11.1 Overview 1 Note <Drawing-in point>...
  • Page 35 Never reach towards the shafts while the machine is running. (Operator side and drive side) Pos. 2 MBO part number: 01310945 Meaning: Pinch point, rotating roller. Drawing-in and crush hazard. Never reach towards the shafts while the machine is running. (Operator side and drive side) Delivery KAS 30ME MC-Control...
  • Page 36 Basic safety instructions Markings on the machine Pos. 3 MBO part number: 10.5171.026 Meaning: Electrical type plate Pos. 4 MBO part number: 10.5171.025 Meaning: Label Delivery KAS 30ME MC-Control...
  • Page 37 Read and understand this manual before using this machine to avoid injury. • Improper use of the machine can result in serious injury or death. • Follow the safety information in this manual. • Follow the local accident prevention regulations and environmental regulations. • Keep this manual. Delivery KAS 30ME MC-Control...
  • Page 38 Drawing-in and crush hazard. Never reach towards the rollers while the machine is running. 2.12 Directions for emergencies The operator must add notes with respect to national regulations concern- ing accident prevention and protection to the operating manual. Delivery KAS 30ME MC-Control...
  • Page 39 • Special delivery technology for especially small-format products. • Infeed table with round belt for spreading the products for multiple-up production. • Marking device for shifting in package. • Continuous shingle stream. • Self-control • Mobile Delivery KAS 30ME MC-Control...
  • Page 40 < 80 dB(A) Airborne sound emis- delivery sion level (L Sound power level Table 8: Emissions a) Noise measurement procedure according to EN 13023:2004 b) Determination of the sound power level according to EN ISO 3746:1995. Delivery KAS 30ME MC-Control...
  • Page 41 Relative humidity Minimum 30 % Maximum 80 % (non-condensing) Max. 1500 m over sea level. Set-up height Table 10: Ambient conditions a) At temperatures below or above the permissible room temperature, special measures must be taken. Delivery KAS 30ME MC-Control...
  • Page 42 If the nominal voltage is 210 V or 230 V at 60 Hz, the tolerance of the power supply must be checked. If the tolerance is between 200 V – 240 V, an isolating transformer is not required. b) Stationary network connection, a ground fault circuit interrupter may not be used. Delivery KAS 30ME MC-Control...
  • Page 43 Infeed table with round belt for spreading the products for multiple-up pro- duction. Marking device for shifting in package. Thanks to the individual controller, use on older machines or third-party machines is also possible. Delivery KAS 30ME MC-Control...
  • Page 44 The following safety and protective devices are present at or on the ma- chine. Operate the machine only if all safety and protective devices are complete- ly present and fully functional! 1 Protective device 3 EMERGENCY STOP palm button 2 Safety handwheel Figure 7: Overview Delivery KAS 30ME MC-Control...
  • Page 45 • Turning machine parts, e.g. drives, shafts • Infeed points • pinch points • Etc. The function and position of the corresponding protective device is listed in the "Safety and protective devices" checklist. See Chapter “4.4 Checklist for safety and protective devices”. Delivery KAS 30ME MC-Control...
  • Page 46 Use this checklist to check the safety and protective devices of the machine regularly. Visual Function- Inspection Pos. Description inspec- Result ing control interval tion Guard over drive Daily Safety handwheel Daily EMERGENCY STOP palm but- Daily Date: Name: Signature: Table 13: Checklist for safety and protective devices Delivery KAS 30ME MC-Control...
  • Page 47 MBO folding units, MBO units or MBO deliveries. • The 230 VAC power sockets of the MBO machines may only be used exclusively for connecting the intended auxiliary equipment, such as gluing devices, for example.
  • Page 48 Appropriate coupling modules are re- quired for this. You can find out which coupling modules can be used from MBO Service or from authorized customer service. For safety reasons, a maximum of one adapter box may be used on a ma- chine assembly.
  • Page 49 "Self-control" operating mode. Non-observance may possibly cause serious personal injuries or even death. If an MBO unit is operated in "self-control" operating mode as part of an assembly including third-party machines, no shared safety shutoff is present. • In case of a dangerous situation, each machine must be switched off separately.
  • Page 50 Operating and display elements, operating modes Operating modes Delivery KAS 30ME MC-Control...
  • Page 51 This table lists the necessary qualification of the personnel related to "Transport and interim storage" of the machine. Transportation Interim storage Set-up Electrical connec- tions Power supply connection Table 14: Qualification of personnel; transport, interim storage Legend: X authorized, - not authorized Delivery KAS 30ME MC-Control...
  • Page 52 "the "Technical data" in the operating manual, an isolating transformer must be used. You can get the necessary information from the manufacturer. Brief instructions The delivery is transported, set up, and started up in these steps: • Transport delivery. See chapter “6.3 Transportation” Delivery KAS 30ME MC-Control...
  • Page 53 Non-observance may possibly cause serious personal injuries and damage to property. • Check the properties and condition and carrying capacity of the under- floor in the set-up location. • Observe the necessary minimum requirements; see the "Specifica- tions" chapter. Delivery KAS 30ME MC-Control...
  • Page 54 Heed the cleaning recommendation in the following table as well as the de- tailed instructions about the "Varn" roller cleaner in the "Cleaning" chapter. Part of machine Cleansing agent Lacquered surfaces Solvent-free cleansing agent Rollers "Varn-Wash VM 111". See "Cleaning" chapter Table 15: Cleaning recommendation Delivery KAS 30ME MC-Control...
  • Page 55 Check that the covers on all control cabinets are grounded and closed ac- cording to regulations. Procedure: Check this by visual inspection. 6.6.4 Checking machine functions Procedure: Check the complete machine function by setting up a customer job/test job. Delivery KAS 30ME MC-Control...
  • Page 56 After 20 hours of operation after the initial set-up, it is necessary to check all belts and tapes. Procedure: Check the belts and tapes on correct center running and on correct ten- sion. If necessary, readjust these. See chapter service/maintenance plan. Delivery KAS 30ME MC-Control...
  • Page 57 Qualification of personnel This table lists the necessary qualification of the personnel related to "Ad- justment and operation" of the machine. Adjustment Operating Table 16: Qualification of personnel, adjustment and operation Legend: X authorized, - not authorized Delivery KAS 30ME MC-Control...
  • Page 58 • Turn the safety handwheel only when the machine is not moving. • Press the EMERGENCY STOP palm button. • Operate the machine with safety handwheels only (otherwise, there is a hazard of being drawn in). Delivery KAS 30ME MC-Control...
  • Page 59 The machine may be restarted only after removing the paper jam. Non-compliance may possible cause property damage (drive belts, trans- port tapes, foldrollers etc.). When removing the paper jam, turn the machine using the safety hand- wheel only. Delivery KAS 30ME MC-Control...
  • Page 60 Disengage the EMERGENCY STOP palm button by turning it towards the right. The machine is ready for operation. When the EMERGENCY STOP palm button is pressed, the machine is stopped immediately. There is no idling of the sheets! Delivery KAS 30ME MC-Control...
  • Page 61 Stopping produc- Procedure: tion: Press the < > (1) button again. Production sheet infeed The sheet feed stops. Calling up single Procedure: sheets: Press the < > (2). Single sheet infeed A single sheet is called up. Delivery KAS 30ME MC-Control...
  • Page 62 4 LEDs for function display Figure 17: Preselection counter The preselection counter has the following functions: • Current preselection counter • Preselection input • Total counter The detailed operation is described in the separate operating manual for the preselection counter. Delivery KAS 30ME MC-Control...
  • Page 63 See operating manual for the machine control of folding unit 1. Adjustment 7.3.1 Overview of adjustment elements 1 Infeed table with marking device 4 Safety handwheel 2 Locking screws 5 Clamping lever/height adjustment 3 Height adjustment of the delivery 6 Catch table Figure 18: Overall view Delivery KAS 30ME MC-Control...
  • Page 64 • Set stop to sheet length. See Chapter “7.3.8 Setting stop to sheet length”. • Set distance between the transport tapes. See Chapter “7.3.9 Setting distance between the transport tapes”. • Adjust pile stops. See Chapter “7.3.10 Adjusting the pile stop”. Delivery KAS 30ME MC-Control...
  • Page 65 Reinsert the screws into both brackets (1). Tighten the screws again. Tighten the clamping screws (2) for the height adjustment on both sides. Fix the position by turning the locking screws in (3). Delivery KAS 30ME MC-Control...
  • Page 66 (2 + 3). Procedure: Loosen the screws (5). Move the guides (4) to the desired position. The tapes must run in the clearance grooves of the tape rollers (2+3). Tighten the screws (5) again. Delivery KAS 30ME MC-Control...
  • Page 67 (1, 2, 3) or spread them out. Change the position of the round belt only laterally at the entry or the discharge of the infeed table. Two round belts are required per up. Two-up: Figure 21: Two-up Three-up: Figure 22: Three-up Delivery KAS 30ME MC-Control...
  • Page 68 (1). Figure 23: Marking device The desired number of sheets per batch is entered in the built-in preselec- tion counter (2). See separate operating manual for preselection counter. Delivery KAS 30ME MC-Control...
  • Page 69 (4) or by the round belts (3). When the preselected quantity of a batch is reached, the round belt (3) is offset to the left or right by the electromagnet (2) and the marking rods (4). Delivery KAS 30ME MC-Control...
  • Page 70 6) Move the tape rollers with the lower transport tapes. To get a fault-free transport of the sheets, the upper and lower transport tapes must al- ways be over one another. 7) Tighten the clamping screws again. 8) Swivel the stops into a horizontal position once again. Delivery KAS 30ME MC-Control...
  • Page 71 Procedure: Loosen the clamping levers (3) on both sides. Set the stop (2) to the length of the sheet being fed in.The sheet may not be clamped. Tighten the clamping levers (3) again on both sides. Delivery KAS 30ME MC-Control...
  • Page 72 (1). Procedure: Loosen the screws (2) on both sides. Move the round traverse (1) so that the desired distance between the transport tapes results. Tighten the screws (2) again on both sides. Delivery KAS 30ME MC-Control...
  • Page 73 Position the guide rail (2) in the middle ot the set-up sheet. Position the pile stop (3) under the stop (1). Adjust the resistance with the adjusting screw (3). Turn clockwise = resistance increases. Turn counter-clockwise = resistance decreases. Delivery KAS 30ME MC-Control...
  • Page 74 Feed a single sheet to check the correct function of the machine. If OK, start production. If not OK, determine and eliminate the cause. Turning the machine forwards/backwards using the safety handwheel makes it easier to remove the paper jam. Delivery KAS 30ME MC-Control...
  • Page 75 See Chapter “8.1.1 Qualification of personnel”. 8.1.1 Qualification of personnel This table lists the necessary qualification of the personnel related to "Maintenance" of the machine. Operational maintenance Maintenance Repair Table 17: Qualification of personnel Legend: X authorized, - not authorized Delivery KAS 30ME MC-Control...
  • Page 76 Maintenance work must be carried out by trained and authorized personnel with specialized technical skills and knowledge only. • Maintenance work must be carried out by one person only. • Observe the local occupational safety regulations. • Observe the maintenance, service, and cleaning plan. Delivery KAS 30ME MC-Control...
  • Page 77 Drawn-in hazard when removing the safety handwheel. Non-observance could result in serious personal injury or death. • Turn the main switch to the position <0>. • Use a padlock to secure the main switch from unintentionally switching on again. Delivery KAS 30ME MC-Control...
  • Page 78 Ordering spare and wear parts You can obtain the spare and wear parts worldwide via the corresponding MBO agency near you. For all questions relating to your machine, please also contact your MBO agency. You can find the address on our home page: www.mbo-folder.com.
  • Page 79 Press the EMERGENCY STOP palm button so that it remains engaged and in an actuated state. Pressing the EMERGENCY STOP palm button must cause all machine functions to shut down. Disengage the EMERGENCY STOP palm button when the test is fin- ished. Delivery KAS 30ME MC-Control...
  • Page 80 • Dispose of the cleaning cloth in an environmentally friendly manner. • Contact your cleaning agent manufacturer to find out about any resid- ual danger as well as about disposal in an environmentally friendly manner. Delivery KAS 30ME MC-Control...
  • Page 81 Transport tapes MBO Binder GmbH & Co. KG recommends the cleaning agent from "Varn" with the no.: "Varn-Wash VM 111 or VWM." "Varn" supplies the printing industry around the world. It is therefore not impossible that other names are used in different coun- tries.
  • Page 82 The optical sensors of the machine get dirty during production due to paper dust and printing powder. Therefore, they should be cleaned after each job (at least once per week). Procedure. Clean the optical elements of the sensors with a dry, lint-free cloth. Delivery KAS 30ME MC-Control...
  • Page 83 If the required tension declines or if the general state is poor, it must be re- placed. 1 Round belts Figure 31: Checking the round belt The round belts cannot be tightened after the fact. Only have the round belts replaced by MBO Service or by an authorized customer service agent. Delivery KAS 30ME MC-Control...
  • Page 84 Insert the new drive belt (3). Tension the drive belt (3) with the belt tensioner (1). Tighten the screw (2) again. Attaching the guard: Procedure: Attach the guard again. Insert the fastening screws and tighten them. Delivery KAS 30ME MC-Control...
  • Page 85 If the required tension can no longer be adjusted or if the general state is poor, it must be replaced. 1 Upper transport tape 2 Lower transport tape Figure 33: Checking the transport tapes Only have the transport belts replaced by MBO Service or by an authorized customer service agent. Delivery KAS 30ME MC-Control...
  • Page 86 Maintenance Lubrication Lubrication 1 Safety handwheel Figure 34: Lubrication Procedure: Use a grease gun to grease the safety handwheel (1) on the grease nip- ple monthly. Delivery KAS 30ME MC-Control...
  • Page 87 Monthly Maintenance 8.4.2 “Checking the drive belt” Monthly 8.4.3 “Checking the transport Monthly tapes” Table 18: Maintenance, lubrication, and cleaning plan MBO recommends attaching a copy of this maintenance, lubrication, and cleaning plan to the machine. Delivery KAS 30ME MC-Control...
  • Page 88 • Observe the local occupational safety regulations. • Carry out a function test after the repair. Only have repair work performed by MBO Service or by an authorized customer service agent. Delivery KAS 30ME MC-Control...
  • Page 89 Non-observance could result in property damage. Observe the corresponding storage conditions. Shutdown 9.2.1 Temporary shutdown: Procedure: Shut down machine. Stop compressed air supply to the machine. Remove products, tools from the machine. Clean and maintain machine. See Chapter "8 Maintenance". Delivery KAS 30ME MC-Control...
  • Page 90 Observe the specifications regarding the weight and size of the machine when selecting the premises. See Chapter "3.2 Technical data" Use a suitable fork lift for transport. See Chapter "3.2.4 Weights, fork lifts, and floor requirements". Cover the machine with foil. Delivery KAS 30ME MC-Control...
  • Page 91 Disposal Tabelle 20: Qualification of personnel; Disposal Legend: X permitted, - not permitted 10.1.2 Property damage messages Improper disposal. Non-observance could result in environmental damage. Comply with the corresponding federal and regional regulations, laws and directives. Delivery KAS 30ME MC-Control...
  • Page 92 All parts, consumables and supplies of the machine: • Separate by type • Dispose of in accordance with local regulations, laws and directives If you have any further questions regarding disposal, please contact the manufacturer! Delivery KAS 30ME MC-Control...
  • Page 93 FRANCE Tel.: +33 1 6935 5090 Fax: +33 1 6935 5099 http://www.mbo-folder.com info@mbofrance.fr MBO China MBO Binder Graphic Systems (Beijing) Co. Ltd. Rm 201, Haishunde Building, No.A1, Donghuanbei Road, BDA, Beijing 100176 P.R. CHINA Tel.: +86 10 6786 4021 Fax: +86 10 6787 3502 http://www.mbo-folder.com.cn...