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Zünd G3 Mounting Instructions

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G3 Light Curtain

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Summary of Contents for Zünd G3

  • Page 1 Mounting Instructions G3 Light Curtain...
  • Page 2 Keep it in a safe place for future use! Original operating manual Software/Firmware version: FW 1.75 Creation date: 02-2022...

  • Page 3: Table Of Contents

    6 Installing the S-box........................31 6.1 Preparing to fasten the S-box......................31 6.2 Installing the S-box......................... 32 6.3 Mounting the Varioface module on the G3/D3 cutter (system A)...........33 6.4 Connect S-box..........................34 7 Cutter without material transport....................37 7.1 Mounting the rear access guard....................37 7.2 Fastening the pillars to the floor (with segment anchors)..............
  • Page 4 Contents 8.3 Fastening the pillars to the floor (with segment anchors).............. 56 8.4 Mounting the pillars onto the auxiliary brackets................63 9 Connecting the light barrier transmitter and receiver..............69 9.1 Laying and connecting cables......................70 10 Setting up the light curtain......................73 10.1 Aligning the pillars vertically......................

  • Page 5: About These Instructions

    Offenders will be liable for damages. 1.4 Other applicable documents • Mounting instructions G3 • Mounting instructions cutter extension G3/D3 • Operating instructions G3 The most current version is found in the reseller area.

  • Page 6: Service Contact

    About these instructions 1.5 Service contact Address Zünd Systemtechnik AG Industriestrasse 8 9450 Altstätten Switzerland Telephone +41 71 554 81 00 E-mail support@zund.com Internet http://reseller.zund.com/...

  • Page 7: Safety

    Safety 2 Safety 2.1 Basic safety General • Read and observe the product operating instructions – particularly the chapter on safety. • Read and observe all other applicable documentation. • Use the product only as intended. • Use the correct tool for each application. Safeguarding against mechanical/physical hazards •...

  • Page 8: Personal Protective Equipment

    Safety 2.2 Personal protective equipment When operating, cleaning, maintaining, or assembling the machine, wear only form-fitting clothing as well as personal protective equipment suited to the task at hand. The following protective equipment is required: • Work clothing • Protective goggles if there is a risk that chips, liquids or gases under pressure can injure the eyes •...

  • Page 9: Tools, Operating And Auxiliary Materials

    Tools, operating and auxiliary materials 3 Tools, operating and auxiliary materials Tip: A list of tools, operating and auxiliary materials is provided in the electronics spare parts catalog. 3.1 Tools Image Description Task Standard toolbox For general installation, service and maintenance work Precision spirit level To level the machine...
  • Page 10 Tools, operating and auxiliary materials...

  • Page 11: Setting Up

    Setting up 4 Setting up 4.1 Overview Cutter with optional light curtain without material with material transport transport without CE 1/2 CE front — 1/2 CE rear — 1/2 CE front + 1/2 CE rear — 1/1 CE front — 1/1 CE rear —...
  • Page 12 Setting up...

  • Page 13: Setting Up The Control Panel/Workstation

    Setting up the control panel/workstation 5 Setting up the control panel/workstation 5.1 Dismantling the existing control panel/workstation Whether the control panel / workstation needs to be dismantled from the cutter depends on whether the control panel / workstation is already free or still attached to the cutter. If the control panel / workstation must be moved, the cables need to be extended.
  • Page 14 Setting up the control panel/workstation 5.1.1 Removing the PC cover Tip: Only the workstation has a PC cover. Screws PC cover A Open the side door of the workstation. B Hold the PC cover in position. C Remove both screws. D Pull the PC cover to the rear out of the workstation.
  • Page 15 Setting up the control panel/workstation 5.1.2 Unplugging the cable Electronics unit LAN cable Video signal cable (ICC camera, optional)
  • Page 16 Setting up the control panel/workstation Workstation power supply (connector control) Workstation/operating unit Control unit cable Operating unit underside Emergency stop control device cable Electronics unit Control unit cable light curtain S16 Signal light cable (Variofac 2, optional) Earthing cable Signal light cable (ACS_IO_BOARD_ENA) optional, cutter with tandem A PC and cutter side support, right: a) Unplug the LAN cable and remove.
  • Page 17 Setting up the control panel/workstation 5.1.3 Remove control panel/workstation from the cutter Caution: Risk of injury from the workstation tipping over The workstation can tip over if weight is applied to the surface area. • Avoid putting weight on the workstation. Connecting cover Connecting plate A Remove the covers from the front sides of the right side support.
  • Page 18 Setting up the control panel/workstation 5.1.4 Mounting the control panel/workstation cover plate Control panel/workstation Screws (2x) Cover plate A Position the cover plate. B Place and tighten both screws.

  • Page 19: Connect Cable To The Cutter

    Setting up the control panel/workstation 5.2 Connect cable to the cutter The signal light is optional and must only be connected if it is present. Electronics unit Ferrite LAN cable Signal light cable (electronics unit, ACS_IO_BOARD_ENA S8)

  • Page 20: Positioning The Control Panel / Workstation

    Setting up the control panel/workstation Video signal cable (ICC camera) EMERGENCY STOP control device cable (power unit, EMM_CON_BOARD S13) Operating unit cable (electronics unit, BF EMM_CON_BOARD board S16) Signal light cable (electronics unit, J2 – J3 Varioface_2) A Plug in the new, longer LAN cable. B Plug in the new, longer video signal cable.
  • Page 21 Setting up the control panel/workstation Blocked area operator protection Blocked area access to the electronics unit Width of the blocked area: > 180 mm Width of the blocked area: > 500 mm...

  • Page 22: Assembly With Segment Anchors (Fastening To The Floor)

    Setting up the control panel/workstation 5.4 Assembly with segment anchors (fastening to the floor) Note: Damage to lines or underfloor heating possible. • Check for any lines in the floor or underfloor heating before drilling the holes. Caution: Crushing risk! •...
  • Page 23 Setting up the control panel/workstation Control panel / workstation base plate Washers and nuts (2x) M8 segment anchor (2x) A Define the position of the control panel / workstation. B Draw both holes for the segment anchors and drill them. a) The minimum distance of the control panel / workstation to the beam is 180 mm.

  • Page 24: Installation With Auxiliary Bracket

    Setting up the control panel/workstation 5.5 Installation with auxiliary bracket Caution: Risk of injury from the workstation tipping over The workstation can tip over if weight is applied to the surface area. • Avoid putting weight on the workstation before fixing it to the auxiliary bracket. Screw (2x) Base plate Auxiliary bracket...

  • Page 25: Connecting The Cable To The Operating Unit

    Setting up the control panel/workstation 5.6 Connecting the cable to the operating unit Shield terminal Direction of rotation Plug connector Locking device EMERGENCY STOP control device View of operating unit from below A Plug in the plug connector of the operating unit and fix the shielding bracket. B Connect the switching element to the EMERGENCY STOP control device and close the locking device.

  • Page 26: Connecting The Earthing And Power Supply For The Control Panel/Workstation

    Setting up the control panel/workstation 5.7 Connecting the earthing and power supply for the control panel/ workstation Tip: The connector control is only available at the workstation. Control panel/workstation earthing Workstation OB4_2 power supply A Lay the control panel/workstation earthing cable to the side support. B Place the blade receptacle from the earthing cable onto the plain connector.

  • Page 27: Connect The Pc Connections

    Setting up the control panel/workstation 5.8 Connect the PC connections Tip: The PC is only available at the workstation. Cable of the internal LAN interface (company network) Cable of the cutter interface Video signal cable of the ICC camera A Connect the cable of the internal LAN interface (1). B Connect the cable of the cutter interface (2).

  • Page 28: Mounting The Pc Cover

    Setting up the control panel/workstation 5.9 Mounting the PC cover Tip: Only the workstation has a PC cover. Screws PC cover A Push the PC cover into the workstation. B Lift the PC cover and fix with the screws. C Close the side door of the workstation.

  • Page 29: Mount The Trip Protection

    Setting up the control panel/workstation 5.10 Mount the trip protection Trip protection A Attach the self-adhesive trip protection to the floor. B Open the trip protection and place the cables inside. C Close the trip protection.
  • Page 30 Setting up the control panel/workstation...

  • Page 31: Installing The S-Box

    Installing the S-box 6 Installing the S-box 6.1 Preparing to fasten the S-box Tip: The S-box is already mounted on the cutter with 120 mm clearance. With older cutters, it is possible that the press-in nuts for the S-box have not yet been prepared at the factory.

  • Page 32: Installing The S-Box

    Installing the S-box F Install the three M4 press nuts (using an insert tool is recommended). G Reinstall and wire the boards and components. 6.2 Installing the S-box The S-box (safety box) contains the safety relais and the connecting terminals of the cables for the light barrier transmitter/receiver.

  • Page 33: Mounting The Varioface Module On The G3/D3 Cutter (System A)

    Installing the S-box 6.3 Mounting the Varioface module on the G3/D3 cutter (system A) S7 plug connector Varioface module (ACS_OPT_BRD1_BOARD) DIN rail with M4 nuts A Open the electronics box. B Fasten the DIN rail with the M4 nuts and washers.

  • Page 34: Connect S-Box

    Installing the S-box 6.4 Connect S-box Tip: Older ACS_BF_BOARDs do not have an S20 slot. In this case, the ACS_BF_BOARD must be replaced with one of version 1.5 or higher. S20 on ACS_BF_BOARD Terminals 16 and 18 on the Varioface module S4 on ACS_OPT_BRD1 Opening for the cables...
  • Page 35 Installing the S-box a) Connect the white cord to terminal 16. b) Connect the brown cord to terminal 18. F Lay the cables properly and secure them with cable ties, if required. G Connect the electronics unit.
  • Page 36 Installing the S-box...

  • Page 37: Cutter Without Material Transport

    Cutter without material transport 7 Cutter without material transport 7.1 Mounting the rear access guard Tip: The rear access guard is already mounted on the cutter with 120 mm clearance. 7.1.1 Replacing the front cover Front cover A Remove the existing front cover. B Mount and tighten the front cover supplied.
  • Page 38 Cutter without material transport 7.1.2 Mounting the rear access guard Rear access guard Screw with washer A Position the rear access guard on the front of the cutter. B Insert and tighten the screws with washers (5x).

  • Page 39: Fastening The Pillars To The Floor (With Segment Anchors)

    Cutter without material transport 7.2 Fastening the pillars to the floor (with segment anchors) Caution: Incorrect set-up of the pillars can lead to accidents The distances of the pillars to the cutter must be strictly observed. • Check the positions of the marked drill holes using the reference dimension (see imprint on the drilling templates orDiagrams on page 99).
  • Page 40 The number and labeling indicate the cutter size and side to which the drilling template applies. Labeling Cutter Position 5209090 G3 M, L, XL Front left and rear right 5209097 G3 M, L, XL Front right and rear left 5209090...
  • Page 41 Cutter without material transport ↔ Reference dimension: width from outer edge to outer edge ↕ Reference dimension: length from outer edge to outer edge Note: Various drilling templates are available! Each cutter size 2XL-3200 and 3XL-3200 has its own drilling template for front right and rear left. A Place the two drilling templates according to the labeling on the bases on one side of the cutter.
  • Page 42 Cutter without material transport Segment anchors used pcs. M12 segment anchor (HST anchoring bolt M12 x 115/20) Note: If the segment anchor protrudes too far after placing, there will be a space issue when assembling the pillars. • The minimum depth of the drill hole is 95 mm. •...
  • Page 43 Cutter without material transport • Washers can be placed beneath the base plate if the floor is not level. A Loosen the nuts of the pillar and remove with the washers (3x). B Remove the base plate and put the pillar aside. C Place the base plate onto the segment anchors.
  • Page 44 Cutter without material transport 7.2.4 Mounting the pillars Note: The pillars are labeled. For installation, make sure the specified space is maintained. Examples of the labeling: Rear/left pillar (mirror) Front/left pillar (mirror) Rear/right pillar Front/left pillar...
  • Page 45 Cutter without material transport Note: Observe prescribed tightening of the nuts. • The thread must overhang at least 8 mm. • The springs may not be completely compressed. Screw Spring Base plate A Position the pillar according to the labeling and place onto the screws of the base plate. B Place the washers and nuts (3x).

  • Page 46: Mounting The Pillars Onto The Auxiliary Brackets

    Cutter without material transport 7.3 Mounting the pillars onto the auxiliary brackets Note: Only pillars with light barrier transmitters/receivers are used for cutters 2XL-3200 and 3XL-3200 due to the large distances. Pillar with mirror Pillar with light barrier transmitter/receiver...
  • Page 47 Cutter without material transport 7.3.1 Placing the base frame onto the auxiliary brackets Caution: Risk of crushing - high cutter weight. • Do not reach beneath the raised base. • Use a tool to remove the leveling pad. Tip: A second person is needed for lifting to place the supports and position the auxiliary brackets. Right front of auxiliary bracket Cutter base Left front of auxiliary bracket...
  • Page 48 Cutter without material transport 7.3.2 Mounting the base plates onto the auxiliary brackets Base plate Screw Pillar nut Washer Auxiliary bracket A Loosen the nuts of the pillar and remove with the washers (3x). B Remove the base plate and put the pillar aside. C Position the base plate on the auxiliary bracket.
  • Page 49 Cutter without material transport 7.3.3 Mounting the pillars Note: The pillars are labeled. For installation, make sure the specified space is maintained. Examples of the labeling: Rear/left pillar (mirror) Front/right pillar (mirror) Rear/right pillar Front/left pillar The pillars are screwed with the base plate directly onto the auxiliary brackets.
  • Page 50 Cutter without material transport Note: Observe prescribed tightening of the nuts. • The thread must overhang at least 8 mm. • The springs may not be completely compressed. Screw Spring Base plate A Position the pillar according to the labeling and place onto the screws of the base plate. B Place the washers and nuts (3x).

  • Page 51: Cutter With Material Transport And Ce

    Cutter with material transport and CE 8 Cutter with material transport and CE 8.1 Mounting the rear access guard Tip: The rear access guard is already mounted on the cutter with 120 mm clearance. 8.1.1 Creating the threaded holes for the rear access guard Note: The dimensions of the drill holes for the front and rear of the rear access guard differ.
  • Page 52 Cutter with material transport and CE Dimension Front left [mm] Front right [mm] Rear left [mm] Rear right [mm] 17.5 17.5 17.5 17.5 794.5 794.5 262.5 262.5 Reference dimension for distance of holes A Mark the middle of the holes on theundersideof the CE. a) Measure dimension A from the outside edge of the longitudinal pipe.
  • Page 53 Cutter with material transport and CE 8.1.2 Mounting the rear access guard Cutter extension Rear access guard Support roller screw Screws with washers (2x) A Remove the screws from both sides of the support roller and set the support roller aside. B Position the rear access guard on the bottom of the cutter extension.

  • Page 54: Mounting The Material Hold-Down Roll

    Cutter with material transport and CE 8.2 Mounting the material hold-down roll 8.2.1 Creating threaded holes for the material hold-down roll Cutter extension, rear A Go to the rear CE. B Mark the holes on the top side of the longitudinal pipes of the CE. a) Measure 20 mm from the outer edge of the longitudinal pipe.
  • Page 55 Cutter with material transport and CE 8.2.2 Mount material hold-down roll Fixing bracket Screw and washer Cutter extension A Position the material hold-down roll bracket on the cutter extension. B Fix the fixing bracket with the washer and the screw. C Repeat the process on the other side D Tighten the screws.

  • Page 56: Fastening The Pillars To The Floor (With Segment Anchors)

    Cutter with material transport and CE 8.3 Fastening the pillars to the floor (with segment anchors) Caution: Incorrect set-up of the pillars can lead to accidents The distances of the pillars to the cutter must be strictly observed. • Check the positions of the marked drill holes using the reference dimension (see imprint on the drilling templates orDiagrams on page 99).
  • Page 57 Number Cutter Position 5210809 G3 with CE and material transport Front left and rear right M, L, XL, 2XL, 3XL 5210771 G3 with CE and material transport Front right and rear left...
  • Page 58 Cutter with material transport and CE ↔ Reference dimension: width from outer edge to outer edge ↕ Reference dimension: length from outer edge to outer edge A Place the two drilling templates according to the labeling on the bases on one side of the cutter. For example, front left and rear left.
  • Page 59 Cutter with material transport and CE Segment anchors used pcs. M12 segment anchor (HST anchoring bolt M12 x 115/20) Note: If the segment anchor protrudes too far after placing, there will be a space issue when assembling the pillars. • The minimum depth of the drill hole is 95 mm.
  • Page 60 Cutter with material transport and CE • Washers can be placed beneath the base plate if the floor is not level. A Loosen the nuts of the pillar and remove with the washers (3x). B Remove the base plate and put the pillar aside. C Place the base plate onto the segment anchors.
  • Page 61 Cutter with material transport and CE 8.3.4 Mounting the pillars Note: The pillars are labeled. For installation, make sure the specified space is maintained. Examples of the labeling: Front/left pillar Rear/right pillar Rear/left pillar Front/right pillar...
  • Page 62 Cutter with material transport and CE Note: Observe prescribed tightening of the nuts. • The thread must overhang at least 8 mm. • The springs may not be completely compressed. Screw Spring Base plate A Position the pillar according to the labelling and place onto the screws of the base plate. B Place the washers and nuts (3x).

  • Page 63: Mounting The Pillars Onto The Auxiliary Brackets

    Cutter with material transport and CE 8.4 Mounting the pillars onto the auxiliary brackets 8.4.1 Placing the base frame on consoles Caution: Risk of crushing - high cutter weight. • Do not reach beneath the raised base. • Use a tool to remove the leveling pad. Tip: A second person is needed for lifting to place the supports and position the auxiliary brackets.
  • Page 64 Cutter with material transport and CE Right front of auxiliary bracket Cutter base Left front of auxiliary bracket Setscrew with tip Right rear of auxiliary bracket Auxiliary bracket with sleeve Left rear of auxiliary bracket A Slightly lift the corner of the cutter and remove the leveling pad beneath it. B Position the auxiliary bracket.
  • Page 65 Cutter with material transport and CE 8.4.3 Attaching the cross braces to the auxiliary brackets Attaching the cross braces stabilizes and centers the auxiliary brackets. U-profile Washers and screws (8x) Auxiliary bracket A Place the U-profile on the auxiliary brackets. B Place a screw on the left and on the right and align the auxiliary brackets.
  • Page 66 Cutter with material transport and CE 8.4.4 Mounting the pillars Note: The pillars are labeled. For installation, make sure the specified space is maintained. Examples of the labeling: Front/left pillar Rear/right pillar Rear/left pillar Front/right pillar...
  • Page 67 Cutter with material transport and CE Note: Observe prescribed tightening of the nuts. • The thread must overhang at least 8 mm. • The springs may not be completely compressed. The pillar with base plate is screwed directly onto the auxiliary bracket. Screw Spring Base plate...
  • Page 68 Cutter with material transport and CE...

  • Page 69: Connecting The Light Barrier Transmitter And Receiver

    Connecting the light barrier transmitter and receiver 9 Connecting the light barrier transmitter and receiver Notes on installing the cables: • The cables to the light barrier transmitters and receivers must be installed on-site. • The cables are labeled. • The cables for the front right pillar (TFR, RFR) are laid in the right side support to the pillar.

  • Page 70: Laying And Connecting Cables

    Connecting the light barrier transmitter and receiver 9.1 Laying and connecting cables Figure 2: Labeling on the yellow light grid (type 445L) Labeling on the transmitter Labeling on the receiver Cable from the S-box Figure 3: Labeling on the red light grid (type 450L-E) Transmitter connection cable (T) Receiver connection cable (R) Cable from the S-box...
  • Page 71 Connecting the light barrier transmitter and receiver Cable from the S-box Opening A Lay the cables along the side supports and the base (cable duct) according to the illustration and secure them with cable ties. B Route the cables in the side support (base plate) to the front side and pass through the opening on the inside.
  • Page 72 Connecting the light barrier transmitter and receiver...

  • Page 73: Setting Up The Light Curtain

    Setting up the light curtain 10 Setting up the light curtain 10.1 Aligning the pillars vertically Nut (3 x) Note: Observe prescribed tightening of the nuts. • The thread must overhang at least 8 mm. • The springs may not be completely compressed. A Use the spirit level on two sides to check whether the pillar is vertical.

  • Page 74: Aligning The Light Curtain

    Setting up the light curtain 10.2 Aligning the light curtain The light curtain is equipped with an integrated laser alignment system (ILAS). The lasers used belong to laser class 2 and transmit a low intensity visible light. The control panels are located at the bottom next to the light barrier transmitters and at the top next to the receivers.
  • Page 75 Setting up the light curtain Red light grid (type 450L-E) A On the transmitter, press the optical key next to the status indicator. A laser grid with 6 laser beams is emitted from the transmitter. B Turn the M12 nuts (1) over the springs of the pillar to adjust the inclination of the pillar.
  • Page 76 Setting up the light curtain D On the receiver, press the optical key next to the status indicator. A laser grid with 6 laser beams is emitted from the receiver. E Turn the M12 nuts (1) over the springs of the pillar to adjust the inclination of the pillar.
  • Page 77 Setting up the light curtain 10.2.1 Removing the external covers Tip: On some pillars, the clamping screws for adjusting the light barrier transmitter/receiver are located behind the inner cover. Cover Screw with washer A Remove the screws from the cover (4x). B Remove the external cover of the pillar.
  • Page 78 Setting up the light curtain 10.2.2 Switching on the integrated laser alignment system (ILAS) Note: The laser alignment system automatically switches itself off after five minutes. Caution: Class 2 laser Possible eye damage. • Do not look into the laser beam. •...
  • Page 79 Setting up the light curtain 10.2.3 Adjusting the height of the light curtain Left light curtain Height from floor to bottom light beam Front light curtain Height from floor/conveyor to bottom light beam Right light curtain Rear light curtain Cutter Height of the bottom light beam h1 (items 1 and 3) h2 (items 2 and 4)
  • Page 80 Setting up the light curtain Cutter Height of the bottom light beam h1 (items 1 and 3) h2 (items 2 and 4) [mm] [mm] max. 680 max. 680 Cutter with material transport min. 640 min. material and CE thickness max. 680 max.
  • Page 81 Setting up the light curtain 10.2.4 Alignment with 2 deflection mirrors Tip: Start the alignment on cutter front left. Always slightly tighten the elements after alignment. A small deviation of the laser point from the target is permissible (see Aligning the light curtain page 74).
  • Page 82 Setting up the light curtain 10.2.4.1 Alignment process Clamping screw Light barrier transmitter/receiver Mirror Clamping screw A Undo the clamping screws on the light barrier transmitter. B Switch on the ILAS on the light barrier transmitter. C Swivel the light barrier transmitter so that the laser point hits the center of the mirror. D Rotate the mirror so that the laser point hits the reflector on the receiver or its vicinity.
  • Page 83 Setting up the light curtain 10.2.5 Alignment without deflection mirror Tip: Start the alignment on cutter front left. Always slightly tighten the elements after alignment. A small deviation of the laser point from the target is permissible (see Aligning the light curtain page 74).
  • Page 84 Setting up the light curtain 10.2.6 Fine adjustment Tip: The pillar can be slightly tilted by hand. This makes it easier to determine the required adjustment. The pillar with mirror is present depending on the cutter size. Light barrier transmitter/receiver Clamping screw A Tilt the pillar slightly to the left until the light barrier is interrupted.

  • Page 85: Cutter With Bhs 150

    Cutter with BHS 150 11 Cutter with BHS 150 This chapter provides an overview of the required work. The specific steps can be taken from the previous identical chapters. A Fasten the pillars to the floor with segment anchors (seeFastening the pillars to the floor (with on page 56).
  • Page 86 Cutter with BHS 150 Drill holes for front right Drill holes for rear left Support line for alignment Reference dimension on the drilling template ↔ Reference dimension: width from outside edge to outside edge ↕ Reference dimension: length from outside edge to outside edge...

  • Page 87: Connecting The Light Barrier Transmitter And Receiver

    Cutter with BHS 150 Note: If only the feeder but not the stacker is attached to the cutter, the drilling templates for the cutter with material transport must be used for the discharge side (front, stacker). A Place the two drilling templates according to the labeling on the bases on one side of the cutter. For example, front left and rear left.
  • Page 88 Cutter with BHS 150 • The cables of the other pillars are routed backwards from the S-box in the right side support and the cables for the pillar on the left side are routed further along the rear base. Cutter with BHS 150 feeder and stacker Pillar Device Abbr.
  • Page 89 Cutter with BHS 150 Cutter with BHS 150 feeder and front CE Pillar Device Abbr. rear/right Light barrier transmitter front/right Receiver front/right Light barrier transmitter front/left Receiver front/left Light barrier transmitter rear/left Receiver...
  • Page 90 Cutter with BHS 150...

  • Page 91: Installing The Covers

    Installing the covers 12 Installing the covers Note: Risk of damage. When installing the covers, it must be ensured that the mirror, light barrier transmitter and receiver module are not damaged. A Mount the covers and fasten them. B Repeat the process on all pillars.
  • Page 92 Installing the covers...

  • Page 93: Initial Commissioning

    Initial commissioning 13 Initial commissioning 13.1 Activating the pillars A Switch to the Service user level with 4-2 Password. B Select 1-11-10-1 Mode and set to on. 13.2 Checking the pillar deflection Yellow light grid (type 445L) Figure 4: System status indicator on the receiver green LED Light curtain without interruption red LED...
  • Page 94 Initial commissioning Red light grid (type 450L-E): Figure 5: Status indicator without interruption Transmitter Receiver A Lightly deflect the top area of each pillar by hand. The indicator for the top half does not light up. "OUT" indicator lights up red on the receiver. Transmitter Receiver B Lightly deflect the bottom area of each pillar by hand.

  • Page 95: Checking The Light Curtain

    Initial commissioning 13.3 Checking the light curtain Test piece Figure 6: Inspection process on the yellow light grid (type 445L) green LED Light curtain without interruption red LED Light curtain interrupted...

  • Page 96: Configuring Travel Keys

    Initial commissioning Figure 7: Inspection process on the red light grid (type 450L-E) Transmitter without interruption Top receiver interrupted Receiver without interruption Bottom transmitter interrupted Top transmitter interrupted Bottom receiver interrupted A Switch on the cutter (e.g., press the F1 key). B Start the self-test with the 3-3-8 S-Test menu.
  • Page 97 Initial commissioning Menu Description 6-15 Positive X direction The positive direction of the cutter X axis is transferred to the operating unit. The Y axis is adjusted automatically.

  • Page 98: Checklist

    Initial commissioning 13.5 Checklist Name of the test point (chapter) Note/adjusting value S-box, electronics unit - The rotary switch of the safety relay in the S-box has the setting "6". - Bridge plug in the S20 slot on ACS_BF_BOARD is removed.

  • Page 99: Diagrams

    Assembly base reference dimension material transport 5210674 Assembly base reference dimension material transport 2XL-3200/3XL-3200 5217535 G3 foam cutter safety device complete light curtain 2S/2E, material t. Bhs150 5217309 G3 foam cutter safety device complete light curtain 3S/3E, material t. Bhs150...
  • Page 100 Diagrams...
  • Page 101 Benennung Werkstoff Bemerkungen Ähnliches Teil Aenderungen Kanten Ra 3.2 gebrochen 0.2 ... 0.4x45 Massstab Gezeich. 09.12.14 G3 Schaumstoffcutter Projekt: Geprüft 17.12.14 Normgepr Montageunterlage Kontrollmasse Ersatz für Für dieses Dokument behalten wir uns 5210682 Status alle Rechte vor. swiss cutting systems...
  • Page 102 Benennung Werkstoff Bemerkungen Ähnliches Teil Aenderungen Kanten Ra 3.2 gebrochen 0.2 ... 0.4x45 Massstab Gezeich. 13.01.15 G3 Schaumstoffcutter Projekt: Geprüft 04.02.15 Montageunterlage Kontrollmasse Normgepr Materialtransport Ersatz für Für dieses Dokument behalten wir uns 5210816 Status alle Rechte vor. swiss cutting systems...
  • Page 103 Benennung Werkstoff Bemerkungen Ähnliches Teil Aenderungen Kanten Ra 3.2 gebrochen 0.2 ... 0.4x45 Massstab Gezeich. 08.12.14 G3 Schaumstoffcutter Projekt: Geprüft 17.12.14 Montageunterlage Kontrollmasse Normgepr 2XL-3200 / 3XL-3200 Ersatz für Für dieses Dokument behalten wir uns 5210674 Status alle Rechte vor.
  • Page 104 Ähnliches Teil Aenderungen Kanten 5217309; - 4175 4174 gebrochen 3XL-3200 0.2 ... 0.4x45 Massstab Gezeich. 12.03.18 G3 Schaumstoffcutter Projekt: 1:10 Geprüft 12.04.18 Sicherheitsvorrichtung komplett Gewicht 547.24 kg Lichtvorhang 2S/2E, Materialt.BHS150 Ersatz für Status Für dieses Dokument behalten wir uns 5217535 alle Rechte vor.
  • Page 105 5210771 Säule komplett S960 / E720 mit Lichtgitter 5209889 Kontrollmasse Beam Montageunterlage Schablone Materialtransport vorne links / hinten rechts Foot Foot 5210809 front left front right Cutter G3 2295 3334 M-1600 2295 4234 M-2500 2765 4234 L-2500 2765 4934 L-3200...
  • Page 106 Cutter Control System Safety Signals Optionboard1/2 ACS_BF_BOARD > V1_5_K Varioface 1 STOP4 STOP3 Logic = 6 24VDC S3/4_2 S3/4_1 S20_1 S20_2 S20_3 S20_4 Kl6_1 Kl11_1 24VDC PGND PGND 24VDC Kl20_1 LOGIC Kl7_1 Kl21_1 &/>1 700-HPSXZ24 Kl24_1 Kl25_1 440R-D22S2 700-HPSXZ24 braun Logic = 6 24VDC 24VDC...
  • Page 107 Cutter Control System Safety Signals Optionboard1/2 ACS_BF_BOARD > V1_5_K Varioface 1 STOP4 STOP3 S3/4_2 S3/4_1 S20_1 S20_2 S20_3 S20_4 24VDC PGND Logic = 6 24VDC 24VDC Kl8_1 Kl5_1 grün Kl10_1 PGND 700-HPSXZ24 weiss Kl18_1 LOGIC braun Kl19_1 PGND Kl12_1 &/>1 700-HPSXZ24 gelb 440R-D22S2...
  • Page 108 Cutter Control System Safety Signals Optionboard1/2 ACS_BF_BOARD > V1_5_K Varioface 1 STOP4 STOP3 Logic = 6 24VDC S3/4_2 S3/4_1 S20_1 S20_2 S20_3 S20_4 Kl6_1 Kl11_1 24VDC PGND PGND 24VDC Kl20_1 LOGIC Kl7_1 Kl21_1 &/>1 700-HPSXZ24 Kl24_1 Kl25_1 440R-D22S2 700-HPSXZ24 braun Logic = 6 24VDC 24VDC...

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