03 Operating Manual Part 1 INDUPRESS General Part 2009 07 v1

operating instructions

English

Vers ion 2009.07 Revis ion 101

OPERATING MANUAL Part I : General Part

Operating Instruction Part I – general part

of 42 © Hornung GmbH INDUPRESS® & Co. KG Revision: 101 | Version 2009.07

W AR NING

Please read the operating instructions before using the system and switching on the machine! This manual contains important information on safety, use and maintenance of the device. This would help you to protect yourself and others from being harmed and also prevent damage to the machine.

Notice The operating instruction consists of two documents (belonging together):

I. Operating manual part I „general part“ II. Operating manual part II „machine part“

Confidentiality These operating instructions include details pertaining to Hornung GmbH INDUPRESS® & Co. KG which are confidential and should not, in whole or in parts, be processed, copied, passed on to third parties or published in any form, by any means without written consent. Violations will cause indemnities. Hornung GmbH INDUPRESS® & Co. KG reserves all rights arising out of patent registration or registration of utility models.

© Copyright INDUPRESS® Nachdruck verboten!

Reproduction prohibited! Réproduction interdit!

All labels marked with the sign of industrial property rights® are registered trademarks of Hornung GmbH INDUPRESS® & Co. KG. The remaining terms in this manual can be brands the use of which by third parties for their own purpose may infringe owner’s property rights. All trademarks approved!

Hornung GmbH INDUPRESS® & Co. KG Alle Rechte vorbehalten. All rights reserved.

Non-liability We have verified that the contents of this book are in accordance with the hardware and software outlined herein. All specifications have been made to the best of our knowledge. However, deviations may arise due to constant technical developments and improvements. Therefore, we do not warrant full conformity, i.e. any claims for non-conformity shall be excluded. The correctness and completeness of technical data is being checked on a regular basis. Necessary corrections shall be included in the following edition.

Hornung GmbH INDUPRESS® & Co. KG Boschstr. 7 D - 63768 Hösbach Tel. + 49 6021 / 6237 - 0 Fax + 49 6021 / 57903 Mail: [email protected] Web: www.indupress.de

INDUPRESS® 2009.07 Revision 101 Technical data are subject to alterations. This instruction manual is not automatically updated!

Trademarks

Operating Instruction Part I – general part Table of Contents

Version 2009.07 | Revision: 101 © Hornung GmbH INDUPRESS® & Co. KG of 42

Table of Contents

1 L E G A L IN F O R M A T IO N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.1 Machine identification label / Rating plate ............................................................................ 51.2 Disclaimer ............................................................................................................................. 51.3 Implicit Guarantee ................................................................................................................. 51.4 Modifications, conversions .................................................................................................... 61.5 Technical changes ................................................................................................................ 61.6 Revision service .................................................................................................................... 61.7 Copyright ............................................................................................................................... 6

2 IN S T R U C T IO N S F O R U S E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.1 Purpose ................................................................................................................................. 72.2 Supplementary documents ................................................................................................... 72.3 Qualified personnel ............................................................................................................... 72.4 Useful reference .................................................................................................................... 8

3 DU T Y O F C A R E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.1 Safety of the device .............................................................................................................. 93.2 Instruction and training .......................................................................................................... 9

4 S A F E T Y IN S T R U C T IO N S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.1 General ............................................................................................................................... 104.2 Correct use ......................................................................................................................... 104.3 Symbols .............................................................................................................................. 11

4.3.1 4.3.1 Symbols Safety Precautions ............................................................................. 114.3.2 4.3.2 More icons and styles of writing ....................................................................... 12

4.4 Basic instructions on safety ................................................................................................ 13

5 T R A N S P O R T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175.1 Inspection for shipping damage .......................................................................................... 175.2 Transport of the machine .................................................................................................... 17

5.2.1 Approved loading devices ......................................................................................... 185.3 Unwrapping the machine .................................................................................................... 20

6 A S S E MB L Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216.1 Requirements for installation .............................................................................................. 216.2 Connecting the machine ..................................................................................................... 22

6.2.1 Electrical connection .................................................................................................. 236.2.2 Steam supply line ...................................................................................................... 236.2.3 Condensate supply line ............................................................................................. 236.2.4 Pneumatic supply line ................................................................................................ 246.2.5 Vacuum supply line .................................................................................................... 246.2.6 Steam extraction system ........................................................................................... 25

7 MA IN T E N A N C E / S E R V IC E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267.1 Safety notices regarding maintenance and service ............................................................ 267.2 Cleansing ............................................................................................................................ 287.3 Pneumatic parts .................................................................................................................. 287.4 Mechanical parts ................................................................................................................. 29

7.4.1 Lubrication of bearing units ....................................................................................... 297.5 Electrical parts .................................................................................................................... 29

Operating Instruction Part I – general part Table of Contents


7.6 Steam circuit parts ............................................................................................................... 297.7 Replacing cover material ..................................................................................................... 30

7.7.1 Cleaning of covers ..................................................................................................... 317.7.2 How to order original INDUPRESS® covering material ............................................. 31

7.8 Work steps following maintenance / service / repair ........................................................... 32

8 S E T T IN G T H E M A C H IN E O U T O F O P E R A T IO N A N D DIS A S S E MB L Y . . . . . . . . . . . . . . . . . . . . . 33

9 DIS P O S A L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349.1 Used materials .................................................................................................................... 349.2 Items to be disposed of separately ..................................................................................... 35

10 L IS T O F A B B R E V IA T IO N S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

11 G L O S S A R Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

12 T A B L E O F IL L U S T R A T IO N S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

13 IN DE X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Operating Instruction Part I – general part Legal information


1 Legal information

1.1 Mac hine identification label / R ating plate

The INDUPRESS® machine is provided with the following rating plate:

Fig. 1 Example rating plate

1.2 Dis c laimer

Hornung GmbH INDUPRESS® & Co. KG is not liable for any material damages or defects caused by negligent or improper use of the INDUPRESS® machine. We have verified that the contents of this document are in accordance with the hardware and software outlined herein. However, deviations cannot be completely ruled out, so we do not guarantee full conformity. 1.3 Implic it G uarantee

Hornung GmbH INDUPRESS® & Co. KG does not give any tacit guarantees on the product’s merchantable quality and fitness for a particular purpose.

Operating Instruction Part I – general part Legal information


1.4 Modific ations , c onvers ions

Any modifications or conversions to the INDUPRESS® machine shall require the explicit written consent by INDUPRESS® & Co. KG. In the event, anyone but Hornung GmbH INDUPRESS® & Co. KG arbitrarily rebuilds the machine; Hornung GmbH INDUPRESS® & Co. KG is not liable as the producer of the appliance. Therefore our grant of the operating permit for the machine as well as its any possible guarantee shall expire. 1.5 T ec hnic al c hanges

Hornung GmbH INDUPRESS® & Co. KG reserves the right to carry out any technical changes to the machine in order to improve it. The correctness and completeness of data given in this documentation is being checked on a regular basis, necessary corrections will be included in the following editions (revisions). 1.6 R evis ion s ervic e

This document is not subject to any revision service by Hornung GmbH INDUPRESS® & Co. KG. Amendments to this documentation can be made without further notice and will be included in the following editions (revisions). 1.7 C opyright

© Hornung GmbH INDUPRESS® & Co. KG In the absence of an explicit written consent by Hornung GmbH INDUPRESS® & Co. KG, no part of this document should be disseminated, copied or exposed to third parties. Non-compliance will result in prosecution for indemnities. Hornung GmbH INDUPRESS® & Co. KG reserves all rights arising out of patent registration or registration of utility models.

Operating Instruction Part I – general part Instructions for use


2 Instructions for use These operating instructions form an integral part of the machine and should be made accessible for users at all times, being positioned directly at the machine for reference. The user is required to follow the instructions given in this document. No section of it should be removed from the manual. Missing pages or sections should be replaced asap. 2.1 P urpos e

These operating instructions contain important information on the correct and safe handling of the INDUPRESS® machine. This instruction manual is part of the INDUPRESS® machine and should be understood and

used by any person working at and/or with the machine. Before using the machine, the operator should be fully familiar with the contents of these

operating instructions. These operating instructions should be kept updated with any changes or improvements in the

machine by the concerned department. 2.2 S upplementary doc uments

Apart from this manual, the following documents may be made available to the operating person:

Electrical switch plans (panels) Pneumatic switch plans (panels)

Declaration of conformity Lists of spare parts

2.3 Qualified pers onnel

The INDUPRESS® machine and its included control module should be installed and/or used in no case without these operating instructions. Switching on and using the machine is restricted to qualified personnel only. Definition: Qualified personnel (Expert / Instructed person)

Qualified personnel are defined in this document as persons familiar with installation, assembly, setting into operation and operation of the product. They are experts with the corresponding specialisation in their assigned work (expert of electronics and mechanics), as for example: Persons familiar with basic regulations on work safety and accident prevention. Persons having read and understood the section on safety as well as the caution notices in this

manual. Persons trained and instructed to operate and use the INDUPRESS® machine. Persons qualified in their field and/or authorized to set up, modify and maintain the electrical

and mechanical modules and work equipments in accordance with the standards of electro technical and mechanical rules and safety techniques. Furthermore, they have the capability to assess the responsibilities being assigned to them as well as anticipate its possible danger.

Instructed person: A person fully informed about his respective responsibilities and possible dangers involved in the event of an accident while working on the machine and, if necessary, also trained by an expert as well as advised of the corresponding safety measures.

Operating Instruction Part I – general part Instructions for use


2.4 Us eful referenc e

To help you find required information in this manual, please note the following references, alongside the table of contents: Abbreviations (Section 10 - List of abbreviations, Page 36) Glossary (Section 11 - Glossary, Page 37) Illustrations (Section12 - Table of illustrations, Page 38) Index (Section 13 - Index, Page 39)

Operating Instruction Part I – general part Duty of care


3 Duty of care The INDUPRESS® machine has been designed and constructed in consideration with the guidelines of all acknowledgeable and pertaining rules of technology. This ensures that the INDUPRESS® machine is a state-of-the-art technology product and guarantees maximum safety. However, this safety can only be guaranteed in operational practice if all the required measures have been taken and followed. It is the operator’s duty to take due care of all such measures and, in particular, to plan the following measures and supervise their implementation. 3.1 S afety of the devic e

The operator particularly should ensure that;

The machine is solely used for its respective purpose. The machine is being operated upon only if free from any defect and in proper working

condition. Integrated safety appliances are maintained on a regular basis and inspected timely for their

proper functionality. Only sufficiently qualified and authorized personnel operates, maintains and repairs the

machine Necessary personnel safety equipment is made available to and ready to be used by the staff in

charge of operation, maintenance and service. 3.2 Ins truc tion and training

The operator is particularly obliged to make sure that:

The personnel is thoroughly introduced to the machine and trained to work with the machine before getting started

The operating instructions are always in a legible state without any missing parts and are kept at the location of the machine

The personnel is familiar with the operating instructions and, in particular, with the safety measures described therein.

The mounted safety instructions and caution notices are not removed and kept legible.

Operating Instruction Part I – general part Safety instructions


4 Safety instructions

DANG E R

Operation and use of the INDUPRESS® machine requires knowledge of and compliance with the documentation and corresponding operating instructions. Disregard of the directions on use and/or negligence, lack of knowledge thereof involves the risk of injury or even death. Such non-compliance may likewise be also detrimental to the machine, the material or the environment.

4.1 G eneral

These operating instructions contain notes which should be followed to ensure personal safety and prevention of material damage. The following safety instructions are meant as supplement to the prevailing directions and laws on accident prevention. Existing directions and laws on accident prevention should also be taken into consideration in any event. 4.2 C orrec t us e

Any use (please refer to Section on the Operating Instruction Part II “machine part” “of the respective INDUPRESS® machine!) which is not in accordance with the below mentioned regulations on correct use is not admissible. Hornung GmbH INDUPRESS® & Co. KG is not liable for any material defects caused by such non-compliance. The appliance should only be operated together with foreign devices and/or component parts which have been recommended or approved by INDUPRESS®. The sound and safe operation of the INDUPRESS® machine requires proper transport, storage, installation and assembly as well as careful handling and maintenance. Correct use means if:

the INDUPRESS® machine is utilized for finishing (smoothing and/or forming) of garments or textiles in the context of industrial production,

the type of fabrics of the garments or textiles as well as the form are approved or appropriate for thermal treatment,

the INDUPRESS® machine is exclusively serviced by a properly instructed and trained personnel,

no person is inside or on top of the INDUPRESS® machine when under operation, the INDUPRESS® machine is operated along with installed safety devices, the service staff is informed about all possible dangers relating to the INDUPRESS® machine

and all the safety and operating instructions are followed, the general directions on maintenance (Section 7 Maintenance / Service) are complied with, the instructions for inspection (please see in the Operating Instruction Part II "machine - machine

part" – maintenance protocol - of the respective INDUPRESS® machine) are properly followed Incorrect use means:

during or after the use of the INDUPRESS® machine, all specific instructions for an appropriate use are disregarded,

objects other than textiles are processed in the INDUPRESS® machine, especially heating of objects and/or any type of food on or between the pressing shapes or within the Tunnelfinisher,

those garments or textiles are operated upon(pressing) for which the machine is not designed for, the service of the machine is done with deactivated, modified or defected safety devices.



4.3 S ymbols

In the following you will find explanations of the symbols used in this text. For typographic reasons the individual colours in this document may divert from the colours used in caution notices and safety instructions in the INDUPRESS® machine. If possible, any direction on safety in this manual is replaced by a clearly comprehensible picture symbols (pictograms). C aution notices and s afety ins tructions are built in mos t cas es according to the following s cheme:

Signal word/ symbol and warning colour

Material damage, Notice or Disposal [ … descriptive text … ] The descriptive text included in the caution notices and safety instructions is in some cases divided into three parts and specified with the following symbols and meanings: type and source of danger possible effects, i.e. what may happen Avoidance or how to stop danger / prohibitions

Attention sign (e.g. safety sign)

Caution level (symbol, warning colour and signal word) Pictogram

(e.g. mandatory action sign)

[ … descriptive text … ]

4.3.1 S ymbols S afety P recautions

Safety sign: General This symbol represents a safety sign. It warns about any danger/risk of injury. Please follow all measures marked with the safety sign to prevent injury of any sort.

Safety sign: Warning of voltage The safety instructions in this manual, which may lead to harm in the event of non-compliance, are additionally marked with the symbol for voltage when used in connection with the warning of voltage.

Notice This symbol refers to information pertaining to a better understanding of the machine’s operating sequences or hint at specific conditions.

CAUTION Material damage This symbol indicates that there is a potential danger of damage to the machine, material or to the environment.



Warning levels Symbol Warning colour Signal word

1st criterion:

Effects

2nd criterion:

Probability

DANGER

Death / serious injury (irreversible) This symbol indicates danger to life and health of persons.

Imminent

WARNING

Death / serious injury (irreversible) This symbol indicates danger for life and health of persons.

Possible

CAUTION

Slight injury (reversible) This symbol marks that life and health of persons are endangered.

Possible

CAUTION

Material damage This symbol refers to the danger of damage to the machine, material or to the environment.

Possible

Übersetzungen | translations GEFAHR = DANGER WARNUNG = WARNING VORSICHT = CAUTION Hinweis = Notice

4.3.2 More ic ons and s tyles of writing

For the description of the control panel and its buttons different illustrations or typefaces are used as outlined below: In the continuous text, a “button” is set between angle brackets => Example: >Programme< Illustration as a graphic symbol, convergent with colour and a caption Illustration as a explanatory photograph

Notice Important words or sentences are written in bold letters or in italics!

Disposal This symbol hints at disposal of component parts or raw materials and supplies.



4.4 B as ic ins truc tions on s afety

Despite of constructive solutions to the sources of danger, the following are some remaining potential dangers for which basic instructions on safety should be followed. Please comply with the safety instructions to prevent personal injury of any sort:

DANG E R

Danger to persons by electric shock Dangerous voltage (up to 400 V). Touching active parts can cause death or serious injury. Never touch active parts. In case the leads show visible damage, contact the service staff immediately. Keep all doors and other forms of access to the electrical modules closed. Electrical devices have to be checked on a regular basis. Please note the applying national regulations!

DANG E R

Danger to pers ons to elec tric s hock in the electric al cabinet

Dangerous voltage (up to 400 V). Danger of capacitor discharge! Touching active parts may cause death or serious injury. Wait a minimum of 5 minutes before opening the electrical cabinet after turning-off the machine. Work equipment with ORANGE wiring can still be live even after the power supply has been disconnected. All directions (on safety) placed inside the electrical cabinet should be followed.



DANG E R

The 5 safety rules of electricity Non-compliance will result in death or serious injury. Before working at live units and operating equipment certain safety precautions should be taken, so that the work can be performed without any risk of injury.

1st Switch off electricity 2nd Ensure that electricity cannot be switched on again 3rd Double check that no electrical current is flowing 4th Ground the circuit 5th Cover or otherwise isolate component parts that are still

electrically active After the completion of work, these steps should be followed in the reverse order to make the machine ready for operation.

W AR NING

Serious dangers to persons by negligent and improper use of the machine Comment: Inappropriate or negligent use of the machine can cause serious burns from the shapes, bruises from the movable units or other injuries. Precautionary measures: Any use of the machine is only admissible in accordance with the regulations, i.e. all actions that are not expressly agreed to in Section 4.2, page 11 “correct use” are prohibited. Do not remove any safety appliances from the machine, nor bypass any safety appliance or related function to the machine! The machine should only be operated if equipped with all functional safety devices and security-related devices, such as detachable safety units, emergency stop, sound insulation and steam extraction elements (for Tunnelfinishers).



W AR NING

Serious dangers to persons to bruises and cuts Comment: There is a substantial risk of injury from the movable parts of the machine as well as from the transport of the machine. Precautionary measures: Make sure that no parts of the body are located between movable parts of the machine when under operation. Take care to keep sufficient distance from all moving parts

W AR NING

Steam emission– burns Comment: Some parts of the INDUPRESS® machine are heated with steam and may reach temperatures more than 160°C! There is still a risk of burns even after the machine is switched off. Precautionary measures: Make sure that no part of the body gets anywhere near the steam coming out of the machine!

W AR NING

Comment: Hot surfaces – burns

Some parts of the INDUPRESS® machine are heated with steam and may even reach temperatures more than 160°C! The risk of burns remains even after the machine is switched off. Precautionary measures: Close the steam valve. Even if the machine is not running and the steam supply is cut off, the system can still cause burns within the following two hours after the machine has been switched off. Ensure that no parts of the body are located between the upper and the lower plate while the machine is under operation. Never touch any part of the machine without heat-insulating protective gloves. Always wear protective gloves while doing the service and maintenance work on the machine



W AR NING

Risk of burns – hot surfaces Comment: Some parts of the INDUPRESS® machine are heated with steam and may reach temperatures more than 160°C! The risk of burns remains even if the machine is not being operated. Precautionary measures: Do not place any temperature-sensitive or inflammable objects on or between the plates. Never iron textiles with a flash point below 160 °C.

W AR NING

Cuts caused by sharp edges and corners Comment: Metal profiles have sharp edges at the interfaces. This is why interfaces are provided with cover caps. Precautionary measures: Always wear protective gloves during any work with the metal profiles. Make sure that the covering caps are fixed at the profile ends (interfaces) at all times.

W AR NING

Laser beam – danger of burning the retina Comment: The used pointer lasers are class II lasers. Additional safety measures are not necessary for the use of these lasers. Precautionary measures: Avoid a direct view into the laser beam.

Operating Instruction Part I – general part Transport


5 Transport

5.1 Ins pec tion for s hipping damage

CAUTION Before transporting and un wrapping the device, it is indispensable to inspect for transport damage (damage to the wrapping suggests material damage).

Notice If you encounter any damage to the system caused by shipping, contact your INDUPRESS® service partner without any delay.

5.2 T rans port of the mac hine

DANG E R

Danger of suspended or lifted loads Never stand under suspended loads when lifting the machine with an elevator. The machine should only be lifted at the stops intended for this purpose. To lift the machine / parts of the machine, exclusively suitable load-carrying and end stop devices should be used. The load carried by the suitable load carrying device should in no case exceed the “approved loading value” for this device.

W AR NING

To ensure a safe transport, the running speed of the vestibule conveyors should not exceed “Approved running speed or load-carrying value” while under operation.



C AUT ION

There are electrical and pneumatic supply pipes under the machine For this reason please lift the machine with an utmost care with the help of an appropriate loading device, such as a forklift or a lifting truck.

C AUT ION

Danger of sharp edges and corners Always wear appropriate gloves when working at the machine to prevent any injuries like cuts or bruises.

5.2.1 Approved loading devic es

Below listed load-carrying equipment are approved for the transport of the INDUPRESS® machines:

Load-carrying device Minimum load capacity Approved running speed

Mobile crane 5,000 kg 0 km/h

Vestibule conveyors: Forklift 2,000 kg 5 km/h

Manual and electrical lift truck 2, 000 kg 5 km/h

Below listed load-carrying equipment is approved to lift the INDUPRESS® machine:

Machine INDUPRESS®

Pressing machine INDUPRESS®

Tunnelfinisher Load carrying equipment

Truck-mounted crane By the use of lifting accessories (e.g. sling gears, nylon round sling)

NO YES

Industrial truck: Fork lift YES NO

Industrial truck: Fork lift By the use of lifting accessories (e.g. sling gears, nylon round sling)

NO YES



5.3 Unwrapping the mac hine

DANG E R

Do not put the packaging over your head

Never put the packaging over your head Danger of suffocation. All packaging – in particular the seaworthy packaging – are hermetically sealed.

C AUT ION

Danger of sharp edges and corners Never work at the machine without wearing appropriate gloves to prevent injuries like cuts.

C AUT ION

Wooden crates may splinter when opened Please take on protective gloves before opening.

Please take the following steps to unwrap the packaging:

Step Action

1. Remove the wooden crate.

2. Remove the foil sealing.

3. Lift the machine from the pallets at the specifically designed application points.

4. Screw the machine legs and fasten the jam nuts.

Disposal After the unwrapping, the packaging must be disposed off in a safe manner consistent with applicable environmental regulations. It consists of the following material: Wood Paper and carton Polythene foil (PET foil) and Aluminium composite film for seaworthy packagings

Operating Instruction Part I – general part Assembly


6 Assembly

6.1 R equirements for ins tallation

CAUTION

Material damage

The machine must be set up in a horizontal position. Only this is in accordance with proper operating principles of the machine The tightness of the machine’s legs might have to be individually

adjusted at the location of the machine.

The final installation location of the machine should meet the following requirements:

Criterion Requirement

Approved ambient temperature Maximum 45 °C.

Load-bearing capacity of the ground

The chosen installation floor should be able to withstand the weight of the machine.

Solar radiation No direct solar radiation on display devices, so that it does not interfere while taking the reading from the display.

Movement of the air at the machine

The installation location should be free of draught. Otherwise the energy loss would increase and the finishing result would worsen.

Lighting at workplace According to applying national rules: Min 700 lux is recommended.

Accessibility to the machine

The machine must be easily accessible with ample space around it, and in particular around the electric cabinet. The minimum distance to the wall or a column must not be less than 1100 mm.



6.2 C onnec ting the mac hine

DANG E R

All connections, in particular- steam, condensate, air and vacuum connections should be set up exclusively by those having appropriate technical training and experience.

DANG E R

All connections, in particular the electrical connections should be set up exclusively by those having appropriate technical training and experience.

W AR NING

Danger of burns resulting from work at the steam unit The steam may reach temperatures of more than 160°C.

C AUT ION

Before first use please remove the transport locking devices and/or transport auxiliary devices!

Notice The media mentioned below have to be provided by the customer



6.2.1 E lec tric al c onnec tion

The INDUPRESS® machine is equipped with a power plug. The electrical connection is set to 400 V, 3 phase, 50 Hz, Null (MP) and earth

.

However the electrical setting can vary according to the country of destination. The alternative prepared connection for countries of the American continent is 240 V, 3 Phase, 60 Hz, Null (MP) and earth. If you need another connection, set up the machine following the rules illustrated below:

Fig. 2 Electrical connection of the machine

6.2.2 S team s upply line

For connecting the steam, a steam duct is required, which is according to the dimension of the machines connections. The steam connection has to be capable of being shut off. It is best to generate saturated steam at a constant pressure. Notice:

INDUPRESS® pressing machine = 5 – 6 bar INDUPRESS® Tunnelfinisher = 4 – 5 bar

CAUTION INDUPRESS® pressing machine: Higher the steam pressure is, faster the covering material is worn out.

6.2.3 C ondens ate s upply line

For connecting the condensate, a condensate duct is required, which is according to the dimension of the machines connections. The condensate must be led into a pressure-free line system. The condensate connection must be capable of being shut off!

CAUTION The difference between the steam pressure level and the condensate pressure level has to be at least 3 bar. Otherwise the proper heating of the pressing plates is not guaranteed danger of water outlet at the pressing plates.

at the cus tomer

machine s ide

blue black black brown yellow/green



6.2.4 P neumatic s upply line

For connecting the compressed air, you need a pneumatic line, which is as per the dimension of the machines connections. The compressed air must be available at 6 bar and should be oil free and dry

. The pneumatic line must be capable of being shut off!

6.2.5 V ac uum s upply line

Notice Vacuum connections are available on INDUPRESS® pressing machines and ironing tables!

For connecting the vacuum, you need a vacuum supply line, which is as per the dimension of the machines connections. The vacuum must be provided at p ≥ 120 mbar on the connection at the machines shape!



6.2.6 S team extrac tion s ys tem

Notice The section 6.2.6 Steam extraction system provides information on the INDUPRESS® machine „Tunnelfinisher“, ONLY!

The extraction duct is usually installed on the part of the customer. Exhaust pipe:

Diameter min 150mm Only use conduit bends with a gradient of 45°. should be detachable in a heat-insulating manner to reduce condensate quantity. must have an outlet to the outside which should not be covered. must be directed to the outside taking into account the downward gradient. Make sure that

generated condensate is not able to flow back into the Tunnelfinisher. Install chimney-like on top of the roof’s top edge and cover with a turned-up cap In case the length of conduit is over 15m or in case of mounting several bends, the conduit

diameter must be increased by min one nominal bore, e.g. from DN 150 to DN 200 If the conduit length exceeds 15 meters, a second fan should be installed. The connection to the exhaust fan must be well sealed.

Fig. 3 Installation examples steam extraction

Over roof

Exhaust ventilator

Downward gradient 1:100 ... 1:200 in flow direction

Wall outlet

Enclosing wall

Operating Instruction Part I – general part Maintenance / Service


7 Maintenance / Service

7.1 S afety notic es regarding maintenanc e and s ervic e

DANG E R

Please do not in any event disregard the safety notices you are given in Section 4.4 Basic instructions on safety, starting on page 13. Furthermore, the safety notices given in the documentation should be applied.

DANG E R

Danger to persons due to electric shock Explanation: The machine works at voltages of 400 V which is accompanied by correspondingly high currents. Because of the deadly currents of 250 mA and higher, it is necessary to take appropriate precautionary measures. Measures to avoid danger: Maintenance and repair work should only be performed by technical experts or staff informed of the maintenance instructions. Measures to avoid danger: Maintenance work should only be carried out at an electrically disconnected machine. Switch off all electricity sources and disconnect the main switch from the mains. Measures to avoid danger: Ensure that the main switch and electricity sources cannot (unintentionally) be switched on again by third parties during maintenance work. Measures to avoid danger: Wear insulating, protective footwear with thick crepe soles during maintenance work.

W AR NING

Maintenance, cleaning as well as repair work should only be performed by technical experts or persons being instructed of these operations (See Section 2.3 Qualified personnel, page 7) An operating person must be instructed by an expert and may then independently carry out maintenance work at the machine (trained service personnel) Daily cleansing work is made by the instructed operating personnel.



W AR NING

Hot surfaces: Only work at the machine after its cooling-down. Some parts of the INDUPRESS® machine are heated with steam and may even reach a temperature of 160°C! Measures to avoid danger: Always wear protective gloves and close the steam and condensate connections during the maintenance work.

W AR NING

Compressed air or unintentional flows Adjust the main compressed-air control pressure to 0 bars. Release all the pressure from the unit. Remove the air inlet tube for the compressed air supply

W AR NING

Improper/premature release of the unit Do not release the machine without having checked the safety devices after completion of work. Defective safety appliances have to be repaired or replaced. Not until then work is accomplished!

C AUT ION

Only use original spare parts. Be aware of all operating instructions of the purchased parts Renew self-locking screws and nuts timely.



7.2 C leans ing

The entire machine, particularly the storage facilities, transport routes and air filters must be cleaned regularly. Clean and dry the machine exclusively with a cloth. Do not use aggressive cleansing agents!

CAUTION

Possible property damage

In no event should the machine be blown on with compressed air! (Exception Tunnelfinisher, cleaning of the heat exchangers) This endangers the cleansing agent and dirt getting into bearings. Use a hair broom if cleaning done with a humid cloth is insufficient.

7.3 P neumatic parts

All pneumatic parts, used in INDUPRESS® machines are made for non-lubricated air supply. All of the parts are equipped with a permanent provision for self-lubrication, which guarantees a maintenance free, long lifetime.

Notice Please ensure that the air supply to the INDUPRESS® machines is free of oil and water!

If there is a need for air lubrication for some existing machines (e.g. for older machines with a pure pneumatic control), there exists a possibility to set up the air lubrication system at the individual machine. However the compressed air system should be kept free of oil. At the compressed air supply of the machine you can find a maintenance unit, designed to separate the condensate which might arise. During continual operation, condensate is regularly generated in the compressed air unit. The water can cause corrosion inside the machine if not drained timely from the maintenance unit. The interval of the drainage depends on the quality of your compressed air supply. Check at first everyday the level condensate. After this, set an interval for drainage as per the expected condensate quantity. Press the drain button at the maintenance unit to drain the condensate.

CAUTION

Material damage:

At longer intervals the gauge glass may overflow and water may get into the compressed air system of the machine. This may cause malfunctions during operation. Please check this on a regular basis!



Notice: If there appears a need for draining the condensate from your INDUPRESS® machines pneumatic system everyday, a defective or missing cool-dryer in your compressed air supply unit could be a possible reason for that.

The fine-mesh filter removes unwanted particles from the compressed air and has to be checked on a regular basis and, depending on it’s the level of dirtiness, it should be cleaned timely. Ensure that the pneumatic system (cylinders, valves and pipes) is fully leak proof. Leakages must be mended at once. Leakages may cause continuous losses which may damage the systems and result in unnecessary costs. 7.4 Mec hanic al parts

7.4.1 L ubric ation of bearing units

Bearing units, linear guiding rails and shafts have to be checked and, if necessary, lubricated on a regular basis. Details on this can be found in the maintenance protocol. Most of the assembled, mechanical parts and drives have almost maintenance-free industrial bearing units. Existing linear guides have to be lubricated on a regular basis.

Disposal Grease, oil and oil-polluted cloths are hazardous waste and need to be disposed off separately from other wastes!

7.5 E lec trical parts

Safeguarding devices and safety switches as well as all electrical parts and component parts are to be checked for their functional order on regular intervals. For more details please refer to the maintenance protocol. 7.6 S team c irc uit parts

Due to mineral deposits occurring by lacking or insufficient water purification or chemical additives (wrong dosage), the steam nozzles/steam valves may become polluted and get clogged. Therefore regular checks and cleaning are necessary of these steam nozzles/valves. Regularly check the steam valves for their leak proof closure, otherwise there may be water getting in the machine due to uncontrolled escape of steam. The steam traps must be checked on a regular basis and, as and when necessary, the lint filters should be cleaned. If the condensate extraction is not working properly, it may cause one hand, too much steam being used or on other hand, too much water remaining in the system. The system may fill up with water. Further details on this are given in the maintenance protocol, (please see in the Operating Instruction Part II "machine - machine part" – maintenance protocol - of the respective INDUPRESS® machine).



7.7 R eplac ing c over material

Notice If you work at an INDUPRESS® machine using covering material, please follow this section. For a detailed description have a look at Section on the Operating Instruction Part II “machine part” of the respective INDUPRESS® machine!

The lifespan of the individual covering materials is dependent on the following factors:

the age of the covering material the number of executed pressing operations the used pressing parameters in average (e.g. pressure, steam volume, program duration)

Keep the below mentioned maintenance cycles for an unchanging, good pressing quality:

1 x per week – visible check for damage, e.g. impressions, cracks, crinkles and worn spots on the surface (perforations)

1 x per week – visible check for stained surface We recommend a complete change of the covering material after three month but not later than

6 month When this is not complied with, a good pressing quality is not guaranteed

W AR NING

Hot surfaces: Danger of burns at pressing shapes! The pressing shapes may have a surface temperature of approx. 150°C. Wear protective gloves and long-sleeve garment while

doing maintenance work Close the steam and condensate supply Drain the rest of steam inside the heating circuit of the

machine by the ball valve, provided for that Allow the machine to cool down for at least 60 minutes

before starting with any work whatsoever.

It is strongly recommended to use original INDUPRESS® covering materials only. The quality and the right material as well as the appropriate order of layers and the correct fit are main factors to obtain a perfect pressing result. However this cannot be guaranteed if any random covering material is used in place of the recommended INDUPRESS® covering material. If original INDUPRESS® covering material is unavailable, please consider the “covering” norms of INDUPRESS® concerning the kind of material, the appropriate order of layers and the correct fit. You will find the original INDUPRESS® cutting templates with this documentation. If there is any damage, because of not considering what is mentioned above, INDUPRESS® as the manufacturer of the pressing/finishing equipment is not to be claimed for any damages or losses.

Disposal Please consider the local regulations for the disposal of each worn out covering materials!



7.7.1 C leaning of c overs

Mostly the upper shapes of INDUPRESS® pressing machines are covered with non-textile materials, such as: Tin-coated copper wire mesh Perforated, teflon-coated glas fibre fabric Perforated, aluminium sandwich plate (KD-plates)

In the machines for intermediate pressing and fusing operations, the adhesive used for fusing (thermo setting tape) forms a residue after a number of successive operations which sticks to the fusing plate and covering material. It is utmost necessary to remove this residue timely so that it does not have any negative effect on the pressing result or the covering material of the machine. Covering materials can be cleaned from adhesives like follows: The cleaning must be done with the plates in hot condition. Subject the relevant covering material to steam (by using head steam function of the machine

manually) Remove the adhesives by means of a soft brush made from natural fibres or fine wires

W AR NING

Hot surfaces: Danger of burns at pressing shapes! The pressing shapes may have a surface temperature of approx. 150°C. Wear protective gloves and long-sleeve garment while

doing maintenance work

Alternative way of cleaning: Clean the covering under cold condition Soak the adhesives with a soft cloth, tinctured by alcohol or for the best result - acetone Remove the adhesives by means of a soft brush made from natural fibres or fine wires

7.7.2 How to order original INDUP R E S S ® c overing material

You can either order an INDUPRESS® covering materials individually by meter or already-sewn together (ready made). In any case the machine type and serial no. has to be given in the “order form”. If you include the machine information also in your order for piece goods, we will be able to let you know if any changes took place regarding the kind of material, size or sequence of layers for that machine. This way, you will be able to take advantage of our improvements. Contact data Hornung GmbH INDUPRESS® & Co. KG

Boschstr. 7 D - 63768 Hösbach Tel. + 49 6021 / 6237 - 0 Fax + 49 6021 / 57903 Mail: [email protected] Web: www.indupress.de

On our website www.indupress.de all INDUPRESS® sales and service partners in all locations are listed with their address and phone number. Many of our representatives have original INDUPRESS® covering material on stock. With this you have a good possibility to shorten the lead time and to cut the costs, for the transportation (from Germany or from a service/sales location nearby

http://www.indupress.de/�



7.8 Work s teps following maintenanc e / s ervic e / repair

Please use the following procedure after having finished work:

Step What to do

1 Draw up an examination/maintenance schedule, work schedule etc..,

2 Check if all the safety devices are fully functional. Do not subject the machine to production if any safety device is not in a perfect state.

3 Set up and secure the dismounted safeguarding device back in its position after servicing the machine.

4 Remove used tools, all external objects as well as raw materials and supplies from the machine location.

5 Do a Test Run of the machine including the operational control of the repaired/serviced component parts.

6 Protect the machine from undesired power supply in case it is necessary leave the machine before completing service/maintenance.

Operating Instruction Part I – general part Setting the machine out of operation and disassembly


8 Setting the machine out of operation and disassembly

DANG E R

Please strictly follow the safety notices in Section 4.4 Basic instructions on safety. Additionally, the safety notices in Section 5 Transport shall apply.

W AR NING

The setting out of operation, disassembly and disposal of the machine may only be performed by experts or trained staff.

Instructions for putting the machine out of operation

Carry out the following work steps to prepare the machine for turning off:

Step Action

1 Inquire about specific regulations on the disposal of the different component parts of the machine and for complete disposal (Section 9 Disposal, page 34). Ask the concerned environmental authorities if the need arises.

2 Make sure that the system is voltage-free.

3 Disconnect the system from the voltage supply.

4 Release the pressure from all units.

5 Disconnect the unit from compressed air, steam, vacuum and condensate connections.

6 Please tight the lose or moving machine parts with the appropriate transportation safety device, or block the movable parts with available instruments.

7 Pay attention during transport to keep the machine under balance – brace top-heavy machines to avoid falling/toppling over.

Operating Instruction Part I – general part Disposal


9 Disposal Please find below the information about disposal and on the used materials.

Disposal Dispose of all parts of the system in such a way as to rule out any damage to health and environment.

Specific information about disposal is given by: the documentation and the data sheets of the appliance parts respective environmental authorities

9.1 Us ed materials

For construction of the machine, following materials are used predominantly:

Material Used at/in

Batteries nickel-cadmium accumulator (Ni,Cd) lithium-accumulator (Li)

PLC

Copper Cable, circuit boards

Steel Base plate/pressing shape, pneumatic cylinders und valves, machine frame, fittings

Aluminium Pneumatic cylinder, pressing shapes, machine housing

Galvanized sheet steel Electric cabinet, assembling boards, machine parts

Plastic, rubber, polyvinyl chloride For sealing, tubes, cables

Tin Covering material, circuit boards

Polyester Covering material, circuit boards

Operating Instruction Part I – general part Disposal


9.2 Items to be dis pos ed of s eparately

The following operating supply items and manufacturing supplies must be disposed of separately:

Material Used at/in

LCD displays Display units (LCD- and TFT displays)

Electronic junk

Electrical supply, control units with electronic components (PLC), circuit boards with electronic components

Insulations Steam supply insulation, Tunnelfinisher insulations, pressing shape insulation

Operating Instruction Part I – general part List of abbreviations


10 List of abbreviations

CE Communauté Européenne (French for “European Union“)

DIN German Institute for Standardization ("Deutsches Institut für Normung e.V.")

etc. et cetera (and so on)

e.g. which means

Fig. Figure

min minimum

max maximum

resp. respectively

TFS Tunnelfinisher

USB Universal-Serial-Bus

Operating Instruction Part I – general part Glossary


11 Glossary

CE marking

Designation for specific products according to the laws of the EU (European Union) in connection with the product safety within the European Economic Area (EEA) and the European Community (EC) being a part thereof. With the CE marking the manufacturer confirms the conformity of the product to the applying EC directives and the compliance with the “fundamental requirements” stipulated therein.

Display User interface

EC declaration of conformity

The EC declaration of conformity is the basis of the CE marking of the respective product. With the EC declaration of conformity the manufacturer confirms that a product circulated by him complies with, e.g. is in agreement with, the basic health and safety requirements of all relevant European directives.

Touchscreen Monitor (computer operation / user interface) which controls the run of the program after a touch on parts of a picture (Pictogram). The technical implementation of the command entry is practically "transparent" to the user.

User interface Display

Operating Instruction Part I – general part Table of illustrations


12 Table of illustrations Fig. 1 Example rating plate ...................................................................................................................... 5Fig. 2 Electrical connection of the machine ........................................................................................... 23Fig. 3 Installation examples steam extraction ....................................................................................... 25

Operating Instruction Part I – general part Index


13 Index

A Approved loading devices ............................. 18 Assembly ....................................................... 21

B Basic instructions on safety ........................... 13

C CE marking .................................................... 37 Cleansing ....................................................... 28 Condensate supply line ................................. 23 Confidentiality .................................................. 2 Connecting the machine ................................ 22 Conversions ..................................................... 6 Copyright ......................................................... 6 Correct use .................................................... 10 Cover material ............................................... 30 Covers cleaning ............................................. 31 Covers order .................................................. 31

D Declaration of conformity ................................. 7 Disassembly .................................................. 33 Disclaimer ........................................................ 5 Display ........................................................... 37 Disposal ................................................... 12, 34 Duty of care ..................................................... 9

E Electric shock ................................................ 13 Electrical connection ..................................... 23 Electrical parts ............................................... 29 Electrical switch plans ..................................... 7 Exhaust pipe .................................................. 25 Expert .............................................................. 7

G General Safety instructions ........................... 10 Glossary ........................................................ 37

H How to order covering material ..................... 31

I Icons and styles of writing ............................. 12 Implicit Guarantee ........................................... 5 Index .............................................................. 39 Inspection for shipping damage .................... 17 Instructed person ............................................. 7

Instruction ....................................................... 9 Instructions for use ......................................... 7 Items to be disposed of separately ............... 35

L Legal information ............................................ 5 List of abbreviations ...................................... 36 Lists of spare parts ......................................... 7 loading devices ............................................. 18 Lubricate of bearing units ............................. 29

M Machine identification label............................. 5 Machine’s legs .............................................. 21 Maintenance ................................................. 26 Mechanic parts ............................................. 29 Modifications ................................................... 6

N Non-liability ..................................................... 2

P Pneumatic parts ............................................ 28 Pneumatic supply line ................................... 24 Pneumatic switch plans .................................. 7 Preparations for putting the machine out of

operation ................................................... 33 Purpose ........................................................... 7

Q Qualified personnel ......................................... 7

R Rating plate ..................................................... 5 Replace cover material ................................. 30 Requirements for installions ......................... 21 Revision service .............................................. 6

S Safety instructions ........................................ 10 Safety notices regarding maintenance and

service ....................................................... 26 Safety of the device ........................................ 9 Safety Precautions ........................................ 11 safety rules of electricity ............................... 14 Service .......................................................... 26 Setting the machine out of operation and

disassembly .............................................. 33 Steam circuit parts ........................................ 29 Steam extraction system .............................. 25 Steam supply line ......................................... 23

Operating Instruction Part I – general part Index


Supplementary documents ............................. 7 Symbols ........................................................ 11 Symbols Safety Precautions ......................... 11

T Table of Contents ........................................... 3 Table of illustrations ...................................... 38 Technical changes .......................................... 6 Touchscreen ................................................. 37 Training ........................................................... 9 Transport ...................................................... 17 Transport of the machine .............................. 17

U Unwrapping Disposal .................................... 20

Unwrapping the machine .............................. 20 Used materials .............................................. 34 Useful reference .............................................. 8 User interface ................................................ 37

V Vacuum supply line ....................................... 24

W Warning levels............................................... 12 Warning levels translations ........................... 12 Work steps following maintenance / service /

repair ......................................................... 32

Operating Instruction Part I – general part

Version 2009.07 | Revision: 101 © Hornung GmbH INDUPRESS® & Co. KG Annex Page I

Author: Hornung GmbH INDUPRESS & Co. KG Subject: Operating instructions Title: Operating manual - part 1

Document name: Operating_manual_part_1_INDUPRESS_general_part_2009_06_v100.doc

File size: 3 MB

Number of pages: 42 Number of words: 7639

Version 2009.07 Revision 101

INDUPRESS® - I n d u s t r i a l P r e s s i n g E q u i p m e n t power supplies and finishing units, pressing machines and Tunnelfinisher Our wide range of services includes the production of Tunnelfinisher, pressing machines, pressing tables, pressing devices as well as planning, delivery and installation of the complete steam, vacuum and compressed air units along with all pipework systems according to the individual requirements of the factories.

Head Office Hornung GmbH INDUPRESS® & Co. KG

Boschstraße 7 D - 63768 Hösbach | Germany

Tel.: +49 6021 / 6237 - 0 Fax: +49 6021 / 6237 - 66 Mail: [email protected] Web: www.indupress.de

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03 Operating Manual Part 1 INDUPRESS General Part 2009 07 v1

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