Operating manual
POT - "Pneumatic Oscil lating Tool "
Version
004
Menu
1.20
POT
G3 Series
Contents
1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2
2.1
2.2
2.3
Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
POT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Maintenance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3
3.1
3.2
3.3
3.4
3.5
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Examples of improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dangers caused by improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Protective clothing and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.8.1
4.8.2
4.8.3
4.8.4
4.8.5
4.8.6
4.9
4.10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Selecting the blade size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Setting the height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inserting/replacing blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inserting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Connecting the tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Description of menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Setting POT as the tool for the module . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Initialisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Defining the zero point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Setting the upper position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setting the lower position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting the Z-offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Tool positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Making material-specific settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Carrying out a test cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5
5.1
5.2
5.3
5.4
5.5
5.6
Cleaning and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Steps for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Maintenance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Oiling the blade holder guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cleaning the blade holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Lubricating the slipper spring O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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1
Introduction
The pneumatic oscillating cutting tool has been designed to cut soft materials such
as leather, textiles, corrugated cardboard and foam. The very high cutting speed
(around 10,000 blade cycles per minute) means that wear of rotating parts is unavoidable. The levels of stress and wear on the tool are also heavily dependent on
the following factors:
–
Consistency of the material
–
Material thickness
–
Blade geometry
–
General operation
Manufacturing tolerances may result in audible fluctuations in the stroke rate. The
tool remains fully operational despite these fluctuations and can be used until it fails.
Important !
Keep a spare tool ready in order to avoid cutter downtime.
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POT
2
2.1
Product description
POT
Fig. 1 POT - Pneumatic Oscillating Tool
1 Slipper spring
5 Blade holder clamp
2 Front part of casing
6 Sound absorber
3 Sleeve 1
7 Pressurised air connection
4 Sleeve 2*
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Maintenance unit
2.2
Maintenance unit
The maintenance unit cleans and regulates the pressurised air used to operate the
POT.
Fig. 2 Maintenance unit
1 Stopcock
4 Pressure regulator
2 Outlet valve
5 Pressure gauge
3 Water separator
6 Magnetic valve
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Technical information
2.3
Technical information
Description
Weight
Stroke rate at 0.8 MPa [116 psi]
Measurements Units
0.8 kg
10200 /min
170 ± 10 Hz
Air consumption
Operating pressure
300 - 400 l/min
0.8 MPa
87 -116 psi
Stroke height
8 mm
Blade holder
0.63/1.5 mm
Continuous sound pressure level
Air purity as per ISO 8573-1
< 80 db(A)
Class 4
1 MPa = 10 bar
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Intended use
3
Safety regulations
Important !
These safety regulations and notes only represent tool-specific supplements to the
Safety Requirements section in the Operating Manual.
This section
–
defines the proper use of the tool
–
contains tool-specific safety precautions and instructions
–
Provides information on the protective equipment required for work and maintenance
Special operational and situation-specific safety requirements are listed in the relevant processing steps in subsequent sections of this manual.
3.1
Intended use
Safe operation is guaranteed when the equipment is used solely for its intended purpose.
The equipment provided determines the possible uses of the tool.
The POT is designed to cut soft materials such as leather and textiles, sealing materials, rubber, carpets, laminated foam and corrugated cardboard using a universal
module.
Any other use which does not meet this description shall be classed as improper use.
The user bears sole liability for any damage arising as a result of improper use.
The tool is deemed to be used as intended under the following conditions:
3.2
–
All nationally imposed safety regulations are complied with
–
The safety instructions listed in this operating manual are complied with
–
The operating conditions are adhered to and the prescribed materials are used
Examples of improper use
–
Use of unsuitable blades
–
Improper or non-intended use
–
Unauthorised operating pressure
–
Incorrect clamping of tools in blade shaft
–
Tool shaft and blade shaft size that do not match
–
Failure to clean the tool at regular intervals
–
Structural alterations to the equipment without the permission of Zünd
–
Non-observance of maintenance instructions
–
Non-adherence to safety requirements
–
Failure to react to signs of wear and damage
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G3 Series
Dangers caused by improper use
3.3
3.4
Dangers caused by improper use
–
Blade breakages
–
Blade may unintentionally slip out of blade shaft
–
Damage to the equipment
–
Cutting injuries due to sharp cutting edges
Protective clothing and equipment
When operating, cleaning or maintaining the equipment, wear close-fitting clothing
and personal protective equipment suited to the task at hand.
Personal protective equipment comprises:
•
Work clothes
•
Safety goggles
•
Protective gloves where injury is possible due to:
– Burns
– Sharp or pointed objects
•
Ear protection if the continuous sound pressure level is over 85 db(A)
Important !
You are personally responsible for:
• Using the required personal protective equipment
• Cleaning and maintaining the equipment on a regular basis
• Replacing damaged and unusable elements of the protective equipment in good
time
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Safety signs
3.5
Safety signs
The equipment is fitted with important safety signs; failure to observe these signs can
result in serious injury.
Warning !
Safety risks due to missing or illegible safety signs.
•
Check all safety signs on a regular basis for legibility and completeness.
•
Replace missing or illegible safety signs promptly with new original signs.
Meaning of safety signs
The symbols on the safety signs
•
have specific meanings
•
are located wherever certain behaviour is prohibited due to it being potentially
dangerous
Order signs
These symbols
•
are blue and circular
•
Stipulate the wearing of personal protective equipment to protect against hazards
Wear eye protection
Wear ear protection
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Selecting the blade size
4
Operation
Attention !
Danger of injury
4.1
•
The blades are extremely sharp and can cause severe cuts.
•
Disconnect the tool from the power supply before removing it from the module.
Selecting the blade size
Attention !
Risk of injury from blade.
If the wrong size of blade is selected there is a risk of the blade breaking off and the
broken off parts may injure people.
•
Use blade sizes appropriate to the type and thickness of material.
Fig. 3 Determining the blade size (with slipper spring)
1 Clamped tool
4 Example: Blade for material
thickness 5 mm
2 Slipper spring
5 Incorrect choice of blade or
slipper
3 Example: Material thickness
5 mm
⇨ Ensure that the slipper spring is always on the material. Use the appropriate
blade for the material thickness.
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Setting the height
4.2
Setting the height
It is possible to change the height of the tool using spacer sleeves in order to be able
to cut thicker material/use longer blades. In this case, the processing height depends
on the blade length.
Processing height
Sleeve 1
Sleeve 2
0 - 28 mm
0 - 51 mm
Fig. 4 Fixing height
1 Slipper spring
3 Sleeve 1
2 Front part of casing
4 Sleeve 2
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Setting the height
⇨ Remove the slipper spring from the tool.
⇨ Remove the blade from the blade holder.
⇨ Remove the front part of the casing (1 x Allen).
⇨ Remove the sleeve (2 x Allen).
⇨ Mount the required sleeve on the POT.
⇨ Fit the front part of the casing.
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Inserting/replacing blades
4.3
Inserting/replacing blades
Fig. 5 Inserting/replacing blades
Attention !
Risk of injury from blades
•
The blade will project out of the slipper when it is fully retracted. Remove/reattach
the slipper spring carefully.
⇨ Remove the slipper spring carefully.
⇨ Undo the Allen screw on the blade holder.
⇨ Remove the blade from the blade holder.
⇨ Insert the new blade into the blade holder until it engages mechanically.
⇨ Tighten Allen screws.
⇨ Reattach the slipper spring carefully.
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Inserting tool
4.4
Inserting tool
Fig. 6 Inserting tool
⇨ Move the module to the lower right-hand corner
⇨ Use
to switch to the operating status STOPPED
⇨ Insert the selected tool into the module holder. Ensure that the red point on the
module is located above the module lock.
Important !
The tool holder and a holding fixture are each marked with a red dot. The tool is in
the correct position when the dots are aligned.
⇨ Lower the shaft of the tool into the module opening until it stops
⇨ Press the module lock and latch the bayonet catch
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Connecting the tool
4.5
Connecting the tool
The tool is supplied with air by means of the interface unit on the module carriage,
P4 connection. If no POT is connected to the interface unit, a stopper prevents dirt
from getting into the air circuit.
Fig. 7 Connecting the tool
1 Stopper
3 P4 air pressure connection
2 Air pressure hose
⇨ Press the air pressure connection coupling down and remove the stopper.
⇨ Press down on the air pressure connection coupling.
⇨ Insert the air pressure hose
Important !
After removing the tool from the module, place the stopper on the connection (P4) on
the interface unit.
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Description of menu
4.6
Description of menu
The examples in the following guide assume that the tool is being used in module 1.
Description
Menu
Setting/function
Initialisation
Define Z init pos
1-1-1-2-1
Defining the zero point
Up Z pos
1-1-1-2-3
Set the upper position (above the material)
Down Z pos
1-1-1-3-4-5
Set cutting depth
Z Offset
1-1-1-2-5
Correction value for lower position
Speed and acceleration
Up X&Y
1-1-1-3-2-1
Movement speed in upper position
Down X&Y
1-1-1-3-2-2
Movement speed in lower position
Lift Z
1-1-1-3-2-3
Lifting speed
Lower Z
1-1-1-3-2-4
Lowering speed
Up X&Y
1-1-1-3-3-1
Tool acceleration in upper position
Down X&Y
1-1-1-3-3-2
Tool acceleration in lower position
Tool connector
1-1-1-3-1-1
Set the tool connector (see "Controls and
operation", "Allocate connector (port)")
Switch-off time
1-1-1-3-1-3
Delay after switching off
After on delay
1-1-1-3-1-4
Delay before starting
Tool connector/delay
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Setting POT as the tool for the module
4.7
Setting POT as the tool for the module
Refer to the "Tool handling" section of the operating manual
4.8
Initialisation
Warning !
Danger of injury when initialising the tool!
The light barriers are not active during manual initialisation!
4.8.1
•
Do not touch the operating area of the tool during initialisation.
•
Define the zero point with automatic initialisation.
Introduction
The following activities are required for successful initialisation:
–
Define zero point (manual/automatic*)
–
Set the upper position
–
Carry out a test cut
–
Correct the cutting depth using the 'Adjust tool init pos' function if necessary
Ensure, that following preconditions are fulfilled:
❏ The machine is in the 'STOPPED' operating state
❏ The tool has been mounted and assigned to the module
Fig. 8 Initialising
1 Zero point
4 Up Z pos
2 Down Z pos
5 Max. Z down1
3 Tool init pos
6 Max. Z up1
a Material
b Base
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Initialisation
1
these values may only be changed at the 'Service' user level.
Calculation of cutting depth
Cutting depth = zero point + Down Z pos ± Tool init pos
4.8.2
Defining the zero point
Fig. 9 Defining the zero point
⇨ Select Manual Initialisation1-1-1-2-1
⇨ Use the travel keys to move to the zero point (cutting base).
⇨ Choose OK to confirm
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Initialisation
4.8.3
Setting the upper position
Important !
If the cutting base is defined as the zero point, the value for the setting Up Z pos must
be greater than the material thickness.
The Up Z pos setting defines the position of the tool when raised.
Definition: Upper position = zero point + Up Z pos
To increase cutter efficiency, this position should only be set as high as is necessary.
Fig. 10 Setting the upper position
a Material thickness
4 Up Z pos
1 Zero point
⇨ Select Up Z pos1-1-1-2-3
⇨ Enter a value
⇨ Choose OK to confirm
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Initialisation
4.8.4
Setting the lower position
Important !
If the cutting base is defined as the zero point, the value used for the Down Z pos
setting must be set to zero. Entering a positive value will damage the cutting base.
The Down Z pos setting defines the position of the tool when lowered. When a zero
point is defined, the value for the lower position is automatically set to zero.
Definition: Lower position = zero point + Down Z pos
Fig. 11 Setting the lower position
1 Zero point
2 Down Z pos
⇨ Select Down Z pos
⇨ Enter 0
⇨ Choose OK to confirm
4.8.5
Setting the Z-offset
Value for correcting the cutting depth (Down Z pos) by ±1.5 mm. When a zero point
is defined, the value for the Z-offset is automatically set to zero.
⇨ Select Adjust tool init pos
⇨ Enter a value
⇨ Choose OK to confirm
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Initialisation
4.8.6
Tool positions
Example: EOT/POT/universal cutting tool
Three tool positions are possible following initialisation
Fig. 12 Tool positions
Item
position
Description
A
Park position
Moves to the highest position on the Z axis
B
Up Z pos
Zero point + Upper position
C
Down Z pos
Zero point + Lower position + Z offset
Key
Signal
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Making material-specific settings
4.9
G3 Series
Making material-specific settings
The speed and acceleration settings must be set for each material.
You can find recommended settings for specific materials on the Zünd homepage or
by contacting your Zünd partner.
4.10
Carrying out a test cut
Ensure, that following preconditions are fulfilled:
❏ The tool has been initialised
❏ The machine is in the 'OFFLINE' operating state
❏ Material-specific settings have been made
❏ The tool is active
Procedure
⇨ Place the material to be cut on the working surface
⇨ Select Test cut
⇨ Use the travel keys to position the tool over the material to be cut. Choose OK to
confirm
⇨ Check the test cut. If necessary, correct or redefine the zero point on the Z-axis
using the Adjust tool init pos function
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Steps for maintenance
5
Cleaning and maintenance
Attention !
Danger of injury
•
The blades are extremely sharp and can cause severe cuts.
•
Disconnect the tool from the power supply before removing it from the module.
Attention !
Risk of damage to the tool
Never clean the tool using ultrasound, a steam jet, compressed air etc.
Never use cleaning products (cleaning spray, grease solvents etc.) for cleaning.
5.1
Steps for maintenance
The maintenance intervals provided are only guidelines. The intervals must be shortened as required, depending on the material worked on.
Interval
Activity
Water separator on the maintenance unit drain water
Daily
Check maintenance unit operating pressure
for tool, set if necessary
(0.6 - 0.8 MPa) [87 - 116 psi]
Oiling the blade holder guide
Every 25 operating hours
Oil the blade holder shaft
Clean the blade holder shaft and guide
monthly
5.2
Lubricate the slipper spring O ring
Lubricant
Attention !
Risk of damage if incorrect lubricant is used.
Only use the lubricant recommended by Zünd to maintain your equipment.
Lubricant
Lubricating points
Teflon Fin Grease MP 2/3
Tracks of guide sleeve, blade holder guide
Guideway oil
General maintenance
Vaseline
Slipper spring O-ring
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Maintenance unit
5.3
Maintenance unit
Fig. 13 Maintenance unit
1 Stopcock
4 Pressure regulator
2 Outlet valve
5 Pressure gauge
3 Water separator
6 Magnetic valve
Draining water
⇨ Press the outlet valve
⇨ Drain water into a suitable container
Disposal !
The water separator also contains compressor oil.
•
Remove used oil and fluids containing old oil in accordance with national regulations
Checking the operating pressure
⇨ Use the pressure gauge to check the operating pressure. Adjust using the pressure regulator if required.
✓ The target operating pressure is approx. 0.8 MPa. If the operating pressure is
lower than this, there may be problems starting the device.
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Oiling the blade holder guide
5.4
Oiling the blade holder guide
Attention !
Risk of injury from blade.
The blade will come out of the slipper.
Take care when placing the slipper spring over the blade.
Fig. 14 Oiling the blade holder guide
Item
Lubricant
Lubricating points
Item 4
Teflon Fin Grease MP 2/3
Blade holder guide
⇨ Remove slipper spring ("Fig. 14, Oiling the blade holder guide", item 1)
⇨ Remove the blade
⇨ Unscrew the fastening screw on the front part of the casing (Fig. 9, item 2).
⇨ Remove the front part of the casing
⇨ Clean the blade holder guide ("Fig. 14, Oiling the blade holder guide", item 4) using a clean cloth and lubricate it
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Cleaning the blade holder
5.5
Cleaning the blade holder
Attention !
Risk of injury from blade.
The blade will come out of the slipper.
Take care when placing the slipper spring over the blade.
Fig. 15 Cleaning the blade holder
⇨ Remove slipper spring ("Fig. 15, Cleaning the blade holder", item 1)
⇨ Remove the blade
⇨ Remove the fastening screw on the front part of the casing ("Fig. 15, Cleaning
the blade holder", item 2)
⇨ Remove the front part of the casing
⇨ Remove the guide sleeve ("Fig. 15, Cleaning the blade holder", item 3)
⇨ Clean the blade holder ("Fig. 15, Cleaning the blade holder", item 4) and the
guide sleeve using a lint-free cloth that has been soaked in guideway oil
⇨ Lubricate the tracks for the blade holder and guide sleeve with grease
⇨ Reassemble the tool by following these instructions in reverse order and tighten
all fastening screws.
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Lubricating the slipper spring O-ring
5.6
Lubricating the slipper spring O-ring
Attention !
Risk of injury from blades
•
Take care when placing the slipper spring on the tool. The blade will protrude
several millimetres out of the slipper when this is fully retracted.
Fig. 16 Lubricating the slipper spring O-ring
⇨ Remove the slipper spring
⇨ Clean the slipper spring
⇨ Rub some Vaseline on the inner side of the O-ring ("Fig. 16, Lubricating the slipper spring O-ring", item 1)
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Lubricating the slipper spring O-ring
G3 Series
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