Hettich BlueMax Mini Modular Plus Operating Manual

Operating manual

BlueMax Mini Modular Plus

Contents

1. Foreword

1. Introduction 5

2. Important advice 5 Revision service 5 Updating 5

3. Validity of this operating manual 5 Application 5 Copyright reserved 5

4. Owner's personal responsibility 5

5. Service 5

2. EC declaration and protocols

1. EC Declaration of Conformity 6

2. Important note 7

3. Verification of instruction 7

3. General safety rules

1. Information on signs, symbols and markings 8

2. General 9

3. Safety advice for the user company 10

4. Noise 10

5. Oils, greases and other chemical substances 10

6. Residual risk 10

7. Safety advice for operating personnel 11

8. Safety advice for operating the machine 11

9. Safety advice for carrying out maintenance work 11

10. Training / instruction 11

11. Personal protective equipment 12

4. Purpose / operating principle

1. General information 14

2. Intended use 14

3. Foreseeable incorrect use 14

4. Operating principle and description of the machine 15 Description of the machine 15

5. Rating plate 15

6. Limit values 15

7. Liability 15

5. Technical information

1. Safety advice 16

2. Attachment points 16

3. Technical specifications 17

4. Equipment 18 Setting 22

5. Safety guards 22

6. Noise mission 23

7. Aligning / fastening 23 General information 23

8. Connections required 23 Main power connection 23 Compressed air connection 23

9. Handling 23 Transportation via fork lift truck or pallet jack 24

10. Internal handling 24

11. Checking delivery for missing items 24

12. Dealing with shipping damage 24

13. Measures for temporary storage 24

14. Site of installation 24

15. Safety guards to be provided by the owner 25

16. Permissible ambient conditions 25

17. Removing preservatives 25

18. Electrics 25

19. Compressed air connection 25

20. Suction extractor 25

6. Start up / trial run

1. General 27

2. Safety check 27

3. Malfunctions on start up 27

4. Starting up for the first time 27

5. Machine versions supplied 28

6. Interchangeable drilling units 29 Interchangeable drilling unit, 3 spindles Selekta 29 Interchangeable drilling unit, System 32 hole line 29 Interchangeable drilling unit, System 32 hole line 90° 29

7. Other accessories 29

8. Assemblies 30 Press in frame for the interchangeable drilling unit, 6 spindles 30 Centre stop 31 Continuation stops 31 Drilling depth settings 32 Drum stop 33 Hold-down clamps 33 Converting from manual operation to foot switch 34 Connecting foot switch for a machine with horizontal drilling unit 34 Connecting foot switch for a machine without horizontal drilling unit 35

9. Carrying out trial run 36

10. Concluding start up 36

7. Setting up

1 . Preparing machine 38 Readiness for use 38 Connecting to extractor system 38 Connecting to compressed air supply 39 Connecting to power supply 39 Switching on 40 Operating 40 Drilling hole line, interchangeable drilling unit, 9 spindles 41 Inserting hinges 42

2. Setting up (preparing for work) 42 Tools used (drill bits) 42 Interchangeable drilling unit, 6 spindles, interchangeable drilling unit, 3 spindles (Selekta 22/9) 43 Interchangeable drilling unit, 9 spindles 43 Interchangeable drilling unit, 90°, 9 spindles 44 Changing interchangeable drilling units 44 Cleaning 44 Fitting drilling units 45 Checking switch for proper working order 45 Setting drilling depth, vertical drilling unit 46 Drilling with horizontal drilling unit 46 Settings on the back of the machine 47 Limiting drilling stroke for drilling hole lines 48

3. Hold-down clamps and centre stop 48 Hold-down clamps 48 Centre stop 49 Setting the drum stops 49 Pendulum stops 49

8. Operation

1. Safety check 50 General information 50 Readiness for use 50 Controls 51

2. Switching on 52 Preparatory work 52

3. Operating 52 Hold-down clamps 53 Fitting Hettich hinges 53 Drilling 54 Pressing in 54

4. Malfunctions during operation 55 Troubleshooting 55

5. Checks during operation 55 Checks for proper working order 55

9. Servicing / care

14. Instructions for installing accessories

1. General information 56 Working on electrical components 56

2. Instructing maintenance personnel 56

3. Making the machine safe on shutdown 57

4. Cleaning the machine 57 Electric motors 57

5. Servicing work 57 Servicing and maintenance 57 Servicing unit 58

6. Instructions on inspections 58 General 58

10. Malfunctions / troubleshooting

1. General information 59

2. Malfunctions caused by the owner 59

3. Troubleshooting 59 General causes of malfunction 59 Malfunctions while machine is operating 59

4. Reporting malfunctions 59

11. Dismantling / disposal

1. General information 60 Before dismantling 60

2. Taking out of service 60

3. Dismantling 61 General information 61 Dismantling the machine / system 61

4. Hazardous substances / disposal 61 Protecting the environment 61 Scrapping 61 Oil and oily wastes 61

1. Press in frame 82

2. Converting from pushbutton to foot switch 82 Connecting foot switch for a machine with horizontal drilling unit 83

3. Installing laser 84

4. Installing continuation stop 85 Precision adjustment of continuation stops 86

5. Installing support block 86

12. Replacement parts lists

1 Base frame 63

2. Work surface 63

3. Eccentric tensioner 64

4. Guide frame 64

5. Foot extension 65

6. Suction extractor 65

7. Cable drag chain 66

8. Console 66

9. Lifting cylinder 67

10. Drilling depth stop 68

11. Adjustable stop 68

12. Clamping element 69

13. Motor with support 70

14. Centre stop 70

15. Press in frame 71

16. Hold-down clamp, rear 71

17. Hold-down clamp, front 71

18. Continuation stop 72

19. Travel limiter 72

20. Drum stop 72

21. Horizontal drilling unit 73

22. Interchangeable drilling unit, 90°, 9 spindles 74

23. Interchangeable drilling unit, 9 spindles 75

24. Interchangeable drilling unit, 6 spindles 75

25. Interchangeable drilling unit, 3 spindles, Selekta (22/9) 75

26. Pneumatics diagram 76

27. Circuit diagram 77

13. Replacement part numbers

1. List of replacement part numbers with designation 78

Foreword

1. Foreword

1. Introduction 5

2. Important advice 5

Revision service 5

Updating 5

3. Validity of this operating manual 5

Application 5

4. Owner's personal responsibility 5

5. Service 5

WARNING

Read these operating instructions carefully in order

to obtain a thorough understanding of the machine and how to install and maintain it. Operate the machine in the proper manner as described in these instructions so as to avoid injury and damage to the system. Do not operate the machine on the basis of suppositions. Keep these operating instructions to hand and consult them if you are in any doubt as to carrying out any particular procedure.

If any questions remain unanswered after reading

through the instructions, you must not put the machine into operation. Settle any unanswered questions first by consulting Hettich FurnTech GmbH & Co. KG.

These operating instructions are intended to make it easier for you to become familiarised with the machine and use its capabilities in the proper manner. The operating instructions contain important information on operating the machine in a safe, proper and cost effective manner. Following them will help to avoid hazards, repair costs and down times, enhance reliability and prolong service life.

Existing national regulations on preventing accidents and on protecting the environment are also applicable.

The machine will only be assembled and installed by persons instructed to do so by Hettich FurnTech GmbH & Co. KG. This also applies in particular to starting it up for the first time.

The operating instructions must be available at the machine all the time. The operating instructions must be read and applied by any person entrusted with working with / on the machine, e.g.:

• Operation

• including setting up, troubleshooting while working, disposal of production waste, care, disposing of consumables and auxiliary substances,

• Maintenance

• Servicing, inspection, repair

• Handling

given the task.

1. Introduction

The main objective of this operating manual is to protect

"man and machine" in accordance with the EC Machinery Directives. It is intended for all persons involved in working with and on this machine or system, in particular the operating personnel.

•

As operating / servicing personnel, first read this operating

manual and familiarise yourself with using the machine and operating it safely as well as with how to perform the necessary set-up, servicing and / or repair work in the proper way while meeting the safety requirements.

•

Your personal safety and that of your surroundings as

well as safe machine operation without risk to other property or the environment will only be ensured if you are familiar with and follow all of the information in this operating manual as well as in pertinent health and safety regulations.

•

As customer and / or owner, make sure that this operating

manual is given to your operating / servicing personnel before putting the machine / system into service for the first time, that it remains available directly at the machine at all times and that all persons concerned observe the information and warnings provided in this operating manual, the code of practice applicable to the site of installation as well as the regulations on occupational health and safety etc.

In other words, this operating manual does not release the

owner from the duty to devise his or her own health and safety rules as well as safe work procedures tailored to his or her production requirements / needs, to any specific system / machine combination, to specific installation conditions, to specific modes of connection and/or tool and component properties etc., and to apply these, have them applied and monitor their observance.

2. Important notes

Revision service

This operating manual is not subject to any revision service.

If changes / additions are made after the machine has been delivered, it is the responsibility of the owner to update this operating manual using his or her own addenda or any addenda provided by Hettich FurnTech GmbH & Co. KG.

The right is at all times reserved to amend and improve

all technical specifications, details and illustrations in the interest of technical progress.

Updating

The laws, provisions, regulations, directives, codes of practice

etc. specified in this operating manual as well as statements derived from them were up to date at the time this manual was compiled.

They must be heeded in their latest, applicable wording,

updated at the responsibility of the owner and always applied in their more restrictive (stringent) wording.

We also point out that the content of this operating manual

is not part of any earlier agreement, assurance or legal relationship or intended to amend such. All obligations on the part of Hettich FurnTech GmbH & Co. KG arise from the pertinent supply contract that also contains the complete and solely applicable warranty arrangements or draws attention to these. Statements made in this operating manual neither extend nor restrict these warranty provisions.

3. Validity of this operating manual

•

This operating manual only applies to this machine.

•

Please always quote the machine no. in all queries and

orders for replacement parts.

Statements made in this operating manual in relation to

items of equipment not included with the machine are for information only. They do not give rise to any legal claim to the machine being equipped with these items.

Application

This operating manual has been produced in compliance

with EC directives, European (harmonised) standards etc. References to occupational health and safety, environmental protection and safety provisions may not yet conform to harmonised accident prevention regulations (UVV) / statutory accident insurance regulations (GUV) applicable in Germany or to the DIN standards or technical regulations stated in the appendix to the German Equipment Safety Act (Gerätesicherheitsgesetz (GSG)).

The customer / owner is personally responsible for:

•

regarding specified laws, regulations, directives etc., as the

basis for safe handling and maintenance practice,

•

implementing and observing them in line with national /

regional / company-internal regulations,

•

providing supplementary safety or protective equipment

prescribed by the responsible local, regional or national authorities and for fitting them before using the machine / system for the first time.

The copyright to these operating instructions remains with Hettich FurnTech GmbH & Co. KG.

These operating instructions are intended for the operating personnel. They contain regulations and drawings of a technical nature that must not be duplicated either in whole or in part, distributed, used without permission for advertising purposes or communicated to others.

Reproduction either in whole or in part is not permitted.

4. Owner's personal responsibility

The customer or owner is personally responsible for ensuring

that

•

provisions on occupational health and safety, environmental

protection and disposal are observed in relation to the machine, handling it as well as in the course of inspections, servicing and repair measures,

•

no improper changes or modifications are made to the

machine or safety guards,

•

the machine is not used in any inappropriate, improper or

non-intended manner.

5. Service

Customer Service

Hettich FurnTech GmbH & Co. KG, Gerhard-Lüking-Strasse 10,

D-32602 Vlotho, Germany

EC declaration and protocols

2006/A1:2009;

2. EC declaration and protocols

1. EC Declaration of Conformity 6

2. Important note 7

3. Verification of instruction 7

1. EC Declaration of Conformity

2. Important note

Information for the owner

In addition to these operating instructions and the accident prevention regulations in force in the country of use or at the place of application, it is also necessary to follow the recognised code of safe and proper working practice.

Without the consent of Hettich FurnTech GmbH & Co. KG, the machine owner must not make any additions, alterations or modifications to the machine that may affect safety.

Replacement parts used must meet the technical requirements defined by Hettich FurnTech GmbH & Co. KG. This is always ensured when using genuine replacement parts from the applicable replacement parts list.

Only ever deploy trained or instructed personnel and clearly define personnel responsibilities with regard to operating, servicing and repair.

Use for other purposes and modifications

We expressly point out that the EC declaration shall become null and void if modifications / changes etc. are made to the machines listed above. The company making the modification must amend the EC declaration and extend or make out new documentation to reflect the latest modification.(Art. 8 paragraph 6 of the EC Machinery Directive)

3. Verification of instruction

By signing this protocol the undersigned confirms that the following details and specifications are correct.

Confirmation

I hereby confirm that I have read and understood the operating manual for the machine:

Designation BlueMax Mini Modular Plus

Type Automatic drilling and insertion machine

Machine no.

have read and understood.

I furthermore undertake to observe and follow the general safety precautions, the servicing and care instructions as well as power-up and operating instructions and the provisions relating to malfunctions. I am aware that any failure to observe these instructions and provisions may lead to accidents, put persons at risk and result in damage to property and the machine.

Name

Date

from / to

Instructor Person instructed Operation Safety rules Servicing

Type of instruction received

Signature

of the per-

son having

received

instruction

General safety rules

3. General safety rules

1. Basics 8

Information for operating personnel 8

2. General 9

3. Safety advice for the user company 10

4. Noise 10

5. Oils, greases and other chemical substances 10

6. Residual risk 10

7. Safety advice for operating personnel 11

8. Safety advice for operating the machine 11

9. Safety advice for carrying out maintenance work 11

10. Training / instruction 11

11. Personal protective equipment 12

1. Information on signs, symbols and markings

The safety advice in these operating instructions is structured

as follows:

DANGER

This danger note draws attention to an immediately dangerous situation that will lead to death or serious injuries if the safety measures are not followed.

WARNING

This danger note draws attention to a potentially dangerous situation that may lead to death or serious injuries if the safety measures are not followed.

CAUTION

This danger note draws attention to a potentially dangerous situation that may lead to minor or slight injuries if the safety measures are not followed

NOTE

This note draws attention to potential damage to property or to a process of particular interest / importance that may occur if the safety measures are not

followed.

In the operating instructions, hazard points are identified as follows:

DANGER

Danger from electric shock!

Working on live components in the improper manner

presents a danger to life!

Work on electrical equipment must only be carried out by authorised electricians!

WARNING

Hearing damage warning!

Some areas of the facility can reach noise levels of

over 80 dB (A).

Wear ear protectors when working in noisy areas!

WARNING

Danger from wood dust!

Wood dust can affect the respiratory tract.

For this reason, wear a dust protection mask.

WARNING

Fire risk!

Grinding and welding work must never be performed

on this machine.

Follow welding regulations and accident prevention regulations.

WARNING

Explosion protection

Machine is not explosion-protected. Do not install

near paint shops.

WARNING

Warning - Hand injuries!

Hands could be crushed, drawn in or otherwise injured.

Never reach into the system's moving parts!

Wear hand protection!

WARNING

Warning - Hot surfaces / objects!

There is a risk of injury from touching hot surfaces

(e.g. electric motors).

Do not touch!

Work requiring specialised knowledge (e.g. electrical, pneumatic system) must only be carried out by persons specifically trained and suitable to do so.

Before attempting any work on the machine, turn the main switch to the "0" position“ (OFF), make the machine safe and disconnect from the compressed air supply.

Switch off energy sources before carrying out repair, servicing, installation or cleaning work.

Energy sources:

• Electrical energy

• Pneumatic energy

CAUTION

Danger from residual energy!

Stored energy will not be dissipated even after switching

the system off at the main switch.

Dissipate residual or stored energy!

Switch off / dissipate energy sources:

For safety regulations applicable to third-party devices, refer to the documentation from the third-party manufacturers (operating instructions for bought in units).

Electrical energy via the motor switch / machine's main switch. Additionally attach a notice when servicing or other work is being carried out on the machine.

2. General

The machine described in these operating instructions is built to the state of the art and is safe to operate. It complies with DIN EN 12100.

Hazard zones are made safe in compliance with the regulations. However, the machine may present hazards if it is used by untrained personnel improperly or not for the intended purpose.

This may then result in risks to life and limb, jeopardise the machine and prevent it from working efficiently.

Any person given the task of installing, starting, operating, servicing or repairing the machine at the user's premises must have read and understood these instructions, in particular the section on "Safety advice".

In his or her own interest, the safety officer at the user company should obtain written conformation from operating personnel that they have received instruction and training and are familiar with all safety advice before they use the machine for the first time.

The safety guards must never be removed or taken out of operation.

If safety guards need removing for maintenance and repair work, they must be refitted as soon as such work has been completed.

The machine must only be used if it is in proper working order and operated by trained, authorised personnel.

Fig. 3: Motor switch

Fig. 4: Main switch (viewed by the operator, on the right hand side of the machine frame)

General safety rules

CAUTION

Warning - Hand injuries!

The main switch only shuts down the drive system, not

the pneumatic system!

The machine has no emergency STOP button or emergency stop facility. This means it is necessary to take particular care when handling and working on this machine.

Pneumatic energy through the supply connection on the machine frame. Make sure that all machine components are depressurised and any stored energy is dissipated. As part of the installation process, the owner will provide a mechanical main cock at which the machine can be disconnected from the compressed air supply.

WARNING

Never

• reach into the machine when it is operating

• remove covers and take safety guards out of operation

• hinder unobstructed access to the controls

• continue operating the machine if changes occur that adversely affect safety

• manipulate or circumvent safety guards

4. Noise

The weighted equivalent continuous sound level is > 80 dB (A).

WARNING

Hearing damage warning!

Local conditions may produce elevated sound pressure and

cause noise induced hearing loss!

Operating personnel must be provided with appropriate protective equipment or be protected by other measures!

Wear ear protectors when working with the machine!

Fig. 4: Pneumatic system servicing unit (viewed by the operator, on the left hand rear side of the machine frame)

3. Safety advice for the user company

All persons entrusted with operating the machine (including line managers) must familiarise themselves with the section on "Safety advice". The safety advice must be followed.

The machine must only be used if it is in proper working order. The user company will issue clear responsibilities, e.g. for servicing, cleaning or repair, and ensure that the persons carrying out this type of work have received the training necessary for it.

The safety regulations applicable in the owner's country must also be observed. Refrain from any work that adversely affects operating safety.

The operating personnel will check the machine for changes or malfunctions, report such to the safety officer responsible and, if necessary, take the machine out of operation.

Only appropriate tools may be used for the work that needs to be done; remove tools after completing work. The place at which staff work must be selected in such a way as to ensure that work operations can be viewed at all times, the machine can always be stopped immediately and safety is never at risk.

5. Oils, greases and other chemical substances

When handling oils, greases and other chemical substances, you must observe and follow the applicable regulations and safety data sheets of the manufacturers of these substances with regard to storing, handling, using and disposing of them.

When working with caustic substances, you must wear protective equipment of a suitable material (safety goggles, rubber gloves, rubber boots, protective clothing).

In the event of contact with the eyes or skin, immediately rinse the area affected with copious quantities of water. Appropriate facilities (eye wash bottle, wash basin, shower) must be provided near the work area.

6. Residual risk

CAUTION

Residual hazards!

Handling the machine involves residual hazards that could

not be eliminated by design measures.

Pay attention to the residual risks in the Technical Documentation!

The machine reflects the state of the art and is built in accordance with recognised safety regulations. All the same, the user or third parties may still be exposed to hazards.

The machine must be used

• for the intended purpose

• in an absolutely safe state.

WARNING

Risk of injury!

Never remove safety devices or render them ineffective by

making changes to the machine!

Malfunctions presenting a safety risk must be rectified without delay!

Before attempting servicing and cleaning work, switch off the entire machine and disconnect from the compressed air supply!

7. Safety advice for operating personnel

• Work on the machine must only be carried out by instructed, skilled personnel

• Only skilled personnel who have received training or instruction must be deployed

• The generally recognised code of occupational health and safety as well as accident prevention regulations must be observed

• Please keep first aid equipment (first aid kit) in easy reach

• · The owner must stipulate that operating personnel are to wear personal protective equipment (safety shoes and sturdy work clothing).

Work which may be done by the operating personnel

• Activate, deactivate the machine

• Change drill bits

• Set the machine to component dimension

• Feed in individual parts (flat panels made of engineered wood, hinges and connecting fittings)

• Start the drilling and inserting process

• Remove finished components

• Clean the machine

Requirements on operators

The operator must organise the work environment so as to permit optimum, continuous production.

The operator must receive instruction before commencing work for the first time and annually thereafter.

Prior to commencing work, all persons working on or at the system shall undertake to

• follow the basic regulations on health and safety at work and on accident prevention

• wear personal / workplace related protective clothing and equipment for the purpose of ensuring work safety and use such while working if they are necessary for safety reasons

Work must only performed for which authorisation has been given. For example

• work on pneumatic equipment must only be carried out by a specialist specifically trained to do so or by instructed persons under the direction and supervision of such a specialist in accordance with the applicable technical regulations

8. Safety advice for operating the machine

• The machine must only be put into operation in a fully installed and operational state

• The machine must only be operated if all protective guards and safety related equipment, e.g. protective claddings or enclosures, are in working order and undamaged

• On putting the system into operation, the operator must make sure that all safety equipment and protective guards as well as the controls are in correct working order and free of damage

• The workplace environment must be kept clean and tidy at all times. This must be ensured by internal checks.

• Immediately report any irregularities or malfunctions to the department / person responsible. If necessary, the machine must be shut down immediately and made safe

9. Safety advice for carrying out maintenance work

• Maintenance work must only be performed by the manufacturer's skilled personnel or under the manufacturer's supervision

• If the machine is completely shut down for servicing and repair work, it must be prevented from switching back on unexpectedly

• If necessary, please cordon off the maintenance zone, providing a wide safety margin!

• Attach a warning sign

•

For maintenance measures, use tools that are appropriate for the work involved

• Servicing and repair work must only be carried out by the owner's qualified personnel

• If safety devices need removing for servicing and repair work, they must be refitted and checked as soon as the work has been completed

• Always tighten screw connections that have been loosened during servicing and repair work

• At the start of work, connections and screw connectors must be cleaned of oil, operating consumables and dirt

•

Make sure operating consumables and auxiliary substances as well as replaced parts are disposed of safely and in an environment friendly manner.

10. Training / instruction

• As owner, you are obliged to inform and instruct the operating personnel in respect of applicable legal and accident prevention regulations as well as the safety guards fitted. In this context, bear in mind the varying specialised qualifications of your staff

• The operating personnel must understand the instruction they are given, follow it as well as sign the documentation

• This is the only way you can be sure that operating personnel work in awareness of safety and of the hazards that are involved. As owner, you should therefore obtain written confirmation from all members of staff that they have received training/instruction

• Applying these safely measures will minimise potential hazards to such an extent that the machine can be operated safety

General safety rules

NOTE

All of the safety guards in place must be checked at least once before the start of each shift to make sure that they are in place and undamaged (visual

inspection).

11. Personal protective equipment

The owner must provide the following personal protective equipment:

• Safety shoes

• Ear protection

• Safety goggles

• Dust protection mask

• Safety gloves (as necessary)

Purpose / operating principle

4. Purpose / operating principle

1. General information 14

2. Intended use 14

3. Foreseeable incorrect use 14

4. Operating principle and description of the machine 15

Description of the machine 15

5. Rating plate 15

6. Limit values 15

7. Liability 15

1. General information

This operating manual must be kept at the machine at all

times and be constantly available there. To ensure safe operation and proper machine handling, it is important for you to have read and understood the operating manual and, in particular, the safety rules. The safety provisions and operating instructions described in this operating manual must be followed exactly.

Regularly check this machine's safety guards and work

sequences.

Danger!

Any person given the task of installing, servicing,

starting, operating or repairing the machine must have read and, in particular, understood these instructions.

2. Intended use

WARNING

The machine must only be used for its intended purpose and be in a perfectly safe condition!

Operating safety is only guaranteed if the machine is used for its intended purpose!

The BlueMax Mini Modular Plus is a semi automatic drilling

and insertion machine for panel type workpieces and the furniture fittings intended for them. This machine must only be used for working on flat panels made of wood-based materials, such as chipboard, blockboard panels, MDF, solid wood or similar materials.

Any other use beyond this is deemed to be improper and nonintended use.

Intended use also includes following the operating, servicing and maintenance conditions prescribed by the manufacturer.

Unauthorised changes to the machine will result in the loss of product liability and liability on the part of the manufacturer for resultant damage.

Any other use beyond this is deemed to be non-intended use. The manufacturer shall not be liable for any damage this causes, with the risk involved being borne solely by the user.

3. Foreseeable incorrect use

WARNING

Hazards may occur if the system is used incorrectly!

The following situations in particular are deemed to be foreseeable hazardous situations:

If the machine is used for any non-intended purpose, treated improperly or operated by untrained or unauthorised persons, it may present a risk of injury to personnel and a risk of damage to the machine itself. For this reason, only trained, instructed and authorised persons must be allowed to operate this machine.

•

Improperly assembling, starting, operating and servicing

this machine

• Operating the machine with faulty safety guards

• Operating the machine with improperly fitted safety guards

• Operating the machine with non-functioning safety

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guards and protective equipment

• Failing to observe the information and instructions given in the operating manual in relation to handling, storing, assembling, starting, operating, servicing and setting up this machine

• Unauthorised structural changes

• Unauthorised changes to this machine's drive system (power output, speed)

• Inadequate monitoring of machine parts subject to particular wear

• Improperly performed repairs

• Disasters caused by the impact of foreign objects or Acts of God

The situations above describe some of the residual hazards which, despite being impermissible, may occur and harm the health of staff.

The owner must observe the safety requirements defined in the German Ordinance on Industrial Safety and Health (Betriebssicherheitsverordnung).

4. Operating principle and description of the machine

Description of the machine

The BlueMax Mini Modular Plus is a semi automatic drilling

and insertion machine for panel type workpieces. This machine must only be used for working on flat panels made of wood-based materials, such as chipboard, blockboard panels, MDF, solid wood or similar materials.

All parts being worked on are fed into the machine by hand. Flat panels made of wood-based materials, such as chipboard, blockboard panels, MDF and solid wood are laid on the work table and fixed into place with the clamping equipment. The drilling process is initiated by pressing the start button / foot switch (optional). The start button / foot switch (optional) must remain pressed until the drilling process has been completed. Using the integrated insertion facility (optional), the furniture fittings are pressed into place by means of a manually operated press in frame (optional). This concludes the machining process.

Fig. 1: BlueMax Mini Modular Plus

5. Rating plate

Note!

The rating place is located on the machine.

The rating plate shows the following information:

Manufacturer

Address

Type designation, machine numbers

Year of manufacture

Technical specifications

(e.g. nominal pressure)

State all of the above details when requesting technical information and ordering replacement parts.

6. Limit values

The following limit values apply to items of equipment

and accessories, such as drive motors, electric / electronic operating equipment etc.:

• ambient temperature: max. 35°C

• rel. humidity: approx. 65%

Space required for the machine

The space required for the BlueMax Mini Modular Plus is largely determined by the dimensions of the machine base frame.

Machine life

The machine's life will depend on whether or not it is used for its intended purpose, on adherence to regular servicing intervals and on the regular replacement of expendable parts.

7. Liability

Defects must only be rectified by competent personnel.

Our liability is restricted to damage caused while using

the system in the intended manner. We shall not be liable for safety defects not yet identifiable on the basis of the current state of the art.

Failure to observe

• safety advice for operating personnel

• advice on particular hazards

• the ban on unauthorised modifications and changes

• the use of replacement and expendable parts or auxiliary materials other than those approved by the manufacturer will rule out any liability on our part for the consequences

Fig. 2: BlueMax Mini Modular Plus with accessories

Technical information

5. Technical information

1. Safety advice 16

2. Attachment points 16

3. Technical specifications 17

4. Equipment 18

Setting 22

5. Safety guards 22

6. Noise emission 23

7. Aligning / fastening 23

General information 23

8. Connections required 23

Main power connection 23

Compressed air connection 23

9. Handling 23

Transportation via fork lift truck or pallet jack 24

10. Internal handling 24

11. Checking delivery for missing items 24

12. Dealing with shipping damage 24

13. Measures for temporary storage 24

14. Site of installation 24

15. Safety guards to be provided by the owner 25

16. Permissible ambient conditions 25

17. Removing preservatives 25

18. Electrics 25

19. Compressed air connection 25

20. Suction extractor 25

1. Safety advice

Observe the regulations, warnings and provisions on health,

safety and environmental protection for all of the work described in this section.

2. Attachment points

Only use suitable and approved lifting gear (crane) for

unloading the machine, assemblies and components as well as for lifting heavy loads; only use appropriate means of transport for handling the machine internally.

Any unloading or internal handling must not be done by hand

if such involves weights in excess of 25 kg.

When using industrial trucks to unload the machine and move

it internally, always take into account the machine's total permissible weight (see Technical specifications).

Danger!

Never stand or work under loads suspended on lifting

gear. This presents the risk of fatal injury!

Observe the following when using lifting gear:

•

Only attach lifting gear at the points marked (lifting

eyebolts etc.) on the machine / assemblies / components

•

Only use appropriate and tested load suspension devices

(lifting belts, ropes, chains, shackles etc.) with a sufficient load carrying capacity

•

Only assign experienced, skilled personnel the task of

attaching the machine / assemblies / components

•

Always ensure level standing for machine / assemblies, lift

vertically, never drag at an angle

Protect projecting machine parts and equipment from damage

when using lifting gear and moving the machine internally.

Set down loads gently with the usual care and take

immediate action to prevent them from falling over / tipping, rolling away, suffering damage from external force, e.g. colliding with industrial trucks and objects falling from above.

3. Technical specifications

Designation: Automatic drilling and insertion machines for panel type workpieces

BlueMax Mini Modular Plus

H x W x D (mm) 862 x 800 x 1856

Weight approx. 145 kg

Power output data

Cycle time manual

Electrics

Operating voltage 400 V

Motor power 1.1 kW

HB unit power 0.55 kW

Rated current 2.65 A

Mains power fuse protection 6 A

Pneumatic system

Air pressure min. 6 bar, max. 7 bar

Noise Max. noise level: > 80 dB (A)

Temperature < 35°C

Working dimensions, vertical drilling unit

Max. workpiece thickness: 38 mm

Max. drill bit diameter: 35 mm

Max. drilling size: 30 mm

Max. pull out distance of drilling unit: 600 mm

Working dimensions, horizontal drilling unit

Max. workpiece thickness: 38 mm

Max. drill bit diameter: 8 mm

Max. drilling height: 5 – 20 mm

Max. drilling depth: 40 mm

Space required for machine

Technical information

4. Equipment

Switches and other controls for operating and monitoring the machine are described below.

2 to 6

1 7

to 6

2 3 4 5 6

Fig. 5: Controls on the automatic drilling and insertion machines

Item Designation Explanation

1 2 3 4 5 6 7

Motor switch Power supply ON / OFF

Pushbutton For activating work process

Change-over switch Drilling vertically / horizontally

Pushbutton For automatically unclamping the hold-down clamps

Pushbutton For manually releasing the front hold-down clamps

Pushbutton For manually releasing the rear hold-down clamps

Main switch Machine power supply ON / OFF

1818

NOTE

The pushbutton is not operational when using the foot switch.

Fig. 6: Foot switch (optional)

Item Designation Explanation

Foot switch (optional) For activating work process

Fig. 7: Compressed air connection

Item Designation Explanation

1 2

Pressure regulator For setting operating pressure (6-7 bar)

Plug in coupler Compressed air connection

1919

Technical information

Digital display

Fig. 8: Position display panel

Operating mode:

Reference value

Chain dimension

Offset dimension

Inch display

2020

Press simultaneously

Switch over incremental

- absolute

This button activates the selectable offset dimensions

Switch over to inch mode, fraction notation (1/64, 1/32, 1/16), decimal 0.001

Parameter level:

Activate parameter level

Select parameter

Select decades

Increase decade

Change sign

Leave parameter level

Press for approx. 3 seconds

Press button once

Press for approx. 3 seconds

Parameter Specification Default

System configuration:

P01: A

P02: A

P03: A Decimal point (0…4) 2

P04: A

P05: ABC

P07: A

A = 0: positive counting direction A = 1: negative counting direction

Display mode: A = 0: mm display symbol " mm " A = 1: inch display symbol " Inch " A = 2: mm display symbol " m " A = 3: mm display symbol " ° " A = 4: mm display no symbol

Standby: 0: Sleep mode deactivated (not recommended) Auto power ON when sensor moving or button press (button F)

Button lock: A: " SET " (0 = not active) -

(1 = active)

B: " Incr/Abs " (0 = not active) -

(1 = active)

C: " * " (0 = not active) -

(1 = active)

Basic resolution: A = 0: resolution 0.01 mm A = 1: resolution 0.1 mm

000

P08: Multiplication factor (0.0001…9.9999) 1.0000

P09: Reference value (-999999.9… + 999999.9) 0.0

P10: Offset dimension 1 (-999999.9… + 999999.9) 0.0

P11: Offset dimension 2 (-999999.9… + 999999.9) 0.0

P12: Offset dimension 3 (-999999.9… + 999999.9) 0.0

Configuration of offset dimensions (0…3) A = 0: offset dimensions cannot be selected

P13: A

P9: Software version X.XX

A = 1: offset dimension 1 can be selected A = 2: offset dimensions 1 and 2 can be selected A = 3: offset dimensions 1 and 2 and 3 can be selected

Calibration:

The sensor must be on the magnetic strip!

> Switch off device

–>

Switch device back on again by simultaneously pressing

button

–> This triggers the sensor calibration and displays "Cal 0".

Slowly move sensor in one direction on the magnetic strip. On completion of calibration (display "Cal 0" … "Cal 4") the display returns to the normal status

2121

Technical information

Setting

WARNING

Setup work may only be performed by qualified staff who,

on the basis of their specialised training, experience and instruction, possess sufficient knowledge of

• safety rules

• accident prevention regulations

• guidelines and generally accepted codes of practice

These qualified staff must be authorised to perform setting up work by the person responsible for the machine's safety.

5. Safety guards

Separating protective guards complying with EN 953 are

installed on the machine to protect staff from mechanical hazards.

Warnings / pictograms are also provided on the machine.

Labelling

Area: entire machine

Warning of the risk of hands being crushed

Fig. 10: Labelling – entire machine

Area: hold-down clamps

Warning of the risk of hands being crushed

Fig. 9: Transparent cover

WARNING

The guards must not be modified, tampered with or taken out of operation.

The machine has no emergency STOP button or emergency stop facility. This means it is necessary to take particular care when handling and working with this machine.

Fig. 11: Labelling – hold-down clamps

Area: protective cover on tools

Warning of the risk of hands being crushed

Fig. 12: Labelling – drilling and insertion unit

Area: motor / drive

Reminder to unplug the mains power plug before changing tools

Fig. 13: Labelling – Motor / drive

6. Noise emission

This machine operates at a noise level above 80 dB(A). We

recommend wearing ear protectors at all times to prevent damage to hearing.

WARNING

Wear ear protection.

7. Aligning / fastening

General information

The machine should be installed on a level, load-bearing

stand with firmly standing feet.

Any machine must be installed in a way that prevents it from

moving about and tipping over.

Area: entire machine

Reminder to unplug the mains power plug and disconnect compressed air before changing tools. Main switch does not disconnect the machine from the compressed air system.

Fig. 14: Labelling – entire machine

Area: protective cover on tools

Labelling on laser beam

NOTE

Securely installed machines prevent accidents.

8. Connections required

Main power connection

Connection to the electrical power supply is made by

connecting a 16 A plug

2 to a prepared socket 1 with

appropriate fuse protection.

Care must be taken not to damage electrical supply leads.

These must be changed whenever necessary.

NOTE

Before plugging in, instruct a qualified electrician to

check the socket.

Compressed air connection

The entire machine is connected to a central in-house

compressed air supply system.

The supply line is fitted with a plug in coupler

The operating pressure must be set to 6 - 7 bar at the

pressure regulator

This must be checked at the pressure gauge.

Fig. 15: Labelling – laser beam

Area: drill bits

Labelling on turning direction of drill bits

Fig. 16: Labelling – turning direction of drill bits

NOTE

Only feed in dry compressed air as the pneumatic

system is largely operated on unoiled air.

9. Handling

The machine must only be transported and installed by companies / persons instructed / authorised to do so by the manufacturer or under the manufacturer's supervision.

After moving the machine, every part of it must be checked for shipping damage as possible harm may impair system operation and safety.

NOTE

To prepare transportation, please bear in mind the weight of the machine!

The machine weighs approx. 145 kg.

Technical information

Transportation via fork lift truck or pallet jack:

If fork lift trucks or hand pallet jacks are used for loading or unloading, they must be in proper working order and suitable for carrying the weights that are involved.

Attention must always be paid to the centre of gravity of the item being moved! During transportation, the machines must be properly secured; the load must be evenly distributed. Avoid jerky movements.

Set the machine down without bumps or jolts as well as in an upright standing position. Take immediate action to prevent these from being damaged by transportation vehicles and from tipping over.

On unloading, handling and keeping the machine in temporary storage, treat it with the greatest possible care and protect it from the weather, impact of external force and from falling objects.

WARNING

Warning of suspended loads!

To relocate the machine, it must be lifted and transported.

The machine can topple over and fall as a result of improper lifting and transportation.

Never stand under suspended loads!

WARNING

Warning of suspended loads!

While transporting the machine, no persons must be

present on the machine or hang from it.

10.

Internal handling:

To move the machine internally, only use trolleys of sufficient stability and load bearing capacity. When handling, always be sure to avoid knocks and vibration. Provide protruding objects (motors, drag chains, wiring harnesses, hoses, cylinders) with effective protection from damage.

13.

Measures for temporary storage

The machine is designed for immediate installation and start

up. The following measures must be taken if this does not take place within a reasonable period of about 3 months after receiving the machine:

•

Coat bare metal parts with corrosion inhibiting oil.

•

Cover the control system, electrical devices / operating

equipment, drive motors to protect them from moisture and dust.

•

Taking particular care, cover / use adhesive tape to seal off

cable inlets into terminal boxes and plugs.

•

Protect wiring harnesses from vermin. Mice and rats are

particularly partial to highly flexible cables.

• Store the machine in a dry, frost free room.

• Also observe the storage instructions.

Apply appropriate measures to protect the stored machine

from tipping over, falling objects, impact from external force (e.g. industrial vehicles bumping into it), knocks and vibrations.

14.

Site of installation

An even standing surface with a sufficient load bearing capacity is essential for setting up the machine in a proper and safe manner. Any unevenness in the standing surface must be evened out by metal shims to ensure that the machine is not standing in a distorted manner.

The BlueMax Mini Modular Plus comes in secure shipment packaging for safe transportation. A number of components must be installed to make the machine ready for operation. After installing the machine, it must be cleaned.

Using the 4 black brackets conjunction with sliding block on the foot profile), secure the machine on a bench / base frame to be provided at the site of installation so as to prevent the machine from falling.

1 supplied with the machine (in

11. Checking delivery for missing items

Refer to the order confirmation or the list in this operating manual as well as the delivery note to ascertain what should be included. On receipt, immediately check to make sure a delivery is complete. Notify the shipping company making the delivery of any missing parts (notice of loss) and also immediately inform Hettich FurnTech GmbH & Co. KG.

12.

Dealing with shipping damage

Immediately after arrival and unloading, thoroughly check the machine for any shipping damage, i.e for externally visible damage (fractures, dents, kinks, cracks etc.).

Any suspected shipping damage must immediately be:

• reported in writing to the shipping company making the

delivery (forwarder) and/or

• reported in writing to your own insurance company as well

if the transportation risk was insured by the owner

CAUTION

Risk of crushing!

Allow a space of at least 500 mm between moving

machine parts and pillars, parts of the building, cabinets etc.!

Do not stand any laden pallets in this safety zone!

15. Safety guards to be provided by the owner

Safety guards provided by the owner must be easily accessible

and in full working order after installing the machine. They must not interfere with the machine's own safety guards in operation on site.

The site of installation must be selected in such a way that

will also allow repairs to be performed at a later date without physical obstruction.

16. Permissible ambient conditions

•

The machine must only be installed and operated in dry

rooms

•

The machine is not explosion-protected. The machine must

not be installed near painting facilities

•

Provide a supply of fresh air to the fan cowls on electric

motors

•

Avoid any external mechanical strain on the machine

17. Removing preservatives

The machine is only coated with preservatives for transportation.

•

Clean dust and shipping dirt from the machine with a dry

cloth.

•

Never use cold-cleaning products, nitrocellulose thinners or

other aggressive chemicals!

•

Remove all transport braces. These should be kept for later

reuse

20. Suction extractor

It is compulsory to use a flexible, fire-retardant hose for connection to an extractor system. A suction extraction line is not included.

• Outside diameter (suction connector) 80 mm

• Air flow rate min. 20 m/s

NOTE

For further technical specifications, refer to the documentation provided by the manufacturers.

Unauthorised changes and modifications to the system are not permitted for safety reasons and rule out any liability on the part of the manufacturer for any resultant damage.

18. Electrics

The automatic drilling and insertion machine is fitted with a

connection cable and a 16 amp plug. The power socket must be checked for proper working order by a qualified electrician.

You will find the applicable connection specifications on the rating plate on the machine.

Requirements on the electrical power supply

Connection must only be made to an electrical system complying with VDE 0100. The electrical safety of this equipment is only guaranteed if it is connected to a protective earth conductor system that complies with regulations. It is very important to check that this basic safety requirement is met and that the machine is provided with adequate fuse protection. The manufacturer cannot be held responsible for damage cause by a lacking or interrupted protective earth conductor. The rating plate provides information on rated input and the appropriate fuse protection.

19. Compressed air connection

The automatic drilling and insertion machine has a fitted coupler plug, nominal width 7.2

• Max. input pressure 8 bar / 100 psi

Start up / trial run

6. Start up

1. General 27

2. Safety check 27

3. Malfunctions on start up 27

4. Starting up for the first time 27

5. Machine versions supplied 28

6. Interchangeable drilling units 29

Interchangeable drilling unit, 3 spindles, Selekta 29

Interchangeable drilling unit, System 32 hole line 29

Interchangeable drilling unit, System 32 hole line 90° 29

7. Other accessories 29

8. Assemblies 30

Press in frame for the interchangeable drilling unit, 6 spindles 30

Centre stop 31

Continuation stops 31

Drum stop 33

Hold-down clamp 33

Converting from manual operation to foot switch 34

Connecting foot switch for a machine

with horizontal drilling unit 34

Connecting foot switch for a machine

without horizontal drilling unit 35

9. Carrying out trial run 36

1. General

The instructions described here are to be understood as

minimum recommendations. Depending on operating conditions, they may need to be broadened in order to maintain the machine's working quality.

Servicing and maintenance work in specific disciplines (pneumatics etc.) must only be carried out by skilled persons trained in that particular discipline.

Observe the following safety advice!

WARNING

You could get crushed by moving parts if the machine is not shut down.

The machine must be depressurised and disconnected from the power supply before carrying out maintenance and cleaning work!

NOTE

Improper repair will result in damage to the machine!

Improper dismantling and assembly may result in property damage or consequential damage to the machine.

Therefore, when carrying out any removal or dismantling activity, always:

• Mark parts that belong together

• Mark and note down position and place of installation

• Remove and keep assemblies separate

After carrying out maintenance work, always:

• Check all screw connections to make sure they are tight. Close and screw down all covers

As with starting up, listen for unusual noises and check to see if there is any heat buildup!

2. Safety check

The machine must only be put into operation by trained and qualified personnel.

Satisfy yourself that:

• installation, set up and servicing work have been completed in full and no persons are present in the danger zone, let alone working on it

• all safety guards / covers are in place

• the compressed air supply is ready for operation

• the controls are readily accessible

3. Malfunctions on start up

On start up, immediately switch OFF the power supply to the machine if:

• unusual operating noises can be heard

• the machine runs irregularly, oscillates or vibrates

• auxiliary units malfunction

• the motors consume too much power

• there are electrical faults

• tools are overheating

DANGER

Danger from electric shock!

Working on live components in the improper manner

presents a danger to life!

Work on electrical equipment must only be carried out by authorised electricians!

Establish the cause of any malfunctions with the machine shut down and made safe and have it rectified by a qualified and skilled person trained to do so or eliminate the malfunction yourself if you are in possession of the necessary qualification.

Only switch the machine back on again once malfunctions / faults have been properly and completely rectified!

4. Starting up for the first time

Before starting up the machine for the first time, observe the

following:

NOTE

The machine must only be put into operation for the first time by a person instructed / authorised to do so by the manufacturer / distributor or under the manufacturer's / distributor's supervision.

• Check to make sure the machine has been installed in accordance with the regulations specified!

• Make sure the machine stands firmly.

• Check to make sure that no foreign objects (tools, construction material etc.) have been left in the area of the machine from the assembly process.

• Check the hoses as well as the pneumatic system's hose connections.

• Check the safety guards for proper working order.

• Make sure that moving components can move without obstruction into the spaces they require and that the safety distances are observed.

+ 61 hidden pages

Hettich BlueMax Mini Modular Plus Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual