RIVKLE ® Type EPK setting tool RIVKLE® type EPK setting tool User and maintenance guide Revision index: | Date: 29/06/2021 BOLLHOFF Bollhoff Otalu SAS Zi de rAlbanne Rue Archiméde CS 40068 F ~ 73493 LA RAVOIRE CEDEX Tel, : +33 (0)4 79 96 70 00 Internet: http://www. boellhoff.com Translation of the original instructions (French)RIVKLE © Type EPK setting tool Symbols mentioned in the user guide ‘The paragraphs in the user guide that are particularly important are identified by the symbols. explained below. Danger pictograms > ee Danger! This symbol indicates a danger for the life or for the health of operators and can cause serious injury, likely to cause death, Attention ~ danger, electric voltage! This symbol warns of risks of electrocution linked to system handling, Attention ~ danger, risk of crushing! This symbol wars of risks of injury by crushing. Personal protection equipment ©@0e Miscellaneous = O Wear safety gloves For the actions indicated by this pictogram itis absolutely necessary to wear safety gloves. Wear safety goggles. For the actions indicated by this pictogram itis absolutely necessary to wear safety goggles. Wear ear protection For the actions indicated by this pictogram itis absolutely necessary to wear ear protection. User Guide This symbol indicates that the instructions in the user guide have to be respected. This symbol gives you tips and advice and extra information for safe and efficient work ‘The figures given in the text in brackets are reference numbers roferring to lists.RIVKLE © Type EPK setting too! Equipment quick start i Control unit installation Power connexion §3.1, 63.2 2 Setting head installation and connexion 53.3.2 Preparing for start up 53.3 4 Calibration of pressure/stroke sensors 53.6 Adjustment of pressure/stroke thresholds and stroke control Doss Production DassRIVKLE ® Type EPK setting tool Contents 1.0 Safety instructions . . 7 44. Precautions for US@ wn so 7 1.2. Authorisation. “ sonar 8 1.3. Transportation and handling eer 9 2.0 Description of the system 10 2.4. Control Unit sou A 244 Description. "1 2.1.3. Technical characteristics 13 22. Setting head oe . 14 2.2.1. EPK setting Head ...nsne 15 2.22. _ EPKC revolver setting head os - 16 2.23. EPKC TOP revolver setting head 7 2.2.4. Vertical EPKC setting head... . 18 2.25. SP 3ML Vertical EPKC setting head eee 19 2.2.6. _ EPKC horizontal setting head. “ 20 2.2.7. EPKHP Setting head 2 23. Options oes ssn 2 2.3.1. *Rollers" option ee - 2 23.2. — “2colours Stack Light” option so 2 2.3.3. “Clamping” option 23 2.3.4. “Screen protection” option oe 24 2.3.5. “Contact” option oe 24 2.38. “Key switch” option 25 2.3.7. « Parameters selection » option... 25 2.38. — « EPKC_SAC » option 25 2.38. — « Gateway » option 26 3.0. Preparing for start up. ; 2 3.4, Transportation a 3.2. Installing the control cabinet... 5 soon BT 27 3.3. Connecting the cabinet. 3.3.1. Pneumatic connection3.3.2 3.3.3, 33.4, RIVKLE © Type EPK setting too! Connecting the head to the cabinet, Connecting the control unit with the two-head option.. Connecting the "Parameters selection option” 3.4. Preparation before start-up, 344 342. 34.3. 34.4 ‘Changing installation tools. EPK heads EPKC heads. EPKHP heads. 3.5. Setting the parameters of the machine .. 3.5.1. 35.2 35.3 3.5.4 355. 35.6. 3.8.7. Putting into service before setting the parameters Parameters menu Language..... Options Serial counting Automatic reset Fault historic display 3.6. Calibrating the sensor. 3.6.1 36.2 36.3 36.4 36.5. 366. 367. 36.8. 36.9, 3.6.10, 36.11 3.6.12 3.6.13, 3.6.14 36.15 3.6.16, Pressure sensor. Calibrating the stroke sensor. Stroke and pressure parameters Determining the pressure threshold with a load indicator, Setting the pressure threshold. Stroke control Timers and counters. Setting start cycle delay. Delay unscrewing timer Unscrewing time Good setting information delay Number RIVKLE® of per part counter Number of parts per series counter ‘Worn mandrel warning Mandre! worn Counter. 29 29 30 30 30 34 33 36 38 38 39 42 42 44 44 45 45 45: 46 48 49 51 53, 57 87 87 57 58 58 58 59RIVKLE © Type EPK setting tool 3.6.17. Saving data and parameters on a USB stick. 59 3.7. Device integration... son 62 3.7.1. Integration of the setting head... 62 3.7.2, Control unit integration anne svn 82 3.7.3. Standard integration options. aa 63 3.7.4. Specific integration options. so 63 4.0 Operating and using the device sone OF 4.4. EPKC operating principle eae a 64 4.2. Putting the machine into operation. 65 4.2.1. Reminder of safety instructions. 65 43. Using the equipment 66 4.3.1. Presentation of the operator interface... 66 4.3.2. Operating cycle.... aa 68 4.3.3. Set of parameters selection 70 4.3.4. Declaration of fauits in production mode. sone TT 4.4, Turing the equipment of. 79 5.0 Maintenance “ . 80 6.1. General information... 80 5.2. Preventive maintenance ssn a1 5.2.1. List of maintenance operations, sone BA 5.3. Disassembly of the internal mechanical parts of the setting head “ 82 53.1. EPK setting head se B2 5.3.2. EPKC setting head 64 53.3. EPKHP setting head 86 5.4. Purging the setting head. soe 5.4.1. Equipment required to perform the purge of the head hydraulic circuit a1 542. Procedure . . 1 5.4.3. Position of the purge screw depending on the type of head... 93 5.5. Mechanical adjustment of the setting head 94 5.5.1. Disassembly / adjustment of the traction dowel 94 5.5.2. Adjusting the Push-Pull valve “ 7 101 56. Replacing seals 5.6.1. EPK setting heads: . 101RIVKLE ® Type EPK setting tool 56.2. EPKC setting head “102 57. Diagnostic 103 5.7.1. Viewing Inputs / Outputs snes 104 5.7.2. Machine status. 107 5.7.3. Settings history snes 107 574. Cycle time 108 5.8. Transfer and updating the software. 108 5.8.1. Transfer with a USB stick... 108 59. Troubleshooting so 110 6.0 Waste discharge am 7.0 Drawings. . 112RIVKLE @ Type EPK setting tool 1.0 Safety instructions 1.1. Precautions for Use The equipment is designed to set blind nuts insert (RIVKLE®) on soft metal parts (steel, stainless steel, aluminium) and plastic parts. ‘The housing of the parts receiving the RIVKLE® has to be accessible to the rivet head and to comply with BOLLHOFF recommendations. It is forbidden to set brittle materials such as glass and derivatives of glass. For all applications using special materials, itis preferable to contact BOLLHOFF to carry out possible testing in order to validate the product and the resistance characteristics requested ‘The equipment is to be used in accordance with the recommendations described in this technical guide. It is mandatory to respect the safety instructions described in this documentation. Do not connect or disconnect live hydraulics. Do not put your fingers into the different holes of the equipment. > O Do not obstruct air vents. Ensure that the setting head is perpendicular to the apy Do not put your fingers on the RIVKLE® when setting. Wearing protective gloves is highly recommended while using the machine, specifically during adjustments and settings. Ob Itis formally not advised to modify the equipment or to work on the program without the written authorisation of BOLLHOFF. ‘The responsiblity of BOLLHOFF will not be retained in case of non-compliance with the recommendations and procedures described in this documentation.RIVKLE © Type EPK setting tool 1.2. Authorisation Only an authorised and competent person is allowed to install the equipment, according to the procedures described in the technical file and safety instructions. The different installation tasks require certain qualifications which are specified in the table below. | Seting automaton parameters x a Feuts identication x |cteaning x Mechanical repairs and maintenance |X x | Hydraulic repairs and maintenance x Etectrcal repairs and maintenance x ]Preumtc repairs end maintenance x [Decommissioning x | Frensport x Waste / Sorting x __ | Personnel trained by BOLLHOFF + The operator trained by BOLLHOFF must be able to make the equipment work and to intervene in case of faults or problems and inform his manager of them. +The technician trained by BOLLHOFF must be able to make the equipment work and to intervene in case of faults or problems and inform his manager of them Personnel trained on hydraulics ‘Must have knowledge of the hydraulic diagrams and the hydraulic system of the equipment. Must be able to carry out maintenance, assembly and disassembly of hydraulic connections and notify possible faults,RIVKLE ® Type EPK setting tool Personnel trained on electrics Must have knowledge of electrical diagrams and of the equipment automatism. Must be able to carry out maintenance, to instal the software, the wires; ensure the correct functioning of the electrical equipment and inform the manager of possible faults. Personnel trained on pneumatics Must have knowledge of pneumatic diagrams and of the equipment automaton. Must be able to carry ‘out maintenance, to ensure the correct functioning of the pneumatic equipment and inform the manager of possible faults. 4.3. Transportation and handling The device is delivered in a “box pallet ‘The handling of the control box is to be made using a “pallet truck’ type device, The rivet heads have to be handled with care with particular attention for the bundle protected by the corrugated tubing (curve radius 500mm minimum). Never lie the control cabinet down. Not respecting this instruction can cause the device A to stop working. A purge of the hydraulic circuit would then be needed to remove the air present in the oil.RIVKLE © Type EPK setting tool 2.0 Description of the system A complete set of equipment is generally composed of ‘+ Acontrol unit (1) ‘+ Asetting head connected to the control unit by a hydro pneumatic and electric bundle (2) a) - ne © (2)RIVKLE © Type EPK setting tool 2.1, Control Unit 2.1.1.Description The control unit is composed of. ‘+ Acommunication interface including an HMI (Human Machine Interface) screen (1) + Anelectrical part (2), ‘= Ahydro pneumatic part: booster, solenoid valve and air processor (3). (a) (2) (3) > Communication interface The following table explains the functions of the different buttons on the communication interface (5) @) Q) (4) a) (6) (Back view)RIVKLE @ Type EPK setting tool the EPKC equipment to 2 |Air pressure manometer! Indicates the pneumatic pressure of the EPKC equipment 3 Fault lamp Flashes red when there’s a fault on the equipment ™ Button to start and pressurise the equipment. 4 ‘ON" iluminated button : ‘When the equipment is “on’, the white lamp is lit ‘Depending on the case, the button can be yellow, which +5 Emergency stop button | means “machine stop” or red, which means “emergency ‘Stops machine sop”. The function of this is to cut all the power on the equipment when it is pressed. Touch screen for automaton tasks. * io Manages all the equipment functioning. a punter pp | _CEPaD wi te orn ee he ser ramber of > Electrical part This part of the cabinet gathers together all the electrical and communication components, needed to operate the equipment (auxiliary contactor, electrical protection, etc.). For more details, refer to the electrical diagram. > Hydro pneumatic part ‘The pressure multiplier provides the setting effort for the setting head to set RIVKLE®. To this end, the pressure multiplier converts a pneumatic force into a hydraulic force, depending on the rmuttiplication ratio mentioned below. ‘© Pressure muttiplier with standard box: aldescripton | Hydraulic pressure max at 6 bars 246 Bar Oil volume. 22 m3 Hydraulic output connector Straight [Pneumatic teed 6 Bar internal min @ of the pneumatic feed 10 mm instrument weight 10 KgRIVKLE ® Type EPK setting tool * Pressure multiplier with high pressure cabinet: |Hydraulic pressure max at 6 bars 306 Bar [Oil volume 36 cm3 |Hydraulic output connector ‘Straight [Pneumatic feed 6 Bar Internal min of the pneumatic feed 10 mm Instrument weight 12 Kg Pressure multiplier (Booster) 2.1.3.Technical characteristics emt ths fa Passa a aan rai ica —— alles Ustasme fecaeay cea Sari Femainveacia iim ae — entailRIVKLE @ Type EPK setting tool 2.2.Setting head The choice of tool depends on the integration of the equipment on the production site and its use. In all cases, the setting head has to be perpendicular to the bearing surface to ensure the a correct setting of the RIVKLE® and to preserve the tooling. In order to facilitate the head positioning and the operator's work, different modules are available: = Pantograph = Balancer © Saxis arm (One setting head consists of the following items: * A specific tooling (T) including: a mandrel (M), an anvil set and its lock nut or a monobloc anvil adapted to the RIVKLE® (A) ‘* Anose to assemble the tooling on the head (1) ‘= Apneumatic motor coupled to a shank for screwing and unscrewing operations (C) ‘+ Astroke sensor (S), located in the back part of the head mM a (M) (s) (c) (A)RIVKLE ® Type EPK setting tool 2.2.1.EPK setting head 28252055501/00 | EPK revolver setting head 5m bundle [28252100501/00 | EPK vertical setting head 5m bundle ‘The EPK setting head consists of: + Assuspension hook for balancer (C) ‘+The tooling (T) made up of an anvil and a mandrel + Acycle start push button (13) ‘+ Arevolver handle (05) ‘+ Anelectro-hydro-pneumatic bundle (F) (F) a. (05) schnical characteristics is Pe a a Max effort at 6 bars of air 25,1 kN [RIVKLE® installation capacity M3 to M10, - Max stroke 7mm Weight 4.3K9 Length (Looting not included) 390mm - [aint curve radius ‘500mm |Notse (Sonometer SDH 80 F) ‘82dBA rations <25ms2RIVKLE ® Type EPK setting tool 2.2.2.EPKC revolver setting head ‘The revolver setting head set is composed of: +A suspension hook for balancer (8) +The tooling (T) made up of an anvil and a mandrel * Amanual unscrew push button (34a) + Acycle start push button (34b) + Arevolver handle (51) + Anelectro-hydro-pneumatic bundle (F) (8) m (34b) (34a) (1) The revolver head is recommended when: > The bearing surfaces are not all in the same direction and the partis difficult to handle. > The EPKC is converted into a mobile post ("Rollers” option) for work on production lines. Technical characteristics / Usable range: 5 to 21KN (22.5kN max) Max effort at 6 bars of air 22,5 kN |RIVKLE® instalation capacity M5 to M8. IMax stroke mm, Weight 3,5 Kg [Length (tooling not included) 315mm, [Mini curve radius 500mm, INoise (Sonometer SDH 80 F) ‘82dBA Vibrations <25ms-22.2.3.EPKC TOP revolver setting head RIVKLE ® Type EPK setting tool 128252212000/00|TOP EPKC revoNer setting head 3m bundle (standard) |28252212500100 TOP EPKC revolver setting head 5m bundle |28252212900/00 TOP EPKC revolver setting head 10m bundlo The top revolver setting head set is composed of. + A.suspension hook for balancer (8) + The tooling (T) made up of an anvil and a mandrel + Amanual unscrew push button (34a) + Acycle start push button (34b) * Arevolver handle (51) + Anelectro-hydro-pneumatic bundle (F) o (34a) _ (340) Technical characteristics ° (8) 1) ae a Max fora 6 bars of 25,0 |RIVKLE® installation capacity M3 to M10, Max stroke Tmm Wei eae eng ootng ot chad) = i ba ed sooth Nose (Gonometor SDH 80 F) aa [Vibrations <25mRIVKLE © Type EPK setting tool 2.2.4.Nertical EPKC setting head |28252142000/00|EPKC vertical setting head 3m bundle (standard) [28252142500/00|EPKC vertical setting head Sm bundle |28252142900/00 |EPKC vertical setting head 10m bundle ‘The vertical setting head set is composed of: ‘+ Assuspension hook for balancer (8) + Two vertical handles (83) and a handle support (78) + The tooling (T) made up of an anvil and a mandrel + Acycle start push button (34a) ‘+ Anelectro-hydro-pneumatic bundle (F) ‘+ Amanual unscrew push button (34b) E © (83) (a40) (8) (34b) o (78) ‘The vertical head is recommended when: The bearing surfaces are all in the same installation direction > The Compact EPK is integrated on a work station Technical characteristics / Usable range: 5 to 21kN (22.5kN max) |RIVKLE® instalation capacity M5 to MB Jax stroke 7mm feight 3.7 Ko [Length @ooling not included) 315mm Jini curve radius ‘500mm |Nose (Sonometer SDH 80 F) ‘820BA [Vibrations <25ms2RIVKLE © Type EPK setting tool 2.2.5.SP 3ML Vertical EPKC setting head |28252242000/00|SP 3ML EPKC vertical setting head 3m bundle (standard) |28252242500/00|SP 3ML EPKC vertical setting head 5m bundle |[28252242000/00|sP 3ML EPKC vortical sotting hoad 10m bundle The vertical setting head set is composed of: ‘= Asuspension hook for balancer (8) + The tooling (T) made up of an anvil and a mandrel + Acycle start push button (34a) © Amanual unscrew push button (34b) + Avertical handle (83) + An electro-hydro-pneumatic bundle (F) a () a) 53) (34a) (34b) m Technical characteristics / Usable range: 5 to 21KN (22.5kN max) [Max effort at 6 bars of air IRIVIKLE® installation capacity M5 to MB [Max stroke Tram [Weight 3.7 Kg [Length (tooling not included) 315mm Mini curve radius ‘500mm INoise (Sonometer SDH 80 F) ‘820A ns <25ms2RIVKLE © Type EPK setting tool 2.2.6.EPKC horizontal setting head {28252166000/00 |EPKC horizontal setting head 3m bundle (standard) {28252166500/00 | EPKC horizontal setting head 5m bundle {28052166900/00 IEPKC horizontal setting head 10m bundle ‘The horizontal setting head set is composed of: ‘©The tooling (T) made up of an anvil and a mandrel ‘+ Amanual unscrew push button (34b) ‘© Acycle start push button (34a) + Three adjustable handles (78) + Anelectro-hydro-pneumatic bundle (F) (78) (O) m (34b) (34a) ‘The position and the number of handles (possibility to assemble up to 6 handles) can be adapted according to needs in terms of ergonomics of the work station. Technical characteristics [_eheracterste |Max effort at 6 bars of air IRIVKLES isaion copay ex soko Wont [Length (tooling not included) [Mini curve radius [Noise (Sonometer SDH 80 F) [vibrations <25ms2RIVKLE ® Type EPK setting tool 2.2.7.EPK HP Setting head 2680030100400, 28800301002/00 | EPK HP vertical setting head 5m bundle ‘The EPK HP setting head must be used with a High Pressure control unit. ‘An EPK HP setting head is composed of: # The tooling (T) made up of an anvil and a mandrel «An anvil support (24) allowing the anvil to be assembled + Ahydraulic cylinder for setting (40) + Ahandle support (6) fitted with 2 handles (7) © An electro-hydro-pneumatic bundle (F) ‘+ Acycle start push button (1a) ‘+ Amanual unscrew push button (1) + Asuspension hook (32) e) (1a) (32) (40) a ‘ @) (1b) (1b) 5) (7) (24) m |Max effort at 6 bars of air SS KN IRIVKLE® installation capacity Mi0 to M14 Stee! IMax stroke ‘Smm [Weight 3.9K9 lLength (looting not included) 530mm Mini curve radius ‘500mm INoise (Sonometer SDH 80 F) 82dBA jibrations <25ms2RIVKLE © Type EPK setting too! 2.3.Options The equipment can be delivered with different options depending on: + Its installation on the production site, + Itsuse, +The safety of the cycle requested ‘+ The integration of these options is planned on the standard control unit (pre-wiring, fixation holes, etc.), The ‘standard’ options available are: + “Rollers” option + "2 colours stack light" option + ‘Screen protection” option © Clamping’ option + "Key switch’ option + “Contact” option + °Gateway’ option ‘+ “Two heads” option Rollers” option This option allows the equipment to be made mobile. Itis made up of 4 caster wheels and 2 rollers with brake to allow the cabinet to be immobilised 2.3.2."2 colours Stack Light” option This option allows the state of the cabinet to be controlled at a distance, Itis made up of a 2 colours Stack Light: + GREEN: in production = RED: fault * Option related to the 2 colours stack light: connection cable 10m.RIVKLE © Type EPK setting tool 2.3.3."Clamping” option This option allows the part to be clamped forthe duration of the planned setting operations. Itis composed of + 4 solenoid valve for guiding the clamping cylinder (cylinder not provided) +1 "Part present” inductive detector #4 sub program for cycle management The integration of the options has to comply with the provisions of Directive 98/37/CE, and the national legislation itis subjected to. Bollhoff Otalu can in no case be held responsible for poor integration causing injury to individuals. Cycle di 4. Positioning the part on the fixturing 2. Detection via the “Part present" detector and automatic clamping 3. Installation of the entire RIVKLE® (preselection counter) 4. Automatic release of the part when all the RIVKLE® have been declared compliant 5. Manual removal of the par triggering the acknowledgement of the end of cycle automatically 6. Positioning of a new part In case of fault: If a faultis detected, the part remains clamped on the work station. It will be released when the operator has acknowledged the fault via the operator interface. /\ The operator must then put aside this part in order to be inspected by an authorised person.RIVKLE ® Type EPK setting tool 2.3.4.“Screen protection” option This option allows the operator interface to be protected via a | Makrolon® case installed on the command console, 2.3.5."Contact” option This option allows the contact of the RIVKLE® on the part, to be guaranteed during the setting operation. It obliges the operator to keep. the material in position and avoid setting the RIVKLE® outside the part or causing a double bulb. Setting Is only authorised if the RIVKLE® head is in contact with the customer part. This option is generally integrated when setting on thin sheet metal (<1mm), as the tolerances on the RIVKLE® do not allow setting into part to be distinguished from setting outside the part. Itis composed of: = Amechanical system installed on the rivet head = Assub program for cycle management This option can be integrated only with a defined RIVKLE®. Cycle details: 1. Screwing of the RIVKLE® on the mandrel 2. Positioning the RIVKLE® in the housing. 3. Starting the setting with control of the state of the sensor during the entire setting operation. In case of fe Ifthe contact detection is lost during the setting, the cycle is stopped and the part is declared non- compliant (see: Art. “Contact” Fault).RIVKLE © Type EPK setting tool 2.3.6."Key switch” option This option allows fault reset to be activated and deactivated by a key operated turning knob. 2.3.7.« Parameters selection » option (for example with a PLC). The corresponding set of parameters will be ZIP zctive in the production mode. c Itis composed of an additional HARTING plug (P3). This option allows selecting one of the 8 sets of parameter by I/O signal 2.3.8.« EPKC_SAC » option This option includes a hydro pneumatic control unit (28259020311) and a pneumatic fiting. It allows running a SAC Head with an EPKC control unit 4RIVKLE ® Type EPK setting tool 2.3.9.« Gateway » option “This type of communication is transparent to the customer. The reference of the « Gateway » will depend on the customer's communication protocol + Parameters entry: selection of the parameters values (pressure, stroke thresholds, number of RIVKLE® on each part). + Set selection: selection of the parameters set (1 to 8). + Local: manual selection. + 3: selection by the option « set of parameters», + Remote: selection by the customer's communication.RIVKLE © Type EPK setting too! 3.0 Preparing for start up 3.1. Transportation ‘The EPKC is delivered in @ wooden box with the following components: » Control unit : 55kg max. > Setting head: 8kg max. The handling of the box must be done with the help of a fork tif. 3.2. Installing the control cabinet ‘The EPK control cabinet has to be installed on a solid and flat horizontal surface, ie 3.3.Connecting the cabinet Power connection is made at the back of the box: ‘* Line automaton link (1) ‘+ Instrument pneumatic connection (2) ‘+ Electrical connection (3) ‘+ Electrical connection of the setting head (4) ‘+ Electrical connection of the second head (option) (4a) ‘+ Hydro pneumatic connection of the setting head (5) ‘© Stack light connection (option) (6) © w 3 Oy (aa) @ ©RIVKLE ® Type EPK setting tool 3.3.1.Pneumatic connection ‘The air supply tube must respect an internal diameter of minimum 14mm, ‘The connection is made on the stop valve (VE) located on the aluminium block at the back of the cabinet. It is recommended to install a quick couple kit in order to be able to quickly disconnect the machine. Then connect the air supply tube to the compressed air supply. The air supply must be between 5.5 bars and 6.5 bars with dry air with no moisture. 5,5 bars mini 6,5 bars maxi The cables must be secured and positioned so as not to cause danger. AN The cables can be a danger due to the coling ofthe tube line after a breach, for example due to external forces.RIVKLE ® Type EPK setting tool 3.3.2,Connecting the head to the cabinet The selting head has to be supplied with air, oil and electricity by the connectors located at the back of the control unit, as shown on the photo below. : (cs) (P2) (P3) (c2) (c1) - 41. Connect the pneumatic energy by the 2 quick couplers that supply the screwing and unscrewing of the device. - ‘a, Female connection (C) for screwing b. Male connection (C2) for unscrewing Connect the hydraulic energy by the quick coupler (C5) for the setting Connect the electrical energy by the Harting 6 points (P2) plug to start the cycle and the management of the “Stroke control" (and the P3 plug for the optional second head). 3.3.3.Connecting the control unit with the two-head option Power connection is made at the back of the control cabinet (see previous chapter “Connecting the head to the cabinet’) z ‘+ Pneumatic energy by 2 quick couplers that carry out the screwing and unscrewing operations. 7 - HEAD 1=Tt - HEAD2=T2 ‘+ Hydraulic energy by a quick coupler that carries out the setting operation. - HEAD1=71 - HEAD2=T2 ‘+ Electrical energy by the HARTING 6 points plug to start the cycle and the management of the "Stroke controf” - HEAD 1= P24 - HEAD 2= P22RIVKLE © Type EPK setting tool 3.3.4.Connecting the “Parameters selection option” The option is wired in Béllhoff workshop during production. 3.4. Preparation before start-up Before starting the equipment, check the following points: +The connections are correctly made for the electric cables, the electric and pneumatic tubes. ©The equipment has to dialogue with an automaton: the line automaton link-up is correctly made through the Harting plug, 3.4.1.Changing installation tools control unit.RIVKLE ® Type EPK setting tool 3.4.2.EPK heads ‘The preparation of the head requires two 19mm spanners and a @ 6mm drift punch Replacing the mandrel Composition of the front part of an EPK setting head: + Mandret (M) ‘© Anvil (206) and locknut (20a) © Shank (10) + Cord (Q) + Limit stop (7) + Traction bushing (8) © Pin (\) © Nose (6) @ (6) (20a) E (8) (20b) T— (10) (mM) @ @ Disassembly 41. Untighten the locknut (20a) and unscrew the anvil (20b). 2. Push the pin () using a drift punch without damaging the cord (2) and completely remove the mandrel (M), Assembly 1. Reassemble the mandrel and replace the pin (I) ensuring that itis tightly held in the cord, 2. Screw back the anvil on the nose (6), adjust the anvil position (20b) if necessary and Immoblise it slightly blocking the locknut. Adjusting the anvil position Before doing anything, check with the technical department that the tooling is adapted to the RIVKLE®. ‘The position of the anvil depends on the length of the RIVKLE® before settingRIVKLE © Type EPK setting tool For open RIVKLE® (opened on both sides), the anvil has to be adjusted so that the threaded rod just touches the end of the RIVKLE®, at the end of the internal thread. For Blind RIVKLE® (opened only on one side), the anvil has to be adjusted so that the threaded rod is held back by one turn in relation to the end of the intemal thread of the RIVKLE® at the end of screwing. Procedure 1. Unscrew the locknut (20a) of the anvil (20b) using a 18mm spanner. 2. Adjust the anvil overhang (see illustration above), 3. Block the anvil by tightening the nut (20a), (torque 10Nm). For specific applications, without a locknut, in order to avoid possible adjustment errors. is possible to make a monobloc anvilRIVKLE © Type EPK setting tool 3.4.3.EPKC heads ‘The preparation of the head requires two 19mm spanners and a @ 5mm drift punch. For applications using standard installation tools, the references are described in the table below: RKMS ‘23611305030 23611305020 RK M6 23611306030 23611306020 RK MB 23611308030 | 23611308020 RK M10 23611310030 23611310020 RK STUDS M4 37611304030 37611304020 RK STUDS M5 37611305030 37611305020 RK STUDS M6 37611306030 37611306020__| RKSTUDSM8 | _ 37611308030 37611308020 How to order standard tools? ey eee + RK Mandrel 2361 13XX020 © RK Anvil 236113XX030 + RKGMandrel —376113Xx020 + RKG Anvil 376113XX030 To place an order, all that is needed is to replace the XX by the RIVKLE® dimension to be set with the mack E.G. RIVKLE® M6 > Mandrel 23611306020 and Anvil 23611306030. For specific RIVKLE® dimensions, please contact BallhofT.RIVKLE © Type EPK setting tool Replacing the mandrel Composition of the front part of an EPKC setting head: ‘Mandrel (M) ‘Anil (A1) and counter nut (A2) ‘Shank (6) Cord (3) Limit stop (7) Traction bushing (2) Pin (4) Nose (1) 7 @) a” (a2) (6) (a1) (2 (M) Cy a) strongly advised to disassemble the nose leaving the anvil on it. This operation avoids WwW To change the mandrel of the head, itis not necessary to disassemble the anvil. Itis adjusting the anvil overhang again. Disassembly 1 Disassemble the nose (1) using a 19mm spanner. 2. Push the pin (4) using a drift punch without damaging the cord (3) and completely remove the ‘mandral (M), Reassembly 1, Reassemble the mandrel (M) and replace the pin (4) ensuring that itis tightly held in the cord (3). 2. Screw the nose (1) back on the head. Manually check if the mandrel (M) turns freely.RIVKLE © Type EPK setting tool Adjusting the anvil position Before doing anything, check with the technical department that the tooling is adapted to the RIVKLE®. ‘The position of the anvil depends on the length of the RIVKLE® before setting For open RIVKLE® (opened on both sides), the anvil has to be adjusted so that the threaded rod just touches the end of the RIVKLE®, at the end of the internal thread. For Blind RIVKLE® (opened only on one side), the anvil has to be adjusted so that the threaded rod is held back by one turn in relation to the end of the internal thread of the RIVKLE® at the end of screwing Procedure 4. Unscrew the counter nut (A2) of the anvil (At) using a 19mm spanner. 2. Adjust the anvil overhang (see illustration above). 3. Block the anvil by tightening the nut (20a), (torque 10Nm). For specific applications, it is possible to make a monobloc anvil without a locknut, in order to avoid possible adjustment errors,RIVKLE © Type EPK setting tool 3.4.4.EPKHP heads The standard EPKHP setting head is fitted with monoblock tools. This means that the tooling is adapted to the RIVKLE® reference to be set. ‘The references of the tooling are provided with the technical documentation. Replacing the mandrel To change the mandrel of the head, itis not necessary to disassemble the anvil ‘Composition ofthe front part of an EPKHP setting head: + Mandrel (M) ‘+ Monobloc anvil (A) ‘© Anvil support (24) © Cord (3) ‘© Traction bushing (2) ‘+ Lock mechanism slug (19) (a9) cm) (24) (a8) «RIVKLE © Type EPK setting tool Disassembly 1, Remove the anvil support (24) by pushing in the lock mechanism slug (19) and remove it by pulling in the axis, 2. Slide the drawing bar (M) transversally. mbly 4. Reassemble the mandrel (M) by laterally sliding it, note the indexing of the flat parts of the bar and on the anvil. Ensure that it is completely inserted in the traction bushing, 2. Replace the anvil support, note the indexing, push the locking mechanism slug and push the anvil support up to the locking mechanism slug, Total duration of the operation: about 10 seconds Adjusting the tooling Monobloc tools mean that they don't have to be adjusted, all that is needed is to ensure the following points: = The mandrel (M) has to be correctly positioned in the traction bushing (18). = The anvil (A) has to be completely screwed in the anvil support (24).RIVKLE © Type EPK setting tool 3.5. Setting the parameters of the machine 3.5.1.Putting into service before setting the parameters (3) (2) (5) C) ie (6) Power up the control cabinet by turning the general switch disconnector (1) to position “I. The touch screen (6) becomes active. (pen the pneumatic cut out valve (VE1) located on the back of the box to supply the cabinet with compressed air. (ven) Press the button “START” (4) so that the lamp lights up. The air pressure is then visible on the manometer (2), If the air supply doesn’t work, check the following points: ‘The emergency stop button (6) is unlocked. The air cut out valve (VE) is open. ‘The air quick connection has been engaged.RIVKLE ® Type EPK setting tool If the pressure gauge shows an air pressure between 6.5 and 6.5 bars, it is necessary to make an adjustment within the hydro pneumatic box located in the lower part of the control cabinet: ‘+ Adjust the air pressure by the general pressure regulator located on the Pressure Regulator Filter (PRP). (PRF) If the compressed air supply pressure is below 5.5 bars, the EPK head performance will decrease (insufficient setting force, degradation of cycle time). 3.5.2.Parameters menu Ensure that the activation of the machine has been made. Before starting to produce, itis necessary to check the equipment adjustment parameters depending on the type of RIVKLE® to be set This control has to be mad by a trained person, who will be able, if needed, to access the “Adjustments” menu with an access code. In the general menu, press the button L MSHS] inorder to change the diferent operating parameters of the machine and calibrate the stroke and pressure sensors.RIVKLE ® Type EPK setting tool BOLLHOFF teen ‘The access code is 2010. This password can be modified in choice n°6 “Changing the password’, in the "Adjustments” menu Procedure for inputting the password: + Press ihe back eld areal. ne not keyboars epeors + Enior the code 2010 using the dita keyboard © Validate with the If the code is incorrect, delete what has been entered with the LL] key and start again ‘After having entered the password, the “Adjustments” menu appears.RIVKLE ® Type EPK setting tool Pee ed ls ding on USB = ‘The choice of parameters to be modified is made by pressing the numbered button in front of the Go back othe previous menu by touching he arrow key Ba In case of a2 heads option, 2 boxes with 1 and 2 appears at the end of the line “sensor calibration”.RIVKLE ® Type EPK setting tool 3.5.3.Language meine ed al eit Inthe language menu, press the Language buton (5) t display the “Language” menu aS ES A EE] Ten Ee LL SLda eye Choose the desired language by pressing on the corresponding flag, Ge back tothe previous menu by touching the arrow key Ka 3.5.4.0ptions ‘The EPK has a standard version of different options for integrating external mechanical systems such ‘as “Clamping” or “Contact option’.RIVKLE ® Type EPK setting tool ‘These options can be activated and deactivated through the “Options” menu (4) — Geir re Gites and counte word modication ed old Birr yj erial counting Cy OCS La Tat Ook Pome cintea Tes: eseting reseting delay ce This screen displays the different options available and their state (ON / OFF). Gj ‘ON (Option activated) Gi ‘OFF (Option deactivated)RIVKLE © Type EPK setting tool 3.5.5.Serial counting This option allows to set up a number of parts OK to produce in the mers and counters” menu (3) Cin Gleries a GES eiieu De dl Ge Ree rewing delay rewing time Good setting Number of RIVKLE per part shes (Salen o i i! Number of part per t ‘Once all those parts are set, a message “Campaign finished” appears to indicate a rack is complete. 3.5.6.Automatic reset This option allows to automatically acquit the message “End of cycle” at the end of a part. Itis possible to set up a timer for this acknowledgement. Ifthe “Clamping” option is activated, the acknowledgement is done when the part is removed. ic ‘when the presence signal is lost.RIVKLE ® Type EPK setting tool 3.5.7.Fault historic display This option allows to display the fault history in the diagnostic menu, 3.6, Calibrating the sensor ADJUSTMEN. a n ed ol ‘ecording on USB 3.6.1.Pressure sensor Access the pressure parameters menu (1) through the adjustments page. ‘The hydraulic pressure control is made with a pressure transmitter (CP1) installed on the pressure ‘multiplier (ML1). It sends an analogic information to the automaton. The pressure multiplier (ML1) ‘comprises an oil tank (R) to automatically compensate little losses or leak. (mua)RIVKLE ® Type EPK setting tool ‘The value of the pressure sensor is directly sont by an analogic signal, OV =0bar 10V = 250 bars for an EPKC. 40V = 400V for an EPK HP. 3.6.2.Calibrating the stroke sensor The calibration of the stroke sensor has to be made after the following tasks: Replacement of the setting head Electrical disconnection of the setting head Maintenance of the setting head (replacement of the linear sensor, disassembly of the hydraulic piston ...) More generally, when the current value for the “Stroke control” is different to 0. ‘Access the sensor calibration menu (2) through the adjustments page, the “stroke sensor calibration” screen appears, imers and counte & Ll Lao iG ST at Leer LA Re) eS gd rding on USB 1C Tua SidesRIVKLE © Type EPK setting tool Itis necessary to calibrate the following values: +The minimum stroke = 0 mm ‘+ The maximum stroke = this value must be measured ‘The kN / bar ratio is an indication to display the force during the production mode. Minimum stroke [ U Using a sliding scale, measure the overhang of the mandrel in relation to the bearing face of the anvil Set the sliding scale to 0. Start stig by posing ne ll ton Wait for the device to have made a complete stroke and measure the bar overhang. Enter here the measured value and validate with the Lil button on the touch panel. key on the bottom right of the screen. The stroke sensor is now calibrated, Then press theRIVKLE ® Type EPK setting tool 3.6.3.Stroke and pressure parameters mre PVvVLLnVrnr nes ic In the adjustments menu, select the button “Stroke/pressure parameters' (1). ‘This menu allows access to set the different thresholds used during the setting operation. In case of a 2 heads option, 2 boxes with 1 and 2 appears so that you can select the corresponding head. The button in white indicates which head is selected ne OT Minimum Son “Two-heads” option: In case of a double-head option, the screen includes two additional buttons [and Ml, tnatatow to show the menu of each head. Ifthe button is displayed in white, it indicates that the laying head is active By default, the machine is programmed on the “pressure level” mode.RIVKLE © Type EPK setting tool However, for some specific applications, in particular for setting RIVKLE@ in plastic materials, itis possible to carry out the setting operation following the “Stroke control” principle ‘As oppose to the ‘Pressure level’, the setting end given by reaching a pre-programmed stroke via the analogical stroke sensor. When this threshold has been reached, the program checks the setting pressure (pre-programmed pressure reading window, same as “stroke control” principle) and declares the setting compliant. 3.6.4.Determining the pressure threshold with a load indicator This threshold has to be set following setting tests made before starting production. The calibration can be made in « CAPA » mode with the load indicator and the appropriate tooling (adapted to the RIVKLE®). ‘The load indicator remains the most precise way to determine this threshold, rite oe rgRIVKLE ® Type EPK setting tool The following table indicates the references of the tooling necessary according to the type of RIVKLE®: TOOLING KIT rsa ut 0 (OF te ee ee ed Washer + Nut Read the setting effort given on the RIVKLE® definition drawing, 1. Adjust the pressure in « CAPA » mode, on (Settingeffor| Pessure | Limiter Head type | Dimension |°°"e tte | adjurmont | Remark ma 3500 9 5,00 7 MS: ‘3000 2 5,50 L PKC M6 12000) 120 600 7 [7 18000. 185 7,00, Z M10 21000, 215 12,00 _ | 65 bar mini M6 12000) 110 5:50, ox va. 118000) 160 8,00 M10 21000) 203 12,00 Miz 23000) 23 12,00 _ | 65 bar mini This values are given as a basis to determine the installation setting effort. 2. Input the pressure threshold with this value in the program following the procedure defined in ‘section “Setting the pressure threshold” Go to production mode by following the procedure defined in section "Using the equipment’. ‘Assemble the load indicator on the selting head (refer to the guide provided with the load indicator) Realize a setting test and check the effort recorded on the indicator's screen. Start the setting again, modifying the pressure threshold until you obtain the target effort and. repeating the operations 2 to 5. 7. Remove the load indicator. 8. Set some RIVKLEG several times on installation sheets with the same thickness as the one of the customer's part. 98. Check the formation of a ridge after setting as well as desired mechanical hold (torque, pulling oft, according to the product drawing).RIVKLE © Type EPK setting tool 3.6.8.Setting the pressure threshold Sa Git [5 IEEE eee nem ek: eee Ti (oer mes ifs \ aa Sees TT To input the pressure threshold that will give the order to stop the setting operation, press the button reRIVKLE © Type EPK setting tool ‘The parameters adjustment screen appears. 1 set of parameters ‘The device has 8 sets of different parameters (pressure thresholds and stroke thresholds), Each line of paramaters, fon the screen corresponds to 2 To set the pressure threshold, press the field area Ill (black box in the first column). The digital keyboard appears. Enter the target value and validate with the fl button In case of using several sets, repeat the operation for each set The traction effort correspondence in Newton is displayed in the second column. Press the arrow Kala located on the top right of the screen, to go back the “Stroke/pressure parameters’ menu. Then select the set of parameters to apply using the up/down buttons on the set area, G ce ‘The pressure adjustment of the salected set should then be displayed in the “pressure level” area.RIVKLE ® Type EPK setting tool 3.6.6.Stroke control The EPK installation device includes the “stroke control’ function to guarantee the quality of the RIVKLE® setting Theory for: + ARIVKLE® reference + Asupport thickness + Ahousing diameter © Asetting effort ‘The device stroke should be down in the window limited by bottom and top stroke control thresholds, The stroke control is made via a linear movement.RIVKLE ® Type EPK setting tool Procedure for setting stroke thresholds: ‘+ Using a sliding scale, measure the length of the RIVKLE® before seiting and set the sliding scale at 0. «Set RIVKLE® several times on installation sheets with the same thickness as the customer's part * Measure the length of the RIVKLE® after setting. * Carry out the above operation § times. «Find the average of the values read. * Determine the control window as below: Bottom stroke threshold = Av value - 0.5 mm Top stroke threshold = Av value + 0.5 mm + Input these values using a digital keyboard. ‘Activate the « Stroke control » by switching the button to ON.RIVKLE © Type EPK setting tool Example: se stroke measured = 4.26 mm Bottom stroke threshold = 4.26 - 0.5 = 3.76 mm Bottom stroke threshold = 4,26 + 0.5 = 4.76 mm OR ‘Access the thresholds parameters via the IHM. In the "Adjustments" menu, access “Stroke/pressure parameters" (1) aI mers and counters Me word modi ¢ Rn RRRS RIE rding on USE ai Once he treshots (bottom and op) determined, check ha the setetor AAs On ona touch the button KEREIZENIENH located at the bottom of the screen. ee Ee LTRIVKLE © Type EPK setting tool ‘The parameters screen appears. Minimum — Maximum 1 set of parameters ‘The device has 8 sets of different parameters (pressure thresholds and stroke thresholds). Each line ‘on the screen corresponds to a set of parameters. To input the stroke and pressure threshold values, press the corresponding field I. (Once the values have been input, return tothe menu by pressing the arrow Kal button Control Before using production mode, it is necessary to control the functionality Set a RIVKLE® without a support and check that the stroke is not in the tolerance window. If itis not the case, itis necessary to add the “Contact option” which guarantees quality of the RIVKLE® setting. In case of setting on different thicknesses, select tho most suitable parameters.RIVKLE © Type EPK setting tool 3.6.7.Timers and counters jord modication a RPwWLLnvrr [ett Recording on USE [ex After pressing the button (3) “Timers and counters” in the adjustments menu, the following screen appears. rewing time Good setting Trae ea [cael Cee pale atlas cs | UT a a ones 3.6.8.Setting start cycle delay ‘This timer allows the start cycle of the machine to be delayed by pressing the “Start cycle” button on the setting head, 3.6.9.Delay unscrewing timer This timer allows the starting of unscrewing to be delayed at the end of the setting 3.6.10. Unscrewing time This timer sets the duration of the unscrewing operation automatically started when pressure threshold Is reached. This value can be adjusted depending on the thread length.RIVKLE © Type EPK setting tool 3.6.11. Good setting information delay This timer allows the “RIVKLE® well set" information to be maintained during the programmed value. This information is retransmitted to the automaton line through the Harting socket for the duration of this timer. 3.6.12, Number RIVKLE® of per part counter This counter is used to determine the number of RIVKLE® that will be set on the customer's part. When this counter reaches the pre-programmed recommended value, the operator interface (HMI) signal that the number of RIVKLE® set has been reached 3.6.19. _ Number of parts per series counter This counter serves to program a part campaign to be made. It informs the operator that the series of parts to be produced has been reached, This information is given to him by the HMI that locks the use of the machine until the operator has acknowledged the message. If the part counting is not used, set the counter to 0. Aer having set hos ferent adjustment pross to arrow Balto each he folowing sreen mandrel warning Coa BOLLHOFF iG 3.6.14. Worn mandrel warning This option displays, at the end of a certain number of cycles, an alarm indicating that the mandrel is, worn 3.6.15. Mandrel worn This option displays, at the end of a certain number of cycles. an alarm indicating that the mandrel is worn and should be changed.RIVKLE © Type EPK setting tool 3.6.16. Counter The button MARE is usec to reset the genera counter. After having set the “counters and timers", press the arrow lil to go back to the main menu. 3.6.17. Saving data and parameters on a USB, iis] em i Pere te Mn B ‘| | This menu allows to get data from the EPKC to a USB stick + Setting curves (stroke and force by time). + Force and stroke peaks Sa) y + Set of parameter date In the “Adjustments” menu, select (7) “Recording on USB" to reach the following screen.RIVKLE ® Type EPK setting tool The format of the files is “CSV" sorted out by Microsoft Excel. ‘Then connect the USB stick on the USB port of the control unit (on the right side or at the back depending on the version) The signal “USB connected” lights on in green. Then select the type of data that you want to export + DVS pressure and stroke curves + HET . setting nistory + PERCHA set ot parameter data (setting pressure, minimum stroke, maximum stroke)RIVKLE © Type EPK setting tool ‘After choosing one of these button, the saving process starts, You can then remove the USB stick by clicking on "Remove USB"RIVKLE ® Type EPK setting tool 3.7.Device integration This equipment is planned for integration on work stations in order to make operator handling easier and to optimise the operating of the machine. The work area will have to be equipped with an ambient lighting of 00 lux minimum. 3.1.1.Integration of the setting head During integration, ensure that the ringed sheath is not in contact with the parts that could accelerate its wear (ground, metal parts, crushing, etc...) and have a curve radius of 500mm minimum, Use the right type of pistol depending on the station ergonomics. 3.7.2.Control unit integration ‘The standard control unit has a communication socket to dialogue with the machine automaton. ‘The details of the exchanges are given in the electrical file supplied as an appendix to the technical guide. ‘Comment: a jumper comprised in the female socket allows the start cyole info to be shunted if the device is not connected to an automaton. A DO NOT REMOVE THE SOCKET or the device can no longer be used.RIVKLE ® Type EPK setting tool 3.7.3.Standard integration options In order to make the device integration easier, options are available on request. For example, itis possible to clamp the part for the entire duration of the setting operations and to release it only when all the RIVKLE® have been set and declared compliant. as Integration of the options has to comply with the provisions of Directive 2006/42 EEC. modified and the national legislation it is subject to, ctive 2006/42 EEC The following Directives have been used: Machinery Electromagnetic Compatibility Directive 2004/108 EEC BOLLHOFF can, in no case, be held responsible for poor integration causing injury to individuals 3.7.4.Specific integration options. For particular applications such as setting different types of RIVKLE® consecutively with the same device, it is possible to make a specific development,RIVKLE © Type EPK setting tool 4.0 Operating and using the device 4.4.EPKC operating principle ‘The EPKC equipment carries out three successive functions needed to set a RIVKLE®: © Screwing © Setting + Unscrewing Setting is carried out by a hydraulic cylinder inside the setting head. Pressure is generated by an air pressure/oll multiplier. ‘Screwing and unscrewing are carried out by a pneumatic motor coupled to a mandrel. A single push of the RIVKLE® on the mandral triggers the screwing up to the anvil (‘Push-pull principle). After screwing the RIVKLE® and introducing it into the support housing, the setting is carried out by the pushbutton on the setting head. ‘Once the RIVKLEG is sot, the unscrewing operation is automatic. The device can work in all positions, hand-held or suspended.RIVKLE ® Type EPK setting tool 4.2. Putting the machine into operation > BPO 4.2.1.Reminder of safety instructions Before any work on the device, disconnect the air supply or close the cut out valve at the back of the control cabinet, When using the machine, wear ear protections, When setting, do not hold the RIVKLE® with your fingers. This machine is subject to pneumatic pressure that may exceed 6 bars and hydraulic pressure up to 250 bars. Therefore, itis advised to handle it with the necessary precautions for this type of device (e.g.: do not disconnect a connection during setting). AIR ENTRY PRESSURE: 5.5 bars MAX = 6.5 bars. Itis advisable to use a BOLLHOFF technician for installation, start-up and training, > The start-up procedure has to be carried out by persons trained.RIVKLE ® Type EPK setting tool 4.3.Using the equipment 4 Presentation of the operator interface ‘The machine is fitted with a programmable touch screen for cycle management, operator dialogue and parameters setting of the device. The operator interface (HMI) is used to dialogue with the equipment via a touch screen. This allows you to access the different operating modes and take action if any faults occur. By pressing the symbols shown on the screen (buttons, error messages, digital keyboard, etc...) you can access the different menus or change the machine parameters In order to facilitate the use of this guide, each screen is explained in a separate chapter. When powering up the device, the welcome screen appears so that the operator can access the different menus. ek [TEE er rp) aay, pe BOLLHOFFRIVKLE ® Type EPK setting tool + “Setting pressure": this threshold has been determined in section “Stroke and pressure settings”. They are given to the operator for information purposes. + "RIVKLE® counters’: this counter informs the operator of the number of RIVKLE® set on the part in progress. ‘+ “Set: this is the number of the active parameters set. ‘+ “Peak”: it indicates the maximum values recorded during the last setting operation. Case of a machine with “clamping” option: I this options present onthe device, the menu comprises an uncamping bston I wtih allows the operator to release the pat manvaly. This buon f only active when the option has been activated Comment: From the first setting on the part, itis impossible to unclamp as long as the part has not been entiraly finished (all RIVKLE® set) Case of a “double head” equipment: If his option is present on the device, the sereen has two buttons [© and lil that alow to select the corresponding setting head information. The button in white shows the active head menu.Details of the tting operation RIVKLE © Type EPK setting tool 1. Screwing operation: by pushing the RIVKLE® against the mandrel, the screwing operation is activated unti the RIVKLE@ jis screwed up to the anvil (push-pull function) 2, Insertion in the part hole: insert manually the in the part hole and maintain the setting head perpendicular to the bearing surface. 3, Setting operation: once the RIVKLE® is in place in the part hole and perpendicular to the bearing surface, activate the cycle start button on the head to engage the setting operation 4, Unscrewing operation: in production mode, the unscrewing operation is automatic, Indeed, a pre~ programmed timer allows a back-friendly unscrewing. The time of the unscrewing can be set in the menu "Timers and counters’. This time varies according to the thread length engaged on the mandrel {As standard, the mastery of setting is ensured by a cut-out of the hydraulic pressure on reaching pre- programmed level. This setting process is called "Pressure setting’ Forced unscrewing It the automatic unscrewing does not star, itis possible to unscrew by force by pressing the “Unscrew” button on the setting head,RIVKLE © Type EPK setting tool Counting As standard, the equipment has two counters which can be set (according to the chosen parameters set) + The RIVKLE® counter * Optional: a counter for the customers parts, called “Part series counter’ (check use with the “Clamping” option), ‘The RIVKLE® counter allows the number of RIVKLEG® left o be set on the part to be displayed (the parameter “Preset” corresponds to the number of RIVILE® to be set on each part). When a part is, complete this counter reaches 0. The part series counter allows the number of customers parts (completed) left to produce. When a batch is complete this counter reaches 0. ‘Comment: ‘The P1 plug at the back of the control unit can be used to acknowledge this end of cycle from the automaton. Cycle safety The quality control of the setting cycle is handled by the stroke read by the linear sensor. The recorded value must be in the pre-programmed range. Emergency stop Pressing the “emergency stop” pushbutton causes stops the current cycle. To continue, the operator has to unlock the “emergency stop", acknowledge the fault on the touch screen and then push the white button “start-up”, The unscrewing operation is now possible.4.3.3.Set of parameters selection RIVKLE ® Type EPK setting tool In case the option “Set of parameters selection” is activated, itis possible to choose the active set of Parameters by using V/O signal in the P3 Harting plug, This figure explains which pin corresponds to which parameter. 0 0 ° 1 0 0 1 5 ° 1 ° 3 0 1 1 7 1 ° 0 2 1 ° 1 6 1 4 0 4 1 1 1 8RIVKLE ® Typo EPK setting tool 4.3.4.Declaration of faults in production mode The machine integrates a certain number of possible controls during the setting operations: Not reaching a threshold, a poorly calibrated sensor, etc... All these faults are shown on the operator interface (HMI) ‘The appearance of faults locks the use of the equipment until itis acknowledge. Acknowledgment generally requires the manual intervention of the operator (removal of a non- compliant part) or of a qualified person (calibration of a sensor, etc...)RIVKLE ® Type EPK setting tool ‘STROKE SETTING FAULT” uv Type of fault: v This fault appears when the peak stroke is not included in the stroke control window (min/max threshold). Cause of fault: ‘The fault can have several origins: ‘* Thickness of the part outside the tolerance. + Diameter of the housing non-compliant (too big). - * RIVKLE® not compliant. - + Mandrel broken. Solution: ‘+ Remove the non-compliant part and isolate it to be reworked manually + Acknowledge the fault by pressing he La tonRIVKLE ® Type EPK setting tool “LOW OIL LEVEL FAULT” Type of fault: Lack of oil in the machine First of all, this fault does not stop operating, the operator can still make 200 cycles. However, he has to inform the maintenance department, At the end of the 200 cycles, the machine blocks. Itis then necessary to fill the oll to be able to start producing again. Cause of fault: Lack of oil in the pressure multiplier (ML1). This fault is detected by the oil level floater fixed on the tank cap (C). Solution: © (cH) (cP1) ) (MLA)RIVKLE ® Type EPK setting tool Procedure: 1. Open the hydro-pneumatic compartment of the control unit, 2. Disconnect the oil level connector (CH), 3. Unscrew the tank cap (C). 4. Fill with oll (Hydrolub ZS46 oil or similar) until reaching the top of the glass part 5. Screw the tank cap (C) back on. 6. Reconnect the oil level connector (CH). 7 Acknowledge te faut on the touch screen by pressing he LEE] pionRIVKLE ® Type EPK setting tool “CONTACT FAULT” (Option) Type of fault: Poor contact of the RIVKLE® head on the part during the setting operation. Cause of fault: The operator has not maintained the RIVKLE® head against the customer's part during the setting operation. Consequently, the stroke sensor has not been activated for the entire setting operation. Solution: ‘= Remove the non-compliant part and isolate it to be reworked manually. * Acknowledge the fault by pressing the | [are] button.RIVKLE ® Type EPK setting tool “CLAMPING FAULT” (Option) Type of fault: Presence of a non-compliant part on the work station. Cause of fautt: The operator has not removed the non-compliant part during the previous cycle. Solution: ‘+ Remove the non-compliant part and isolate it to be reworked manually. + Acknowiedge the fault by pressing the a on,RIVKLE © Type EPK setting tool “PRESSURE FAULT” Type of fault: Insufficient hydraulic pressure. Cause of fault: ‘The fault can have several origins: ‘© Presence of air in the hydraulic circuit + Hydraulic leak. Solution: * Find the possible oil leak and repair it. * Check the oll level and fill if needed (see procedure in section “Low oil level fault’). + Make a complete hydraulic purge (see procedure in section “Hydraulic purge") + Acknowledge te faut by pressing the a tn,RIVKLE © Type EPK setting tool “LINEAR SENSOR FAULT” Type of fault: The value of the sensor is checked at the beginning and the end of each oycle. If this value is not in the -0,3mm and +0,3mm range, this fault appears. Cause of fault: The fault can have several origins: ‘+ Bad calibration of the stroke. ‘+ Defective linear sensor. + The sensor may have moved from its position inside the setting head. Solution: + Check the current value at rest to compare it to the sensor tolerance (-0,3mm +0,3mm), + Re-calibrate the linear sensor if the value is not in the range. + Acknowledge the faut by pressing the a on, If despite this procedure, the fault comes back regularly, please contact BOLLHOFF after-sales department.RIVKLE ® Type EPK setting tool 4.4.Turning the equipment off 3) @) (>) (2) 1 a) (6) 1. Tum off the control unit by turning the general power switch (1) off (position ©). The touch screen turns off and the air supply inside the unit is cut 2. ‘Tur off the pneumatic cut-out valve (VE) located on the back of the control unit to stop the supply of compressed air. (VE1)RIVKLE ® Type EPK setting tool 5.0 Maintenance Before any maintenance operation, please take note of the safety instructions given in section “Safety instructions” 5.1.General information Maintenance, inspection and repair work have to be carried out by authorized personnel only (see section “Authorization’) Preventive maintenance has to be respected following the recommended periods, Before working on the equipment, ensure that all the power is cut (see section “shutting down’ Check the complete stop of the machine before working on disassembling the protection devices. After disassembly: ‘+ Clean all the parts that are going to be reassembled. ‘+ Tighten all the disassembled screws. Do not carry out work if the equipment has not been secured. ‘+ Type of oll recommended: type ZS46 or similar. ‘+The checking and filing up is to be made on the tank located on the pressure multiplier (Fill to 213). + When handling the oil, take the precautions mentioned by the supplier.5.2. Preventive maintenance 5.2.1.List of maintenance operations RIVKLE © Type EPK setting tool | Operation Detection Frequency Lubrication between the mandre! and the anvil If vibration noise a Tite RIVKLE® must be |Mandrel replacement or cleaning at hard point |Every 5 000 to 15 000 cycles |Head cleaning - |Once a day Ifthe value at rest is |Once every 15 days and every eee eee diferent than 0+/-0 3mm. fime the head is replaced he pressure drops in [Hydraulic purge calibration mode or if the - effort is unstable the diameter of the |Anvil replacement mandrel passage is —_|Every 50 000 cycles >D+0.5mm_ Replacement of the EPK HP anvil support - |Every 250 000 cycles |Nose replacement - |Every 250 000 cycles In case of ovalization of the | |Traction replacement it damaged pdidirn lEvery 250 000 cycles [Drive shaft replacement - - |Oil replacement and air system purge - |Every 1 000 000 cycles |Pressure multiplier seals replacement - |Every 1 000 000 cycles [Complete head maintenance (seals, eer t Every 250 000 cycles ‘The BOLLHOFF society includes an Internal After-Sales Department for EPK repairs.RIVKLE © Type EPK setting tool 5.3. Disassembly of the internal mechanical parts of the setting head 5.3.1.EPK setting head In order to correctly carry out the maintenance of an EPK head, it is recommended to use BOLLHOFF maintenance tools. The main internal mechanical parte of tho EPK head are made up of the following items: = Hydraulic piston (3) ‘+ Needle thrust bearing (H). + Pneumatic motor (L) + Pneumatic motor distributor (17). © Drive shaft (10). an Disassembly: 1. Remove the rear cap at the back of the head 2. Disconnect the connector from the stroke sensor. 3. Unscrew the 3 screws on the stroke sensor holder. 4, Remove the 2 pneumatic tubes from the motor distributer (17). 5, Remove the spring retaining ring by holding tight the return spring and the bearing washer (spring compressor ref. 28259010067), 6. Remove the hydraulic piston (3) 7. Unscrew the distributor (17) (distributor tightening ref. 28259010069). 8. Remove the pneumatic motor (L). 9. Unscrew the driving shaft (10),RIVKLE © Type EPK setting tool Reassembly: 1 2. ‘Assemble the needle thrust bearing (H) on the greased driving shaft (10). Position the distributor (17) on the pneumatic motor (|). Then introduce the unit into the piston (3), taking care that the motor turns freely after tightening. Tighten torque of the distributor on the piston: 5 mdaN Re-conneet the pneumatic tubes on the distributor (17). ‘Screw back the 3 screws on the stroke sensor holder. Re-connect the stroke sensor connector. Recalibrate the stroke sensor. Screw the rear cap back on.RIVKLE © Type EPK setting tool 5.3.2.EPKC setting head In order to correctly carry out the maintenance of an EPKC head, it is recommended to use BOLLHOFF maintenance tools. The internal mechanical parts of the EPKG head are made up of the following items: + Rear cap & screws (26). » Threaded ring (24). * Washer (23). * Sensor holder (20). + Return spring (18) + Stroke sensor (27) + Hydraulic piston (17) + Driving shaft (6) «Purge screw (11). (27) ag) go” (17) ° a a) - (24) (23) (20) (18)RIVKLE ® Type EPK setting tool Disassembly: 41. Disassemble the tooling (anvil & mandrel) as well as the nose, 2, Remove the grub screw and unscrew the traction dowel 3. Remove the purge screw (11) 4. Disassemble the rear cap by unscrewing Its 3 screws (26). 5. Loosen the Stroke sensor (27) by unscrewing the 3 screws on the holder. (28239010304) 6. Remove the threaded ring (24) using a special dial key (ref. 28259010304), 7. Remove the return spring (18). 8. Remove all the internal mechanical parts by pushing on the driving shaft (6) extremity. Reassembly: 1. Carry out the operations above in the reverse order, taking care of not damaging the piston (17) seals. 2. Before replacing the purge screw (11), fill up with oil using an oil can. 3. Make a hydraulic purge of the head (see section "Hydraulic purge’).5.3.3.EPK HP setting head RIVKLE ® Type EPK setting tool In order to correctly carry out the maintenance of an EPK HP head, it is recommended to use BOLLHOFF maintenance tools. ‘The internal mechanical parts of the EPK HP setting head are made up of the following items: (2) (28) (27) (18) (8) (40) Rear cap (15) ‘Sensor holder (9) Stroke sensor (38) Cylinder (40) Drive shaft (8) Traction dowel (18) Pneumatic motor (2) Rear sleeve (22) Stop flange (28) Motor suppor flange (27) Pneumatic drilled block (25) (15) (22) (38) (9) (25)RIVKLE © Type EPK setting tool Disassembly 1. Remove the rear cap (15) by unscrewing the 7 MS screws, 2. Remove the sensor holder (9) by unscrewing the 4 MS screws. 3. Disassemble the stroke sensor (38) by unscrewing the 2 CHC M4 screws and the 2 fixation clamps.RIVKLE © Type EPK setting tool 4, Unscrew and remove the pneumatic elbow fiting Disassemble the fiting unit and the pneumatic reducing element located at the back of the pneumatic motor. 6. Disassemble the rear sleeve (22) by unscrewing the 7 CHC M4 screws and the M5 screw in - order to remove the pneumatic drilled block.RIVKLE © Type EPK setting tool 7. Untighten the stop flange (28) by unscrewing the M5 screws in order to access the motor support flange (27) 8. Disassemble the pneumatic motor unit (2) and the motor support flange (27) by unscrewing the 6 MS screws. 9. After having removed the setting tools, unscrew the tightening screw inside the traction dowel (18), Then unscrew the drive shaft (8) using a BTRB key while holding the drive shaft in rotationRIVKLE © Type EPK setting tool Reassembly 1, Carry out the previous operations in reverse order respecting the standard torque for the screws. 2. Position the motor in order to have the pneumatic fiting of the cylinder body offset from the sensor axis (right side of the head),RIVKLE © Type EPK setting too! 5.4, Purging the setting head If too much is present in the hydraulic hose, itis necessary to manually purge the head. 5.4.1.Equipment required to perform the purge of the head hydraulic circuit + Aplugged and in working order contro! unit + The special key to open the doors * Afunctional EPKC head connected to the cabinet + AZS46 oil can = AShex key © Arag ‘© Awatertight oil recovery tank 5.4.2.Procedure 41. Reduee the pressure of the control unit (= 4 bars) av 2. Enter the “Adjustment” menu from the interface. ePkC SCROTEEN BOLLHOFFRIVKLE © Type EPK setting tool 3. Enter the password. cme at ad BOLLHOFF 4. Enter the “Sensor calibration’ menu. 5. Check that there is no RIVKLE® on the mandrel. 6. Touch the "GO" button. BULLHOFF iE 7. The hydraulic pressure on the sereen must increase (if there is air in the hydraulic circuit, the max pressure will tend to decrease.RIVKLE © Type EPK setting tool Unscrew the purge screw with precautions. Tighten it back when the pressure is close to 40, bars and then push the STOP button (which appears in place of the “GO” button) in order to release the air from the circuit and refill it Readjust the oil level in the tank. TANK 10. Repeat the last 3 steps until the pressure max is stable. 11. Bring the control unit pressure back to 6 bars. 5.4.3.Position of the purge screw depending on the type of head Eres EPKC heads EPKHP headsRIVKLE ® Type EPK setting tool 5.5. Mechanical adjustment of the setting head 5.5.1.Disassembly / adjustment of the traction dowel, 55. 1. EPK setting heads This adjustment has already been made when the head is delivered, it only has to be set again in case of disassembly (for example to replace the seals) or when replacing the drive shaft. We thus adjust the maximum stroke (when the drive shaft (8) reaches the stop flange). Procedure 1. Disassemble the nose and the tooling, 2. Screw the stop flange (7) all the way back and hold the traction dowel (8) pulled forward, adjusting the value to 31,5mm. 3. Tighten the internal stop screw. [— 31,5 | ” ® ©RIVKLE ® Type EPK setting tool 5.5.1.2. EPKC setting heads This adjustment has already been made when the head is delivered, it only has to be set again in case of disassembly (for example to replace the seals) or when replacing the drive shaft. We thus adjust the ‘maximum stroke (when the drive shaft reaches the stop flange). To make this adjustment, the mandrel, the nose and the anvil must first be removed. Procedure 1. Disassemble the nose and the tooling 2. Screw the stop flange (7) all the way back and hold the traction dowel (2) pulled forward, adjusting the value to 38mm, 3, Tighten the internal headless stop screw (5) ” ~ @ s)RIVKLE ® Type EPK setting tool 5.5.1.3, EPK HP setting heads This adjustment has already been made when the head is delivered, it only has to be set again in case of disassembly (for example to replace the seals) or when replacing the drive shaft. We thus adjust the maximum stroke (when the drive shaft reaches the stop flange). To make this adjustment, the mandrel, the nose and the anvil must frst be removed. 1, Disassemble the nose and the tooling 2. Hold the traction dowel (18) pulled forward, adjusting the value to 30,5mm. 3, Tighten the internal stop screw (50). (50)RIVKLE © Type EPK setting too! 5.5.2.Adjusting the Push-Pull valve 5.5.24. EPKC setting heads The entire Push-pull mechanism is composed of 4 parts: © AM2.5 screw (31a) + Aspring (31b) ‘© Abrass body fitted with an o-ring (31¢) +A push-pull uide (32) — (22) (31c) _ yal (31b) It is housed in the distributor, sea inthe direction ofthe guide. Its purpose is to supply or cutoff the air from the pneumatic motor (for screwing or unscrewing functions). Itis stressed through the push-pull guide. ‘The adjustment is extremely important. Adjustment: By adjusting the length of the valve (with M2.5 screw), the aim is to find the right compromise to obtain ‘a setting that does not run the motor at rest and when opening the valve, to obtain the maximum torque of the pneumatic motor. Ideal length for starting the adjustment is 1.5mm. 11.5 mm ‘The o-ring must be stuck with LOCTITE 496. Itis vital to ensure the good condition of the push-pull guide, ‘The length of the guide has to be 76.75mm.RIVKLE ® Type EPK setting tool There are 2 possible cases: * Case 1: the motor is constantly supplied without pushing the mandrel (permanent screwing funetion activated). Solution: it is necessary to increase the length of the valve using the M2.5 screw. © Case 2: the motor is not supplied even when pushing on the mandrel (no screwing). Solution: itis necessary to reduce the length of the valve using the M2.6 screw. Optimal adjustment will allow you to reach the maximum motor torque when it will be called on and not to have movement or leaking when the command is stopped. So that the valve does not lose its adjustment when functioning, it is mandatory to glue the M2.5 screw with LOCTITE 290 glue. In order to do this, apply the glue directly onto the screw and on the back of the valve.RIVKLE © Type EPK setting tool 5.5.2.2. EPK HP setting heads ‘To access the push-pull mechanism, repeat the disassembly steps described in the section “EPK HP heads’. The entire Push-pull mechanism is composed of § parts: © ~AM4X4 screw (S) © Aspring (R) + Abrass body (A1) fitted with an o-ring (A2) +A push-pull guide (P) +A spring guide ring (W) (P) (s) (a2) tS Ve Itis housed in the distributor, seal in the direction of the guide. Its purpose is to supply or cut-off the air from the pneumatic motor (for screwing or unscrewing functions). It is stressed through the push-pull (w) guide. ‘The adjustment is extremely important. Adjustment: By adjusting the length of the valve (with M4 screw), the aim is to find the right compromise to obtain ‘setting that does not run the motor at rest and when opening the valve, to obtain the maximum torque of the pneumatic motor. ©) é., (a2) oY Measure the length between the valve and the end of the push-pull guide before the new adjustment. (s)RIVKLE © Type EPK setting tool There are 2 possible cases: © Case 1: the motor runs as soon as we put air: the push-pull valve is open Solution: itis necessary to reduce the length of push-pull unit by unscrewing the M4 screw. © Case 2: the motor does not run when pushing the mandrel: the push-pull valve stays closed. Solution: itis necessary to increase the length of push-pull unit by screwing the M4 screw, ‘Comment: to ensure the contact of the RIVKLE® against the anvil (the manual unscrewing must be quite hard), tighten the M4X4 screw slightly (1/10 X 1/10 to increase the length). (Optimal adjustment will alow you to reach the maximum motor torque when it willbe called on and not to have movement or leaking when the command is stopped. So that the valve does not lose its adjustment when functioning, itis mandatory to glue the M2.6 screw with LOCTITE 290 glue. In order to do this, apply the glue directly onto the screw and on the back of the valve.RIVKLE © Type EPK setting too! 5.6. Replacing seals, 5.6.1.EPK setting heads Components: + Cylinder (02) + Seal (A) + Seals (0) + Guide ring (B) Guide rings (E) ‘+ Hydraulic piston (03) oo (03) a) © ©) 8) ©) © @) Disassembly Itis necessary to use the appropriate tooling for “guiding” the different seals: ‘+ Retractor and seal filter D21 = Ref. 28259010066 ‘+ Retractor and seal filter D42 = Ref. 28259010068 ‘+ Compressor and spring = Ref. 2825901 10067 Assembly according to procedure ‘+ Assembly of the o-rings using appropriate pliers + Assembly of the seals using the template cones + Anexternal cone for stretching the seal to a diameter over the piston diameter ‘Assembly of the guide ringsRIVKLE ® Type EPK setting tool 5.6.2.EPKC setting head Components: Body (70) Seal (10) Guide ring (16) Guide ring (9) Seal (15) Hydraulic piston (17) (70) qs) 7 . NB (16) (9) qa) ‘The tightness of the hydraulic chamber is ensured by: ‘A seal and a guide ring assembled on the front of the cylinder. ‘Aseal and a guide ring assembled on the hydraulic piston. Procedure 1 2 3 4, Remove the damaged seals Clean and check the state of the piston (17) and the body bores (70) ‘Assemble the new seal on the piston (15) and the guide ring (9) witha bit of grease ‘Assemble the new seal in the body (10) and the guide ring (16) with a bit of greaseRIVKLE © Type EPK setting too! 5.7.Diagnostic ePkC SERUSERIEREE) ait Dp) Dg BOLLHOFF ‘The system includes a "Diagnostic" menu that you can access by pressing the appropriate button. The following screen appears. — fi cm ce This screen displays the total number of cycles recorded by the system as well as the different menus.RIVKLE @ Type EPK setting too! 5.7.4.Viewing Inputs / Outputs The following screen displays the active inputs. If the inputs are active, the buttons light up in green. ption of the input light “In running”: when this light is on, the system is ready to operate. When it is off the breaker is on machine stop position “Start button”: this light is on when the start cycle button is active on the setting head “Unscrewing push button”: this light is on when the unscrewing button is active on the setting head “Setting authorisation”: when ths light is on, the Harting socket P1 is connected, “Customer start cycle”: Information of cycle start given by the customer's communication. “End cycle from customer: acknowledges end of cycle given by the customer's communication. “Fault acquitement”: means that the fault acknowledgment has been made. “Booster oil level” active when the oil level is OK.RIVKLE © Type EPK setting tool Pressing the G bottom right button (on the inputs screen) allows you to access the outputs screen. res Description of the outputs ligh “Setting” when this light is on, the setting function has been triggered, “Unscrewing”: when this light is on, the unscrewing function has been triggered. “End of cycle”: when this light is on, the end of cycle function has been triggered. “Part fault”: when this light is on, the part fault sensor is activated. “Setting OK”: when this light is on, the setting cycle has been correctly made.RIVKLE ® Type EPK setting tool IG Inputs/Outputs screen. The following screens will appear. OPTION: Description of the outputs lights: “Acquitement default with key”: when this light is on, the key switch acquitement of default option is active. “Part present”: when this light is on, the part presence sensor is activated. “Platted part”; when this light is on, the contact option sensor is activated “Setting fault del”: when this light is on, the output signalling a setting fault is activated, “Tightening”: when this light is on, the clamping sensor is activated, “Green del”: when this light is on, the green output light is activated Pressing the MMlll button takes you back to the DIAGNOSTIC menu,RIVKLE ® Type EPK setting tool 5.7.2.Machine status This menu displays a summary of the equipment configuration (activated/deactivated options, counters, etc.) 5.7.3.Settings history This menu displays the history of the settings made with the equipment. Each setting made is stored in the memory with information about the date, time, pressure, stroke and set of parameters used. To scroll down the history, use the arrow buttons at the bottom of the screen.RIVKLE © Type EPK setting tool 5.7.4.Cycle time This menu displays the cycle times of the setting and unscrewing operations and the total cycle time. Sra ati) een) oO ee aL Pressing the & button takes you back to the DIAGNOSTIC menu. 5.8. Transfer and updating the software 5.8.1.Transfer with a USB stick Files can be found on the USB stick: “prj001” folder and 2 “boot.cfg" files. Procedure Connect the USB stick to the USB port located on the je or at the back of the control unit Press on 2 opposite comers of the screen one after the other, starting by the comer at the top of the screenRIVKLE ® Type EPK setting tool strip appears at the bottom of the screen (Offline, CF/USB, Reset) Press “USBStart’ ‘Anew page is displayed: the device looks for the file on the stick ‘Another page is displayed in Japanese: select “English” and wait for the display in English. Select “Download USB" > “Display’. ‘Anew page is displayed: select “START” Then: “Do you want to download the data” > select "YES" The program is now downloaded and the screen is automaticaly restarted. ‘Anew page appears: select “BACK’ at the bottom<; New lines are displayed: “Successfully completed, please push Back Button’ > select “BACK. On the new page displayed, select "BACK" again. The start screen is displayed again with the transfer direction: select “EXIT” ‘A message appears: “Are you sure to restart the system” > select "YES" ‘The system restarts. ‘Once the system has finished restarting, you can remove the USB stick.5.9. Troubleshooting RIVKLE © Type EPK setting tool Mandrel thread damaged Hard screwing Hard unscrewing RIVKLE® thread damaged after setting ‘The RIVKLE® runs freely in its groove Unscrewing is not triggered Normal wear or setting force too high Push-Pull badly set Distributor or motor damaged ‘or broken - Distributor or motor damaged or even broken = Mandrel axle not perpendicular to the support = RIVKLE® or mandrel thread damaged RIVKLE® not completely screwed on the mandrel Setting force too high Thickness to be crimped not adapted to the RIVKLE® Setting force not sufficient Unscrewing time equal to 0 Replace the mandrel Replace the damaged part Ensure the perpendicularity of ‘the mandrel axle to the support during unscrewing To release the material: bring the pin in front of one of the holes in the nose, remove it, unscrew the nose and replace the mandrel Set the anvil position according to the instructions in chapter = Maintenance > Adjust the setting force Check the range of setting in the RIVKLE® brochure Adjust the setting force Change the timingRIVKLE ® Type EPK setting tool 6.0 Waste discharge Respect the law regarding the waste discharge according to local legislation. ‘The machine, accessories and packaging must be recycled to respect the environment. The following materials must be sorted out according to local legislation: = Lubricants and oils © Cloth soaked with lubricant or oil iners used for lubricant or oil + Empty contRIVKLE ® Type EPK setting tool 7.0 Drawings 28252128000 - EPKC REVOLVER HEAD BULLHOFF "AUTOMATION DEPARTVENTRIVKLE © Type EPK setting toolRIVKLE © Type EPK setting tool 28252128000 - EPKC REVOLVER HEAD aE RF |[_atorarion cement eone == ve bear (eRe IERIVKLE ® Type EPK setting tool 28252128000 - EPKC REVOLVER HEAD [ee se me c owe re FCT z ie] famine ane UNA * = = [+ [sense eT ACTON z os [ara AC OUTER 0 = [aera ico FORK * = = [1 fran fe. TLaeccrs n me [2 | psraeon vs aT n = a [2 [rasan ec ere 7 I [1 [aero Fre astra n EI a [1 ansreane ice 7 m= a mea 7 = [1 [rssrenoe ec TELAT 7 me [> [aesres nce + a Fe a ES Ae FETE 7 BI 36 [1 [aemion eae 16a ? 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