A2112c-216 Pallet Welding Equipment

Machine version：A2112C-216
Date：2021.
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Contents
1.1 Foreword ............................................................................................................................... - 6 -
1.2Operation party duty and responsbility .............................................................................. - 6 -
1.3Notes for the operator ......................................................................................................... - 6 -
1.4operation regulation ............................................................................................................ - 6 -
1.5 Illegal operation ................................................................................................................. - 7 -
1.6Safe measures for the machine ........................................................................................... - 7 -
1.8After-sales service .............................................................................................................. - 8 -
1.8.1KEBER service hotline： ............................................................................................... - 8 -
2.safety .................................................................................................................................... - 9 -
2.1. Basic safety tips ................................................................................................................ - 9 -
2.2 Commonly used safety tips, symbol structure.............................................................. - 10 -
2.3 Special safety tips,sign and label ..................................................................................... - 11 -
2.4 stop sign ........................................................................................................................... - 13 -
2.6Notes for the operation ..................................................................................................... - 15 -
2.7 Requirement on the operator ........................................................................................... - 16 -
2.8 Transport, storage and installation................................................................................... - 18 -
2.8.1 Installation and commissioning notes/safety measures ............................................. - 18 -
2.9 Specific energy ................................................................................................................ - 20 -
2.9.1 Fire/burn danger ........................................................................................................ - 20 -
2.9.2 Electricity danger ......................................................................................................... - 21 -
2.9.3 Pneumatic device danger ........................................................................................... - 22 -
2.9.4 hydraulic device danger........................................................................................... - 23 -
2.9.5 Conventional danger.................................................................................................. - 23 -
3. Machine description .......................................................................................................... - 24 -
3.1 Machine description ........................................................................................................ - 24 -
3.1.1 Preparation before operation ........................................................................................ - 25 -
3.1.1 Operator station ............................................................................................................ - 26 -
3.1.2 Dangerous zone ............................................................................................................ - 26 -
3.1.3 Safety and protection devices ....................................................................................... - 27 -
3.1.3.1 safety circuit .............................................................................................................. - 27 -
3.2 Drive unit ......................................................................................................................... - 28 -
3.2.1 Hot tool drive unit ........................................................................................................ - 28 -
3.2.2 Upper cold drive unit .................................................................................................... - 29 -
3.3 Mould Description ........................................................................................................... - 30 -
3.3.1hot tool ........................................................................................................................... - 30 -
3.3.2Upper mold .................................................................................................................... - 31 -
3.3.3 lower cold tool .............................................................................................................. - 32 -
3.4 Equipment action flow .................................................................................................... - 33 -
4.Transportation/storage/installation..................................................................................... - 34 -
4.1target object ...................................................................................................................... - 34 -
4.2disassembly ...................................................................................................................... - 34 -
4.2.1Required work tools ...................................................................................................... - 34 -
4.2.2Disassemble the machine .............................................................................................. - 35 -
4.3Transportation................................................................................................................... - 37 -
Hotline：86-512-82288666 FAX：86-512-68091510 WEB：http://www.keber.cn
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4.3.1Security information ...................................................................................................... - 37 -

4.3.2 deliver equipment ......................................................................................................... - 38 -
4.3.3 Check the goods ........................................................................................................... - 38 -
4.3.4Delivery ......................................................................................................................... - 38 -
4.4Installation ........................................................................................................................ - 38 -
4.4.1Install the machine......................................................................................................... - 38 -
4.4.2Install the machine......................................................................................................... - 40 -
4.5Stop point, forklift accepted ............................................................................................. - 41 -
4.6 storage ............................................................................................................................. - 41 -
5.Operation and commissioning ........................................................................................... - 42 -
5.1 safe operation tips ............................................................................................................ - 42 -
5.1.1safe protection unit ........................................................................................................ - 42 -
5.1.2 Input and output interface.......................................................................................... - 42 -
5.1.3 Check the function of the safe prevention unit............................................................. - 42 -
5.2 Operating and display components ................................................................................. - 43 -
5.2.1 Equipment overview..................................................................................................... - 43 -
5.2.2. Operating unit .............................................................................................................. - 44 -
5.2.2.1 Start button ................................................................................................................ - 44 -
5.2.2.2 stop button ................................................................................................................. - 44 -
5.2.2.3 power switch.............................................................................................................. - 44 -
5.2.2.4 Reset button ............................................................................................................... - 44 -
5.2.3.5 scram button .............................................................................................................. - 45 -
5.2.3.6 Three color indicator ................................................................................................. - 46 -
5.2.3manual connection valve（compress air supply） ....................................................... - 47 -
5.3 Operation panel usage guidelines .................................................................................... - 48 -
5.3.1 Main screen and each function screen .......................................................................... - 48 -
5.4Troubleshooting ................................................................................................................ - 59 -
6. Maintenance and Repair ................................................................................................... - 64 -
6.1 Safety and protection devices：Emergency stop button ................................................. - 64 -
6.2 Safety and protection devices：limit position switch ..................................................... - 65 -
6.3 Exhaust device: exhaust fan ............................................................................................ - 66 -
6.4 transmission unit: gear rack transmission unit ................................................................ - 67 -
6.5 Drive units: linear rail...................................................................................................... - 68 -
6.6 Transmission unit: linear bearing .................................................................................... - 69 -
6.7 pneumatic structure: valve/valve pipe/valve port ............................................................ - 70 -
6.8 pneumatic structure: maintenance unit ............................................................................ - 71 -
6.9 Pneumatic system: gas storage tank ................................................................................ - 72 -
6.10 Distribution cabinet: cooling device.............................................................................. - 73 -
7. Technical documentation .................................................................................................. - 74 -
7.1 machine parameter .......................................................................................................... - 74 -
7.2 Parts List .......................................................................................................................... - 74 -
7.3 Recommended spare parts list ......................................................................................... - 74 -
7.4Assembly parts list ........................................................................................................... - 75 -
7.5 Gas path diagram ............................................................................................................. - 81 -
7.6 Electrical assembly parts list ........................................................................................... - 83 -
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7.7 Circuit diagram ................................................................................................................ - 86 -

8. warranty card .................................................................................................................. - 111 -
9. Supplier documentation .................................................................................................. - 113 -
9.1 Brand: Schneider // Accessory name: Limit switch ...................................................... - 113 -
9.2 Brand: Siemens // Part Name: Motor ............................................................................ - 115 -

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Abbreviation：
abbreviation Meaning
AS Working position
Bh Running hour
EN English
ZH Chinese
FE Transmission unit
GS Original position
IR Infrared
IT(IP) Instrument panel
n.i.o. Abnormal
OT Upper tool
OWZ Upper fixture
SP Welding points
US Ultrosonics
UWZ Base plate
FC Frequency changer
BC Bar code
WHN Melting unit
NH Pressing device

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1.1 Foreword
Dear customers:
We are honored and appreciate that you purchase our company’s pallet welding machine, the number
of which is A2112C-216!
This operation manual can help you to have a better knowledge on KEBER’s machine, please read
the manual and tips carefully, thus to reduce the machine’s break down time, increase the lifetime and
avoid the potential dangers
Before running this equipment, all the operators and related person should read the operation manual
carefully, especially the safety chapter (illegal operation is hardly forbidden)
If you have any questions regarding this operation manual, you are welcome to contact us at any time,
the detail information is listed at the end of this manual.
Notice！！
！
This operation manual should be placed near the equipement so that the
operator can have a easy access to it any time
1.2Operation party duty and responsbility

Operator who is allowed to run this machine must：
1.3Notes for the operator

①.Must obey the related working safety information and acccident prevention basic
requirement in this operation manual
②.Read the safety chapter in this operation manual carefully,and make sure yourself
understand it,meanwhile sign your name for confirmation
Warning：
Do not operate the machine disobey the
regulation！！！
1.4operation regulation
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operation regulation:
* The operators must take the training lessons;
* Keep daily check and maintenance;
* Check the evenness of the machine before turning on to ensure the stability;
* Turning off the power when change the tool,pay attention to the cooperation with the
Partner;
*Know about the position of the emergency stop button and power switch;
*The operators are required to wear the safety outfit;
*Do not remove the safety or warning sign on the machine and keep them visible and clean；
*Obey the required environment temperature and humidity value;
*The equipment must keep clean;
1.5 Illegal operation

If the machine is not ran according to the regulation,the life of the user or others
may be threatened and it will also affect the performance of the machine.
Notice：
*Do not change the structure of the machine without the permission of KEBER
*Do not run the machine without enough knowledge of operation and maintenance
*Do not adjust the stroke of the cylinder casually
*Do not put any unnecessary items on the machine
*Do not touch the fixtures on manual mode
*Do not change the tool under the high temperature
*Do not shield the safety curtain
1.6Safe measures for the machine

*Alarm of the three color light:the red light will be on when the error occur during the operation,the green light
will be on during the normal operation, the yellow light will be on if the machine stops
*Emergency stop:Anything emergent happens,press the emergency stop button then the
machine will stop immediately
*Safety curtain:the machine will alarm and stop when any items (including any part of the body)enter in during
its operation.

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1.7Disclaimer
Our company will not accept the responsibility of repair under the following circumstances：
*Operate this machine without following the regulations

*Install,maintain and operate the machine incorrectly
*operate this machine without following the operation manual
*Replace the components or structure without permission
*Use the unoriginal parts
*Change the parameter or working condition without permission(like temperature,sealing and pressure)
*Maintain the machine incorrectly
*Maintain the machine without following the regulation
*The machine is not appropriately stored
* Did not use it under the required conditions
1.8After-sales service
Our after-sales service including：

* Our after-sales service including：
* Inspection,repair and maintenance
* spare parts management
* Emergency service and maintenance
* Machine updating
* Transposition of the machine
1.8.1KEBER service hotline：
You can call us any time from Monday to Friday 08:30-17:00(holidays excluded)
Hotline:86-512-82288666
Fax:86-512-68091510

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2.safety
2.1. Basic safety tips
Before operation:
*Check if the helmet comply with the machine
*Wear and use the safety outfit correctly
*Check if there is any leakage of the valve and pipe
*Check the sensitivity and stability of the emergency stop buttons
*Check the sensitivity and stability of the limit the stroke switch
*Check the stability of the ground connection system
*Check the condition of the safety device and outfit
*Check if there is any broken and exposure of the handle wire
*Check the oil position of the oil tank
*Check if the safety curtain is sensitive or reliable
During the operation：

*The machine must be ran without loading the parts first to check if everything is ok
*Do not operate the machine when it need to be repaired or overload
*The operator should not let himself at the edge or below any processing items, and also pay attention to
the position of the other stand
*Large-size items welding should be accompanied by specially-assigned person
After the operation：

*Turn off the power and close the distribution box
*Clean the workshop to keep the machine clean

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2.2 Commonly used safety tips, symbol structure
The operating instructions provide safety information, the content of the equipment involved in the
operation of the inevitable security risks, please read carefully, according to the provisions of the
operation, to reduce the occurrence of accidents;
The potential risk including：

* Operator danger
* Product and machine danger
* Environment danger
This sign means there is potential danger to people
*After realizing the sign,the related measures should be taken to avoid the
danger。
danger
This sign also means there is potential danger to the machine,materiall or the
surrounding。
* After realizing the sign,the related measures should be taken to avoid the
danger。
Note

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2.3 Special safety tips,sign and label
*CE label
CE label means that our equipment meet up to the current EU machinery

standard,as the manufacture,we assure you that the equipment has past the
evaluation process and satisfies the EU standard
*Warning sign
Hot surface warning
The symbol may be created to generate danger (harm)
See the sign, as a result of strengthening awareness, to avoid the occurrence of such hazards (in the equipment,
the high temperature of the mold, the prohibition of unarmed contact)
Warning hands hurt danger

It points out the potential position where you may hurt your fingers or hands
Dangerous voltage warning
It means the electric danger

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It means potential danger for the operator

Warningto run
You should aware there is potential risk here when you see this sign(unprofessional people are forbidden
this machine)
Mechanical danger warning
It means there is potential danger if you approach the machine during the
operation
Fall off danger
It means there is risk that you may fall off at this area
Hang out heavy thing warning
It points out the position that may lead to danger cause something heavy is above

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2.4 stop sign
keep clean
it means the machine should be kept clean
Wearing a safety helmet
In the operation of the equipment, must wear a safety helmet.
Wear protective gloves
Before operating the equipment, please wear gloves to prevent injury caused by
personnel (equipment running, mold temperature is higher).
Wear protective shoes

This equipment operation, please wear safety shoes to prevent causing
unnecessary injury to personnel (especially when the hanging mold,
mold unloading, for the sake of the safety of personnel, be sure
to wear labor insurance shoe).
Wear protective glasses
Please wear protective glasses when operating the machine

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2.5 Forbidden sign
People are not allowed to enter without permission
It means there is potential danger at this area, people are not allowed to enter in
without permission
People are not allowed to climb without permission
It points area that people are not allowed to climb without permission。
Prohibit standing
It points out the area near the machine where people are not allowed to stand on
People are not allowed to wear heart pacemaker
It points out the area where people who wear a heat pacemaker can not.

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2.6Notes for the operation

The operation side should assure that：
*The machine is in good condition,check if all the functions are ok on a regular basis
*Strictly obey the relevant national regulation about the technical inspection
*Provide all the necessary safety outfit and device for the operators
*The operator cannot has his hair disshevelled or wear the loose clothes or ornaments(there is risk the hair
maybe rolled by the machine)
*keep the surrounded environment clean
*Do not use the material that will cause the health issues after the welding。
*Keep the safe sign on the machine visible and clean。
*Train the operator about the safe production on a regular basis。
*The operation area of the machine should equipped with anti-skid floor。
*The machine must be ran according to the regulation(refer to the ‘basic tips’
chapter)
*Obey the required temperature and parameter/pressure value。 danger
*Do not change the program without permission。
Danger to life due to failure of certain components

Error in the specific component may leads to below danger：
*No protection for the dangerous area of the machine, continuous quick：
movement can not be avoided.。
*The heavy items may fall off due to the shortage of braking and clamping force.
danger
*May leads to the damage or unrepairable damage to human.
prevention measures
* Check the machine on a regular basis
* Turn off the machine
* Arrange the maintenance immediately after turning off the machine
Poison danger！
Processing on the chemical plastic (like PVC,PU foam,ABS and so on)may
cause the gas that will lead to poison(as phxia,respiratory tract,sick and vomit)
d
anger
Prevention measures
* The related people or operation party or authorized people can install
the exhaust system to exhaust the poisonous gas ,or as well as
the extinguishing device or anti-exposure device.

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2.7 Requirement on the operator

Misoperation or lack of the necessary knowledge may lead to the human life’s the
financial loss.
Prevention measures
otice
*qualified and can assign the tasks
*Have a sense of safety and risk
*Took the taining lessons of the machine
*Read the operation manual carefully and understand it
*Do not operate the machine after drinking
The following activity should be conducted by the qualified people：
*The transportation can only conducted by the lifting gear and trained people
*The installation and disassembly of the machine must be conducted by professional people
*The initial installation and commissioning must be conducted by KEBER
*The maintenance of the machine must be conducted by professionals
*The maintenance of the machine must be conducted by KEBER
The lack or damage of prevention device may lead to life danger or financial loss：
The lack or damage of prevention device will leave no protection for the dangerous area,thus people at the
dangerous area can not avoid the threaten cause by the quick movement of the machine,which will lead to
the damage or death of people
Prevention measures:
*Check the prevention device every time before turning on the machine
*Check if the installation is finished according to the regulation and if the position
*If there is any damage to the device
*Make a checking list and check everything according to the list
danger

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Attention!
If any loss or damage to the machine, or there is any error,please turn off the machine and arrange the
maintenance immediately
The quick movement of machine may lead to life danger：

The safety of heads and limbs may be threatened by the pressing,rolling and the
equipment.
d
anger
Prevent measures:
*Only one operator is allowed to run the machine if there is no
special clarification
*Do not shield the safety curtain and skip the safety prevention device
*Make sure all the safety doors are closed before producing,and nobody stand in the dangerous area of the
equipment.

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2.8 Transport, storage and installation

*Assign the experienced driver to drive the folklift and someone to assist the driver, and the assistant
must stand at the visible area so that the driver can talk with him
*Use the qualified folklift or crane, so not stay under the heavy items hung
*During the transportation and lifting , the machine and tool should be placed on the special used device
and fixed on it
*Some heavy component should be fixed on the proper crane so that nothing
dangerous would happen
*Move and transmit the tools slowly so that the machine or component won’t fall
off.
*The moving parts must be fixed before transportation
otice
2.8.1 Installation and commissioning notes/safety measures
After the assembly and installation ,the machine will be commissioning by KEBER。
No prevention safety measures to the equipment will lead to the life risk
Decide the final parameter during the commissioning
* The machine and tool can only be tested when equipped with the complete safety device
* Operator is only allowed to enter in or climb on the dangerous area of the machine when using the
interlocking and prevention device
If the machine has already be assembled well or installed well,you can

commission after connecting with the machine。
*The initial comissioning should be conducted by KEBER
*Only the trained people can operate the machine
*Any operation may lead to dangers is prohibited
*Do not change anything about the machine without permission note
*Please use the climbing safety assistant tool when work high above the ground
*No parts of the machine can be used as the climbing tool
*Please operate under the required safe tempreature
*Make a checking list,check it at least one time a day,to make sure the machine is under safe
condition
*Do not touch the heating area with your exposed hands during the operation
When there is error in function,stop the machine immediately and fix the fault
When checking the faults, a second hand is needed cause when one person is checking and
operating,the other one can press the emergency button if something emergent happens

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 Notes
Before turning on the machine,make sure that

*Nobody at the dangerous area of the machine
*Avoid damage caused by turning on the machine
*If all the safety device can work well
*No any damage to the machine
*Report and fix in time if anything abnormal happens
*Remove all the unnecessary material and items out of the working area of the machine

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2.9 Specific energy

The machine operation need specific energy
The specific energy is electricity,hydraulic,vacuum and heating
The following clarification point out the dangers maybe caused by the
specific energy.
2.9.1 Fire/burn danger
Before welding,clean up the flammable material around the machine and provide enough ventilation
If there is a fire within the cabinet,the burnt cables will release the poisonous gas,usually the fire should
be put out with the powder and carbon dioxide fire extinguisher
* You can only put out the fire after turning off the main switch
There is potential burning risk around and the surface of the generator, infrared radiator,hot plate and
heating tube
*Do not grab the generator during its operation
*Do not touch the infrared radiator during and 30 mins later after the operation
*Do not touch the surface of high temperature component,even the temperature of the fan and hydraulic
tube can up to 70 degree
*Wear safety gloves
*Make sure the parts you need to touch have already cool down before the maintenance
Using the incorrect material or setting the incorrect time may cause the fire！
*only the specified material can be used
*Pay attention to the operation condition of the machine
*Do not put any inflammable on the machine
*The parameter can only be changed within the range
*Turn off the heating device before leaving the machine

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2.9.2 Electricity danger
The operation on the electric device can only be conducted by the trained operator
or electrician.
Attention!
Current intensity＞ 250mA can lead to death, so the relevant prevention measures are needed, people
maybe burnt or dead if touch it
Electrical shock will lead to the life risk

* If anything dangerous happens,stop the machine immediately and turn off the main switch
* Check the electrical device on a regular basis
* Replace the broken cables or sockets in time
* Please wear insulation shoes when maintain the machine
* Only the original fuse with the specified current intensity is allowed to use
*Prevent the wires and cables from being damaged by the outer reasons
The outer cover of cabinet and electrical device should always be closed, only the authorized people
are allowed to have access
The outer cover of cabinet and electrical device cannot be celaned by water, the machine should be
protected from water or moisture
A second hand is needed if working on the conductive parts to press the emergency button or
turnoff the main switch if any emergency

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2.9.3 Pneumatic device danger
Operation on the pneumatic device should only be conducted by the professional people
*The pneumatic device should be checked one time a week (if any faults like leakage,outer damage and
soon is found, it should be solved immediately)
*Even if nothing danger is found about the hose, the pneumatic hose must be replaced according to the
specified time(the max.using time is 6 years)
*assemble the air pressure tube correctly, do not mix up the connector
The broken or unlink of the hose and screw-plug will cause the heavy damage to people
Remnant danger of the storage device(some of them happens when pressing the emergency button,open
the safe door or close the compressed air：
*cylinder stop valve
*Reversing valve
*close the compressed air’ or ‘turn off the main switch would not cause the exhausting of the tank
*Before working on the pneumatic system,make sure there is no pressure and turn off the main switch to
prevent it on unintentionally
*Separate the pneumatic hoses for the machine and mold respectively
*Wear protective glasses
Restart the pressure after decrease may squeeze your hands
When the pressure is unusual , the value goes even less than the min.setting values, the machine
willstop immediately, your limbs may be squeezed if you restart it
*Do not enter in the dangerous area of the machine

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2.9.4 hydraulic device danger

The operation of the hydraulic device can only be conducted by the professional people
* The hydraulic device should be checked one time a week (if any faults like leakage,outer damage and
soon is found, it should be solved immediately)
* Even if nothing danger is found about the hose, the pneumatic hose must be replaced according to the
specified time(the max.using time is 5 years)
*Check all the pipes,hoses and threded pipe conncetor on a regular basis to see if there is any leakage
orvisible damage outside(the damage must be repaires immediately cause the splashed oil will lead to the
human injury or fire
* Assemble the hydraulic device corecctly, do not mix up the connector
The contractive hoses or spashed oil will injure the operator’s eyes
Potential danger on the storage device(emergency stop may happen)：
*Before the repair or maintenance, reduce the pressure in the tube or system that you are going to work on
*Cylinders and lockable valve must be vaccum up manually
*Separate the hydraulic hoses for the machine and the tool respectively
*Do make sure that there is no pressure within the hydraulic system before working on it, turn off the
main switch to prevent it start unintentionally
*A protective glasses is necessary to operate the machine
2.9.5 Conventional danger
*The loose of the bolt may cause danger

*The broken of moving parts may cause danger
*The danger of scalding, burning or poisoning,especially that caused from the chemical material

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3. Machine description
3.1 Machine description
Pallet machine work order number：A2112C-216
The role of the pallet welding machine is the

work piece to run to the designated position
of the lower mold, through the scheduled
program, the upper and lower pieces of
separation, the hot plate set by the thermostat
to reach the predetermined temperature, run
to the work area, and then up and down the
work piece to the hot plate direction to
Specify the location, the work piece surface
is hot plate melting and produce a layer of
melting layer between the hot plate and
weldment, and then quickly separated from
the upper and lower mold, hot plate to leave, then the upper and lower pieces of welding through a certain pressure
together.

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3.1.1 Preparation before operation

1）Check the power supply and whether the air source is normal (as shown in the below picture)
ON
Show pressure
value
OFF
（开）
3）Whether all the signals are normal and the equipment has alarm.

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3.1.1 Operator station
Area marked as the operator station, that is, pick and place station. The operator performs the specified manual
production steps.
Embed and extract stations

Operator manual activity:
* Embed a single component.
* Press the start button.
* Observe the device controller on the right
side of the console.
* After welding is complete, remove the
entire part that has been welded.
3.1.2 Dangerous zone

Dangerous zone
The arrow indicates the area for the hazardous area, ie the equipment work area, during operation, the
equipment runs the following steps:
Equipment work area

* Operate the device with the safety door open (with potential safety hazards)
Safety door

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3.1.3 Safety and protection devices
Safety devices are part of the equipment's normal equipment state, which is used to protect personal life and
health and safety, if the safety device failure, the behavior of careless and fault.
3.1.3.1 safety circuit
The device is equipped with the following safety circuits:

1. Maintain door safety switch。
2. The operator station emergency stop button is located on the operator panel left / right and the operator
panel operator panel.
1 Stop button
2 safety switch behind the
Maintenance door

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3.2 Drive unit
Damage to the drive unit.

Hot mold temperature danger.
Danger of mold feed movement
3.2.1 Hot tool drive unit

Hot drive: The gear motor or servo motor drives the sprocket chain through the timing belt.
Mechanism: hot mold by the linear slide and slider to form a front and rear movement, the cylinder drag
the hot mold with the guide column linear bearing up and down movement.
Both ends of the mold before and after the mold has a limit switch detection and hard limit
1 Linear slide guide

2 Sprocket chain
3 Up and down movement cylinder
4 Hot mold
5 FE-level
6 Horizontal motor reducer

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3.2.2 Upper cold drive unit

Upper cold drive: hydraulic system to drive the upper and lower cold up and down movement.
Organization: Cylinder link on the cold mold slide, guide column with a linear bearing for the cold
skateboard guide
Displacement sensor detects cold mold displacement distance.
1 servo mechanism
2 servo motor
3 Tooth column
4 Guide column linear bearings
5 FE - vertical movement

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3.3 Mould Description

3.3.1hot tool
Risk of crushing due to tool feed movement.

Danger of burns on the mold surface.
1 Hot mold frame

2 Thermal plate
3 Heating pipe
4 Limit block

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3.3.2Upper mold
Danger of crushing the upper and lower molds.

Danger of injury from the clamping device.
Risk of crushing due to tool feed movement.
1 upper cold tool

2 Clamp cylinder
3 limit pillar
4 fixture

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3.3.3 lower cold tool
Danger of crushing the upper and lower molds.

The compression device is in danger of injury.
Die feeding movement is dangerous.
1 Lower cold mould

2 Fixture
3 limit pillar
4 Clamp cylinder

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3.4 Equipment action flow
load product
Press start button
Slide fixture clamps and moves to work area
The upper mold is lowered, and the clamping work is completed.
upper cold tool up
Hot mold moves to work area
Hot tool cylinder pushes the hot plate down
Upper cold mold lowered, hot melt
After the hot-melt is completed, the upper cold tool move up and the hot mold move down
Upper cold mold lowered to curing position
After curing is completed, the upper clamp is loose and the upper cold tool is up
The left slide slides out to the load and unload position, and the clamp is loose
unload and repeat the above operation

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4.Transportation/storage/installation
4.1target object
This chapter applies to operators who are responsible for disassembly, transport and assembly operations, and
the operator should meet the requirements of the operator (see chapter "2.7 Personnel requirements").
Disassembly, transport and installation of operators are professional and technical personnel, professional
electrician or assigned to transport personnel.
So need to meet the professional and technical personnel, electrical and transport requirements.
Attention！！！
For horizontal and vertical transport of goods and loads, it is important to note the relevant requirements of the
State and the Professional Association. For transport specialists, it is important to:
* Valid land transport vehicles and crane driving licenses (eg cranes and forklifts) have been obtained.
* Obtain the assignment of transport tasks.
* Understand the risks and risks in transporting the load.
* Understand that there is a risk of injury and life due to the non-compliance with the passage of the load due
to the swing, falling, unprotected, and placement of the load.
4.2disassembly
Disassembly refers to the removal of the machine into parts for transport to the place outside the operator.
Note the following basic principles:

* It may be possible to disassemble the machine as needed, prepare it according to the existing transport route,
and pay attention to existing available ground transportation tools and lifting gear. KEBER's employees should
disassemble the machine as much as possible.
4.2.1Required work tools

Disassembly requires personal protective equipment, protective gloves, goggles, safety belts and suitable
workstation for aerial work.

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4.2.2Disassemble the machine

Before disassembling the machine, it should be shut down.
And then replace the specified energy pipeline to no pressure, no flow and no pressure state. Then disconnected
the designated energy and supply pipe network .
* Ventilation compressed air system.
* Ventilation vacuum system.
* Clear the hydraulic system (if any!).
Environmental hazards
In the machine, the unit is integrated with oil-containing media, which may cause contamination of the
environment if uncontrolled.
Precaution
Clear the machine。
Frozen water can cause damage to property
Remove the residual water from the machine supply pipe.。 Attention
If the machine is stopped and the specified energy is separated from the supply pipe and switched to
no pressure, no flow and no pressure, the machine can be disassembled.
Note the following information about personal safety.
Danger of cutting
The sharp corners of the parts are easily injured when disassembling the
equipment.
Precaution
Wear appropriate protective gloves。

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Be careful when the equipment is working
When work on a high-altitude equipment, tripping and slipping can cause a risk of
falling.
Precaution
Please use a seat belt.
Use the appropriate workbench when operating on high altitude and equipment
Current is easy to cause injury and danger!

Measures
Only electrical professionals are allowed to operate on electrical equipment
To ensure that the staff without current, no pressure.
Pneumatic pressure instruments and components under high pressure are

easy to explode and bounce!
Precaution
Only the technical commissioner is allowed to operate pneumatic device.

Attention
Remove the machine and supply lines without pressure
Check and ensure that the supply line and the compressed air supply are free of
pressure.
Turn the locking device of the supply line to "off" and use the padlock to
prevent it from turning on again.
Wear goggles to prevent the explosion of pneumatic components from danger.

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4.3Transportation
After the disassemble the machine,it can transport equipment and components, this machine has a dedicated
device.
KEBER company in accordance with the above principles dismantling the machine, and try our best to ensure
that can be assembled. Remove the parts of machine and send it by train.
Activities within the scope of transport can only be carried out by professionals who comply with the relevant
transport, safety and accident prevention regulations.
For horizontal and vertical transport of goods and loads, should comply with the specific requirements for
driving means of transport.
4.3.1Security information
Transport of heavy objects and goods, there is a high risk of injury and financial damage.
Observe and follow the following information about personal safety.
The goods to be transported will cause life danger!
Abnormal movements or emergency stops in the process of transport

may cause product movement and fall from the transport.
Measures danger
Use the appropriate strap or sling to fix the transport product.
Please be careful to transport.
Transport to avoid emergency stop.
Attention the safety of the site operator.
Suspended product may cause a risk of injury!
Abnormal action or emergency stop in the process of transport

can cause product vibration. The site person may be hit by vibrated product.
Measures Attention
Keep the distance from the dangerous area of the suspended item.
Attention the safety of the site operator.

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4.3.2 deliver equipment

Before shipping a machine or other component, take the following activities:
* Ensure that the specified energy pipeline is disconnected from the supply pipe network.
* Empty containers and devices which has lubricant,
* Fixed moving parts.
* To prevent unsealed pipes and hoses from dirt, use a blind plug, PVC plug or PVC cover.
* Ensure that instructors are within sight and communicate with them.
* During transport, avoid collision and rapid movement.
4.3.3 Check the goods

If the carrier send the machine to the destination, please take the following activities:
* Immediately check the machine and its parts after arriving at the destination.
* Immediately check for damage to the machine and its components for transport.
* Immediately report the existence of transport damage and retain evidence of the image, such as the
occurrence of transport damage, should immediately notify KEBER in writing.
4.3.4Delivery
After checking whether the delivery is complete and damaged, remove the loading and unloading
equipment, the seamless ring and the rings. Transport the machines and components to the specified place
of placement.
4.4Installation
4.4.1Install the machine
After disassembled and transport, start assembling machine. CAUTION Before starting the assembly of
the machine, it is necessary to select the place of installation according to recognized technical regulations
and technical information. Select the place to place according to the following criteria.
Installation location selection

* Strong industrial building.
* Ground: level, smooth and stable.
* Ground, foundation, must be able to bear static and dynamic loads.
It is forbidden to place the equipment in explosive spaces.

This device is not explosion proof.
Attention

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When placing equipment, attention:
* Keep the perimeter of the equipment at all angles, and the door at the entrance can be opened.
* All required operating stations are adequately illuminated.
* Place no airflow.
* The conveyor has enough space to supply the raw materials and transport the waste.
* Connect the specified connection cable to ensure that there is no risk of tripping.
* Power ground is safe and secure;
* Please put a safe post in a reasonable position;
* Check whether it’s solid of three-color lights before start machine;
* Touch screen protection;
* Make a device checklist and hang it on the device.
The equipment shall be placed on a supporting foundation which is flat and capable of withstanding the
weight of the equipment.
Before placing the equipment and components, ensure that the foundation absorbs static and dynamic
loads.
Place the equipment flat after placement.
Use the leveling feet to adjust the machine to a higher level, the machine should be placed horizontally.
Fix the pedal pad which is djustable to the ground.

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4.4.2Install the machine

The placement and installation of the machine should be carried out at the same time, the professional
staff to assemble, be sure to pay attention to the machine parts of the machine bearing the center and
focus.
Be sure to note the following security tips:
Suspension of heavy objects can lead to personal injury and life risk!
Suspended items fall easily lead to serious injuries, irreparable damage or even death.
Precaution
Always keep it outside the dangerous area of the suspended transport load.
Only use special device suspension and transport equipment and its components.
Suspension and transport of equipment and other parts, only load support tools and spreaders are
permitted.
Note the safety of the site operator.
Danger of cutting
The sharp sharp corners of the parts are easily injured when disassembling the
equipment.
Precaution
Wear appropriate protective gloves.
Be careful when the equipment is working

When stuck on a high-altitude equipment, tripping and slipping can cause a risk of
falling.
Do not climb the machine parts! If necessary, you must use the appropriate climbing
aids.
Precaution
Please use a seat belt.
Use the appropriate workbench when operating on high altitude and equipment.

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4.5Stop point, forklift accepted
The equipment is equipped with a special stop point for unloading and lifting by means of a forklift or
lifting system.
（1） rings at the corner of the top frame. (If any!)
（2） forklift stapler with lower part of the equipment.。
The device is only allowed to rise or fall at the stop point.
Forklift hole
Suspended heavy may fall down!

Prohibited to stay under the hanging weight!
For the use of suitable and trouble-free lifting aids and stopping measures for the lifting and lowering
of the equipment components, it must be carefully tightened to the lifting device and to ensure safety
when replacing individual components and larger components.
Lifting auxiliary spreaders and stop measures must comply with accident prevention specifications.
Load stop and crane and forklift truck driver guidelines can only be authorized with those who are
very familiar with the contents of these operations.
The choice of lifting aids and stop measures must be taken into account when taking into account the
individual components of the equipment and the overall weight.
The person providing the guidance must be within the operator's line of sight or be able to talk to it.
4.6 storage
Tips for temporary storage and environmental conditions
If the machine is not installed at the delivery location after delivery, take temporary storage measures.
* Temporary storage can not be carried out in the open air, but should be placed in a closed space on the
flat wooden base.
* Air temperature 10 ℃ to +40 ℃, relative humidity 20% to 80%, no condensation.
* Equipment must be protected against corrosion and irritation.
* Anti-corrosion protection of all exposed machine parts when the equipment is transported, which will be
removed after installation and installation.

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5.Operation and commissioning

5.1 safe operation tips
5.1.1safe protection unit
The initial commission of the machine after the installation will be conducted by KEBER
*Before the initial operation,check if all the tools are taken out from the machine
*For the first comssion, check all the safe and prevention device as well as the emergency circuit
*make sure nobody stay in the dangerous area of the machine
Please read ‘safe’ chapter of this operation manual
5.1.2 Input and output interface

Electrical connection::
*The incorrect connection may cause the unintentional start or make the machine out of control during
theoperation
*The mix of the connection may reduce the lifetime of the machine
*The incorrect connection may reduce the lifetime of the electrical components
Compressed air connection：
*Check if the compressed air hose is connected to the maintenance unit and if the position is fixed
*The manual switch valve must be opened for the operation
*Check if the pressure displayed is 6 bar
5.1.3 Check the function of the safe prevention unit

The disfunction of safe prevention unit will cause life danger！
*Before the initial or daily operation or after a long time operation, the function of safe prevention unit
should be checked
*Make sure all the safe prevention unit under the normal condition
The daily check can be conducted according to the following：
safe prevention units what to check standard

all the movement about the machine should
Emergency and stop button pressing
stop immediately

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5.2 Operating and display components

5.2.1 Equipment overview
Front view of the device: device operation / display components
Position Description
1 Tri-color indicator
2 Touch screen
3 Emergency button
4 Reset button
5 Power switch
6 Start button
7 Reset button
8 Stop button

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5.2.2. Operating unit
5.2.2.1 Start button
Function: after the automatic condition is completely satisfied, press the start
button, the device will run automatically.
5.2.2.2 stop button
Function: In the automatic state, after pressing the stop button, the device stops
running.
5.2.2.3 power switch
Function : to switch on/off power
5.2.2.4 Reset button
Function: used for the fault reset

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5.2.3.5 scram button

Function: by pressing the emergency stop button, the device switches to a safe
state so that the motion flow does not occur.
Emergency stop button can only be used in case of endangering the safety
of personnel or equipment.
How to press the quick stop button:

→Press the stop button.。
→All movement in the machine stopped immediately。
→No follow-up, device not operational。
Quick stop button unlock mode:

→Turn the arrow to reset and pull out ，
Use this to unlock the emergency stop button

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5.2.3.6 Three color indicator
sign meaning
1.red The red light indicates that there is something wrong with the equipment
2.yellow The yellow light indicates that the device is in standby mode
3.green The green light indicates that the equipment is in normal operation

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5.2.3manual connection valve（compress air supply）
The hoses may hurt your eyes！

There is potential risk of the storage device(sometimes
happen when the machine emergent stop)
Danger
*The pneumatic equipment must be without any air pressure before working
(the air exhaust will be finished automatically when the valve is turned off)
the compressed air used for the machine

is processed by the maintenance unit,
when the pressure within the input pipe
is up to 6 bar, the condensed water will deposit.
1 switch valve
2 air intake
3 filter bowl
4 Pressure adjusting knob
5 barometer

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5.3 Operation panel usage guidelines

5.3.1 Main screen and each function screen
Operation instructions: Check the status of each part of the equipment, turn on the power when there is no
other abnormal condition, turn on the power switch.
1. When the power is turned on, the following screen will appear on the HMI:
ZhongWen：Click to enter Chinese screen.
English：Click to enter English screen.

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2. After clicking, the following screen will appear on the HMI:
"Total Count": The number of times the machine has performed a complete automatic operation and
cannot be cleared.
“Current program recipe(parameter No.)”: The program recipe selected at this time, if you need to change,
you can enter the parameter setting interface to change.
"Servo off": Servo power switch Used to: turn on or off the use of servo power. Click the button to switch
on / off. After power on, the servo power is off by default.
"Heating off": heating power switch Used to: turn heating power on or off. Click the button to switch on /
off. After powering on, the heating power is off by default.
"Manual mode": Automatic mode switch Used to: turn on or off the use of automatic mode. Single button
to switch on / off. After power on, the default is manual mode.
"Clamping time(Pick up)": After the mold is closed, the delay time set by the upper mold to grasp the
product. After the time, the upper mold returns to the original position.
"Delay time": the time during which the upper tool delays falling before the hot melt. After the delay time
reaches, the upper tool starts to fall.
"Hot Melt Time(welding)": The time required for the upper mold / lower mold to fuse. This time starts
from the time when the upper mold reaches the hot melt position.
"Cure time(solidify)": the time required for the upper and lower molds to cure and weld.
"Upper mold": Display the current position of the upper mold. The latter is the torque of the upper mold.
If the later value exceeds 100%, a servo alarm will occur.
"Lower mold": Show the current position of the lower mold. The latter is the torque of the lower mold. If

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the later value exceeds 100%, a servo alarm will occur.
"Hot plate": Displays the current location of the hot plate. The following is the torque of the hot mode. If
the following value exceeds 100%, a servo alarm will occur.
"Automatic operation cycle(Auto cycle)": The time period required for the entire automatic operation,
depending on the specific set time.
"Auto Counter": the number of times the machine has performed a complete automatic run, which can be
cleared.
"Clear": Click to clear the output count.

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1. Manual screen
Button Condition
“upper tool
The machine has no alarm; both the upper left safety lock back position I3.0 and the upper
up(upper die right safety lock back position I3.1 are powered on. Use the upper mold to raise it. Click the
button to raise the upper mold and release the button, upper tool stop action. To use.
rise)”：
When the lower mold slide plate is in or out, the hot mold down I3.3, the hot mold in I3.5
lights up, and the hot mold is in the forward position or hot mold is in the backward
“upper die position I3.4 lights up and the hot mold is in the backward position; the device has no
down”： alarm; Both the upper left safety lock release I3.0 and the upper right safety lock release
I3.1 must be powered up. Use the upper mold to lower it. Click the button to lower the
upper mold. Release the button to stop the upper mold and use it.
I3.4 of the hot mold is on; the upper mold is in the backward position; the hot mold is in the
“lower table backward position; the device has no alarm; Make the lower mold to move left, click the
left”： button, the lower mold moves to the left, release the button, and the lower mold stops. Jog
use.
“lower table The hot die backward position I3.4 lights up; the upper tool is in the back position; the hot
die is in the back position; the device has no alarm; Make the lower die to the right, click
right”： the button, the lower die moves to the right, release the button, the lower die stops, Jog use.
The device has no alarm; the upper mold is at the home position; the lower mold is at the
“Hot plate home position or forward position; the hot mold up I3.2 is lit; the hot mold is used for
forward”： forward, click the button, the hot mold forward, release the button, the hot mold stops
moving Can be used by jog.
The device has no alarm; the upper mold is at the home position; the lower mold is at the
“Hot plate home position or forward position; the hot mold up I3.2 is lit; the hot mold is used for
backward”： backward, click the button, the hot mold backward, release the button, the hot mold stops
moving Can be used by jog.
In manual mode; the system has no alarm; use the hot mold up, click the button, the hot
“hot plate rise”：
mold will rise, release the button, the hot mold will stop and can be used by jog.

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“hot plate In manual mode; the system has no alarm; use the hot mold down, click the button, the hot
down”： mold will move down, release the button, the hot mold will stop and can be used by jog.
“upper fixture In manual mode; the system has no alarm; clamp the upper fixture for use. Click the button
forward”： to clamp the upper fixture.
“upper fixture In manual mode; the system has no alarm; Loose the upper fixture for use. Click the button
backward”： to loose the upper fixture.
“lower fixture In manual mode; the system has no alarm; clamp the upper fixture1 for use. Click the
forward 1”： button to clamp the upper fixture1.
“lower fixture In manual mode; the system has no alarm; Loose the upper fixture 1 for use. Click the
backward 1”： button to loose the upper fixture 1.
“lower fixture In manual mode; the system has no alarm; clamp the upper fixture 2 for use. Click the
forward 2”： button to clamp the upper fixture2.
“lower fixture In manual mode; the system has no alarm; Loose the upper fixture 2 for use. Click the
backward 2”： button to loose the upper fixture 2.
"Upper mold": Display the current position of the upper mold. The latter is the torque of the upper mold.
“Lower mold": Display the current position of the lower mold. The latter is the torque of the lower mold.
"Hot tool": Displays the current position of the hot mold. The following is the torque of the hot mode. If
the following value exceeds 100%, a servo alarm will occur.
"Heating off": heating power switch Used to: turn heating power on or off. Click the button to switch on /
off. After powering on, the heating power is off by default.
"Manual mode": Automatic mode switch Used to: turn on or off the use of automatic mode. Single the
press button to switch on / off. After power on, the default is manual mode.

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1. parameter setting
"Upper die back position": the position where the upper mold backward after the mold clamping is
completed, after the heat fusion is completed, and after the curing is completed.
"Upper die weld slow start position": The position when the upper mold starts to move down slowly
during hot-melt.
" Upper die weld slow end position ": The position finally reached after the upper mold is slowly lowered
during hot-melt.
“Upper die solidify slow start position ": The position at which the upper mold starts to descend slowly
during curing.
“Upper die solidify slow end position ": The position finally reached after the upper mold is slowly
lowered during curing.
“up fast speed”： Speed setting when the upper tool moves fast.

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“up slow speed”：When hot-melting, the upper mold runs at the slow-melting speed after the upper mold
reaches the slow-melting position.
"Upper mold torque setting (up torque)": If the torque setting of the upper mold is smaller than the actual
torque of the upper mold on the first page, there will be an alarm.
"Slide table left station position (low table left position)": The position of the lower mold slide table when
it is at the left station.
“Slide table right station position (low table right position)": The position of the lower mold slide table
when it is at the right station.
"Running speed": The speed setting of the lower mold slide forward and backward.
"Open": Click Open to open the recipe.
"Program /parameter number": After entering the program number, click it to open the recipe.
"Program/ parameter name": The program name is the name set by the user.
"Save": Click Save to save the changed parameters and overwrite the previous parameters.
“hotplate back position”: The position where the hotplate back into position.
“hot plate work position” : the position of hot plate when it is normally welding.
“hotplate back speed change position” : Position of the hotplate during slow operation.
“hot plate work speed change position”: Position for slow running during hot plate welding.
“hotplate fast speed”: Speed setting when hot plate runs fast.
“hotplate slow speed”: Speed setting for slow running of hot plate.

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1. parameter-temperature
Set temperature: The temperature required for the hot plate during hot-melt welding.
Alarm/Offset temperature: When the temperature is less than the set temperature minus the offset
temperature, there will be an alarm to indicate a temperature failure, and the alarm can be eliminated by
increasing the offset temperature.
Actual/Display temperature: real-time temperature of each area on the hotplate.
Limit temperature: The limit temperature in each area set. The set temperature must not exceed the limit
temperature. If the displayed temperature exceeds the limit temperature, an alarm fault will occur.
The parameters of this interface are affected by specific molds, products, etc. There is no exact data,
which needs to be set according to specific conditions. This screen parameter can be input by directly clicking
in the text box.

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2. temperature graph
In this interface, you can observe the real-time temperature change curve.
3. Parameter-time
In this interface, you can set the pickup time, delay time, hot melt/welding time and curing/solidify time
during automatic operation. You can set it in the white box, and the gray box is the actual time. This parameter
can also be set on the home screen, and is not repeated here.

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4. Error record
Quickly find alarm faults according to the prompt information on the alarm screen.
5. System parameter
“Upper tool return to zero/upper search zero”: the system has no alarms other than zero return; both the
upper left safety lock release I3.0 and the upper right safety lock release I3.1 are powered up, and the upper
tool is used to return to zero.
"Hotplate return to zero/hot plate search zero": the system has no alarms other than zero return; the upper
plate has been reset to zero; the hot plate rising position I3.2 is lit; the upper tool is in the back position; the hot
plate is returned to zero for use.
“lower tool return to zero/lower search zero”: the system has no alarms other than zero return; the upper
tool has been reset to zero; the hot tool rising position I3.2 is lit; the upper tool is in the back position; the
lower tool is used to return to zero.

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“up/upper tool”： Show the current position of upper tool. The latter is the torque of the upper tool. If the
later value exceeds 100%, a servo alarm will occur.
“lower/lower tool”： Show the current position of lower tool. The latter is the torque of the lower tool. If
the later value exceeds 100%, a servo alarm will occur.
“hot/hot plate”： Show the current position of hot plate. The latter is the torque of the hot plate. If the later
value exceeds 100%, a servo alarm will occur.
Monitor-I/O DI1
The green light indicates that it is detected or the button is on.

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5.4Troubleshooting
ID Alarm name Alarm action content

hot plate slide plate not In the automatic mode, when the automatic welding is not performed, the
1
back in position alarm can be released by returning the hot plate slide to the position.
1. In the automatic mode, when the automatic welding is not performed,
Hot plate cylinder not rise the alarm can be released by returning the hot plate to upper position.
2
up in position 2. The alarm has not been cleared, check whether the magnetic switch on
the cylinder is damaged
1. Close the front door to cancel the alarm. 2. If the alarm is not cleared,
3 The front door is not closed
check whether the access switch is damaged.
1. Turn on the servo 2. If the alarm is not cleared, check the alarm code
Upper mold servo system
4 displayed on the upper mold servo driver in the electric box, and check the
failure
cause of the fault and the countermeasure according to the servo manual
Sliding table servo system displayed on the servo drive of the slide table in the electric box, and
5
failure check the cause of the fault and the countermeasures according to the
servo manual
Hotplate servo system displayed on the hot-mode servo driver in the electric box, and check the
6
failure cause of the failure and the countermeasures according to the servo
manual
1. Close the left door to cancel the alarm. 2. If the alarm is not cleared,
7 The left door is not closed
1. Close the right door to cancel the alarm. 2. If the alarm is not cleared,
8 Right door is not closed
1. Close the back door 1 to release the alarm. 2. If the alarm is not cleared,
9 Back door is not closed 1
1. Close the back door 2 to release the alarm. 2. If the alarm is not cleared,
10 Back door is not closed 2
Panel emergency stop was 1. Pull out the emergency stop on the panel to cancel the alarm. 2. If it
11
pressed is not released, check whether the emergency stop button is damaged
Left emergency stop was 1. Pull out the left emergency stop to cancel the alarm. 2. If not, check
12
pressed whether the emergency stop button is damaged.
Right emergency stop was 1. Pull out the right emergency stop to cancel the alarm 2. If it is not
13
pressed cleared, check whether the emergency stop button is damaged
Turn on the heating and raise the temperature in the temperature zone 9 to
14 Temperature 9 abnormal the set temperature within the deviation temperature range to eliminate the
alarm.
alarm.

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alarm.
The upper tool has not After other alarm faults have been eliminated, switch to automatic mode
17 returned to zero and press the reset button. Or switch to manual mode, and click the upper
tool return to zero button on the touch screen to manually return to zero.
After other alarm faults have been eliminated, switch to automatic mode
Slide plate does not return
18 and press the reset button. Or switch to manual mode, and click the slide
to zero
plate return to zero button on the touch screen to manually return to zero.
After other alarm faults have been eliminated, switch to automatic mode
Hotplate does not return to
19 and press the reset button. Or switch to manual mode, and click the hot
zero
plate return to zero button on the touch screen to manually return to zero.
Over vacuum pump 1. Check if the upper vacuum pump is damaged 2. Check if the thermal
20
overload relay is damaged
Turn on the heating and raise the temperature in the temperature zone 10
Temperature 10 abnormal
21 to the set temperature within the deviation temperature range to eliminate
the alarm.
alarm.
23 Temperature 12 abnormal to the set temperature within the deviation temperature range to eliminate
the alarm.
alarm.
alarm.
alarm.
alarm.
alarm.
alarm.
Down vacuum pump 1. Check if the vacuum pump is damaged 2. Check if the thermal relay is
31
overload damaged
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The display temperature area 9 exceeds the set limit temperature. 1. Check
Temperature 9 is out of
32 whether the temperature setting is reasonable 2. Check the wiring 3. Check
limit
whether the temperature module is damaged.
1. Check whether the safety lock is energized 2. If it is energized, check
Upper left security lock is whether the air supply is sufficient 3. If sufficient, check whether the
33
not returned safety lock is returned 4. If returned, check whether the magnetic switch is
damaged
1. Check whether the upper safety lock is energized 2. If it is energized,
Upper right safety lock not check whether the air supply is sufficient 3. If sufficient check whether the
34
returned safety lock is returned 4. If returned, check whether the magnetic switch is
damaged
Hot tool does not rise in Raise the hot tool into place to release the alarm; if it is determined that it
35
place has risen into place, check the magnetic switch for damage
Hot tool does not drop into Lower the hot plate into place to release the alarm; if it is confirmed that it
36
place is in place, check the magnetic switch for damage
Hot tool does not forward Forward the hot tool into place to release the alarm; if it is determined that
37
into place it is in place, check the magnetic switch for damage
The alarm can be cleared by moving the hot plate back into place; if it is
Hot tool does not back into
38 determined that it is back into position, check whether the magnetic switch
place
is damaged
1. Check whether the air source is sufficient 2. Check whether the upper
upper Negative pressure
39 vacuum pump is turned on 3. Check whether the product is put in place 4.
fault 1
Check whether the upper negative pressure meter 1 is damaged
upper Negative pressure
40 vacuum pump is turned on 3. Check whether the product is properly
fault 2
placed 4. Check whether the upper negative pressure gauge 2 is damaged
lower Negative pressure
fault 1
placed 4. Check whether the lower negative pressure gauge 1 is damaged
lower Negative pressure
fault 2
placed 4. Check whether the lower negative pressure gauge 2 is damaged
Increasing the upper mold torque setting in the device parameter interface
43 upper tool Over-torque to make it larger than the actual torque value will release the alarm; reduce
the load.
The display temperature area 13 exceeds the set limit temperature. 1.
Temperature 13 exceeded
44 Check whether the temperature setting is reasonable 2. Check the wires 3.
limit
Check whether the temperature module is damaged.
45 Check whether the temperature setting is reasonable 2. Check the wiring 3.
limit

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limit
limit
48 whether the temperature setting is reasonable 2. Check the wires 3. Check
limit
limit
limit
limit
limit
limit
limit
limit
limit
limit
the alarm.
the alarm.

- 62 -
.1

the alarm.
the alarm.
the alarm.
the alarm.
upper tool doesn’t return to In the automatic mode, when the automatic welding is not performed, the
80
place alarm can be released by retracting the upper mold into place.
lower tool slide plate In the automatic mode, when the automatic welding is not performed, the
81
doesn’t return to place alarm can be released by return the lower tool slide plate into place.
The display temperature zone 10 exceeds the set limit temperature. 1.
limit
limit
limit

- 63 -
.1
6. Maintenance and Repair

Maintenance and maintenance personnel must wear suitable protective equipment.
6.1 Safety and protection devices：Emergency stop button
Safety and protection devices
Emergency stop button
Feature
Check item/ → When the device is in the initial position, press each emergency stop
→ operation content button.
→ Do not allow the device to be turned on.
Check the time interval 8Bh
Check by operator
Clean the interval weekly
→ Wipe the button with a damp cloth.
Cleaning tips
→ Use mild detergent.
Interval safety inspection At least annually
Safety technology inspection Professional staff
See the documentation

- 64 -
.1
6.2 Safety and protection devices：limit position switch
Safety and protection devices
Limit position switch
Feature
Check item/
→ Check whether the press frame is closed.
→ operation content
→ Do not allow adsorption before the press frame closes。

Check by operator
Clean the interval per month
Cleaning tips → Closed contacts are blown with gentle compressed air。
At least annually
Interval safety inspection
Please refer to the manufacturer's instructions
Safety technology inspection Professional staff
See the documentation Page 9-113

- 65 -
.1
6.3 Exhaust device: exhaust fan
Exhaust device
exhaust fan
Check item/ Filter / shell of the dirty situation

→ operation content → Clean or replace the filter if necessary。

Check by Service maintenance personnel
Clean the interval per month
Cleaning tips →Use a slight air jet to blow the shell。
See the documentation

- 66 -
.1
6.4 transmission unit: gear rack transmission unit
Transmission unit
Gear rack transmission unit
Check the running noise/lubricating unit

→ add lubricating oil on the gear rack transmission unit through
Checking project oilinput port
→ using the total loss system（GB443-89）L-AN46。The lubricating
number is about：
→ 2.5 cm³/gear rack
→ maintenance description, the transmission unit/ gear rack
movement unit
→ add the lubricating oil on a regular basis, and check if any
abnormal on the gear rack
According to the actual situation.
Cheking interval at least 480Bh（every three days）
Checked by maintenance technician
Cleaning interval when necessary
Cleaning tips
Documentation reference

- 67 -
.1
6.5 Drive units: linear rail
the transmission unit

Linear slide rail
Check running noise / Lubricating device →

Lubrication of linear rails with no. 0 lithium grease。
→ When using the lubricating oil, pay attention to whether the oil
inspection item → supply is sufficient, and if the lubrication is not easy, the linear slide
Operation content rail can be used for regular grinding to lower its service life.
→ Avoid processing dust or debris into the slider。
→Clean as needed.
Check the time interval Minimum 480Bh (monthly)
Check by Service maintenance technician
Cleaning interval time sos
Cleaning Tip
View documentation

- 68 -
.1
6.6 Transmission unit: linear bearing
Transmission unit
linear bearing
Check the operating noise / lubrication device

→ Use No. 0 lithium base grease.
Check the project → Regular lubrication, check whether the sliding film wears out
- > operation content during the movement of the linear bearing.
Check the time interval At least 480Bh (monthly)

Inspection Service Technician
When needed
Cleaning interval time
Cleaning tips
Reference documentation

- 69 -
.1
6.7 pneumatic structure: valve/valve pipe/valve port
pneumatic structure
valve/valve pipe/valve port
Sealing/leakage
Checking project → check if the nut is fixed and tight it if necessary
→ check if any damage on the pipe and replace it if necessary
→ check the valve
checking interval every 1000Bh
checked by maintenance technician
cleaning interval When necessary
cleaning tips Please refer to the regulation
documentation reeference

- 70 -
.1
6.8 pneumatic structure: maintenance unit

pneumatic structure
maintenance unit
condensed water
Checking project →emission
→ setting inspection:according to the machine pressure setting
→ visual check: check the dirty of filter
Checking interval every 120Bh（every week）
Checked by maintenance technician
Cleaning interval at least 3 months
Cleaning tips → use gas clean filter and filter component when necessary
→ refer to the regulation
Documentation reference

- 71 -
.1
6.9 Pneumatic system: gas storage tank
Pneumatic system:
gas storage tank
Image for reference
Accumulate liquid at the bottom of the tank → periodically drain the

remaining liquid at the bottom
Check the project → Check the valves and other places of the gas storage tank for air
- > operation content leakage. If there is any air leakage, take measures to ensure that the gas
storage tank meets the production requirements.
→ Check the looseness of each interface, seal it in time, and replace it
in time.
Check interval Every shift
Check by Service Technician
Cleaning intervals Every shift
Cleaning → The gas storage tank should be kept ventilated and dry, and no
debris should be piled around.

- 72 -
.1
6.10 Distribution cabinet: cooling device
Distribution cabinet
cooling device
Cooling device diagram→
Checklist→Operation content Filth of filters and radiators

→Replace the filter as needed。
→Clean the radiator fin as required。
→See manufacturer's specifications。
Check interval Every 2000Bh
Checked by Service and maintenance technician
Cleaning interval When it is necessary
Cleaning hint →Wipe the surface with a damp cloth。
→Clean the heat sink with a slightly compressed air jet。

- 73 -
.1
7. Technical documentation
7.1 machine parameter
Working No. A2112C-216

Type： Pallet welding machine
Manufacture year：： 2021
Operating Voltage： 380V
Total power： 98kw
Heating tube： 84kw
machine size 5590*4100*2900mm
Weight: 4.5T
Maximum ambient humidity: 5-80％
Ambient temperature: 10-40℃
7.2 Parts List

Machine 1set
Operation manual (with CD) 1pc
Certificate 1pc
Warranty Card 1pc
7.3 Recommended spare parts list
No. Parts name Specification Brand

1 Heating pipe
2 Thermocouple LCW-106

- 74 -
7.4Assembly parts list
No. Parts name Specification Unit Qty Brand

Guide pillar flangeCold mold guide post
1 F40B PCS 12 KEBER
stabilizing flange
2 Locating pin 3 PJ-11 PCS 4 KEBER
3 Limit screw PJ-17 PCS 4 KEBER
4 Mold positioning A PJ-10-A PCS 1 KEBER
5 Mould positioning B PJ-10-B PCS 1 KEBER
6 Safety lock unit B AQ-B-N1 PCS 4 KEBER
7 Cold mold guide pillar flange TP-03 PCS 4 KEBER
8 Cold mold guide pillar stabilizing flange TP-04 PCS 4 KEBER
9 Foot pad reinforcement TP-05 PCS 4 KEBER
10 Hot mold limit block TP-06 PCS 4 KEBER
11 Table limit block TP-07 PCS 4 KEBER
12 Airway block TP-08 PCS 3 KEBER
13 Front rotation axis TP-10 PCS 1 KEBER
14 Rear rotation axis TP-11 PCS 1 KEBER
15 Flat key 2 TP-13 PCS 2 KEBER
16 Encoder connection shaft TP-15 PCS 1 KEBER
17 Servo motor gear TP-17 PCS 1 KEBER
18 table connection block TP-26 PCS 2 KEBER

- 75 -
19 Upper cold mold limit column fixing block TP-27 PCS 4 KEBER
20 Countertop column fixing block TP-28 PCS 8 KEBER
21 125 cylinder fixing plate TP-31 PCS 2 KEBER
22 Thermal insulation sheet 160 TP-32 PCS 2 KEBER
23 Guide pillar lower plate TP-33 PCS 4 KEBER
24 Motor sprocket TP-51 PCS 2 KEBER
25 Flat key 1 TP-12 PCS 1 KEBER
26 Pulley 30 LB-24 PCS 1 KEBER
27 Pulley 50 LB-25 PCS 1 KEBER
28 Throttle standard ISC08-01 PCS 16 ISAIAH
29 Compact cylinder ADN-40-50-I-P-A PCS 8 FESTO
30 Standard cylinder DSBC-125-125-PPVA-N3 PCS 2 FESTO
31 Slider HGH20CA PCS 16 Hiwin
32 gas tank 30L PCS 1 Yueli
33 Access switch XCMN2102L1 PCS 9 Schneider
34 Linear Bearings LMF50LUU PCS 4 Rongda
35 Male connector (female) 8820-13R1/4 PCS 12 Yongrui
36 Linear Bearings LMF60LUU PCS 4 Rongda
37 Slider HGW45HA PCS 14 Hiwin
38 Reducer SPL160-20(5.5) PCS 1 Kefeng
39 Chain 12A PCS 1 From market
- 76 -
40 Self-lubricating bearings SF-1-6070 PCS 4 Bangsheng
41 Anti-Dust ring DH-60-68 PCS 4 From market
42 Horizontal motor reducer CH3700-15S-G1-L（Output shaft Φ50, with brake） PCS 1 Chengbang
43 Displacement lever sensor MTC-360-N-V2-P PCS 1 Miran
44 Encoder EI38S6-600-BC-30Y3(PNP) PCS 1 Tongxin
45 Coupling 6×6 PCS 1 From market
46 Guide pillar flange F50B PCS 4 KEBER
47 Foot Screw JD-02 PCS 8 KEBER
48 Adjustment block PJ-02 PCS 2 KEBER
49 The electromagnetic valve VUVS-L30-P53C-MD-G38-F8-1C1 PCS 1 FESTO
50 Socket connector MSSD-EB PCS 9 FESTO
51 Mounting brackets HR-D-MIDI PCS 1 FESTO
52 L-shaped elbow IPL12-03 PCS 2 ISAIAH
54 Polyurethane shock absorbing material AXNHK20-10 PCS 14 MISUMI
55 Pin retaining clip CLIP16 PCS 2 MISUMI
56 6B High Structure Single Port Lower Shell WK-A001 PCS 1 HARTING
57 6B high structure single port upper shell WK-A002 PCS 1 HARTING
58 8-core electric module MK-A005 PCS 2 HARTING
59 8-core electric module MK-A006 PCS 2 HARTING
60 Plastic cable chuck GD-A002 PCS 1 HARTING
- 77 -
61 BlockagesBlock bearingRings DT-A001 PCS 1 HARTING
62 2Modular frame A-B upper base KJ-A001 PCS 1 HARTING
63 2 module frame a-b lower base KJ-A002 PCS 1 HARTING
64 Filter pressure reducing valve LFR-1/2-D-MIDI-MPA PCS 1 FESTO
65 bearing with base plate UCP206 PCS 4 NSK
66 ring M8 PCS 3 KEBER
67 Machine foot pads φ160 PCS 12 KEBER
68 φ20 steel cap 129M20 PCS 2 OBO
69 φ20 tube clamp 73321G PCS 2 OBO
70 Steel cap 129M40 PCS 2 OBO
71 φ40 tube clamp 73348G PCS 13 OBO
72 Corrugated pipe holder AD34.5(M32*1.5) PCS 2
73 Rings M12 PCS 8 KEBER
74 Corrugated pipe holder AD42.5(PG36) PCS 2
75 Guard coil ∅26 PCS 2 KEBER
76 Power supply holder PG21 PCS 1 KEBER
77 Aviation socket 25M-12A PCS 2
78 Thermocouple (K type) LCW-106 PCS 12 KEBER
79 Roof-mounted air conditioner WK2105DZ PCS 1 George
80 Servo Structure A PCS 1 KEBER
81 Guard coil φ45 PCS 3 KEBER
- 78 -
82 Quick-screw connector (male) 8813-04 PCS 12 Yongrui
83 Guard coil φ30 PCS 4 KEBER custom made
84 Side mounted air conditioner WK1-003A(320W) PCS 2 George
85 Reducer FA87-36.15-M5 PCS 1 Juwei
86 The electromagnetic valve VUVS-L25-M52-MD-G14-F8-1C1 PCS 1 FESTO
87 The electromagnetic valve VUVS-L25-B52-D-G14-F8-1C1 PCS 3 FESTO
90 Throttle standard ISC12-04 PCS 4 ISAIAH
91 L-type stop valve ISPL12-04 PCS 1 ISAIAH
92 Plastic positive tee IPE06 PCS 14 ISAIAH
93 Plastic positive tee IPE12 PCS 3 ISAIAH
94 Lengthened L-shaped elbowIPLL08-02 PCS 6 ISAIAH
95 Throttle standardsilencer ISC06-01 PCS 15 ISAIAH
97 silencer BSLM03 PCS 2 AIRTAC
98 silencer BSLM04 PCS 4 AIRTAC
99 Proximity switch SME-8M-DS-24V-K-0.3-M8D PCS 4 FESTO
100 Empty plate VABB-B10-25-E PCS 2 FESTO
101 Double external thread straight IBB03-03 PCS 1 ISAIAH
102 Base plate VABM-B10-25E-G12-4 PCS 1 FESTO
- 79 -
103 Base plate VABM-B10-25E-G12-2 PCS 1 FESTO
Thread throughpush-button boxpush-button
104 IPC12-04 PCS 1 ISAIAH
boxMotor
105 Thread through IPC12-03 PCS 3 ISAIAH
106 Standard chain transition link DCEZ12A-1 PCS 3 A&T
107 Ball valve PT3/8 PCS 1
108 Aviation plug 25m-12B PCS 2 From market
109 Triangle belt B55 PCS 2 Gates
110 Brake motor 1FL6094-1AC61-2AB1 PCS 1 Siemens
111 push-button box KEBER-left PCS 1 KEBER
112 push-button box KEBER-右 PCS 1 KEBER
113 Motor 1FL6096-1AC61-2AB1 PCS 1 Siemens
114 Power cable 2KW-7KW 6FX3002-5CL12-1BA0 PCS 2 Siemens
115 Drive 7kW 6SL3210-5FE17-0UF0 PCS 1 Siemens
116 Driver 5KW 6SL3210-5FE15-0UF0 PCS 1 Siemens
117 Brake cable 5KW / 7KW 6FX3002-5BL03-1BA0 PCS 2 Siemens
118 Cable 6FX3002-2CT12-1BA0 PCS 2 Siemens

- 80 -
7.5 Gas path diagram

- 81 -
7.6 Electrical assembly parts list

1 Touch screen breaker 6AV2 124-0GC01-0AX0(7 吋) PC 1 Siemens
2 Power circuit breaker NSC250S3250N(250A) PC 1 Schneider
3 Single-stage fast circuit 5SY41406CC(40A) PC 12 Siemens
4 Fuse terminal 1879750000 PC 50 Weidmuller
5 Cross link 1609030000 PC 12 Weidmuller
6 Terminal baffle 1814710000 PC 12 Weidmuller
7 CPU 6ES7 215-1AG40-0XB0 PC 1 Siemens
8 Signal board 6ES7 241-1CH30-1XB0 PC 1 Siemens
9 Aviation plug I16-4-A PC 2 No brand
10 Aviation socket I16-4-E PC 2 No brand
11 Miniature Circuit Breaker 5SY6 350-8CC PC 1 Siemens
14 Miniature Circuit Breaker 3RT6027-1AN20(32A) PC 1 Siemens
17 Temperature module DTE-10T PC 2 delta
18 Temperature module DTE-20T PC 1 delta
19 Temperature module DTE-20V PC 3 delta
- 83 -
20 solid state relay CWD48125P 个 12 CRYDOM
21 Double terminal A2T 2.5 个 300 Weidmuller
22 Shorting link ZQV 2.5N/10 个 20 Weidmuller
23 Bezel AEP 2T 2.5 个 20 Weidmuller
24 Ground terminal A2T 2.5PE 个 10 Weidmuller
25 16mm²terminal block WDU 16/ZA 个 120 Weidmuller
26 16mm²terminal partition WAP 16+35 WTW 2.5-10 个 24 Weidmuller
27 16mm²10-bit horizontal connection WQV 16/10 个 20 Weidmuller
28 Double stud terminal blocks WFF 35/AH 个 2 Weidmuller
29 Baffle AEB 35 SC/1 个 20 Weidmuller
30 Marker Block EM8/30 个 20 Weidmuller
31 Tag number DEK5/5MC NE.WS(1-50) 个 1200 Weidmuller
32 Tag number DEK5/5MC NE.WS(PE) 个 40 Weidmuller
33 switch YW1S-2E10 个 1 idec
34 emergency button YW1B-V4E02R 个 3 idec
35 start up button YW1B-M1E10W(flat head white) 个 2 idec
36 reset button YW1B-M1E10S(flat head blue) 个 2 idec
37 Emergency stop sign 个 1 No brand
38 Tri-color indicator YLT-3CDA-60D-BDC24V 个 1 No brand
39 Ground copper 17*150 个 1 No brand
40 Proximity switch IME08-02BPSZTOS(PNP, often open) 个 3 SICK
- 84 -
41 Stop button YW1B-M4E01B(Mushroom head black) 个 2 idec
42 IM 155-6 PN ST 6ES7 155-6AU01-0BN0 个 1 Siemens
43 Bus adapter 2xRJ45 6ES7 193-6AR00-0AA0 个 1 Siemens
44 DI 16x24VDC ST 6ES7 131-6BH01-0BA0 个 2 Siemens
45 DQ 16x24VDC/0.5A ST 6ES7 132-6BH01-0BA0 个 2 Siemens
46 Push-in terminal 6ES7 193-6BP00-0DA0 个 5 Siemens
47 power supply PRO ECO 240W 24V 10A 个 2 Weidmuller
48 AQ 4xU/I ST 6ES7 135-6HD00-0BA1 个 1 Siemens
49 Relay module 8 relay modules 个 1 Weidmuller
50 Relay module supporting cable IB-C10C10D100015-WS06 个 1 Weidmuller
51 Heavy-duty connector HE-024-M(1-24) 个 1 SIBAS
52 Heavy-duty connector HE-024-F（1-24）个 1 SIBAS
53 Double buckle lower shell for heavy-duty connector H24B-SGR-PG21 个 1 SIBAS
54 Double-shell upper shell for heavy-duty connector H24B-TS-PG21 个 1 SIBAS
55 Heavy-duty mount PG21（white）个 2 No brand
56 Inverter 6SL3210-5BE24-0UV0 台 1 Siemens
- 85 -
7.7 Circuit diagram
- 86 -
8. warranty card

- 111 -
Maintenance union
凯尔博设备保修卡
KEBER EQUIPMENT WARRANTY CARD
device name： unit type ：
Device password number： Purchase time：
name of user ： address：
telephone： contacts：
Please fill out this warranty card in detail and send it back to our company with a copy of the purchase
invoice within 2 weeks, or brought back by our debugging personnel. Warranty card does not do return, will
not be able to obtain a free warranty.
Sales unit stamp：

Warranty recond
date Warranty content Inspector
(Customer association)
凯尔博设备保修卡
KEBER EQUIPMENT WARRANTY CARD
evice name： unit type ：

Device password number： Purchase time：
name of user ： address：
telephone： contacts：
Warranty record
date Warranty content Inspector

- 112 -
9. Supplier documentation
9.1 Brand: Schneider // Accessory name: Limit switch

- 113 -
- 114 -
9.2 Brand: Siemens // Part Name: Motor

- 115 -
- 116 -
- 117 -
- 118 -
- 119 -

A2112c-216 Pallet Welding Equipment

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A2112c-216 Pallet Welding Equipment

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Machine version：A2112C-216

4.3.1Security information ...................................................................................................... - 37 -

7.7 Circuit diagram ................................................................................................................ - 86 -

Hotline：86-512-82288666 FAX：86-512-68091510 WEB：http://www.keber.cn

Hotline：86-512-82288666 FAX：86-512-68091510 WEB：http://www.keber.cn

operator can have a easy access to it any time

1.2Operation party duty and responsbility

1.3Notes for the operator

1.5 Illegal operation

1.6Safe measures for the machine

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*Operate this machine without following the regulations

Our after-sales service including：

1.8.1KEBER service hotline：

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During the operation：

After the operation：

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2.2 Commonly used safety tips, symbol structure

The potential risk including：

This sign means there is potential danger to people

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2.3 Special safety tips,sign and label

CE label means that our equipment meet up to the current EU machinery

Hot surface warning

The symbol may be created to generate danger (harm)

the high temperature of the mold, the prohibition of unarmed contact)

Warning hands hurt danger

Dangerous voltage warning

It means the electric danger

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It means potential danger for the operator

Mechanical danger warning

Fall off danger

Hang out heavy thing warning

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2.4 stop sign

it means the machine should be kept clean

Wearing a safety helmet

In the operation of the equipment, must wear a safety helmet.

Wear protective gloves

personnel (equipment running, mold temperature is higher).

Wear protective shoes

Wear protective glasses

Please wear protective glasses when operating the machine

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2.5 Forbidden sign

People are not allowed to enter without permission

People are not allowed to climb without permission

People are not allowed to wear heart pacemaker

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2.6Notes for the operation

Danger to life due to failure of certain components

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2.7 Requirement on the operator

The following activity should be conducted by the qualified people：

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The quick movement of machine may lead to life danger：

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2.8 Transport, storage and installation

If the machine has already be assembled well or installed well,you can

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Before turning on the machine,make sure that