Olympic VC-19D Operator's Manual

Introduction 4 Safety regulations 4 Electric and pneumatic connections 4 Holding - Transportation 5 Maintenance of cooling unit 5 Technical data & Dimensioning 5 Lubrication 5 Panel Adjustments 6 Operation 7 Maintenance 7 VC-19D Assemblying 8 VC-19D Hot Station Head Assembly 9 VC-19D Hot Station Support Base with Ø160 Cylinder Assembly 10 VC-19D Cold Station Head Assembly 11 VC-19D Cold Station Support Base with Ø160 Cylinder Assembly 12 VC-19D Bottom Base Valves Assembly 13 VC-19D Projector 14 VC-19D FRL with components 14 VC-19D Top Valve assembly with components 14 VC-19D Pneumatic Diagram 15 VC-19D Electrical Diagram 16 VC-19D Electronic Board Diagram 17 VC-19D Troubleshooting 18 VC-19D Operator’s manual OLYMPIC

machine for its operation, its maintenance and for all the safety regulations. Please read carefully all the instructions and follow them in order to use the machine properly in the production and avoid any case of injuries. Our company does not have any responsibility for any changes happened on the machine by the owner, or actions which are different to what this manual refers. SAFETY REGULATIONS This machine is intended for professional use only. WARNING! Only one operator may work on the machine at a time. WARNING! Read and follow carefully all the relative instructions to avoid serious injury. Only qualified and authorized personnel must use the machine. � Operators are expressly forbidden to use the machine under the influence of alcohol or drugs capable of affecting physical and mental capacity. � Keep unauthorized persons away from the work area. � Make sure that the machine has been installed in compliance with the established legislation and standards. � Always keep this user manual in a place where it can be readily consulted when working on the machine. Consult it whenever you are in need of information or explanation. � Do not remove or deface the safety, danger, warning or instruction signs. Replace any missing or illegible Danger, Warning or instructions signs. � Never use the machine if you notice any damaged electric wires. � Never install the machine outdoors or in any place with a lot of moisture. WARNING Use only original spare parts, which can be supplied by the manufacturer or the local agent. Otherwise, your machine will not be a CE product. WARNING The machine frame must be earthed using the outside connection point marked according to the CE norms. Electric and pneumatic connections 1. Connect the machine (SINGLE PHASE 230V - 50Hz). 2. Before plugging in the machine, check that the main supply voltage is the same as that indicated on the label situated on the back side of the machine. 3. Check if the plug and socket have the same technical type. If not, use the suitable adapter after having consulted a certified electrician. 4. To disconnect the machine, turn the main switch off and remove the plug from the outlet. 5. Connect the machine to air pressure 6 - 8bar. 6. Connect the proper pneumatic hose. Set the main pressure regulator, which is found, on the back part of the machine to 6 Bar. VC-19D Operator’s manual OLYMPIC

1. Use the clevy’s existed on the top of the machine with proper belts to lift the machine. 2 . Pass the trans-pallet's forks under the pallet as shown in the Figure below. Technical data & Dimensioning Maintenance of cooling unit Clean the condenser (radiator) of the cooling unit once per month by using air pressure. Lubrication Keep the FRL (air-filter-regulator & lubricator) always filled with oil. We note that with 8 hours of work per day, the lubricator oil is consumed within 20-25 days approximately. If this does not occur, adjust the oil flow using the adjuster on upper part of lubricator. We recommend the use of ISO Class V632 or ISO 3448 oil. Once per week lubricate all moving parts of the machine. Cooling gas type R404A Cooling gas qty 470gr Compressor Power 1/2 Hp COOLING UNIT SPECIFICATIONS Use only ISO CLASS V632 or ISO 3448 oil OPERATION Electric - Pneumatic PRESSURE 6 Bar VOLTAGE 230V single phase 50Hz CAPACITY 1200 pairs per 8 hours POWER CONSUMPTION 1500 W DIMENSIONS (mm) 920 X 847 X 1686 WEIGHT 385 Kgs Technical Data 920 mm 1686 mm 847 mm VC-19D Operator’s manual OLYMPIC

Cold Station Temperature °C 5 10 15 20 25 30 0 SEC Timer 5 10 15 20 25 30 0 SEC Timer Head Lock VC-19D Cooling Unit M A D E I N G R E E C E 2. Cold Station Temperature: Set the temperature from 9 to 11°C (find the suitable temperature for the minimum condensation). 4. Head Lock: Heads’ lock ON/OFF. 6. Cold station Time: Set the timer from 5 to 30 sec. Less time at cold station will result in a more shallow angle. Panel Adjustments 1 3 5 4 6 2 Panel Adjustments 1 Hot Station Temperature: Set the temperature from 60 to 110°C. Temperature is a basic factor for the crimping. Choose the higher temperature (according the material you use) for higher crimping result. (Suggested Temperature 110°C). To adjust thermoregulator press the DOWN arrow. When the digits start blinking use the UP and DOWN arrows to adjust the temperature. Then you press instantly the button. 3. Hot station Set the timer from 5 to 30 sec. By Time: increasing the time a higher crimping is succeeded. 5. Cooling unit ON/OFF. VC-19D Operator’s manual OLYMPIC

Figure 1 Step 2. Press the pedal to hold the vamp (Figure 2). Before continuing the procedure be sure that the vamp is in the right crimping position. For correct placing release the pedal, correct the place of the vamp and press it again. 2 1 3 Step 3. Press the START buttons simultaneously and release the pedal to complete the procedure. The machine will revert to its initial position after the end of the setting time. Maintenance � Once a week lubricate the rod of the cylinders ASM-00694 with oil type SAE 30. � Once a week check the oil level of the air pressure lubricator P1 and add oil type ISO Class V632 or ISO 3448 or something similar. � Once a month clean the radiator. Every six months check the good operation of the lubricator. Note: The lubricator must drip approximately one drop every 20 operation cycles. Repeat the procedure in the hot and cold station in order to stabilize the materials Tip: Hot and cold is necessary either for leather or synthetic vamps and helps maximize and retain the final shape of the vamp and finally the shoe VC-19D Operator’s manual OLYMPIC

( age 9) Hot Station Support Base with Main Cylinder (page 10) Cold Station Head Assembly p ( age 11) Cold (page 12) Station Support Base with Main Cylinder Bottom Valve Assembly (Page 13) Projector with rest of Pneumatics (Page 14) VC-19D Operator’s manual OLYMPIC

126 178 1097 151 1163 156 12 138 178 45 125 9948 74 124 81 146 11 145 150 39 35 149 80 7 147 9946 543 178 1098 BOM ID PartNo Description Qty 7 CAS-00150 HOT MOULD HEAD INTERCHANGE PART 1 11 CAS-00154 VC-19 HOT STATION MOULD 1 12 CAS-00155 VC-19 HOT STATION MALE MOULD 1 35 ELE-00516 HEATING SENSOR 6x35 (L=80CM) 1 39 ELE-00660 HEATING ELEMENT Φ20X110 1 45 GEN-00486 SLIDING BODY 2 74 LAS-01129 SUPPORT INTERNAL SIDE PLATE 2 80 LAS-01137 VC-19 MOULD STOPPER 1 81 LAS-01146 HEAD PUSHING INOX PLATE 1 124 PNE-01090 FISH-EYE, UNIVERSAL JOINT M16x1.5 2 125 PNE-01164 CB-DOUBLE EAR FLANGE Φ100 1 126 PNE-01169 Φ80 DOUBLE EAR FLANGE 1 138 CAS-00160 VC-19D MALE MOULD HOLDING BASE 1 145 REV-00530 VC-19 CYLINDER JOINT PIN 2 146 REV-00531 VC-19 ROTATING BASE PIN 2 147 REV-00535 VC-19 HOLDING WASHER Φ50 1 149 REV-00538 VC-19 Φ50 HOUSING SHAFT 1 150 REV-00541 Φ20 PIN 2 151 REV-00542 VC-19 Φ16 PIN 2 156 REV-00558 VC-19D SLIDING BODY GUIDE 2 178 PNE-09916 ELBOW MALE ADAPTOR 4-1/8" 5 1163 PNE-01163 CYLINDER Φ100x100 1 9946 PNE-09946 CYLINDER Φ80x100 1 9948 PNE-09948 CYLINDER Φ50Χ50 1 543 REV-00453 RESTRICTOR, 1/8 (M) - 1/8 (F) - Φ1.0 1 1097 PNE-01097 STRAIGHT MALE ADAPTOR 6-1/8" 1 1098 PNE-01098 ELBOW MALE ADAPTOR 6-1/8" 1 VC-19D Operator’s manual OLYMPIC

132 99 103 96 115 112 107 118 178 694 152 50 155 1015 9 1238 144 46 153 BOM ID PartNo Description Qty 9 CAS-00151 VC-19D SUPPORT MOULD BASE 1 46 GEN-00488 VC-19 MOULD SUPPORT COVER 1 50 LAS-00589 PISTON GUIDE, VC-2014 1 96 PNE-00059 NIPPLE, TAPER, 1/4 (M) - 1/4 (M) 1 99 PNE-00074 NON-RETURN VALVE, 1/4 1 103 PNE-00094 SILENCER, 1/4, PLASTIC, BLUE 1 107 PNE-00171 REDUCING NIPPLE 1/4-1/2 1 112 PNE-00213 CAP ALLEN, +OR 1/4 1 115 PNE-00725 SOLENOID VALVE 1/4 5/2 1Ρ 1 118 PNE-00951 REDUCER, TAPER, 3/4-1/2 1 BOM ID PartNo Description Qty 132 PNE-09925 ELBOW MALE ADAPTOR 8-1/4" 1 144 REV-00376 NUT, CUSTOM, M36X2.0 1 152 REV-00543 GUIDE INTERNAL THREADED WASHER 1 153 REV-00544 WASHER, CUSTOM, Φ20 4 155 REV-00557 GUIDE CYLINDER 1 178 PNE-09916 ELBOW MALE ADAPTOR 4-1/8" 2 694 ASM-00694 MAIN CYLINDER Φ160 1 1015 PNE-01015 CYLINDER Φ40 1 1238 ASM-01238 HOT STATION COVER 1 VC-19D Operator’s manual OLYMPIC

35 1098 147 178 543 9946 15 126 1240 74 1097 80 151 1163 150 156 138 125 81 9948 124 146 45 13 14 145 BOM ID PartNo Description Qty 13 CAS-00156 COLD STATION MALE MOULD 1 14 CAS-00158 COLD STATION MOULD, NORMAL 1 15 CAS-00159 COLD MOULD HEAD INTERCHANGE PART 1 35 ELE-00516 HEATING SENSOR 6x35 (L=80CM) 1 45 GEN-00486 SLIDING BODY 2 74 LAS-01129 SUPPORT INTERNAL SIDE PLATE 2 80 LAS-01137 MOULD STOPPER 1 81 LAS-01146 SHORT HEAD PUSHING INOX PLATE 1 124 PNE-01090 FISH-EYE, UNIVERSAL JOINT M16x1.5 2 125 PNE-01164 CB-DOUBLE EAR FLANGE Φ100 1 126 PNE-01169 Φ80 DOUBLE EAR FLANGE 1 BOM ID PartNo Description Qty 138 CAS-00160 VC-19D MALE MOULD HOLDING BASE 1 145 REV-00530 CYLINDER JOINT PIN 2 146 REV-00531 ROTATING BASE CONNECTION PIN 2 147 REV-00535 HOLDING WASHER Φ50 1 150 REV-00541 Φ20 PIN 2 151 REV-00542 Φ16 PIN 2 156 REV-00558 SLIDING BODY GUIDE 2 178 PNE-09916 ELBOW MALE ADAPTOR 4-1/8" 5 543 REV-00453 RESTRICTOR, 1/8 (M) - 1/8 (F) - Φ1.0 1 1163 PNE-01163 CYLINDER Φ100x100 1 1240 ASM-01240 EVAPORATOR INSERT 1 9946 PNE-09946 CYLINDER 80x100 1 9948 PNE-09948 CYLINDER Φ50Χ50 1 1097 PNE-01097 STRAIGHT MALE ADAPTOR 6-1/8" 1 1098 PNE-01098 ELBOW MALE ADAPTOR 6-1/8" 1 178 VC-19D Operator’s manual OLYMPIC

1 46 GEN-00488 VC-19 MOULD SUPPORT COVER 1 50 LAS-00589 PISTON GUIDE 1 52 LAS-00822 VC-16 LIQUID HOLDER 1 96 PNE-00059 NIPPLE, TAPER, 1/4 (M) - 1/4 (M) 1 99 PNE-00074 NON-RETURN VALVE, 1/4 1 103 PNE-00094 SILENCER, 1/4, PLASTIC, BLUE 1 107 PNE-00171 REDUCING NIPPLE 1/4-1/2 1 112 PNE-00213 CAP ALLEN, +OR 1/4 1 115 PNE-00725 SOLENOID VALVE 1/4 5/2 1Ρ 1 118 PNE-00951 REDUCER, TAPER, 3/4-1/2 1 132 PNE-09925 ELBOW MALE ADAPTOR 8-1/4" 1 144 REV-00376 NUT, CUSTOM, M36X2.0 1 152 REV-00543 GUIDE INTERNAL WASHER 1 155 REV-00557 GUIDE CYLINDER Φ22 1 163 RUB-00131 RUBBER CAP 4 178 PNE-09916 ELBOW MALE ADAPTOR 4-1/8" 2 694 ASM-00694 ΜΑΙΝ CYLINDER Φ160 1 1015 PNE-01015 CYLINDER Φ40 1 1239 ASM-01239 COLD STATION COVER 1 VC-19D Operator’s manual OLYMPIC

19 7 2 3 16 15 11 9 10 18 8 12 17 14 13 BOM ID PartNo Description Qty 2 GEN-00093 CAP 6 3 ASM-00461 VALVE 5/2 G1/8, 24V 6 7 PNE-00094 SILENCER, 1/4, PLASTIC, BLUE 2 8 PNE-09919 STRAIGHT MALE ADAPTOR 4-1/8" 6 9 PNE-00072 PLUG, MALE, PARALLEL, 1/8 2 10 PNE-00059 NIPPLE, TAPER, 1/4 (M) - 1/4 (M) 1 11 PNE-00213 CAP ALLEN, +OR 1/4 2 12 PNE-01040 MANIFOLD, 1/4, 6 STATIONS 1 BOM ID PartNo Description Qty 13 PNE-00608 SAFETY VALVE, 1/4, P.T. 6 bar 1 14 PNE-09923 ELBOW MALE ADAPTOR 4-1/4" 1 15 PNE-00082 MANIFOLD, 1/4, 4 STATIONS 1 16 PNE-00896 SILENCER 1/4 1 17 PNE-09921 STRAIGHT MALE ADAPTOR 8-1/4" 2 18 PNE-01097 STRAIGHT MALE ADAPTOR 6-1/8" 4 19 PNE-09925 ELBOW MALE ADAPTOR 8-1/4" 2 VC-19D Operator’s manual OLYMPIC

1 42 ELE-00674 LED PROJECTOR DRIVER 1 158 REV-00561 VC-19D PROJECTOR ARM HOLDER 1 159 REV-00562 VC-19D LED PROJECTOR HOLDER 1 1236 ASM-01236 1/2 ARTICULATED PATTERN 1 178 116 461 104 BOM ID PartNo Description Qty 104 PNE-00096 CONNECTOR, Y, MALE, 1/8 - Ø4 2 116 PNE-00741 SILENCER, SPRING REGULATOR, 1/8 2 178 PNE-09916 ELBOW MALE ADAPTOR 4-1/8" 1 461 ASM-00461 VALVE ELECTRIC PILOT 5/2 G1/8, 24V 1 VC-19D FRL with components VC-19D Top Valve with components 304 303 91 114 84 132 BOM ID PartNo Description Qty 84 PNE-00001 FRL G1/4 SIZE 300 1 91 PNE-00023 MALE-FEMALE ELBOW 1/4" 1 303 PNE-00204 OFF SET MALE TEE 4050 1/4 1 114 PNE-00619 MALE HOSE ADAPTER (TAPER) 9-1/4 1 304 PNE-09921 STRAIGHT MALE ADAPTOR 8-1/4" 1 132 PNE-09925 ELBOW MALE ADAPTOR 8-1/4" 1 VC-19D Operator’s manual OLYMPIC

FRL FRL Ø80 Ø160 Ø100 Ø80 Ø160 Ø100 Ø50 Ø50 Ø40 Ø40 A A B B B B L L K K C C D D E E F G G F I I J M SV2 SV4 B B B SV4 SV3 SV2 SV1 SV4 SV2 P/N DESCRIPTION A PNE-09948 CYLINDER ACE Φ50Χ50 B ASM-00461 VALVE 5/2 1/8, 24V C PNE-09946 CYLINDER ACE 80x100 D ASM-00694 CYLINDER SI 160x240 E PNE-00725 VALVE 1/4 5/2 1Ρ F PNE-00074 NON-RETURN VALVE, 1/4, FEMALE G PNE-01163 CYLINDER ACE Φ100x100 I PNE-01015 CYLINDER ACQ 40X120 J PNE-00001 FRL G1/4 SIZE 300 K REV-00453 RESTRICTOR,1/8 (M)-1/8 (F)-Φ1.0 L PNE-00741 SILENCER, REGULATOR, 1/8 HOT STATION COLD STATION

VC-19D Electrical diagram B K1 L1 L2 L3 T1 T2 T3 A2 A1 K2 L1 L2 L3 T1 T2 T3 A2 A1 R M PCB 24VAC L1 F5 F5 F4 F4 b F2 F2 F3 F3 230V AC 24V AC Tr1 5 6 F1 F1 F1 F1 3 4 L N PE L3 L2 11 31 34 S1 + 11 TH1 8 7 6 4 12 11 TH1 8 7 6 4 12 TH2 12 11 8 7 6 4 TH2 12 11 8 7 6 4 S2 + TH2 12 11 8 7 6 4 S2 + TH2 12 11 8 7 6 4 S2 + 7 N1 N2 - - SW1 2 1 230 VAC 50Hz 12 8 SW3 C9 8 9 SW2 SW2 35 32 SYMBOL Part No Description SW1 ASM-00807 MAIN SWITCH SW2, SW3 ELE-00670 SWITCH 24V b ELE-00002 STOP BUTTON Tr ELE-00021 TRANSFORMER, 230V – 24V 12V 100 VA K1, K2 ELE-00028 RELAY TH1, TH2 ELE-00264 THERMOREGULATOR R38S N1, N2 ELE-00664 DRIVER 1W 230V R ELE-00660 HEATING ELEMENT 230V 900W M ASM-01228 VC-19D COOLING UNIT L1 ELE-00407 LED BAR L2, L3 ELE-00663 PUNT 1 LED 32 ROSSO 1W 3,8VDC B ELE-00331 BRIDGE 10A/1000V F1 ELE-00336 CHINT NB1 63C10A F2, F3 ELE-00378 FUSE 6A 5X20 F4, F5 ELE-00377 FUSE 4A 5X20 S1, S2 ELE-00516 HEAD TEMPERATURE SENSOR C1 - C9 COIL 24 VAC U PCB-00028 M-USE T1, T2 ELE-00076 POTENTIOMETER 10kΩ P1, P2 ELE-00615 FOOT SWITCH BLACK b1, b3, b4, b6 ELE-00001 START BUTTON b2, b5 ELE-00506 STOP BUTTON HOT STATION COLD STATION b2 IN7 b2 IN7 IN2 b1 b1 IN2 b1 IN3 b3 b3 IN3 b3 b5 IN8 b5 IN8 IN5 b4 b4 IN6 b6 b6 IN6 b6 13 14 15 16 17 N 18 23 22 21 Τ1 TIMER1 23 22 21 Τ1 TIMER1 26 25 24 Τ2 TIMER2 P1 N 19 IN1 P2 N 20 P2 N 20 IN4 IN4 P2 N 20 IN4 C1 C1 L C2 C3 L28 L L30 L L27 L29 C4 C5 C6 C7 C8 33 36

PCB-00028 M-USE MAINBOARD ELECTRONIC PCB 1 2 3 4 5 6 7 8 9 10 VC-19D LEFT IMPORTANT: THE SWITCHES MUST BE STRICTLY SET AS SHOWN (DIP2, DIP4 UP) SV1 SV2 SV3 SV4 SV5 SV6 SV7 SV8 USB 24VAC FUSE 15A FUSE 2A SV9 SV10 INPUT-1 INPUT-2 INPUT-3 INPUT-4 INPUT-5 INPUT-6 INPUT-7 INPUT-8 TIMER-1 TIMER-2 TIMER-3 TIMER-4 TIMER-5 1 2 3 4 5 6 7 8 9 10 RIGHT LEFT RIGHT PEDAL1 INPUT1 PEDAL2 INPUT4 BUTTON b1 INPUT2 STOP b2 INPUT7 BUTTON b3 INPUT3 BUTTON b4 INPUT5 STOP b5 INPUT8 BUTTON b6 INPUT6 INPUTS SV1 HOT STATION CYLINDER ACQ Φ40x120 HOT STATION CYLINDER ACE Φ100x100 HOT STATION CYLINDER ACE Φ80x100 HOT STATION CYLINDER SI Φ160x240 SV3 COLD STATION CYLINDER ACQ Φ40x120 COLD STATION CYLINDER ACE Φ100x100 COLD STATION CYLINDER ACE Φ80x100 COLD STATION CYLINDER SI Φ160x240 OUTPUTS SV2 SV4 Cooling Unit Hot Station Temperature °C Cold Station Temperature °C 5 10 15 20 25 30 0 SEC Timer 5 10 15 20 25 30 0 SEC Timer Head Lock VC-19D Cooling Unit M A D E I N G R E E C E VC-19D Operator’s manual OLYMPIC

SV3 output led Fault at pedal contact Solenoid L3 Fault at main board Pedal2 led on Pedal1 led off on off Pull-up cylinder Ø40 is not working SV1 output led Fault at pedal contact Solenoid L1 Fault at main board Pedal1 led on Pedal1 led off on off Pull-up cylinder Ø40 is not working SV1 output led Fault at pedal contact Solenoid L1 Fault at main board Pedal1 led on Pedal1 led off on off Cylinders Ø160, Ø80, Ø100 are not working SV2 output led Fault at Butt1 and/or Butt2 Butt1 and/or Butt3 led on Butt1 and/or Butt3 led off Solenoid L2 Fault at main board on off Cooling unit is not working Fault at on/off switch SW2 Fault at thermocouple TH2 Upper cylinder Ø50 is not working Fault at on/off switch Solenoid C7 Cylinder Ø160 is not working SV4 output led Fault at Butt5 and/or Butt6 Solenoid L4 Fault at main board Butt4 and/or Butt6 led on Butt1 and/or Butt2 led off on off Resistance is not working Fault at relay K1 Fault at thermocouple TH1 Fault at relay K2 VC-19D Operator’s manual OLYMPIC

GR-17778 Athens Greece email: [email protected] website: www.hydrotab.gr REV.D VC-19D Operator’s manual OLYMPIC