Manual de Operacion - Cador - 500 - Engl - Rex

Cador 500 Operating Manual
Operating Instructions
for the
Cador 500 Concrete Reinforcing Steel Cutter
© Pedax Bitburg Maschinenbau GmbH 1 25_11_2003GB

All rights reserved. Reproduction or distribution of these operating instructions

or parts of them in any form such as photocopying, microfilm or any other
process is not allowed without our explicit written approval. The same applies
to the right of publication.
In accordance with statutes the user must ensure that the documents are only
used for their intended purpose, and in particular that they are not passed on
to third parties or used to facilitate duplication.
The manufacturer may make changes at any time without giving prior notice.
© Pedax Maschinenbau GmbH

Machine type Concrete reinforcing steel cutting

equipment
Model name Cador 500
Serial number ..................................................
Order number ..................................................
Year of construction..................................................
Inventory number ...................................................
Manufacturer PEDAX
Street address Industriestraße 5
Town and postcode D-54634 Bitburg
Phone 06561 96670
Fax 06561 966790
Customer service 06561 966731

The purpose of the documentation:
The present documentation makes the operator of Cador 500 concrete

reinforcing steel cutting equipment familiar with
the working method,

the operation,
the safety instructions and
the servicing
of this machine.
Operating personnel:
The Cador 500 concrete reinforcing steel cutting equipment must only be
operated by properly instructed personnel. The completion of the instruction
process is to be recorded in a hand-over record. Additional requirements,
qualifications and responsibilities are described in each chapter.
Storage:
Always keep these operating instructions with the machine!

The instructions must always be within reach.

Table of Contents
1 Basic Safety Instructions....................................................................................7
1.1 Duties and Liabilities...................................................................................7
1.2 Safety Symbols...........................................................................................9
1.3 Use for the Proper Purpose......................................................................10
1.4 Incorrect Usage.........................................................................................10
1.5 Organisational Procedures........................................................................11
1.6 Protective Equipment................................................................................11
1.7 Informal Safety Procedures.......................................................................11
1.8 Training of Personnel................................................................................12
1.9 Safety Procedures for Normal Operation..................................................12
1.10 Hazards Presented by Electrical Energy..................................................13
1.11 Hazards from Residual Energy.................................................................13
1.12 Places of Particular Hazard.......................................................................14
1.13 Servicing and Maintenance, Rectification of Faults..................................14
1.14 Alterations to the Construction of the Machine.........................................15
1.15 Cleaning the Machine and Disposal of Materials......................................15
1.16 Machine Noise..........................................................................................16
1.17 Fire Fighting..............................................................................................16
2 Packing, Transport............................................................................................17
2.1 Safety Regulations....................................................................................17
2.2 Requirements on the executing staff........................................................17
2.3 Packing......................................................................................................18
2.4 Transport...................................................................................................18
3 Description of the Machine..................................................................................19
3.1 General View..............................................................................................19
3.2 Working Locations.....................................................................................19
3.3 Hazardous Areas.......................................................................................20
3.4 Identification of the Machine.....................................................................20
3.5 Technical data...........................................................................................21
3.6 Machine Fittings........................................................................................22
4 Structure and Function........................................................................................23
4.1 Structure....................................................................................................23
4.2 Safety Equipment......................................................................................26
4.3 Description of the Working Procedure......................................................28
5 Operating and Display Elements.........................................................................30
5.1 Fault Displays:...........................................................................................33
5.2 Error Messages on the Screen:................................................................33
5.3 Malfunctions during the automatic operation............................................34
5.4 Operating Modes.......................................................................................35

6 Commissioning.................................................................................................36
6.3 Technical Documentation..........................................................................36
6.4 Erection.....................................................................................................37
6.5 Assembly...................................................................................................37
6.6 Initial Operation.........................................................................................39
6.7 Acceptance................................................................................................40
7 Operation..........................................................................................................41
7.3 Data Entry and Programming...................................................................43
7.4 Operation of the Machine..........................................................................58
8 Fault Finding and Rectification.........................................................................64
8.3 Faults and Their Rectification....................................................................65
9 Servicing...........................................................................................................67
9.3 Servicing Plan...........................................................................................68
9.4 Servicing Work..........................................................................................76
10 Overhauling...................................................................................................79
10.3 Fault Finding and Rectification..................................................................80
10.4 Repair........................................................................................................85
11 Removal from Service and Storage..............................................................88
11.3 Storage Conditions....................................................................................89
11.4 Removal from Service...............................................................................90
12 Disposal........................................................................................................91
12.3 Disposal.....................................................................................................92
12.4 Assemblies Suitable for Disposal..............................................................93
13 Options..........................................................................................................94
13.1 Operation with Scanner.............................................................................95
13.4 Plant control without a PC......................................................................101
13.5 Digital display for the support frame.......................................................104
13.6 Transport roller tracks.............................................................................105

13.7 Fixed track end piece..............................................................................106
1 Basic Safety Instructions
These operating instructions contain the most important advice required to

operate the machine in safety.
1.1 Duties and Liabilities
Observe the notes given in the operating instructions:
Knowledge of the fundamental safety instructions and the safety regulations

constitute a fundamental requirement for safe handling and smooth operation
of the machine.
These operating instructions, in particular the safety instructions, are to be
observed by all persons who work with the machine. In addition, the rules and
regulations for accident prevention applying to the location where the machine
is used are to be observed.
Hazards when dealing with the machine:
The Cador 500 concrete reinforcing steel cutting equipment has been
constructed in accordance with modern technical standards and with
recognised technical safety rules. Nevertheless, risks to the life and limb of the
user or of third parties, or damage to the machine or other valuable property,
can arise during use.
The machine must only be used
- for its proper purpose

- when in a technically sound condition
Faults that could impair safety must be rectified without delay.

Guarantee and liability
Our "General Conditions of Sale and Supply" apply. Claims under guarantee
or for liability in the event of injury to persons or damage to property cannot be
entertained if they arise from one or more of the following causes:
- use of the machine other than for its proper purpose,

- improper assembly, commissioning, operation or servicing of the machine,
- operation of the machine with defective safety equipment or with safety and
protective equipment that has not been properly fitted or which is not
functioning correctly,
- failure to observe the instructions in the operating instructions concerning
transport, storage, assembly, commissioning, operation, servicing and
preparation of the machine,
- unauthorised alterations to the construction of the machine,
- unauthorised alteration of the machine parameters (such as lengths, power,
speed),
- inadequate monitoring of machine parts that are subject to wear,
- improperly carried out repairs,
- catastrophes due to the effects of foreign bodies or acts of God.

1.2 Safety Symbols
The following identifiers and signs are used in the operating instructions to
indicate various hazards:
This symbol indicates an immediate threat to

human life or health.
Failure to observe such an instruction has serious

effects ranging from damage to health up to life-
threatening injuries.
Danger!
This symbol indicates a situation that may be

dangerous.
Failure to observe such an instruction can easily

result in injuries or to damage to property.
Warning!
At this symbol you obtain tips on use and

particularly useful information.
They help you to get the best use out of the

machine's functions.
Note!

1.3 Use for the Proper Purpose
Using the machine for its proper purpose, in accordance with the technical
data, consists in cutting concrete reinforcing steel! Only use the equipment
when it is in a technically correct condition, in accordance with regulations,
with attention to matters of safety and of danger, and whilst observing the
operating instructions.
In particular, faults that could impair safety must be

rectified without delay.
Proper use also includes observation of the
operating instructions and maintenance of the
inspection and servicing regulations.
Warning!
1.4 Incorrect Usage
Usage other than as described above is forbidden.

Hazards can be created by incorrect use.
The machine is designed, in accordance with its
technical specification, only for machining concrete
reinforcing steel.
Any use outside or beyond that is improper.
The manufacturer/supplier are not liable for any
damage caused in that way. The user bears the full
responsibility.
Danger!

1.5 Organisational Procedures
The necessary personal protection gear (such as

protective helmets, gloves and hearing protection)
is to be provided by the operator.
All safety equipment must be regularly

inspected.
Note!
1.6 Protective Equipment
All safety equipment must be properly fitted and correctly functioning

every time that operation of the machine is started.
Protective equipment (such as a padlock on the

main switch) may only be removed
- when the machine has stopped,

- and with steps having been taken to
prevent the machine being started up again
When spare parts are supplied, the safety

equipment must be fitted by the operator in
accordance with the regulations.
Warning!
1.7 Informal Safety Procedures
The operating instructions are always to be kept at the machine. In addition to

the operating instructions, both generally applicable and local regulations for
accident prevention and for protection of the environment are to be made
available and observed.

All safety and hazard instructions at the machine are to be maintained in
a readable state, and are to be replaced if necessary.
1.8 Training of Personnel
The Cador 500 concrete reinforcing steel cutting equipment is usually erected
by the Pedax customer service department. They will also train the personnel
in operation and maintenance.
The operator is responsible for ensuring that only

trained and instructed personnel works on the
machine.
The responsibilities of the various members of staff for

operating, retooling and servicing are to be clearly
specified.
Personnel requiring training may only work at the

machine under the supervision of an experienced
person.
Warning!
All persons working in the area of the machine must
be able to make themselves understood to each
other.
1.9 Safety Procedures for Normal Operation
Only operate the machine when all the safety

equipment is fully functional.
Before switching the machine on, ensure that

nobody can be endangered by the running
machine.

The machine must be checked for externally visible
damage and for proper function of the safety
equipment at least once a day.
Warning!
1.10 Hazards Presented by Electrical Energy
Only allow work on the electrical supply to be

carried out by qualified electricians.
Check the machine's electrical equipment regularly.

Loose connections and scorched cables should be
rectified immediately.
The switch cabinet should always be kept locked.

Access is only allowed to authorised personnel with
the aid of a key or tool.
Danger!
1.11 Hazards from Residual Energy
Note that residual mechanical, hydraulic, pneumatic

and electrical energy can remain in the machine,
and take appropriate measures when instructing
staff.
Further details are given in the relevant chapters of
these instructions.
Danger!

1.12 Places of Particular Hazard
- Area of the material placement frames.

- Area of the shears.
- On both sides of the measuring track with transfer.
- Area of the collection troughs.
- On both sides of the transport roller tracks.
- Area of the end piece with transfer and collection
troughs.
Danger!
1.13 Servicing and Maintenance, Rectification of Faults
Carry out prescribed adjustments, servicing and inspection work at the correct
times.
Secure all operating media such as compressed air

and hydraulics against accidental operation.
For all servicing, inspection and repair work
- voltage must be removed from the machine, and

the main switch secured against accidentally
being switched on again,
- the main switch locked and the key removed,
Danger! - a sign that warns against switching on must be
attached.
When large assemblies are being replaced, they

must be carefully attached and secured to lifting
gear.

Check that any bolts that may have been undone
are tightened up. When maintenance work is
complete, check that safety equipment is
functioning correctly.
1.14 Alterations to the Construction of the Machine
No alterations, additions to or modifications of the

machine are permitted without the approval of the
manufacturer. This also applies to welding onto
load-carrying members.
Any modifications require written approval from
Pedax GmbH.
Any machine parts that are not in proper condition

must be exchanged immediately.
Only use original replacement and wearing

parts.
Note! It cannot be guaranteed that parts obtained from

third parties are designed or manufactured
appropriately for the demands or the requirements
of safety.
1.15 Cleaning the Machine and Disposal of Materials
All materials used must be correctly handled and

disposed of, in particular
- when working with lubricating systems and

equipment, and
- when cleaning with the aid of solvents.

Warning!
1.16 Machine Noise
The noise level created by the machine through

impacts to the material during its transport can
exceed 85 dB(A). The operating personnel are to
be protected through appropriate equipment for
(hearing) protection.
Warning!
1.17 Fire Fighting
In the event of a fire it is essential that the machine

is switched off at the main switch, otherwise
electrical fires cannot be effectively combated.
Only attempt to extinguish burning oil or grease with

suitable extinguishing materials.
Danger!

2 Packing, Transport
2.1 Safety Regulations
The machine is dismantled for transport, and the accessories packed in

boxes.
In order to prevent damage to the machine and

potentially fatal injuries during transport:
- Load supporting materials and load-securing

device must accord with the specifications of the
accident prevention regulations!
- Only make load-securing device to the transport
eyelets.
- The weight of the machine must be considered
when selecting the load carrying materials and the
attachments.
- Carrying distance are to be closed off so that no
unauthorised persons can enter the hazardous
area.
Danger!
2.2 Requirements on the executing staff
The machine may only be transported by qualified and authorised

persons. See also Chapter 1.8

2.3 Packing
- Dismantle the elements of the equipment and lash them down.

- Pack the switch cabinet in sheeting.
- Pack the accessories into boxes and lash them to the machine.
- Preserve bare metal parts of the machine with rust preventative.
2.4 Transport
Data Relevant to Transport:
Longest element approx. 7 m (variat.poss.)

Widest element approx. 2 m
Heaviest element approx. 3000 kg
Total weight depends on the particular version
Transport Method:
The length of the parts means that 2 cranes are necessary for transport.
Both cranes need to be operated at the same time.
Ensure that the load carrying capacity of the crane

and the means of attachment are adequate.

Danger!
3 Description of the Machine
3.1 General View
Material placement
frame Shears
Measuring track with collection
troughs
Control panel
3.2 Working Locations

Other than the working location at the operating panel, there are also working
places:
- on the material placement frame

- at the measuring track
- in the region of the collection troughs
3.3 Hazardous Areas
The following areas are hazardous:
- The area of the material placement frame.
- The region of the Shears.
- The region of the measuring track and delivery point.
- Area of the collection troughs.
- On both sides of the transport roller tracks.
- Area of the end piece with transfer and collection troughs.
3.4 Identification of the Machine
The type plate is located at the protective grille for the shears.

3.5 Technical data
Total length, standard 12 m measuring length approx. 30 m (variat. poss.)

Total width approx. 6 m
Height approx. 2.3m (variat. poss.)
Measuring range, standard 12 m (variations possible)
Shortest cut length 750 mm
Width of the feed track 500 mm
Width of the measuring track 500 mm
Transport speed 2 m/s
Cutter width 500 mm
Air requirement approx. 120 lt. / min at 6 bar
Connected load approx. 35 kW
Voltage, standard 400 V / 50 Hz
Cutting capacity
Nbr of bars Nbr of bars

Max. Ø 650 N/mm² 850 N/mm²
55 1 -
40 6 1
36 7 5
32 11 11
28 15 15
25 16 16
22 19 19
20 21 21
18 23 23
16 26 26

14 30 30
12 35 35
10 42 42
8 52 52
The switching devices are designed according to

“allocation type 1“. After a short-circuit at the
machine, the switching devices may no longer be
operational.
We recommend replacing the devices.
Warning!
3.6 Machine Fittings
The machine is supplied with:
- Operating instructions
- Spare parts list
- Accessories

4 Structure and Function
4.1 Structure
Material placement frame
The material placement frame is composed, in accordance with customers'

wishes, of individual stands with two, three or four compartments.
These compartments, with the exception of the last one, are opened and
closed by pneumatically operated points.
To position the bars to be cut before each cutting process, a counting trough,
opened and closed pneumatically, is located immediately in front of the feed
track.
A display unit for the bar diameter and the number of bars can be supplied as
an option.

Counting in the bars to be cut for the next cutting process is normally done by
a second operator working from the catwalk.
Cutting line
Consisting of:
Feed track
Frame shears
Measuring track
Feed track:
A roller conveyor with powered transport rollers, reversible, roller spacing
approx. 1000 mm. The roller conveyor is lowered with each cutting process
approx. 6 m in front of the shears.
Frame shears:
The frame shears are arranged within the frame and can be moved by a motor
over a distance of 1 m. The shears are positioned automatically. A powered
guide roller is located on the side of the feed track. A push-button allows this to

be pivoted downwards, so that the bar scraps are sure to fall into the waste
tub.
To support the rods there is a powered intermediate roller between the
measuring track and the shears.
Measuring track:
Powered, reversible transport rollers are located at 1 m intervals.
Automatically activated guide plates are located at 1 m intervals.
A pneumatically operated delivery system, divided after 6 m, guides the cut
material to the desired side, into the collection troughs.

Feed track, shears and measuring track
Collection troughs
The collection trough system is composed, in accordance with customers'

wishes, of individual stands with two, three or four sections. These
compartments, with the exception of the last one, are opened and closed by
pneumatically operated points.
The cut bars are removed by a crane. As an option, collection trough systems
emptied by roller conveyors can be supplied.

4.2 Safety Equipment
"Control Panel" Workplace
The control panel is where data is input and the installation is controlled.
The operator supervises the machine's production from this location.
The machine can be stopped immediately with the EMERGENCY OFF switch.
The concrete reinforcing steel shears are fitted with a protective grille. The
movement of the shears is halted if the protective gate is opened.
EMERGENCY
OFF

"Collection Trough" Workplace
The cut concrete bars in the collection troughs are packed by the operator.
Bundling should only be carried out when the

machine is switched off and the EMERGENCY OFF
switch latched.
Danger!
Removing Material.
In order to remove the cut material with a crane the arms of the points can be
opened by operating a switch. If the guides are manually opened, transfer to
this side is blocked.
The machine can be, additionally, be stopped with the EMERGENCY OFF
switch.

4.3 Description of the Working Procedure
Put material in place
The material is sorted into the compartments of the material placement frame
in order of diameter.
The uncut bars are rolled by a second operator from the material placement
frame into the counting trough.
Data entry at the operating system:
All the data related to cutting the material is entered at the operating system.
The system expects an entry at every location, and unsuitable entries are
rejected.
Start the process:
When the counting trough is opened, the concrete bars drop onto the feed
track.
The cutting process is started by the function key F2.
The operator supervises the machine during

production.
If danger arises, the machine is immediately
stopped with the EMERGENCY OFF switch.
Danger!

Positioning the cutting length:
The length stop is raised, and the feed and measuring tracks move the
material up to the length stop.
The shears move to the cutting position.
Cut:
The shears cut the material. At the same time the feed track in the front region
is lowered. A clamp holds the material down, and prevents it jumping as it is
cut.
Eject material:
The programmed box stop is raised.

The cut material is transported on the measuring track to the box stop.
A delivery device rolls the material into the collection trough.
If other cut lengths have been programmed, the material is repositioned, cut
and ejected.
The operator supervises the machine during

production.
If danger arises, the machine is immediately
stopped with the EMERGENCY OFF switch.
Danger!

5 Operating and Display Elements
Control panel
Function keys
Automatic mode
F1 = Unused F2 = Start
F3 = Request data F4 = Optimise
F5 = Unused F6 = Label
F7 = Continue F8 = Delete
F9 = Stop F10= Menu

Operating and Display Elements
Manual Control:
8 9 10 11 12 13
14 15 16 17 18 19
1 2 3 4 5 6 7 20 21 22 23 24 25
26 27 28 29 30 31
32 33 34 35 36 37
1 EMERGENCY OFF 2 Controller off

3 Controller on 4 Fault
5 Setting up - manual – automatic 6 Roller track automatic 0 / 1
7 Stopper select 8  Infeed conveyor 
9  Measuring track  10 Evenstopper up/down
11 Infeed guide roller 12  Shears 
13  Shears  14 Material fast 0 / 1
15  Transfer Measuring track  16  Roller track 1 
17  Roller track 2  18  Roller track 3 
19  Roller track 4  20  Transfer Roller track 1 
21  Transfer Roller track 2  22  Transfer Roller track 3 
23  Transfer Roller track 4 . 24  Chainconveyor 1 
25  Chainconveyor 1  26  Selector 1 left 
27  Selector 2 left  28  Selector 3 left 
29 Counting trough left 30
31 Emptying left, 0, right 32  Selector 1 right 
33  Selector 2 right  34  Selector 3 right 
35 Counting trough right 36
37 Compartment selection

Operating unit at the end of the final roller conveyor
Operating elements:
EMERGENCY OFF, crane emptying left, 0, right

5.1 Fault Displays:
The indicator lamp for "Drive malfunction" lights if a drive motor is overloaded
or is defective.
5.2 Error Messages on the Screen:
The following error messages can appear on the screen in the course of
production:
Message Procedure
Shears not up Use button to move shears upwards.
Check limit switches 2S1 + 2S2. Check valve
2Y2 / 2Y3
Shears movement disrupted Check contactor K14M, relays K26A-K29A.
No reference point Use switch to move the shears to the end

position at the measuring track.
Check approach switch 2S3.
Protective grid open Close protective grille.

Check safety switch 2S7.
Drive fault Check motor.

Unlatch over-current trip.
Check travel time to length Check approach switch S04

stop, Check measuring roller
Hydraulics not switched on Check contactors K1M – K3M.

5.3 Malfunctions during the automatic operation.
Should a fault occur during the cutting process the operating mode switch
must be switched to “Manual”.
The process will be interrupted; all equipment functions are halted.
The box stop and the collection troughs remain raised.
If the fault occurred before cutting took place, the fault must be corrected and
the material moved by hand to the feed track. After switching to “Automatic”
the process will continue after pressing key “F2” on the PC.
If the material has already been cut, after correcting the fault the material must
be moved by hand to in front of the box stop. Transfer to the collection trough
must also be initiated by hand. The cutting process will then continue after
switching to “Automatic” and pressing the “F2” key.

5.4 Operating Modes
Manual Operation
With the exception of the length measurement and the control of the stops, all
the equipment's functions can be controlled with the corresponding buttons
and switches at the operating panel.
Setting-up mode
The data for a cutting order, which has already started, is deleted.
Automatic mode
After insertion of the concrete bars in the counting trough, a button is pressed
to open the counting trough and the material drops onto the feed track.
Now, after pressing the "Alignment stop" button and operating the "Material
forwards / backwards" switch, it can be positioned so that the ends are flush.
Alternatively the cutting process is started by the function key F2.
The length stop is raised and the shears move into position.
The concrete bars that have been inserted are automatically transported to the
first cutting position on the measuring track.
The cut is made.
Now the box stop is raised.
The cut material is automatically positioned in front of the box stop.
The points arms of the collection troughs operate, and the delivery system
rolls the material into the programmed collection trough.
If further cuts have been programmed, the material is positioned in front of the
new length stop, cut, and placed in the desired collection trough.

6 Commissioning
Electrical connections
The machine must be connected in accordance with VDE (German

Electricians' Association) regulations and the specification of the responsible
electricity supply company.
Cador cutting equipment is generally installed by staff of the Pedax customer

service department. They will also instruct the personnel in operation and
servicing of the machine.
Work on electrical equipment, and the connection of devices to electrical plant

must only be carried out by authorised specialists.
6.3 Technical Documentation
The erection and foundation plans contain information about:
- Foundation loading
- Equipment dimensions
- Cable layout
- Position of the electrical connection
- Connected load

6.4 Erection
Before commencing assembly, please check that:
- there are no obstacles on the transport path or at the

assembly location,
- the cranes are of sufficient capacity (see Chapter 2.4),
- the paths along which it will be transported are clear,
- materials needed to set up the machine are available.
Assembly and transport work may only be carried

out by qualified and authorised persons (see
Chapter 1.8).
Do not fail during transport to observe the data
given in Chapter 2.4
Danger!
6.5 Assembly
The equipment is dismantled for transport and packed as separate modules.
- Unpack the cutting line, assemble it, and secure it firmly to the
ground with heavy duty pegs.
- Unpack the modules, assemble them, and secure them firmly

to the ground with heavy duty pegs.
- Connect the feed cable to the switch cabinet.
- Install a supply of compressed air.

Compressed air connections for the collection troughs
Compressed air supply to the installation's shearing frame

Disposal
All cleaning cloths and other materials used for

cleaning and degreasing must be disposed of in an
environmentally sound manner.
Note!
Provide collecting vats and containers for the cleaning material that will be
produced daily.
6.6 Initial Operation
Preparatory measures
- have all the transport fixings been removed,
- power supplies installed
- safety equipment fitted,
- the hydraulics been filled with oil,
- check all the connection screws at the controller,
- direction of rotation of the motors,
- sealing of the hydraulic equipment,
- lubrication of the bearings and sliding surfaces,
- visual check before starting.
Starting operation for the first time

- check the EMERGENCY OFF and safety equipment,
- test all functions in the "Manual" operating mode,
- test functions in the "Automatic" operating mode,
- simulation of faults,
- instruction of the operating personnel,
- trial production by the operator,
- instruction in fault rectification by the user,
- instruction of the servicing personnel.

6.7 Acceptance
- demonstration of the EMERGENCY OFF and safety equipment,

- demonstration of function in all operating modes,
- demonstration of faults and their rectification,
- demonstration important servicing work,
- indication of servicing intervals,
- trial production with check of the cut lengths,
- filling out and signing the acceptance record with the customer.

7 Operation
All persons present within the working area of the

machine must be able to make themselves
understood to each other.
While the machine is cutting and transporting the

concrete bars, individual bars can get caught, and
can jump out of the transport track.
The operator watches over the entire working area

of the machine during production. He shuts it down
immediately in the event of danger.
Danger!
Danger of crushing and shearing occurs at

- both material placement frames,
- around the feed and measuring track,
- the area of the transfer station,
- the area of the shears,
- the area of the collection troughs
- both sides of the transport roller tracks,
- the hole area of the end piece with transfer and
collection troughs.
The operator is responsible for protecting persons

from injury.
Danger!

When not used for its proper purpose (see

Chapter 1.3) other kinds of hazard can arise.
Danger!
Cador cutting equipment must only be used by

trained and instructed personnel.
See also Chapter 1.8
Danger!

7.3 Data Entry and Programming
Switch on the machine
- Switch on the main switch on the left hand side of the switch cabinet
- Switch on the controller at the switch panel
The Production screen is displayed.
Switch the machine off
In order to store all the data that has been entered, the program must be
ended with the key combination of Alt F10 with Alt X before the main switch
at the switch cabinet is switched off.

Data input:
A PC is built into the machine for management of the data, optimisation and
display of faults. The data can be entered by way of the keyboard, by scanner
or via a cable from a host PC.
The data for the raw material is entered into the upper line of the screen under
Mat. length and Diameter. A length greater than the “max. cut length” from
the machine data will not be accepted.
The maximum cutting capacity, the number of bars that can be cut at the same
time, is automatically entered into the Number box from the stored table of
materials. This value can only be edited for lower values.
The Cycle and List boxes do not have to be filled in, since they are completed
by the system when the cutting data is transmitted electronically from a host
PC.
It is then possible after this to enter ten lines for Required number and
Length in the cutting data table. A length between 750mm (the shortest length
that can be cut) and the remaining length can be entered.
After each entry the box for the Remaining length is once more updated.

The Cuts box does not have to be filled in, as it will by completed
automatically during optimisation.
A box is suggested in the space for Box. It can be overwritten.
The Remaining pieces box is automatically updated during the cutting

process.
F2 Start. After the material has been placed on the feed track in accordance
with the figures on the monitor, the cutting process can be started.
F3 Request data. Data is requested manually from the host PC.
F9 Stop. The cutting process is interrupted after delivery of the cut material.
F7 Continue. The interrupted cutting process is continued.
F8 Delete All the data on the monitor is deleted. A "security question" is asked
before the data is lost, and this must either be confirmed with F1 OK or, if the
deletion was requested in error, rejected with F2 Cancel.

System Data
File menu
The system menus are called with the F10 Menu function key.
Using the arrow keys it is possible to select the following functions:
About. Information about the software status is displayed.
Exit, Alt-x. The program is closed with this menu item. All data is saved, and
will be available again when the equipment is again switched on.
F10 Menu. Pressing this function key leaves the menu and returns to
production.

Test menu
These functions are intended for customer service, and are used to
record control data in the event of a fault. These functions have no
significance for the operation of the machine.
Log All. The entire data flow is recorded in report files.

BVBS. The data exchange is switched over to test-BVBS format.
Log BVBS. The cutting data is recorded in BVBS format.
Log PLC. The data exchange between the PC and the PLC is recorded.
Sim PLC. A simulated production run is made, without a machine being
connected to the PC.
PLC. The data transfer to the PLC is tested.

Delete menu
Line, no function.
Cycle. Deletes a cycle after the data has been transferred from a host PC.
List, no function.
All, deletes all cutting data at the monitor and in the main memory, acts like
the function key F8 delete.

Control menu
These functions are also intended for customer service, and do not have
any effects on the machine's function.
Restart PLC. If a data communication has been interrupted as a result of a

fault it is started again.
Restart cycle. The cutting cycle is started again.
Status req. A status message is requested.
Display. Presently has no function.
Scanner, go to scanning (data transmission) with or without response

Parameter menu
The data in the following menus does have an

effect on the machine's function, and should not be
changed without the agreement of our customer
service department.
Warning!
Production. Return from other menus to production

Capacity. Go to the capacities table
Machine data. Go to the machine data table
Box plan. Go to the box table

Capacity menu
Data must be entered for every diameter that is to be processed.
Diameter of the material

Number of bars that can be cut at the same time
(cutting capacity)
F7 Production back to Production Menu

F10 Menu back to Parameter Menu

Machine data menu
Min cut length Minimum length of bar that can be transported and ejected
Max cut length Maximum cut length, which depends on the measuring track

Additional setting parameters relating to the equipment can be

displayed. These are explained in the equipment data sheets.

Box plan menu
The minimum and maximum box lengths must be entered.
F5 Test box switch to enabled or disabled

F8 Delete Tab delete whole table

Data Entry via Scanner (Option)
Point the scanner at something of an angle to the symbol pattern. When the
trigger key has been pressed, the scanner creates a rectangular raster
pattern.
It opens, and reads in the code.
The scanner has successfully read the code if the green LED lights up and
you hear a short high-pitched beep.
Scan pattern
The data that has been scanned in appears on the screen.
Incorrect Correct
Angled at 30°
Bar code
Bar code

If the following label is scanned, the following data should appear on the
monitor:
Diameter 20
Desired number of items10
Length 2521
Variant 1:
If the table for the cutting data is empty, a label can be read by the scanner.
The diameter of the label is entered in the header line. Only the Mat. length
still has to be entered manually.
From now on it is only possible to scan labels with this diameter.
The data on the label must be coded in PDF format in accordance with the
BVBS guidelines.
A maximum of ten labels can be scanned.
If a position is finished a new label can be scanned in this line
The operation of the scanner is described in the “Options” section.
Variant 2:
The data for a cutting order is contained on a label.
The data for the first label is displayed on the monitor. Further labels can be
scanned.
When the first cutting order is finished, the data of the next label appears
automatically.
The data is processed in the order, in which it was scanned.

Optimise
Optimising is carried out in accordance with a simplified optimising process.

If several cutting lengths are entered in the table for the cutting data, after
pressing the F4= Optimise key the maximum of 10 cutting positions are
combined so that a short remaining length is left over. When optimising, the
number of bars that are to be inserted at the same time according to the top
line of the screen is taken into account. It can happen that the number is
corrected downwards, so that the cutting position is taken into account by the
further optimisation and is finished.
Cutting positions with less residues than “number of bars”, will not be taken
into account when optimising.
If the data is read in from a scanner, the box distribution is carried out
automatically when optimising. This can be altered manually.
When optimising, the number of cuts of the selected cutting positions will be
entered in the “Cuts” column.
The filling capacity of the boxes is not monitored by the system. The operator
must empty the box in good time.
If a cutting position is finished, optimising must take place again.
The box of the completed cutting position is not used, it is used again only
when the operator has overwritten the box number with “00000” manually.

Data transmission from a host PC (higher-level system).
Two variants are possible:
Variant 1:
 The host PC automatically sends 10 cutting positions to the operator PC
 Optimising and processing is carried out in a similar manner to the scanner
operation in the “Production” menu.
 The host PC automatically transmits new cutting positions.
Variant 2:
 The host PC sends optimised cutting lists.
Up to 60 cutting positions may be contained in each cutting list.
 The transmitted cutting lists are stored in the main memory of the operator
PC.
 A maximum of 60 cutting lists can be stored, each with one cutting position
(or 60 cutting positions).
 A cutting position is displayed in the “Production” menu.
 The cutting positions are finished in the order, in which they are received.
 Finished cutting positions are automatically overwritten by new ones.

7.4 Operation of the Machine
The following points must be checked before production starts:
- Is the oil level in the hydraulic reservoir correct?

- Has the equipment been greased?
- Is all the safety equipment functioning correctly?
- Are all the EMERGENCY OFF switches unlatched?
The machine can now be switched on.
- Turn on the main switch at the switch cabinet.

- Switch on the controller.
- The hydraulic motor starts running.
- Enter the cutting data at the monitor.
If the ambient temperature is less than 5° Celsius,

the machine's hydraulic system should be allowed
to warm up for about 5 minutes in manual operating
mode.
Note!
The raw material is stored on the material placement frame, arranged

according to diameter.
If the message No reference point appears, the "Shears

forwards/backwards" button must be used in the manual operating mode to
move the shears to the end position at the measuring track.

Place Concrete Reinforcing Steel in the Counting Trough
In order to remove material, the individual compartments of the material

placement frame can be opened by means of twist switches.
According to the figures on the monitor for the diameter and number of bars
that can be cut at the same time, the material is counted into the counting
trough by way of a discharge chute.
The bars should not be placed so that there is too much longitudinal difference
between the positions of their ends.
 Open the counting trough with the “counting trough” key; the
material falls onto the feed track.
Flush alignment
 In the “Manual” operating mode raise the 0.5 m stop with the
“Alignment stop” key.
 The twist switch for "Material forwards/backwards" is used to move
the front end of the material flush with the stop.
 Move the material out of the cutting area.
It is possible for individual bars to get caught as the

material is transported and to jump out of the track.
No other persons must remain by the machine.
The operator watches to ensure that nobody can be
hurt by the movement of the machine or of the
material.
Danger!

Start Automatic Operation.
 Switch on the “Automatic” operating mode.

 Start the cutting process with the "F2= Start" key on the PC.
The operating mode switch may not be altered

before the end of the cutting process.
All cutting data is lost if the operating mode is
changed.
Warning!
 The alignment stop is automatically lowered and the length stop

raised, the shears move to the cutting position.
 The material is positioned in front of the length stop for the first
cutting length.
 The shears make the cut, a clamp holds the material and prevents
the "jumping" of the material. The front part of the feed track lowers.
The concrete bars must lie next to each other both

during transport and during cutting. They must not
be jumbled.
That could upset the automatic process and the
machine operation.
Warning!

 The box stop is moved automatically into position.

 The cut bars are positioned in front of the box stop.
 The trough arms of the chosen collection trough are opened.
 The delivery system is activated and rolls the material into the selected
collection trough.
The operator supervises the machine's production

from the control panel.
In case of danger he can immediately stop the
machine with the EMERGENCY OFF switch.
While production is taking place the material in the

collection troughs may not be packed.
Danger!
If other cut lengths have been programmed, the material is again transported
to the length stop, the shears move to the cutting position, the material is cut
and thrown into the programmed box.
Labelling
The label parameter in the machine data must be set at “1”, the system then
recognises when the last cut of a position is taking place.
 After the material has been flush aligned, the “F2= Start” key on the PC is
used to start Automatic Operation.
 The labelling stop is raised and the material positioned in front of it.
The message for labelling appears on the display.
 After the operator has attached the label to the material he must confirm
the labelling with the “F6= Label” key on the PC and the process continues.

Danger of crushing and shearing occurs between

material, measuring track and shear area.
The operator is responsible for protecting himself
from injury.
Danger!
Final cut
When the final cut has been made the guide roller lowers automatically. This
makes it easier for the residual scrap to fall out.
Remnants of bars, which are left, must be removed

from the shears by hand.
Warning!
Using the “Guide Roller down” key the latter can be swung downwards,
making it easier to remove the residual scrap.

Removing Material
The collection trough points can be made to move "open" from the control
panel and from an operating unit at the end of the collection troughs for
emptying by crane.
The particular trough can be selected by a button as soon as crane disposal
has been switched on.
Danger of crushing and shearing occurs through

the motion of the collection trough arms and
through the material sliding down in the area of the
collection trough.
Anyone entering the collection trough area when
the machine is switched on does so at their own
risk.
The operator is responsible for protecting persons
from injury.
Danger!

8 Fault Finding and Rectification
Only rectify a fault if you have the required qualification.
In order to avoid incorrect operation or accidents

when identifying and rectifying faults, first secure
the machine against being accidentally started by
turning off the main switch at the controller and
securing it with a padlock.
Danger!
Work on the electrical equipment may only be

carried out by qualified and authorised electricians.
Work on the mechanical and hydraulic equipment

may only be carried out by qualified and instructed
persons.
Danger!

8.3 Faults and Their Rectification
The following error messages can appear on the monitor in the course of
production:
Fault Rectification By
No reference Move shears to the end position of the Operator

point. measuring track.
Check approach switch 2S3 Technician
Check contactor K14M, relays K26A- Technician
K29A.
Shears movement Check shaft encoder Technician

disrupted Check contactor K14M, relays K26A- „
K29A.
Shears not up Move shears up Operator

Check limit switches 2S1 + 2S2 Technician
Check valve 2Y3 + 2Y2 Technician
Protective grid Close protective grille Operator

open Check safety switch 2S7 Technician
Drive fault Correct mechanical overload Operator

Unlatch over-current trip. Technician
Check travel time Check approach switch S04 Technician

to length stop, Check photocell 2S8 Technician
measuring roller
Hydraulics not Check drive motor Technician

switched on Check contactors K1M – K3M Technician
Start conditions Check approach switches 4S1– 4S4, Technician

for automatic 4.1S1-4.1S4
cutting process
not satisfied.

Error messages when entering data:
Fault Rectification By
Too short for box Select smaller box no. Operator
Too long for box Select bigger box no. Operator
Unknown Diameter is not in the materials table Operator

diameter Enter diameter into the table
Too many bars for Machine capacity exceeded, Operator

this diameter Reduce the number of bars
Too few remaining Reduce the number of bars Operator

pieces for this
quantity

9 Servicing
It is essential that the following safety instructions are observed when

maintaining the machine.
In that way potentially fatal injuries, damage to the machine or other property
and environmental damage are avoided.
Cleaning, lubricating and servicing work may only

be carried out by authorised members of staff.
The operating instructions are to be followed
precisely.
Warning!
The repair work may only be carried out by

authorised technicians.
The accident prevention regulations must be
obeyed.
Before starting maintenance, adequate space

around the working area must be safely marked off.
The specified sequence of working procedures

must be followed exactly.
All work on the machine's electrical equipment must

only be carried out by trained electrical technicians.
Danger!

9.3 Servicing Plan
Daily servicing:
What Where By
Check oil level Inspection glass at the Operator

hydraulic reservoir
Check oil temperature Inspection glass at the Operator
hydraulic reservoir
Check water trap Air supply servicing unit Operator
Visual check Whole equipment Operator
Inspection glass

Servicing unit
Pressure regulator
Manometer
Water trap
Drain valve

Weekly servicing:
What Where By
Clean, Slide rails, spindles, guides Operator

grease
Glide rails, guides,

spindles

Monthly servicing:
What Where By
Check threaded joints Hydraulic equipment on the whole of Technician

and other connections for the machine
sealing
Check hoses for damage. Hydraulic equipment Technician
Check oil filter for soiling Hydraulic reservoir Technician
Grease and retense Feed track and measuring track Technician

chains.
Top up lubrication pump Shears Technician
Drive chain on the measuring track

Lubrication pump at the shears

Central lubrication pump
1
2
3
1 Reservoir 4 Connecting plug

2 Pump element 5 Control circuit board
3 Safety valve 6 Filling nipple for the pump

Fill up with grease:
Use a grease gun to fill the container through the nipple – 6 – or via the filling
opening above up to the "Max" mark on the reservoir.
When filling the pump via the filling opening on the

top the main switch at the switch cabinet should be
switched off before performing the work.
Warning!
The grease must not be contaminated, and its

consistency must remain constant over time.
Select the grease from the table of lubricants.
When it has been completely emptied, the pump

may need to run for up to 10 minutes before it is
operating again at full capacity.
Note!

Servicing after 1000 hours of operation:
What Where By
Oil change Hydraulic reservoir Technician
Oil filter change Hydraulic reservoir Technician

sealing
Servicing after 2500 hours of operation or yearly, whichever is sooner:
What Where By
Oil change Hydraulic reservoir Technician
Oil filter change Hydraulic reservoir Technician

sealing

9.4 Servicing Work
Top up oil
If the level of the hydraulic oil sinks below the minimum mark on the
observation glass in the course of operation, the oil must be topped up so that
the level is again between the minimum and maximum marks.
Important!! Find the cause for the loss of oil.
1. Switch off the machine.

2. Switch off the main switch and secure it against being switched on
(padlock).
3. Open the filling hole –2.
4. Fill with hydraulic oil using a funnel. Use the recommended oil.
5. Close the filling hole– 2 – again.
Observe the safety regulations during servicing

work.
Do not carry out any servicing work when the
machine is running.
Before starting servicing, adequate space around
the working area must be safely marked off.
The specified sequence of working procedures
must be followed exactly.
Danger!
Any materials used in the course of operation,

lubricants or auxiliary materials are to be disposed
of in an environmentally sound manner.
Warning!

Oil change:
1. Switch the machine off.

2. Switch off the main switch and secure it against being switched on
(padlock).
3. If the optional reservoir heater is installed, switch off switch Q 201.
4. Open filling hole– 2 – and remove the sieve.
5. Pump out the old oil with a barrel pump.
6. Unscrew cleaning opening.
7. Remove any oil sludge and residues entirely from the tank.
8. Screw cleaning opening –1 – shut again.

9. Refill with about 320 l of new hydraulic oil.
10. Check the oil level at the inspection glass .
11. Refit the sieve and screw the filling hole shut.
12. Switch the main switch on again.
13. If the optional reservoir heater is installed, switch on switch Q 201.
14. Check the function of the safety equipment.

Table of lubricants:
Agip Mehrzweckfett GR MU/EP 2
Recommended mineral oils:
Agip Aral BP Castrol Esso

OSO 46 Vitam GF 46 Energol HLP- Hyspin AWS 46 NUTO H 46
HM 46,
OSO/D 46 Vitam DE 46 Hyspin SP 46, HLPD –OEL 46
Energol HLP-D
46 Hydrauliköl
HLPD 46 SF.
Fuchs Mobil Optimol Texaco Shell

Renolin MR 15 DTE 25 Hydo 46 RANDO HD 46 HLPD 46
VG 46,
Hydrauliköl Hydo MV 46 RANDO HDZ
Renolin B 15 VG HLPD 46 46
46, Hydo E 46
ALCOR DD 46
Renolin ZAF 46 D
The normal operating temperature for the units is

about 50°C. At lower temperatures, and in the
winter, the equipment must be warmed up for about
5 minutes before starting operation. This is
necessary to achieve proper function.
Note!

10 Overhauling

overhauling the machine.
All the working procedures for overhauling the

machine must be carried out in the stated
sequence.
First of all, safely mark off adequate space around
the area needed for the overhauling work.
Switch off all sources of electrical power, and
secure them against being accidentally switched on
again.
Ensure that pressure is removed from all
pressurised units.
Only use spare parts that are listed in our spare
parts lists.
Warning!
The repair work may only be carried out by

obeyed.

Danger!

10.3 Fault Finding and Rectification
In the "Manual" operating mode all the machine's functions can be controlled
with switches and buttons. Use this table to localise a fault.
The machine cannot be switched on:

- Is the main switch on?
- Are all the emergency off switches unlatched?
- Is the electrical supply to the switch cabinet correct?
- Check fuses Q12, Q13, F40 and F10-F21.
Fault indicator lights:

- Motor protection relay has triggered. Remove the cause of the
overload and unlatch the motor protection relay.
Shears do not move up / down:

- Are valves 2Y2 / 2Y3 switching?
Valve 2Y2 / 2Y3

Shears can not be operated:

- Is the positioning motor running?
- Is contactor K14M switching? Check relay K26A-K29A
- Check approach switches 2S3 and 2S4.
Positioning motor
Approach switch
2S3

Shears do not take the correct position but move to the end position:
- Check the shaft encoder
Shaft encoder
Guide roller does not drop:
- Check valve 2Y4
Valve 2Y4

Feed track does not drop when cutting
- Check valve 2Y1
Valve 2Y1
Material impacts hard against the length stop:

- Check photocell 2S8.
- Check approach switch S04.
- Check valve 2Y5 / 2Y6.
- Check the function of the measuring roller.
Valve 2Y5 /2Y6
Approach
switch S04
Photocells
2S8

Equipment does not start in automatic mode:
- Check approach switches 4S1 to 4S4.
Approach switches
4S1 bis 4S4
Individual measuring stops or collection troughs are not operated:
- Check valves 4Y1 to 4Y9 and 4.1Y3 to 5Y8.
Valves 4Y1 – 4Y9,

4.1Y3 – 5Y8

10.4 Repair
Exchanging the lower blade:
Bolts for fixing the blade
- Switch the controller off, switch off the main switch and secure it against
being accidentally switched on (padlock).
- Remove the Intermediate rollers
- Undo bolts for fixing the blade
- Remove the lower blade.
- Clean the blade seat.
- Check the supporting base of the blade, and replace it if necessary.
The lower blade has four cutting edges, and must

be turned so that another edge can be used.
First of all any burring should be removed from the
worn cutting edge, since this can damage the blade
seat.
Only use the fastening bolts once.
Warning!
- Insert the blade and screw it tight.

Exchanging the upper blade:
- Switch the controller off, switch off the main switch and secure it against
being accidentally switched on (padlock).
- Unscrew the Inlet funnel.
Inlet funnel
- Undo the bolts for fixing the blade.

- Remove the upper blade.
- Clean the blade seat.
- Check the supporting base of the blade, and replace it if necessary.
Bolts for fixing the blade

The upper blade has four cutting edges, and must

be turned so that another edge can be used.
First of all any burring should be removed from the
worn cutting edge, since this can damage the blade
seat.
Only use the fastening bolts once.
Warning!
- Insert the blade and screw it tight.

11 Removal from Service and Storage

removing the machine from service.
All the working procedures for removing the

machine from service must be carried out in the
stated sequence.
the area needed for the work involved in removing
the machine from service.
again.
pressurised units.
Warning!
The work of removing the machine from service

may only be carried out by authorised technicians.
obeyed.

Danger!

11.3 Storage Conditions
The machine should be stored in a dry hall.

The following protective measures must be taken:
- Treat all bare metal parts with corrosion protection.
- Add drying agent to the electrical equipment.
- Arrange for any leaking oil to be collected.
If stored in the open, extensive measures to protect from the weather are
required:
- Protection from rain and driving rain.
- Treat all bare metal parts with corrosion protection.
- Add drying agent to the electrical equipment.
- Arrange for any leaking oil to be collected.
The load-carrying capacity of the ground must be adequate for the full weight
of the machine – see Chapter 3.5.

11.4 Removal from Service
Final shutdown
- Switch off the main switch

- Remove feed line safety devices to the machine
- Unfasten the power cable
- Release pressure from the hydraulic equipment – see Chapter 9.4.
Cleaning
- Thorough cleaning
- Remove traces of old grease.
Conservation
- Apply corrosion protection to all bare metal and glide surfaces,

- Fill the hydraulic reservoir to the brim with oil,
- Close the lid of the reservoir, making it airtight,
- Place drying agent in the switch cabinet and the operating panel,
- Cover the machine with tarpaulins.
Restarting Operation
- Remove corrosion protective from bare metal parts and glide surfaces,
- Change the oil
- Remove drying agent from the switch cabinet and the operating panel.

12 Disposal

disposing of the machine.
In that way potentially fatal injuries, damage to other property and
environmental damage are avoided.

the area needed for the disposal work.
again.
pressurised units.
Warning!
The disposal work may only be carried out by

obeyed.

Danger!

12.3 Disposal
All the points related to weight and transport in

Chapter 2 are to be observed.
The total weight must always be considered when

selecting suitable load carrying equipment.
Improperly fastened machine parts can fall down or

overturn.
Suspended loads can fall down, so injuries could be

fatal!
Do not pass under suspended loads.
Warning!
Ensure that materials used in operation, lubricants

and auxiliary materials are disposed of in an
environmentally sound manner.
The regulations governing the proper utilisation or
disposal of waste must be obeyed.
Warning!

12.4 Assemblies Suitable for Disposal
The machine consists of the following material groups:
- Metals and non-ferrous metals

- Plastics, seals and glide bearings
- Oils and greases
- Electrical and electronic components and storage batteries
All these material groups must be separated and

disposed of in an environmentally sound manner.
Note!

13 Options
The cutting equipment has a modular construction. By combining the various

modules the equipment is adapted to differing requirements.
These optional modules are not able to function on their own. They form a part
of the entire cutting equipment.
During production the operator supervises the

whole of the cutter's working area and the optional
modules.
Nobody may remain in the hazardous area.
In case of danger, the operator can halt the
equipment as a whole by means of the
EMERGENCY OFF switch.
Danger!

13.1 Operation with Scanner
The scanner includes a Class 2 laser.

Do not look into the light beam.
Danger!
Installation:
LED display
com 2 PC
Port
Trigger key
Plug-in mains
power supply
Switch off the equipment and connect the scanner to the PC in accordance
with the picture above.

Scan label.
Point the scanner at something of an angle to the symbol pattern. When the
trigger key has been pressed, the scanner creates a rectangular raster
pattern.
It opens, and reads in the code.
The scanner has successfully read the code if the green LED lights up and
you hear a short high-pitched beep.
Scan pattern
The data that has been scanned in appears on the screen.
Incorrect Correct
Angled at 30°
Bar code
Bar code

Initial Operation:
When the scanner is operated for the first time it is possible that it is not
configured for the PDF 417 code.
In that case, the following codes must be scanned one after another in
sequence.
4.
1.
2. 5.
3. 6.
The configuration is now stored in the scanner.

13.2 Pocket System
1
2
4
3
The individual pockets are managed by the equipment's operating system.

The filling capacity is monitored.
The pockets are partially opened so that the material can roll into and fill them.
When the material is removed, the pockets are completely opened and the
material is lifted out. The compartment is chosen by means of a "Select" key at
the operating unit at the end of the Pocketsystem. After the "Removal" key has
been switched on, this key must be pressed according to the pocket number.

13.3 Distributing wagon with points control
Operating unit
Points manipulation
Elements on the operating unit:
Large button EMERGENCY OFF,

Pushbutton Controller on
Pushbutton Controller off
Indicator light Fault
Twist switch Rollers 1 forwards / reverse
Twist switch Moving gear forwards / reverse
Pushbutton Moving gear fast

Function:
The distributing wagon can be positioned at the equipment and the individual
bending lines using the twist switch for Moving gear forwards / reverse at
the operating unit.
If the Moving gear fast key is pressed as well as the twist switch for Moving
gear forward / reverse, the distribution wagon will move at a higher speed.
Using the twist switch Rollers 1 forwards / reverse at the operating unit, the
material is moved from the transport rollers in the collection track onto the
bending lines.
There is a twist switch for each collection track.
The points are operated by the two pneumatic cylinders that are fitted to the
equipment. These pneumatic cylinders are controlled by the equipment.
Technical data:
Carrying capacity of each collection track 3 tonnes

Transport speed 1 m / sec
Shortest transportable length 2m
Connected load 9 kW

13.4. Plant control without a PC
Using this option, production can be carried out on the plant even without the
services of the PC.
For this all functions are controlled manually.
Method of operation:
The material is lying ready in the counting trough

- Open the counting trough
- Switch on the length stop and move the shears into position, the position
can be read on a display close to the PC.
- Move the material to the length stop,
- Switch off the length stop,
- Lower the shears and raise them again,
- Switch on length stop for the box,
- Raise the collecting trough,
- Move material to the length stop (box); only the measuring track is running;
the direction to the material placement frame is barred.
- Raise the transfer unit for the desired side,
- Switch off the length stop for the box,
- Switch on the length stop for the next cut and move the shears into
position,
- Remaining procedure as described above.

Arrangement of the buttons on the operating panel:

Key functions:
1= Box 10122 2= Box 20122

3= Box 30122 4= Box 10222
5= Box 20222 6= Box 30222
7= Transport track 3rd stop 7= Transport track 4th stop
9= ????? 10= Distributing wagon in position
11= 0.5 m 12= 1m

13= 2m 14= 3m
15= 4m 16= 5m
17= 6m 18= 7m
19= 8m 20= 9m
21= 10m 22= 11m
23= 12m 24= 13m
25= Unused 26= Unused
27= Shears up / down 28= Unused
31= Transfer left / right 32= Feed track forwards / backwards
Material transport
forwards/backwards
33= Guide roller down 34= Shears forwards/backwards
35= Alignment stop 36= Measuring track
forwards/backwards
39= Points 0 left 40= Points 1 left
41= Counting trough left 42= Left collecting troughs up
43= Compartment selection left 44= EMERGENCY OFF
45= Off 46= On
47= Fault 48= Unused
49= Automatic 0 / 1 50= Material distribution 0/1
51= Unused 52= Points 0 right
53= Points 1 right 54= Counting trough right
55= Counting trough right up 56= Compartment selection right

13.5 Digital display for the support frame
The digital display can be seen from the support frame.

The number of bars and the diameters are shown for the next cutting
sequence.

13.6 Transport roller tracks
Function:
The rollers of the transport roller track can be moved forward or back via a
button at the control panel, if the "Roller track automatic" switch is switched off.
If the switch "Roller track automatic" is switched on, the rollers are controlled
automatically.
A photocell in the upstream transport roller track detects the material and
starts the transport rollers. The photocell at the end of the transport roller track
detects that the material has left the transport roller track and switches the
rollers off.

13.7 Fixed track end piece
Function:
If the "Roller track automatic" switch is switched off:

- the transport rollers can be moved forward and back via a button on the
control panel,
- the stops can be controlled individually via the button "Select stops".
If the switch "Roller track automatic" is switched on, all functions are controlled
automatically.
A photocell in the upstream transport roller track detects the material and
starts the transport rollers. The guides of the collection troughs and the stops
are controlled according to the programmed collection box. Photocells in front
of the stops detect the material and switch the transport roller track to slow
speed. After a fixed time, the transport rollers switch off and the transfer is
switched on, and after a fixed time switched off again.
Photocell in front of the stops

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Cador 500 Operating Manual

© Pedax Bitburg Maschinenbau GmbH 1 25_11_2003GB

All rights reserved. Reproduction or distribution of these operating instructions

© Pedax Maschinenbau GmbH

© Pedax Bitburg Maschinenbau GmbH 2 25_11_2003GB

Machine type Concrete reinforcing steel cutting

Model name Cador 500

Serial number ..................................................

Order number ..................................................

Inventory number ...................................................

Street address Industriestraße 5

Town and postcode D-54634 Bitburg

Phone 06561 96670

Fax 06561 966790

Customer service 06561 966731

© Pedax Bitburg Maschinenbau GmbH 3 25_11_2003GB

The purpose of the documentation:

The present documentation makes the operator of Cador 500 concrete

the working method,

Always keep these operating instructions with the machine!

© Pedax Bitburg Maschinenbau GmbH 4 25_11_2003GB

© Pedax Bitburg Maschinenbau GmbH 5 25_11_2003GB

© Pedax Bitburg Maschinenbau GmbH 6 25_11_2003GB

1 Basic Safety Instructions

These operating instructions contain the most important advice required to

1.1 Duties and Liabilities

Observe the notes given in the operating instructions:

Knowledge of the fundamental safety instructions and the safety regulations

Hazards when dealing with the machine:

- for its proper purpose

Faults that could impair safety must be rectified without delay.

© Pedax Bitburg Maschinenbau GmbH 7 25_11_2003GB

Guarantee and liability

- use of the machine other than for its proper purpose,

© Pedax Bitburg Maschinenbau GmbH 8 25_11_2003GB

1.2 Safety Symbols

This symbol indicates an immediate threat to

Failure to observe such an instruction has serious

This symbol indicates a situation that may be

Failure to observe such an instruction can easily

At this symbol you obtain tips on use and

They help you to get the best use out of the

© Pedax Bitburg Maschinenbau GmbH 9 25_11_2003GB

1.3 Use for the Proper Purpose

In particular, faults that could impair safety must be

1.4 Incorrect Usage

Usage other than as described above is forbidden.

© Pedax Bitburg Maschinenbau GmbH 10 25_11_2003GB

1.5 Organisational Procedures

The necessary personal protection gear (such as

All safety equipment must be regularly

1.6 Protective Equipment

All safety equipment must be properly fitted and correctly functioning

Protective equipment (such as a padlock on the

- when the machine has stopped,

When spare parts are supplied, the safety

1.7 Informal Safety Procedures

The operating instructions are always to be kept at the machine. In addition to

© Pedax Bitburg Maschinenbau GmbH 11 25_11_2003GB

1.8 Training of Personnel

The operator is responsible for ensuring that only

The responsibilities of the various members of staff for

Personnel requiring training may only work at the