Danfoss ET9500 Operator'S Manual Download | Manualshive

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5.3 Work piece cutting

5.3.1 Prerequisites

ATTENTION!

Damage to the machine

The knife may be damaged when the machine is operated wit-
hout hose prestressing.
• Never cut without bending (X).
• Adjust the bending pin and the workpiece.

Prerequisites for a correct cutting process:
•

The bending pin position and the hose diameter are matched to
each other:
–

(1) Large hose diameter = large bolt distance

–

(2) Small hose diameter = small bolt distance

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Summary of Contents for ET9500

Page 1: ......

Page 2: ...German Date of revision 2022 10 05 Version 1 0 Copyright by UNIFLEX Hydraulik GmbH Technical modifications reserved The reproduction distribution and utilization of this document as well as the communication of its contents to others without explicit authori zation are prohibited Offenders will be held liable for the payment of damages All rights reserved in the event of the grant of a patent util...

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Page 4: ...ch Strasse 50 52 D 61184 Karben The following standards codes and specifications have been applied EC Directive 2006 42 EC EMC Directive 2014 30 EC EN ISO 12100 2010 EN 60204 1 2018 UK Supply of Machinery Safety Regulations 2008 UK Electromagnetic Compatibility Regulations 2016 This declaration are invalid when the machine is modified or if unau thorized and unapproved third party components are u...

Page 5: ...ase of fire 12 2 4 Safety 13 2 4 1 Working area 13 2 4 2 Emergency stop 13 2 4 3 Warning signs on the machine 15 3 Machine description 17 3 1 Design and function 17 3 2 Technical data 19 4 Transport and commissioning 21 4 1 Transport 21 4 2 Intermediate storage of machine unit 22 4 3 Commissioning 22 4 3 1 Extraction 24 4 3 2 Extraction process for TMC cutting knife 24 4 3 3 Electrical connection ...

Page 6: ...replacement 37 6 4 Motor brake readjustment 38 7 Troubleshooting 41 8 Decommissioning disposal 42 8 1 Dismantling 42 8 2 Recycling 42 8 3 Consumables and waste 43 9 Annex 44 9 1 Accessories upgradable 44 9 2 Spare parts list 45 9 2 1 Mechanical equipment 45 9 2 2 Electric equipment 46 9 2 3 Wear parts 47 9 3 Electric diagram 48 9 4 Maintenance log 51 9 5 Declaration of qualified staff 52 ...

Page 7: ...n this Operation Manual The machine unit may only be operated by staff who has read the Operation Manual has understood it has been instructed in the operation of the machine unit and has signed in the Annex Figures may include accessories options Customer specific equipment may vary The product images shown are for reference only and may differ from the product delivered 1 1 Target groups The tar...

Page 8: ...achine unit fitters Machine unit fitters must be at least 18 years old and have completed training for the task i e they must have attended a specialist voca tional training A fitter must observe the instructions in the Operation Manual must inform the owner on failures and damage Operator An operator is a person charged with and instructed in the proper op eration of the machine unit by the owner...

Page 9: ...1 3 Name plate The name plate is fixed near the power cable 1 4 Abbreviations TM cutting knife plain TMG cutting knife with slots TMC cutting knife coated ...

Page 10: ...upplemented by a triangular hazard symbol The signal word ATTENTION identifies a potentially hazardous situa tion in which the product or property in the environment may be dam ages This warning is supplemented by a hazard symbol or a excla mation mark 2 2 Intended use This machine is intended for industrial use it is only suitable for cut ting pneumatic and hydraulic hoses up to a specific permis...

Page 11: ...rkpieces misuse of consumables and waste materials WARNING Risk for life and health Use not in compliance with the intended purpose imposes risks for life and health Consequences resulting from use for other than the intended purpose shall be under the sole responsibility of the owner Always use the machine in compliance with its intended pur pose 2 3 Product specific risks The machine unit is des...

Page 12: ...l restart before maintenance 2 3 3 Risks imposed by noise The noise level meter acc to IEC 804 Class 2 was calibrated before measuring The operation of the machine causes noise emissions of 90 dB A at the workplace Noise protection is required Higher noise emissions may occur when other machinery is simulta neously used at the workplace The machine owner must provide for appropriate protection e g...

Page 13: ...king area The working area is designed as the area 1 metre all around the ma chine shaded Keep the working are free from trip hazards Use ducts for lines and cables Provide good illumination 2 4 2 Emergency stop The machine is fitted with an emergency stop button ...

Page 14: ...Immediately activate the emergency stop function 1 in cases of emergency Remedy the cause of the emergency stop first before re starting the machine ...

Page 15: ...2 4 3 Warning signs on the machine Cutting risk on the cutting knife Danger from electric current at the power supply line Risk of eye injuries Wear safety goggles ...

Page 16: ...Risk of hearing damage Wear ear protection Illegible or missing warning signs must immediately be replaced by the owner ...

Page 17: ...3 Machine description 3 1 Design and function Basic machine 1 Motor 2 Bending pin 3 Cutting plate 4 Main power switch 5 Feed fork 6 Knife covered 7 Knife protection yellow 8 Handle ...

Page 18: ...rive and pushes the workpiece to wards the knife 6 The knife is driven by the motor 1 Move the handle 8 back to the starting position after cutting the feed fork will move back The cut counter option counts the number of completed cutting processes and can be reset by activating the pushbutton Accessories The machine may be fitted with accessories A list of the available ac cessories is included i...

Page 19: ...s IP 42 Operation mode S6 60 Function Hose feed Manual Brake motor Yes Extraction connection Ø 60 mm Cutting knife EM 6 2 TM G 350 x 3 x 30 mm Cutting knife EM 6 3 TM C 350 x 3 x 30 mm Cut counter Optional Workpiece capacity Workshop SAE R13 SAE R15 2 Production SAE R13 SAE R15 11 4 SAE R12 2 Industry 3 Max outside Ø 95 mm ...

Page 20: ...orkbench with a carrying capacity of approx 500 kg We recommend industrial flooring meeting the following struc tural requirements Permanent floor loading Approx 0 07 kg mm2 Floor carrying capacity Min 2500 kg m2 Floor quality B25 Evenness Max unevenness 5 mm m Inclination max 5 mm m Ambient conditions Ambient temperature 5 o C 40 o C Air humidity 45 65 The data are theoretical computed values or ...

Page 21: ...s and regulations relating to securing loads shall be ob served during transport The machine may only be unloaded and transported by means of a lift truck or a crane When a crane is used for transport lifting gear with a sufficient length and lifting capacity has to be used The lifting gear must be attached to the lifting lug 1 For machine weight please refer to Technical data in Section 3 ...

Page 22: ...o the in stallation site 4 2 Intermediate storage of machine unit If the machine unit cannot be mounted immediately upon delivery it must be protected against Contamination Weather influences Mechanical damage The machine unit components may only be stored in closed rooms and under the following conditions temperature between 10 C and 35 C maximum air humidity 80 non condensating 4 3 Commissioning...

Page 23: ...ge 5 Check the electric cables for damage 6 Train the operating staff and record training sessions in Decla ration of trained staff Section 9 WARNING Risk of injuries Machine components might loosen during transport Such com ponents might be flung out during the cutting process There is a risk of being injured Perform a cutting process in idle mode and without a work piece Check the machine for at...

Page 24: ...m min as well as a filter element and a spark sep arator suitable for this purpose 4 3 2 Extraction process for TMC cutting knife WARNING Risk of fire During cutting there is a risk for life and health due to the fire ha zard from flying sparks Only operate the machine with a spark extinguisher Clean the machine and spark extinguisher after each use see Cleaning in Section 5 ...

Page 25: ...tach the metal hose to the spark extinguisher 4 and extrac tion device 5 We recommend an extraction fan with 100 mm water column and a capacity of 4 m min as well as a filter element suitable for this purpose Figures may include accessories options Customer specific equipment may vary The product images shown are for reference only and may differ from the product delivered ...

Page 26: ...tentional restart 2 Have the power cable of the machine connected to the local mains by a qualified electrician according to the regulations of the Electricity Board 3 Check the electric motor rotational direction according to the ar row Exchange outer cable phases of the connection if requi red ATTENTION Risk of damage to machinery Operating the motor in the wrong direction of rotation results in...

Page 27: ...ation of the working area of the machine During operation Observe the safety instructions on the machine Make sure that no other persons stay in the working area Each movement of the hand must be observed Eating drinking and smoking at the workplace is prohibited Wear close fitting clothes Do not wear watches or jewellery 5 2 Start 1 Check that there is no emergency stop situation 2 Activate the m...

Page 28: ...hine is operated wit hout hose prestressing Never cut without bending X Adjust the bending pin and the workpiece Prerequisites for a correct cutting process The bending pin position and the hose diameter are matched to each other 1 Large hose diameter large bolt distance 2 Small hose diameter small bolt distance ...

Page 29: ...dual hoses WARNING Cutting risk There is a risk of cutting your extremities when cutting work pieces Make sure that no extremities are between the feed fork and the knife protection when moving the handle 1 Attach the bending pin 3 at the appropriate location The correct position is shown by the marks on the cutting plates 4 2 Insert the hose manually ...

Page 30: ...Remove the workpiece 5 4 Deactivation 1 Complete the cutting process 2 Deposit the workpiece outside the machine 3 Deactivate the power switch 1 4 Check the machine for contamination and outside damage 5 Check the cutting knives for damage and cracks 6 Remove dirt dust and chips by using a vacuum cleaner WARNING Risk by bursting screens Workpieces may penetrate porous screens which may result in d...

Page 31: ... immediately deactivate the machine at the main power switch The cutting process is stopped The drive unit is shut down Restart after an emergency WARNING Risk of injuries The emergency stop button was probably activated due to the occurrence of a hazardous situation A restart of the machine may cause injuries if the hazardous situation has not yet been remedied Remedy the hazardous situation befo...

Page 32: ...The restart protection prevents an unintentional restart of the ma chine Starting the machine is only possible by activating the main power switch again ...

Page 33: ...r may ingress in the machine and cause serious da mage Do not use a steam jet to clean the machine Do not use compressed air to clean the machine 5 8 Cleaning ATTENTION Risk of damage to machinery If the machine is cleaned with a steam jet or compressed air dirt and water may ingress in the machine and cause serious dam age Do not use a steam jet to clean the machine Do not use compressed air to c...

Page 34: ...3 Remount the cover plate ...

Page 35: ...on in Section 5 Use the lock to prevent the main switch from being switched on and also attach a sign Example text Machine unit out of service for maintenance work Do not switch on Welding flame cutting and grinding work on and in the ma chine unit and its environment must be approved in advance There is a risk of fire The machine unit must be cleaned from dust and inflammable substances Adequate ...

Page 36: ...To be cleaned 1 Safety equipment Knife protection To be checked for function Press the knife protection on the outside edges towards the motor with both thumbs wearing cutting protection gloves There must be a significant resistance X Warning signs on machine Check legibility see Warning signs on the machine in Section 2 X Motor break To be checked for function and readjust if required see Motor b...

Page 37: ...replacing the knives 1 Complete the cutting process 2 Deposit the workpiece outside the machine 3 Disconnect the machine from the power supply 4 Loosen the five bolts on the cover plate 5 Remove the cover plate 6 Hold the shaft 4 with a hexagon socket wrench and release the nut 3 using an open end wrench The nut size 46 is a left hand thread type ...

Page 38: ...otation before starting the machine 6 4 Motor brake readjustment Due to wear on the brake linings the braking effect of the motor brake may decrease over time In this case the brake has to be readjusted If the brake cannot be re adjusted anymore the brake linings are worn and must be replaced WARNING Risk of injuries The motor brake is a major safety element of the machine For this reason the mach...

Page 39: ...on the plastic cover and check the brake function 5 If the braking effect is insufficient repeat the process WARNING Hot surface risk of burns The brake may become very hot There is a risk of burns Check the temperature carefully 6 Let the motor run for 1 minute after adjusting the brake and then check the temperature on the adjusting nut If the brake is hot the adjustment has to be corrected 7 Tu...

Page 40: ...If the problems with the brake continue immediately contact the manufacturer ...

Page 41: ...plug defective Check power plug and replace if required Motor defective Contact Service desk Cutting knife worn Check cutting knife for wear and replace if required Knife not centred Flange disc is not positioned correctly on the feather key Turn flange disc and insert it into the feather key ...

Page 42: ...fety instructions see data sheet Wear personal protection equipment Do not eat drink or smoke in the working area and when handling consumables Ensure good ventilation 8 1 Dismantling This section describes activities to be performed by you as the opera tor to ensure the safe dismantling of the machine unit The machine unit may only be dismantled by entrusted and qualified staff Check the machine ...

Page 43: ...egulations have to be complied with 8 3 Consumables and waste Observe applicable national environmental protection and waste dis posal regulations Return consumables e g oils greases test media to supplier they are hazardous waste Also observe the information given on the safety data sheet ...

Page 44: ...000 mm UHG 14 EXT Suction system UVC S36 Hose length measuring device UMS 4 Spark quencher standard with EM6 3 330 050 Vacuum adaptor standard with EM6 3 777 055 Bench TU Cutting knife with inclined slots standard with EM6 2 TM G 350 x 3 x 30 Cutting knife coated standard with EM6 3 TM C 350 x 3 x 30 Batch counter set 329 1 Suction filter system UVC 100 2 MVA FSD Please contact our Sales departmen...

Page 45: ...9 2 Spare parts list 9 2 1 Mechanical equipment Item Quantity Part code Designation 1 1 328 010 4 Feed fork 2 2 328 012 3 Cutting plate 3 1 320 111 Brake motor ...

Page 46: ... 9 2 329 053 4 Guiding piece 10 1 329 020 4 Stop 11 1 329 025 Auto spring 12 1 304 021 Pressure spring 13 1 329 019 Roller chain 14 2 329 042 Locking link 15 2 798 050010 Sleeve 16 1 329 040 4 Sticker EM6 17 1 329 1 Cut counter optional 9 2 2 Electric equipment Item Quantity Article code Designation 1 2 52015740 Bolted connection strain relief 2 1 8 11 240 Mounting rail 240 mm ...

Page 47: ...18 Axle 11 1 800 023 End supports 12 2 800 022 Fuse terminal 13 2 800 084 Protective conductor terminal 14 1 322 400 Rectifier No figure 1 530 217 Fine wire fuse 9 2 3 Wear parts Quantity Part code Designation 1 TM G 350x3x30 Cutting knife with inclined slots 1 TM C 350x3x30 Cutting knife coated 1 320 118 Spare brake Soga see motor nameplate 1 320 116 Spare brake Seimec see motor nameplate 1 329 0...

Page 48: ...9 3 Electric diagram ...

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Page 51: ...9 4 Maintenance log Cutting knife Guide unit Extraction line Knife protection Motor brake Remark Date Signature ...

Page 52: ... of the UNIFLEX machine and have been informed on all safety related details In addition I declare that I have read and under stood this Operation Manual completely City Date Name Signature City Date Name Signature City Date Name Signature City Date Name Signature City Date Name Signature City Date Name Signature ...

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