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Pertici CM4/S Instruction Manual For Use And Maintenance

Automatic corner cleaner
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MANUALE D'ISTRUZIONE PER L'USO E LA
MANUTENZIONE PULITRICE AUTOMATICA CM4S
Via delle Città (SS. 429) 41/43
P.O. BOX 196 - 50052 CERTALDO (FI) ITALY
TEL. +39 0571 651204 - FAX +39 0571 652991
e-mail: pertici@pertici.it - http://www.pertici.it
File: 2240.doc - 03/11/03 14:27
Ver.: 2.0
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Summary of Contents for Pertici CM4/S

  • Page 1 Via delle Città (SS. 429) 41/43 P.O. BOX 196 - 50052 CERTALDO (FI) ITALY TEL. +39 0571 651204 - FAX +39 0571 652991 e-mail: pertici@pertici.it - http://www.pertici.it Ver.: 2.0 File: 2240.doc - 03/11/03 14:27 MANUALE D’ISTRUZIONE PER L’USO E LA...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS ......................2 1. INTRODUCTION........................4 2. GENERAL PRECAUTIONS ....................5 3. CHARACTERISTICS ......................6 3.1 Description of the machine ..................6 3.2 Technical features ....................10 3.3 Use limits .........................10 3.4 Standard kits ......................11 3.5 Optional/Spare parts....................11 3.6 Tools to be used ......................11 3.6.1 Groups of milling cutters ................11 3.6.2 Height of milling cutter groups..............12 3.6.3 Base diameter of the milling cutters ............12...
  • Page 3 8.1 Ordinary maintenance .....................39 8.2 Extraordinary maintenance (weekly) ...............39 8.3 – Replacement of milling cutters................39 8.3 – Replacement of knifes for welding seal removal...........41 9. SPARE PARTS ........................42 10. LIST OF ENCLOSURES TO THE INSTRUCTION MANUAL..........43 ENCLOSURE 1 ....................44 ENCLOSURE 2 ....................45 ENCLOSURE 3 ....................48...

  • Page 4: Introduction

    1. INTRODUCTION This manual is intended for the operator and in particular for the personnel responsible for safety in the use of the machine. It is therefore recommended to carefully read the contents of this manual, and in particular those sections on precautions and methods of use, and to keep the manual in its holder in a safe place near the machine to facilitate future consultation as and when required.

  • Page 5: General Precautions

    2.2 Safety in the use of the machine can only be guaranteed for the functions and materials listed in this instruction manual. PERTICI S.p.A. declines all liability if the machine is used for purposes other than those stated and in ways that do not conform to the user instructions.

  • Page 6: Characteristics

    (locking zone and milling zone) with your hands. 3. CHARACTERISTICS The CM4/S produced by PERTICI S.p.A. must be used to remove the rests of PVC that have been generated during the thermowelding process of the frame and door angles, for the construction of window and door fixtures.
  • Page 7 CONTROL TOTAL PROTECTION PANEL OF WORKING AREA LOAD BEARING LEFT OPENABLE FRAME PANEL BASE PLATE DOOR OF ELECTRIC CABINET DOOR OF PNEUMATIC PANEL Dwg. A1.1 B) Load bearing frame (Dwg. A1.1) It consists of a structure of steel plates and tubular. The elements composing the frame are assembled by intermittent weld in order to obtain the maximum rigidity.
  • Page 8 Dwg. A1.2 D) Group for lifting and forward movement of cutter’s pack and lower cutting device for welding seal removal (Dwg. A1.3) - (Dwg. A1.4) It consists of a structure made of iron casting details, steel sheet assembled by means of intermittent weld, steel plates and rods.
  • Page 9 E) Motor and milling cutter pack holding group (Dwg. A1.3) It consists of a structure made of steel sheet details, assembled by means of intermittent weld, aluminium plates and steel rods. A special electric motor with a long shaft has been fixed on this structure, in order to permit to place up to 4 milling cutter packs.

  • Page 10: Technical Features

    SPECIFIED IN THIS MANUAL. 3.3 Use limits The corner cleaning machines type UNIVER CM4/S, produced by PERTICI S.p.A. are used for the processing of plastic profiles, mainly of PVC (Polyvinyl chloride). The machines have been designed and built to be used in covered industrial environments.

  • Page 11: Standard Kits

    Device for the automatic turning on of exhaust unit Set of milling cutters (by sample) 3.6 Tools to be used To execute the corner cleaning the CM4/S uses two types of tools. Packs of milling cutters Knifes for welding seal removal 3.6.1 Groups of milling cutters...

  • Page 12: Height Of Milling Cutter Groups

    All milling cutter diameters have a direct ratio with a reference diameter (base diameter). The base diameter for the CM4/S is of 80 mm and refers to the milling cutter, which has to polish the profile part in contact with the holding shoulders.

  • Page 13: Quantity Of Cutting Bits

    3.6.7 Connecting hole of milling cutter pack The diameter of the milling cutter holding shaft of the CM4/S is Ø 32 h6 (tolerance 0 / -0.016). The optimum coupling happens when the connecting hole of the milling cutter has a diameter of Ø...

  • Page 14: Conformity With Safety Standards

    These knifes are suitable for coloured and/or coated profiles. 3.7 Conformity with safety standards The corner cleaner machines type UNIVER CM4/S have been designed and built in compliance with the following directives: EEC STANDARD 89/392 and following modifications (Machine directive).

  • Page 15: Commissioning

    4. COMMISSIONING 4.1 Transport The corner cleaner machines type UNIVER are shipped fully greased and wrapped in heat- shrink nylon. The sturdy design and form of the machines guarantee their safe and damage-free shipment and storage. A forklift truck can lift the machines by inserting the forks at the points marked on the machine packaging.
  • Page 16 Avoid knocks, jolts and sudden movements when handling the machine. PERTICI SPA declines all liability for damages caused during shipment. It is therefore important to check the state of the packaging at the time of purchase.

  • Page 17: Safety Zones And Dimensions

    4.3 Safety zones and dimensions Once the machine has been moved to the place of its definitive installation and the packaging has been removed, proceed with the installation. Take care to leave around the machine the necessary space for the personnel for normal operations and for inspection and maintenance works.

  • Page 18: Setting Up For Work

    4.4 Setting up for work Levelling. Position a spirit level on the frame support surface and verify that the machine is levelled both lengthwise and crosswise. To level the machine act as follows: - screw or unscrew the four vibration-damping feet 1 (Dwg. A1.10) by inserting the 12 mm key, supplied with the machine, into point (A).
  • Page 19 REMOVE DWG. A1.12 At this moment, the operations to be done concern the connection of the various systems as described in chapters 4.5 and 4.6. Before setting the machine to work, especially if it is the first start-up or when it is installed in a new working place, it is necessary to consider the following technical information and the indications concerning the various connection types.

  • Page 20: Compressed Air Circuit Hook-Up

    DWG.A1.13 DWG.A1.14 4.5 Compressed air circuit hook-up Connection to the line can be made by means of a rubber or Rilsan (Din 74324) hose with a suitable fitting. We recommend to use a supply hose with an internal diameter of not less than 10 mm.

  • Page 21: Connection Of The Electric Equipment

    The filter’s function is to filter the dust and moisture out of the air, which may otherwise damage the valves and pneumatic actuators. When condensate and impurities reach the maximum level in the container, empty the container by means of the relevant breather. The approximate air consumption, calculated on the maximum work load is 11 lt/work cycle.

  • Page 22: Connection To The Exhaust System

    Should the direction of rotation be opposite, invert the connection of two phases on the terminal board in the power supply circuit. ATTENTION: DO NOT MODIFY ANY CONNECTION INSIDE THE ELECTRIC CABINET DWG. A1.15 4.7 Connection to the exhaust system An electrically independent exhausting device can be connected to the machine.
  • Page 23 KW. 1,5 – an exhausting mouth with a diameter of 200 mm, complete with the connection accessories. Should the final customer refuse the supply of this optional, PERTICI SPA recommends the use of an exhausting device with at least the same characteristics.

  • Page 24: Use

    5. USE 5.1 Checks before use The following precautions must be taken each time before using the machine: - Check that the work surface is free of waste materials and cuttings. - Check the state of the milling cutters before each use of the machine: WORN MILLING CUTTERS.
  • Page 25 POWER SIGN. LAMP KEY SEL. SWITCH EMERGENCY FOR PROGRAMMING PUSH BUTTON RESET PUSH EMERGENCY BUTTON SIGN. LAMP DWG. A1.18 Pneumatic controls: DISCONNECTING SLIDE VALVE It is connected to the lubricator-filter group, pushing the collar towards the group the machine is energised, moving it in the opposite direction the machine is disconnected and the pneumatic circuit is unloaded, thus making all cylinders free for the manual movement.

  • Page 26: Operating Cycle

    5.3 Operating cycle To carry out the angle polishing, the operator has to observe the following procedure: 1) Turn the machine on and act on RESET push button On the display appears: F1 UPP.CUT.DEV. ON F2 LOW.CUT.DEV. ON F3 MILL. CUTTER SET MIL.CUT:1 2) Act on keys F1 and F2 to include or exclude the processing of the lower and upper knifes for welding seal removal.

  • Page 27: Emergency Device

    5.4 Emergency device At any time it is possible to stop the machine operations acting on the emergency push button PE (Dwg. A1.18). With this action, the milling cutter returns immediately into its home position inside the protection and the motor stops. To re-activate the machine, turn the push button in order to let it raise upwards.

  • Page 28: Microswitches For Safety Of The Locking Plate

    The positioning of such microswitches has been carried out by the PERTICI company during the official acceptance and is suitable to the greater part of profiles that can be found on the market.

  • Page 29: Reed Sensors

    5.5.3 Reed sensors The Reed sensors are installed on the cylinders for the forward movement of the milling cutter, of the positioner and of the upper cutting device. These sensors do not need regulation in any case. In case of malfunction, the PLC will send a message on the display.

  • Page 30: Adjustments For Tools Operations

    6. ADJUSTMENTS FOR TOOLS OPERATIONS IMPORTANT! ALL OPERATIONS DESCRIBED IN THIS CHAPTER MUST BE CARRIED OUT BY AUTHORISED PERSONNEL, WHICH MUST STRICTLY OBSERVE THE INDICATED PROCEDURE. 6.1 Adjustment of milling cutter packs height The corner cleaning machine type CM4-S can host up to 4 milling cutter packs (with a 97 mm height each) mounted at the same time (one upon the other) on the milling cutter holding shaft.

  • Page 31: Adjustment Of The Height Of The Milling Cutter Pack 1

    To change the height of the milling cutter group act as follows: 9) Enter the 10 mm Allen wrench (T-shaped wrench, supplied with the machine) in the relevant seat of the milling cutter holding shaft with ref. 3 (DWG. A1.22) 10) Enter the 46 mm wrench into the nut with ref.

  • Page 32: Adjustment Of The Height Of The Milling Cutter Pack 2

    DWG. A1.24 DWG.A1.25 6.1.3 Adjustment of the height of the milling cutter pack 2 Repeat the above described operations from point 1 to point 8 (setting milling cutter 2). 18) Use the 17 mm wrench to loosen the nut with ref. 1 (DWG. A1.26). 19) By means of the 17 mm Allen wrench (supplied with the machine) adjust the screw with ref.

  • Page 33: Adjustment Of The Height Of The Milling Cutter Pack 4

    (DWG. A1.28) The machine is regulated by PERTICI SPA in such a way that the 80 mm guide disc has a milling depth of 2 mm with respect to the theoretical angle root (whose two external surfaces rest on the positioning shoulders).

  • Page 34: Adjustment And Replacement Of Knifes For Welding Seal Removal

    The CM4-S has two knifes for the welding seal removal (an upper and a lower one), which are regulated by the PERTICI SPA during the acceptance test, and that should not need any further regulation. Anyway, should it be necessary to carry out the adjustment of their working depth, proceed as follows: - turn the main switch to position “0”...
  • Page 35 - Lower knife: - open the upper right lateral panel (DWG. A1.1) and move the support of the upper knife manually in the direction of the milling pack groups. - partially loosen the nut 1 (DWG. A1.30) and carry out the regulation by turning the screw 2 (DWG.

  • Page 36: Programming Of The Automatic Profile Recognition System

    6.4 Programming of the automatic profile recognition system The corner cleaning machine type CM4-S can be equipped with an electronic system for the automatic recognition of the profile to be polished. With this optional it is not necessary to enter the type of milling cutter that has to be used.

  • Page 37: Modification Of The Data For The Automatic Recognition

    Enter the number of the milling cutter to be used (from 1 to 9 ). ATTENTION The machine can control a maximum of 9 milling cutter packs, while on the milling cutter holding shaft can be mounted only 4 groups at the same time. The controller memorises which milling cutter packs are mounted at every moment on the machine and asks the operator to mount a different milling cutter should it be necessary.

  • Page 38: Noise

    R. N 141516 A.1 1 9 1 1 1 1998 3014 2 0 0 0 0 0 3 0 0 0 0 0 On the R column appears the number of the memorised line. (99 different profiles can be memorised) On the N column appears the number of the milling cutter to be used (from 1 to 9) The columns 14, 15 and 16 indicate the status of the limit switch sensors 14 15 and 16.

  • Page 39: Maintenance

    8. MAINTENANCE The corner cleaning machines type UNIVER CM4/S do not require any special maintenance operation. The technical solutions, the materials used and the protective paints have been specially developed and selected to reduce maintenance work. However, we do recommend a series of operations, divided up into ordinary and extraordinary maintenance operations, aimed at guaranteeing the safety, reliability and efficiency of the machines over time.
  • Page 40 1) Act on key ↑ to move the milling cutters holding shaft upwards. 2) Open the left lateral door and, by means of the 10 mm Allen wrench and of the 46 mm wrench remove the nut 2 (DWG. A1.31) (unscrew by turning the key in the direction indicated by the arrow) 3) Tighten the levers 3 (DWG.

  • Page 41: Replacement Of Knifes For Welding Seal Removal

    DWG. A1.32 IMPORTANT!!! PERTICI S.p.A. ACCEPTS NO LIABILITY IN CASE TOOLS ARE USED, WHICH DO NOT HAVE THE SPECIFICATIONS DESCRIBED AND REQUIRED IN THIS INSTRUCTION MANUAL. 8.3 – Replacement of knifes for welding seal removal To replace the knife for the welding seal removal, turn the main switch to position “0” and disconnect the pneumatic equipment by acting on the disconnecting valve.

  • Page 42: Spare Parts

    - Lower knife 1 (DWG. A1.34): open the right openable panel (DWG. A1.1) and manually move the upper knife support towards the milling packs. Loosen the headless screw 2 (DWG. A1.34), using the 4 mm hexagonal key supplied. DWG. A1.34 9.

  • Page 43: List Of Enclosures To The Instruction Manual

    10. LIST OF ENCLOSURES TO THE INSTRUCTION MANUAL ENCLOSURE No. CONTENT DESCRIPTION Page 1 - DRAWINGS TABLE OF CONTENTS..........A1.1 TABLE OF CONTENTS..........A2.0 2 - EXPLODED DRAWINGS OF MECHANICAL PARTS TABLE OF CONTENTS..........A3.1 3 - ELECTRIC EQUIPMENT TABLE OF CONTENTS..........A4.1 4 - PNEUMATIC EQUIPMENT 5 - DOCUMENTATION OF TABLE OF CONTENTS..........

  • Page 44: Enclosure 1

    ENCLOSURE 1 (DRAWINGS) TABLE OF CONTENTS........………..…………………………….. A1.0 BASE PLATE AND LOAD BEARING FRAME (machine description)…….… A1.1 GROUP OF PROFILE HOLDING SURFACES (machine description)………….. A1.2 GROUP FOR LIFTING OF CUTTER PACKS (machine description).……..… A1.3 GROUP OF LOWER SEAL REMOVING CUTTING DEVICE (machine description).. A1.4 GROUP OF FRAME BLOCKING DEVICES (machine description)…………………...

  • Page 45: Enclosure 2

    ENCLOSURE 2 (DISEGNI ESPLOSI PARTI MECCANICHE) TABLE OF CONTEST…..........A2.0 INTRODUCTION............A2.1 LIST OF DRAWINGS..........A2.2 EXPLODED DRAWINGS..........A2.3 LIST OF COMPONENTS OF PREVIOUS DRAWING A2.4 File: 2240.doc - 03/11/03 14:27 MANUALE D’ISTRUZIONE PER L’USO E LA MANUTENZIONE PULITRICE AUTOMATICA CM4S...
  • Page 46 DWG. (DRAWING REFERENCE NUMBER) POS. (POSITION) DESCRIZIONE (DESCRIPTION OF COMPONENTS) CODICE (PERTICI CODE) MACCHINE TIPO This permits to know to which machine type a list refers DWG. Reference number linking a mechanical part list to a specific exploded drawing. POS.
  • Page 47 LIST OF EXPLODED DRAWINGS OF MECHANICAL PARTS AND LIST OF COMPONENTS DESCRIPTION OF GROUPS BASE PLATE........A2.3 BEAR HOLDING FRAME …..... A2.4 PROFILE HOLDING SURFACE AND AUTOMATIC FRAME POSITIONING GROUP A2.5 GROUP FOR LIFTING AND FORWARD MOVEMENT OF CUTTER’S PACK AND LOWER CUTTING DEVICE..

  • Page 48: Enclosure 3

    ENCLOSURE 3 (ELECTRICAL EQUIPMENT) UNIVER CM4/S TABLE OF CONTENTS ........…... A3.1 INTRODUCTION ..........…... A3.2 DIAGRAM ............... A3.4 INTERNAL LAYOUT OF ELECTRIC CABINET A3.18 LIST OF DETAILS............. A3.19 File: 2240.doc - 03/11/03 14:27 MANUALE D’ISTRUZIONE PER L’USO E LA MANUTENZIONE PULITRICE AUTOMATICA CM4S...
  • Page 49 RIF. (REFERENCE) TAV. (DRAWING) DESCRIZIONE (MATERIAL DESCRIPTION) NUM. (NUMBER OF PIECES) TIPO (TYPE OR CODE - MATERIAL MANUFACTURER) FORNITORE (MATERIAL SUPPLIER) NS. CODICE (PERTICI CODE) File: 2240.doc - 03/11/03 14:27 MANUALE D’ISTRUZIONE PER L’USO E LA MANUTENZIONE PULITRICE AUTOMATICA CM4S...
  • Page 50 RIF. This column lists the part references used in the electrical diagram in alphanumerical order (e.g. C1 ,F2) If the component comprises several elements, the relevant reference is given on several lines, with each line describing the individual element making up the component. If the component is different in terms of supply voltage, several lines indicate the voltages for which said component is used.

  • Page 51: Enclosure 4

    ENCLOSURE 4 (PNEUMATIC EQUIPMENT) TABLE OF CONTENTS ..........A4.1 INTRODUCTION ............A4.2 FUNCTIONAL DIAGRAM A4.3 DIAGRAM OF CONNECTIONS AND COMPONENTS. A4.4 File: 2240.doc - 03/11/03 14:27 MANUALE D’ISTRUZIONE PER L’USO E LA MANUTENZIONE PULITRICE AUTOMATICA CM4S...
  • Page 52 PNEUMATIC EQUIPMENT HOW TO USE THE DOCUMENTATION THE DOCUMENTATION IS SET OUT AS FOLLOWS: TABLE OF CONTENTS FUNCTIONAL DIAGRAM DIAGRAM OF CONNECTIONS AND COMPONENTS LIST AND POSITION OF CONNECTIONS AND COMPONENTS FUNCTIONAL DIAGRAM This diagram provides the co-ordinates of a component through letters along the horizontal axis and numbers along the vertical axis and helps explaining its function on the machine.

  • Page 53: Enclosure 5

    ENCLOSURE 5 (DOCUMENTATION OF COMPONENTS) TABLE OF CONTENTS..........A5.1 EXPL. DRAWING OF CYLINDERS......A5.2 EXPL. DRAWING OF MOTOR………………………..A5.3 EXPL. DRAWING OF REDUCER…......A5.4 File: 2240.doc - 03/11/03 14:27 MANUALE D’ISTRUZIONE PER L’USO E LA MANUTENZIONE PULITRICE AUTOMATICA CM4S...

  • Page 54: Enclosure 6

    ENCLOSURE 6 (ELECTRICAL TESTS) The following tests have been performed and passed: PERFORMED TESTS CM4/S CONTINUITY..……………...... Passed ISOLATION ......…………... Passed DIELECTRIC STRENGTH..… …....Passed ELECTROMAGNETIC COMPATIBILITY ……………..Passed FUNCTIONAL TESTS......……………..Passed CONSUMPTION WITHOUT LOAD (VOLT. 400 – HZ. 2.1 A CONSUMPTION WITH LOAD (VOLT.

  • Page 55: Enclosure 7

    2000 mm. SOUND LEVELS ACCORDING TO THE ISO - 3746 STANDARD The results shown in the tables below were obtained from the tests performed: AVERAGE ACOUSTIC PRESSURE LEVEL IN THE ATMOSPHERE CM4/S LpAm dB(A): 78.8 ACOUSTIC POWER LEVEL CM4/S dB(A): 108.4...

  • Page 56: Enclosure 8

    ENCLOSURE 8 (TEST SHEET) File: 2240.doc - 03/11/03 14:27 MANUALE D’ISTRUZIONE PER L’USO E LA MANUTENZIONE PULITRICE AUTOMATICA CM4S...

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