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Summary of Contents for Danfoss ET9700
- Page 2 Imprint Manufacturer: UNIFLEX-Hydraulik GmbH Robert-Bosch-Strasse 50-52 D-61184 Karben Germany Phone: +49 (0) 60 39 / 91 71 - 0 Fax: +49 (0) 60 39 / 91 71 - 181 This Operating Manual of the machine is a translation; the origi- nal is in German.
- Page 4 In accordance with EC Machinery Directive 2006/42/EC and UK-Sup- ply of Machinery (Safety) Regulations 2008. The following machine Danfoss ET9700 was developed, designed and manufactured in compliance with EC Directive 2006/42/EC and UK-Supply of Machinery (Safety) Regulations 2008, in the sole responsibility of...
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Page 5: Table Of Contents
Contents About this document ..................8 1.1 Target groups ....................8 1.2 Storage ....................... 10 1.3 Name plate ....................10 1.4 Abbreviations ....................10 Safety instructions .................... 11 2.1 Presentation of warnings ................11 2.2 Intended use ....................12 2.3 Product-specific risks .................. 13 2.3.1 Risks imposed by mechanical equipment ........ - Page 6 5.4.1 Prerequisites ..................32 5.4.2 Aligning the bending pins ..............33 5.4.3 Setting the cutting speed ..............34 5.4.4 Setting the return stroke ..............36 5.4.5 Cut counter ..................38 5.4.6 Individual cutting of work pieces ............39 5.4.7 Continuous cutting of work pieces ............ 40 5.5 Stop ......................
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Page 8: About This Document
About this document The "Cutting machine Danfoss ET9700" is consistently designated as machine in this Operation Manual. This Operation Manual includes important notes on how you operate your machine/unit safely, properly and economically. Use not in compliance with the intended purpose may result in hazard to the operator's health and life and/or in the risk of damage to/the machine/unit. - Page 9 • national provisions, occupational safety regulations and applica- ble environmental protection regulations are fully complied with; • persons working on the machine/unit are adequately qualified; • persons working on the machine/unit are suitable for operating the machine/unit; • the Operation Manual has been read and understood. One hard- copy of the Operation Manual must always be kept at a desig- nated place where the machine/unit is used.
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Page 10: Storage
Storage The Operation Manual is part of the machine/unit and must be kept near the machine/unit at all times. Upon disposal of the machine/unit, the Operation Manual must also be handed over. Name plate The name plate is fixed near the power cable. Abbreviations cutting knife, plain cutting knife, with slots... -
Page 11: Safety Instructions
Safety instructions Presentation of warnings Warning notes in the Operation Manual warn against risks involved with the handling of the machine/unit. Risk levels are identified as fol- lows: The signal word HAZARD identifies an imminent hazard resulting in HAZARD! serious injuries or death. This warning is supplemented by a triangu- lar hazard symbol. -
Page 12: Intended Use
Intended use This machine is intended for industrial use; it is only suitable for cut- ting pneumatic and hydraulic hoses up to a specific permissible dia- meter, see “Technical Data” in Section 3. Intended purposes include: • Single user workplace for one person only •... -
Page 13: Product-Specific Risks
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. -
Page 14: Risk Imposed By Pneumatic System
• Work on electric systems may only be performed by qualified electricians or instructed and trained persons under the supervi- sion of a qualified electrician. • Deactivate the machine/unit and secure it against unintentional restart before maintenance. 2.3.3 Risk imposed by pneumatic system Risks are imposed by all pneumatic lines and connections. -
Page 15: Safety
Safety 2.4.1 Working area The working area is defined as the shaded area all around the ma- chine (see illustration). • Keep the working area free from trip hazards. • Use ducts for lines and cables. • Provide good illumination. -
Page 16: Warning Signs On The Machine
2.4.2 Warning signs on the machine Hand injury on the cover Crushing risk on the cover Cutting risk on the cutting knife Danger from electric current at the power supply line... - Page 17 Risk of eye injuries Wear safety goggles Risk of hearing damage Wear ear protection Illegible or missing warning signs must immediately be replaced by the operator.
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Page 18: Machine Description
Machine description Design and function (1) Protective cover (2) Catch bolt (3) Operation indicator lamp... - Page 19 (4) MOTOR START button (5) MOTOR STOP button (6) Hose guide (7) Main switch (8) Foot pedal (9) Cutting fork (10) Bending pins (11) Speed setting (12) Return stroke setting (13) Return stroke, manual (14) Cut counter The machine is switched on and off at the main switch (7). The oper- ation indicator lamp lights up when the machine is switched on (3).
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Page 20: Technical Data
Technical data Machine Dimensions L x W x H 1240 x 650 x 1650 mm Weight approx. 245 kg Noise level 80 dB(A) Protection class IP 44 Operation mode S6-60% Function Hose feed Pneumatic Brake motor Extraction connection Ø 100 mm Cutting knife TMC 520 x 4 x 40 mm Optional variant, see “Wear... - Page 21 Electrical connection Power rating 7.5 kW Voltage rating 400 V ±10 % 50 Hz, 3 phases (_00) 230 V ±10 % 60 Hz, 3 phases (_20) Back-up fuse 400 V = 16 A (delayed) 230 V = 20 A (delayed) Pneumatic connection Power rating 7 bar...
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Page 22: Transport And Commissioning
Transport and commissioning Transport The goods should be transported in the original packaging. During transport, the goods must be secured safely within the packaging. All applicable laws and regulations relating to securing loads shall be ob- served during transport. The machine/unit may only be unloaded and transported by means of a forklift, a lift truck or a crane. -
Page 23: Intermediate Storage Of Machine/Unit
WARNING! Danger from tilting machine/unit! The machine/unit may tilt if it is transported improperly. There is a risk of being injured. • Consider the machine/unit's centre of gravity (1). • Only lift the machine/unit at the designated points. Lift the machine/unit with a forklift, lift truck or crane at the desig- nated points (2) and transfer it to the location of installation. -
Page 24: Commissioning
Commissioning The machine is commissioned by the customer's fitter. Place the machine on an even ground at the place of installa- tion. WARNING! Danger from tilting machine! If not bolted to the floor, the machine may tilt. There is a risk of being injured. -
Page 25: Extraction Process For Tm/Tmg Cutting Knife
4.3.1 Extraction process for TM/TMG cutting knife Mount a metal hose for smoke and particle extraction to the ex- traction nozzle (1). We recommend an extraction fan with 100 mm water column and a capacity of 4 m³/min, as well as a filter element and a spark ex- tinguisher suitable for this purpose. -
Page 26: Extraction Process For Tmc Cutting Knife
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”... -
Page 27: Connection Of Compressed Air
4.3.3 Connection of compressed air The compressed air connection must supply 7 – 8 bar. Establish the connection between the compressed-air system and the compressed-air connection (1) on the back of the ma- chine. Check the pressure at the compressed-air maintenance unit (2) and adjust to 7 bar if necessary. -
Page 28: Electrical Connection
4.3.4 Electrical connection WARNING! Danger from electrical voltage! There is a risk of electrocution near the live parts! • Work on electric systems may only be performed by qualified electricians or instructed and trained persons under the su- pervision of a qualified electrician. •... - Page 29 Check rotational direction Remove the right-hand hose guide (2) from the machine. Dismantle the right-hand, upper side cover (1). Switch on the main switch. Switch on the motor. Switch off the motor. While motor is coming to a standstill, check the direction of rotation from the fan wheel (3) of the motor.
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Page 30: Operation
Operation What you have to observe The operator has received the Operation Manual from the owner, has read and understood it and will observe it. Before starting and/or re-starting • Ensure sufficient illumination of the working area of the machine. During operation •... -
Page 31: Replacing The Cutting Fork
Replacing the cutting fork The machine can be fitted with two different sizes of cutting fork. This allows the cutting fork to be adapted to the hose size. Switch off the main switch. Open protective cover (1). Release the quick fastener (3) by positioning it vertically. Pull the cutting fork (4) out of the cutting fork holder (2). -
Page 32: Workpiece Cutting
Workpiece cutting 5.4.1 Prerequisites ATTENTION! Risk of damage to machinery! The knife may be damaged when the machine is operated wit- hout work piece prestressing. • Never cut without using the bending pins. Exception: 3” work pieces are cut without the aid of bending pins. •... -
Page 33: Aligning The Bending Pins
5.4.2 Aligning the bending pins Work pieces up to 3” Open protective cover (1). Attach the bending pin (2) at the appropriate location. • The bending pin position and the work piece diameter must be matched to each other: • Large work piece diameter = large bending pin distance •... -
Page 34: Setting The Cutting Speed
5.4.3 Setting the cutting speed WARNING! Cutting risk There is a risk of cutting your extremities when cutting work- pieces. • Make sure that no extremities are in the working area behind the protective cover. - Page 35 Open protective cover (5). Set the speed setting (4) to a medium value. Insert the workpiece. Close protective cover (5). Start the motor (1). Press the foot pedal (3) until the work piece has been cut. Switch off the motor (2). WARNING! Cutting risk Once the motor has been switched off, the cutting knife will con-...
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Page 36: Setting The Return Stroke
5.4.4 Setting the return stroke To enable quicker working processes, the return stroke setting can be used to adapt the return stroke path of the cutting fork to the work piece diameter. WARNING! Cutting risk There is a risk of cutting your extremities when cutting work- pieces. - Page 37 Close protective cover (7). Set the return stroke setting (6) to 0. Switch on the motor (1). Press the foot pedal (4) until the cutting fork (5) has reached the lowest position. Release the foot pedal (4). Position the work piece on the side next to the cutting fork (5). Check whether the opening between the cutting fork (5) and the cutting plate (3) is large enough for the work piece to pass through.
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Page 38: Cut Counter
Manual return stroke Using the manual return stroke (1), the cutting fork can be returned to the uppermost position manually, irrespective of the return stroke set- ting. 5.4.5 Cut counter... -
Page 39: Individual Cutting Of Work Pieces
The cut counter counts the cut once the lowest position of the cutting fork has been reached. Pressing the RESET button resets the display to 0. Move the reset button to the lowest position in order to prevent it from being pressed unintentionally. -
Page 40: Continuous Cutting Of Work Pieces
5.4.7 Continuous cutting of work pieces Insert the work piece and move it to the desired position. If necessary, secure the work piece using the hose guide. Close the protection cover. Switch on the motor. Press the foot pedal until the cutting fork has reached the lowest position and cut the work piece. -
Page 41: Stop
Stop Complete the cutting process. Deposit the work piece outside the machine. Deactivate the main switch (1). Check the machine for contamination and outside damage. Check the cutting knife for damage and cracks. Remove contamination, dust and chips using a vacuum. WARNING! Risk by bursting screens Workpieces may penetrate porous screens, which may result in... -
Page 42: Overload Protection
Overload protection The motor is protected against overload by a motor protection switch. After a motor overload, if any, let the motor cool down and restart it. 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 43: Maintenance
Maintenance Regular maintenance will ensure the continuous operation reliability of the device. What you have to observe This Section describes action to be taken by you as the fitter regularly to ensure the troublefree use of the machine/unit. • Maintenance work may only be performed by qualified mainte- nance staff (machine/unit fitters). - Page 44 Maintenance item Cutting tool Cutting knife: check cutting edge for sharpness, cracks and breakouts, check for changes in colour, resharpen or replace knives as appropriate. Coating: check (TMC cutting knives only). Bolted connections: check and retighten if necessary. Machine: Cleaning Extraction line: Cleaning Safety equipment Knife protection: check for function Open the protection...
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Page 45: Replacing The Cutting Knife
Replacing the cutting knife WARNING! Cutting risk! Replacing the cutting knife imposes a significant risk of injuries to the hands. • Always wear cut-proof gloves when replacing the knives. Complete the cutting process. Deposit the workpiece outside the machine. Disconnect the machine from the electrical and pneumatic sup- ply. - Page 46 ATTENTION! Risk of damage to machinery! If the directions of rotation of the motor and the cutting knife do not match, there is a risk that the cutting knife will be destroyed during cutting. • Check the direction of rotation before switching on Observe the cutting direction! The direction of rotation is to the left when viewing the free end of the shaft.
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Page 47: Replacing A Resharpened Cutting Knife
6.3.1 Replacing a resharpened cutting knife Replacing the cutting knife (see “Replacing the cutting knife” in Section 6) If the outside diameter of the resharpened cutting knife is ≤ 515 mm, the height of the motor must be adapted to the outside diameter of the cutting knife. - Page 48 Release the four locking screws (5). WARNING! Cutting risk! If the position of the cutting knife is set too high, the result will be insufficient protection and a significant risk of injuries to the hands. • There must always be a safety distance of at least 20 mm between the cutting knife and the knife protection.
- Page 49 Adjust the height using the height adjustment screws (6). The distance between the cutting knife (6) and the knife protec- tion (7) must be 20 mm. ATTENTION! Risk of damage to machinery! If the cutting knife is at an angle, this will result in damage to the cutting knife and machine.
- Page 50 ATTENTION! Risk of damage to machinery! If the outside diameter is set incorrectly, this will result in damage to the cutting knife and machine. • If a new cutting knife is assembled, the height of the motor also has to be readjusted.
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Page 51: Checking The Motor Brake
Checking the motor brake Due to wear on the brake linings, the braking effect of the motor brake may decrease over time. In this case the motor brake has to be readjusted. WARNING! Risk of injuries The motor brake is a major safety element of the machine. For this reason, the machine must in no event be operated without any functional motor brake and only with mounted fan runner co- ver. -
Page 52: Motor Brake Readjustment
Motor brake readjustment Switch off the machine and secure it against switching on unin- tentionally. Dismantle the right-hand hose guide (1). Dismantle the right-hand, upper side cover (2). Adjust the motor brake according to the motor variant (see “Mo- tor brake variants” in Section 6). Assemble the side cover (2) and hose guide (1) in reverse order. - Page 53 WARNING! Hot surface - risk of burns The motor brake can become very hot. There is a risk of burns if this part is touched. • Do not touch parts of the motor without sufficient protection. WARNING! Risk of injuries The fan wheel imposes a risk of serious injuries.
- Page 54 Motor brake with adjusting screw Remove the fan wheel cover (1). Secure the fan wheel (2) with a suitable tool. Use a hexagon socket wrench to turn the adjusting screw (3) clockwise by approx. 30° (30° = 0.1 mm). Attach the fan wheel cover. Switch on the motor.
- Page 55 Motor brake with adjusting nut Remove the fan wheel cover (1). Bend up the locking washer (3) of the adjusting nut (4). Secure the shaft (2) using a hexagon socket wrench. Use an open-end wrench to turn the adjusting nut (4) clockwise by approx.
- Page 56 ATTENTION! Risk of damage to machinery If the motor brake adjustment is too tight, this will result in increa- sed wear and high heat generation. • Check that the time taken for the motor to come to a standstill is between 9 – 10 seconds. 10.
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Page 57: Troubleshooting
Troubleshooting Error Cause Remedy Machine does not cut Switch "OFF" Activate switch Power 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 Turn flange disc and insert it correctly on the feather key... -
Page 58: Decommissioning, Disposal
Decommissioning, disposal WARNING! Risk by electrical voltage! There is a risk of electrocution near the live parts! • Shut down the machine/unit. • Disconnect the machine/unit from the power supply. CAUTION! Risk of injuries! Contact with consumables, e.g. oils, greases, test media, im- poses a risk of injuries for the skin, eyes, respiratory and intesti- nal tracts! •... -
Page 59: Consumables And Waste
As regards disposal, the applicable national environmental protection and waste disposal regulations have to be complied with. 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. -
Page 60: Annex
Annex Individual machine/unit components may deviate in their features. Please indicate the serial number of the machine for spare part or- ders. Accessories (retrofittable) Accessories Part code Hose length measuring device UMS 4 Hose guide, 2000mm UHG 14 Extension, 1000mm UHG 14 EXT Suction system + Adaptor UVC S36 + 777.061... -
Page 61: Spare Parts List
_BD b1050 Spare parts list 9.2.1 Mechanical equipment Item Quantity Part code Designation PJ_GLS1050 Front protective screen 501.071 Catch bolt PJ_10.0410.04 Telescopic rail... - Page 62 Item Quantity Part code Designation 1 set UJ_70.0410.15 Bending pins (1 set = 2 pins) UJ_20.30.171 Main power switch UJ_70.0410.09 Hold-down, small nominal widths UJ_70.0410.08 Hold-down, large nominal widths UJ_70.0410.23 Guide roller horizontal UJ_70.0410.13 Guide roller vertical UJ_70.0410.11 Protective plate cutting knife(1 set = 2 pins) UJ_30.10:01 Oil pressure spring 888.140...
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Page 63: Pneumatic
9.2.2 Pneumatic Item Quantity Part code Designation PJ_40.10:05 Pneumatic cylinder 305.070 Throttle valve UJ_40.50.02 Compressed-air maintenance unit UJ_40.50.19 5/3-way pneumatic valve... -
Page 64: Electric Equipment
9.2.3 Electric equipment Item Quantity Part code Designation 888.641 Assistance switch 888.639 Motor protection switch 24 – 32 A 888.642 Contactor 24 V DV 888.645 Time block 0.1 – 30 s... -
Page 65: Electric Control Unit
Item Quantity Part code Designation 888.643 Contactor 24 V DC 888.640 Motor protection switch 13 – 18 A 888.646 Time relay, pick-up delayed 888.647 Voltage selector switch PLC-RSC24DC/21AU Relay VME 0231 Microfuse 3,15 A delayed / 500 V 888.648 Switching power supply 306.083 Brake motor 7.5 kW No pic-... -
Page 66: Wear Parts
Item Quantity Part code Designation UJ_20.30.158 Indicator light UJ_20.30.160 Start button motor UJ_20.30.170 Motor stop button UJ_20.30.171 Main Switch UJ_20.30.166 Potentiometer UJ_20.30.189 Button for raising the cylinder piston 9.2.5 Wear parts Quantity Part code Designation TMC 520x4x40 Cutting knife, coated UJ_70.0410.11 Protective plates for cutting knife PJ_70.0410.10... -
Page 67: Electric Diagram
Electric diagram... -
Page 70: Pneumatic Diagram
Pneumatic diagram... -
Page 71: Maintenance Log
Maintenance log Remark Date Signature ... -
Page 72: Declaration Of Qualified Staff
Declaration of qualified staff I herewith declare that I have attended an internal training for the operation 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...
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