Danfoss ET9650 Operator's Manual
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Danfoss ET9650 Operator's Manual

Danfoss ET9650 Operator's Manual

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  • 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 ET9650 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...

  • Page 5: Table Of Contents

    Contents About this document ..................7 1.1 Target groups ....................7 1.2 Storage ......................8 1.3 Name plate ....................9 1.4 Abbreviations ....................9 Safety instructions .................... 10 2.1 Presentation of warnings ................10 2.2 Intended use ....................10 2.3 Product-specific risks .................. 11 2.3.1 Risks imposed by mechanical equipment ........
  • Page 6 5.1 What you have to observe ................31 5.2 Start ......................31 5.3 Work piece cutting ..................32 5.3.1 Prerequisites ..................32 5.3.2 Cutting individual hoses ..............33 5.3.3 Setting the return stroke ..............35 5.4 Stop ......................36 5.5 Overload protection ..................36 5.6 Cleaning ......................

  • Page 7: About This Document

    About this document The "Cutting machine Danfoss ET9650" 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 8: Storage

    • 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.

  • Page 9: Name Plate

    Name plate The name plate is fixed near the power cable. Abbreviations cutting knife, plain cutting knife, with slots cutting knife, coated...

  • Page 10: 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 11: Product-Specific Risks

    ➢ persons with a restricted capability for the operation of ma- chines (e.g. under the influence of drugs, alcohol or narcot- ics) Use of the control in compliance with the intended purpose also inclu- des compliance with the instructions in this Operation Manual. Use for other than the intended purpose Any other use is considered as being not in compliance with the in- tended purpose, in particular:...

  • Page 12: Risks Imposed By Electricity

    Risk of squeezing There is a risk of squeezing on the moving parts. Tilting hazard The risk of tilting mainly exists while the machine is being trans- ported. • Observe the machine's centre of gravity during transport. 2.3.2 Risks imposed by electricity There is a risk of electrocution near the live parts! •...

  • Page 13: Risks In Case Of Fire

    • provide information/instructions on risks • identify hazardous areas • provide health monitoring 2.3.5 Risks in case of fire The operating staff has to be familiar with the location as well as with operating the fire alarm and fighting means. Free access to this equipment must be ensured.

  • Page 14: Emergency-Stop

    2.4.2 Emergency-stop The machine is fitted with an emergency-stop button. 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: Warning Signs On The Machine

    2.4.3 Warning signs on the machine Cutting risk on the cutting knife Hand injury on the cover 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 operator.

  • Page 17: Machine Description

    Machine description Design and function (1) Bending pin (2) Protective cover (3) Strap grip (4) Machine cover (5) Compressed air maintenance unit (6) Foot pedal (7) Motor (8) Cutting plate (9) Main switch (10) Control valve for feed speed (11) Knife protection (12) Hose feed...

  • Page 18: Accessories

    (13) Return stroke setting The machine requires an electrical connection and a compressed air connection. The pressure of the compressed air can be adjusted at the compressed air maintenance unit (5). The bending pins (1) prevent the cutting knife from getting jammed by the work piece and enhance the cutting performance.

  • Page 19: Operation And Display Elements

    Operation and display elements (1) Return stroke setting (2) Feed speed (3) Main switch / emergency-stop button...

  • Page 20: Technical Data

    Technical data Machine Dimensions L x W x H 983 x 760 x 540 mm Weight approx. 140 kg Noise level 85 dB(A)* Protection class IP 42 Operation mode S6-60% Function Hose feed Pneumatic Brake motor Extraction connection Ø 60 mm Cutting knife TM C 400 x 4 x 30 mm Work piece capacity...
  • Page 21 Electrical connection Power rating 4.6 kW Voltage rating 400 V ± 10 % 50/60 Hz, 3 phases Back-up fuse 20 A (delayed) Short circuit current lk3p 6,7 kA Short circuit current lp3p 9,7 kA Full load current of circuit 16,5 kA Full load current of 0,48 kA control circuit (primary)
  • Page 22 Ambient conditions C – 40 Ambient temperature 45 % – 65 % Air humidity The * data are theoretical/computed values, or values measured on a prototype. Actual values may vary slightly, depending on the ma- chine.

  • Page 23: 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 may only be unloaded and transported by means of a lift truck or a crane.

  • Page 24: Intermediate Storage Of Machine/Unit

    WARNING! Danger from tilting machine! The machine may tilt if it is transported improperly. There is a risk of being injured. • Only lift the machine at the designated points. Lift the machine using the lifting lug (1) and transfer it to the in- stallation site.

  • Page 25: Extraction Process For Tm/Tmg Cutting Knife

    Check the electric cables for damage. Check the pneumatic hoses for damage and secure fitting. 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.

  • 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

    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. 4.3.3 Connection of compressed air ATTENTION! Damage to the machine Contaminated compressed air may cause damage to the ma- chine.

  • Page 28: Electrical Connection

    4.3.4 Electrical connection WARNING! Risk by 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: Initial Operation

    4.3.5 Initial operation WARNING! Risk for life and health! Improper use imposes risks for life and health. • The initial operation may only be performed by qualified maintenance staff (machine fitters). • If unusual noises can be heard, switch off the machine im- mediately and eliminate the cause.
  • Page 30 Loosen the foot pedal and wait until the hose feed (5) has re- turned completely. Test run with work piece Open the protection cover (1). Position the bending pin (2) according to the hose diameter; see “Cutting the work piece” in Section 5. Position the work piece on the cutting plate between the bending pin (2) and the hose feed (5).

  • Page 31: 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 32: Work Piece Cutting

    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: •...

  • Page 33: Cutting Individual Hoses

    • The work piece must protrude over the two bending pins by at least 50 mm. • The work piece must completely bear on the cutting plate. 5.3.2 Cutting individual hoses WARNING! Cutting risk There is a risk of cutting your extremities when cutting work pieces.
  • Page 34 Open protective cover (1). Position the bending pin (2) according to the hose diameter; (see “Cutting the work piece” in Section 5). Position the work piece on the cutting plate between the bending pin (2) and the hose feed (5). Close protective cover (1).

  • Page 35: Setting The Return Stroke

    Open protective cover (1). WARNING! Cutting risk The motor continues to run when the protective cover is opened. The knife protection is only blocked mechanically in order to elim- inate danger. • Do not reach into the cutting knife operating range. 10.

  • Page 36: Stop

    Stop Complete the cutting process. Deposit the work piece outside the machine. Deactivate the main switch (1). Check the machine for glowing embers. Check the machine for contamination and outside damage. Check the cutting knife for damage and cracks. Remove contamination, dust and chips using a vacuum. Inform the fitter in case of damage or other irregularities.

  • Page 37: Cleaning

    Cleaning WARNING! Risk for life and health! There is an acute risk of injuries when working in the danger zone of the cutting knife. • Disconnect the machine from all energy sources and secure it against switching on unintentionally. • Wear cut-proof gloves.
  • Page 38 Use a vacuum cleaner or a soft cloth to clean the machine. Open protective cover (1). Vacuum the hose guide (5). If necessary, remove the machine cover to gain better access to the hose guide. Release the four screws (4) of the machine cover (2). Lift up and remove the machine cover (2) using the strap grips (3).

  • Page 39: 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 40 Maintenance item Cutting tool Cutting knife: Check cutting edge for sharpness, cracks and breakouts; resharpen (only TM and TMG cutting knife) or replace knives as appropriate. Coating: check (TMC cutting knives only). Bolted connections: check and retighten if neces- sary. Machine: Cleaning Extraction line: Cleaning Safety equipment...

  • Page 41: Knife Replacement

    Knife replacement WARNING! Risk for life and health! Knife replacement imposes a significant risk of injuries to the hands. • Always wear cut-proof gloves when replacing the knives. Complete the cutting process. Deposit the work piece outside the machine. Disconnect the machine from the power supply. Open the protective cover (3).

  • Page 42: Motor Brake Readjustment

    The machine cover should be lifted up by two people using the strap grips. Release the four screws (4) of cutting knife cover (5). Remove the cutting knife cover (5). Hold the shaft (8) with a SW 8 hexagon socket wrench and re- lease the nut (7) using an SW 46 open-end wrench.
  • Page 43 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 machine must in no event be operated without any functional motor brake and only with mounted fan runner cover.
  • Page 44 Release the four screws (4) of the machine cover (2). Lift up and remove the machine cover (2) using the strap grips (3). The machine cover should be lifted up by two people using the strap grips. Remove nuts on the plastic cover (5) and remove the plastic cover.
  • Page 45 15. Check the braking effect and the temperature again. 16. Attach the plastic cover (5) and tighten the nuts. 17. Attach the machine cover (2). If the problems with the brake continue, immediately contact the service department of the manufacturer.

  • Page 46: Troubleshooting

    Troubleshooting Error Cause Remedy Machine does not cut Main switch is off Switch on the main switch. Power plug defective Check the power plug, replace if necessary. Motor defective Contact service. Main switch defective Contact service. Cutting knife worn Check cutting knife for wear, replace if necessary.

  • Page 47: 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 48: 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 49: 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 (upgradable) Accessories Part code Hose guide 2000 mm UHG 14 Extension 1000 mm UHG 14 EXT Suction system + Adaptor UVC S36 + 777.055 Suction filter system UVC 100.2 MVA FSD...

  • Page 50: Spare Parts List

    Spare parts list 9.2.1 Mechanical equipment - Chassis Item Quantity Part code Designation 323.001.0 Chassis 323.040.1 Electric drawer 323.116.3 Cover plate 323.051.3 Base plate 323.006.3 U-Profile 323.024.4 Path adjustment axle 323.026.4 Guidance 323.028.4 Guidance connection 323.107.3 Positioner 323.121.3 Extraction connection...

  • Page 51: Mechanical Equipment - Knife Protection

    Item Quantity Part code Designation 323.122.3 Retaining tab 1 set 304.2001 Set of bending pins TM C 400x4x30 Cutting knife, coated 233.111 Rubber-metal buffer 9.2.2 Mechanical equipment - Knife protection Item Quantity Part code Designation 323.111.0 Knife protection 323.002.3 Hose feed 323.025.4 Switch bracket 323.029.4...

  • Page 52: Mechanical Equipment - Covers

    Item Quantity Part code Designation 323.102.4 Power connector 323.043.4 Transducer 323.091.4 Distance block 323.092.4 323.212 Pressure spring actuator 323.206 Adjusting ring 798.510007 Pin EN 22340 Type B 8 x 30 798.610002 Splint 798.310010 Hexagonal nut DIN EN ISO 4032 M8 Countersunk screw with hexagon socket 798.110140 DIN EN ISO 10642 M8 x 30...
  • Page 53 Item Quantity Part code Designation 323.018.1 U-Machine cover 323.1071 Macrolon parts EM 8.5 P: 323.131.1 Protective screen 323.110.3 Protection case 323.132.2 Protective plate 323.036.3 Sliding piece 322.054 Mushroom-head handle 323.200 Telescopic rail 323.120.3 Eyebolt M12 501.068 Strap grip 323.105.3 Switch bracket 304.101.4 Knife sign 716.4...

  • Page 54: Electric Equipment

    9.2.4 Electric equipment Item Quantity Part code Designation 322.401 Main power switch 322.400 Rectifier 800.083 Serial terminal 800.022 Securing clip 800.084 Protective conductor terminal Motor protection switch 8.06.002 800.021 Safety isolating transformer 8.06.003 Auxiliary switch block No picture VME 0265 Fine wire fuse 323.204 Roller lever switch...

  • Page 55: Pneumatic Equipment

    Item Quantity Part code Designation No picture 888.228 Socket insert Foot pedal No picture 8.00.030 Metal oxide varistor 9.2.5 Pneumatic equipment Item Quantity Part code Designation 323.201 Pneumatic cylinder 323.202 Bracket for pneumatic cylinder 323.203 Fork head for pneumatic cylinder 322.050 Solenoid valve 322.406...

  • Page 56: Wear Parts

    9.2.6 Wear parts Quantity Part code Designation 1 Piece TM C 400x4x30 Cutting knife, coated (standard) 1 Piece TM G 400x4x30 Cutting knife with inclined slots (accessory) 1 Piece TM 400x4x30 Cutting knife, plain (accessory) Spare parts kit (Seimec/Habasit) Flange disc 1 Kit 320.121 set and shaft nut...

  • Page 57: Electric Diagram

    Electric diagram...

  • Page 58: Pneumatic Diagram

    Pneumatic diagram...

  • Page 59: Maintenance Log

    Maintenance log Remark Date Signature                                    ...

  • Page 61: 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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