Danfoss ET9600 Operator's Manual
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Danfoss ET9600 Operator's Manual

Danfoss ET9600 Operator's Manual

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Summary of Contents for Danfoss ET9600

  • 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 ET9600 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 5.3.2 Cutting individual hoses ..............32 5.4 Stop ......................33 5.5 Overload protection ..................33 5.6 Cleaning ...................... 35 5.1 Cleaning ...................... 35 Maintenance ....................... 37 6.1 What you have to observe ................37 6.2 Maintenance schedule ................. 37 6.3 Knife replacement ..................39 6.4 Motor brake readjustment ................

  • Page 7: About This Document

    About this document The "Cutting machine Danfoss ET9600" 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: Safety

    Use extinguishing powder in case of fire. Safety 2.4.1 Working area The working area is defined as the area all around the machine (shaded). • Keep the working area free from trip hazards. • Use ducts for lines and cables. •...

  • 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 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) Lever (2) Motor (3) Bending pin (4) Cutting knife (5) Main switch (6) Hose feed (7) Knife protection The work piece is placed on the cutting plate between the retaining pin (3) and the hose feed (6). The machine is switched on using the main switch (4), starting the motor (5) which in turn drives the cutting knife (5).
  • Page 18 For cutting, the hand lever (1) is moved downwards in the direction of the cutting plate. The lever (1) pushes the hose feed (6) and the work piece mechanically in the direction of the cutting knife (4). The knife protection (7) prevents the operator from unintentionally reaching into the rotating cutting knife (4).

  • Page 19: Technical Data

    Technical data Machine Dimensions L x W x H 900 x 780 x 880 mm Weight approx. 122 kg Noise level 85 dB(A)* Protection class IP 42 Operation mode S6-60% Function Hose feed Manual Brake motor Extraction connection Ø 60 mm Cutting knife TM C 400 x 4 x 30 mm Work piece capacity...
  • Page 20 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 21: 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 22: 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 load hook (1) and transfer it to the in- stallation site.

  • Page 23: Extraction Process For Tm/Tmg Cutting Knife

    Place the machine in a way so that it is easily accessible for main- tenance work from all sides. Check the machine for damage. Check the electric cables for damage. Train the operating staff and record training sessions in “Decla- ration of trained staff”, Section 9.
  • Page 24 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 25: 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 26: Electrical Connection

    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 Electrical connection WARNING! Risk by electrical voltage! There is a risk of electrocution near the live parts! •...

  • Page 27: Initial Operation

    ATTENTION! Risk of damage to machinery! Operating the motor in the wrong direction of rotation results in the loosening of the knife attachment. • Ensure that the rotational direction of the motor is correct. Observe the red arrow on the motor cover. •...
  • Page 28 Test run without work piece Switch on the machine using the main switch (3). Move the lever (1) downwards steadily and slowly. Move the lever (1) upwards into the starting position. Test run with work piece Position the bending pin (2) according to the work piece diame- ter (see “Cutting the work piece”...
  • Page 29 These ten careful cutting processes are important for the durability of the cutting knife TM or TMG.

  • 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: 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 32: 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 33: Stop

    Place the work piece onto the cutting insert between the bending pin (3) and hose feed (6). Switch on the machine using the main switch (5). Move the lever (1) downwards steadily and slowly. This pushes the hose feed (6) and in turn the work piece to- wards the cutting knife (4).
  • Page 34 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 35: 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 36 Use a vacuum cleaner or a soft cloth to clean the machine. Release the four screws (3) on the machine cover (1). Remove the machine cover (1) by the handle (2). Extract the entire area of the hose feed (4). Reattach the machine cover (1) using the lever (2).

  • Page 37: 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 38 Maintenance item Cutting tool Cutting knife: check cutting edge for sharpness, cracks and breakouts; resharpen or replace knives as appropri- ate. 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 Press the knife protec- tion on the outside edges towards the motor with both thumbs wearing cutting protection gloves.

  • Page 39: Knife Replacement

    Knife replacement WARNING! Cutting risk! 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. Release the four screws (3) on the machine cover (1).
  • Page 40 Hold the shaft (4) with a hexagon socket wrench and release the nut (3) using an open-end wrench. The nut has a left-hand thread! Remove the washer (2) and cutting knife (1) from the shaft and place them down carefully. Attach the new cutting knife in the reverse order.

  • Page 41: Motor Brake Readjustment

    Reattach the machine cover using the lever. 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.
  • Page 42 Block the shaft using a hexagon socket wrench and turn the ad- justing nut to the right using an open-end wrench. Secure the plastic cover. Switch on the motor. Once the motor has reached full speed, allow the motor to run for a further 30 seconds.

  • Page 43: 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 44: 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 45: 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 46: 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 guide, 2000mm UHG 14 Extension, 1000mm UHG 14 EXT Suction system + Adaptor UVC S36 + 777.055 Extraction system for cutting machines UVC 100.2 MVA FSD...

  • Page 47: Spare Parts List

    Spare parts list 9.2.1 Mechanical equipment Item Quantity Part code Designation 323.094.1 Machine cover 323.075.3 Lever No picture 323.116.3 Protective plate 323.111.0 Knife protection 323.002.3 Hose feed No picture 323.071.4 Tension rod No picture 323.070.4 Holder for tension rod 304.2001 Set of bending pins No picture 330.050.3...

  • Page 48: Electric Equipment

    Item Quantity Part code Designation 304.101.4 Knife sign 3127/60 Mandatory Eye and Hearing Protection sticker 300.100.4 Cutting risk warning sign 777.031 Power supply disconnection warning sign 9.2.2 Electric equipment Item Quantity Part code Designation No picture 800.021 Safety isolating transformer 8.06.002 Motorschutzschalter_00 No picture...

  • Page 49: Wear Parts

    9.2.3 Wear parts Quantity Part code Designation 1 item TM C 400 x 4 x 30 Cutting knife, coated (standard) 1 item TM G 400 x 4 x 30 Cutting knife with inclined slots Spare parts kit (Seimec/Habasit) Flange disc 1 kit 320.121 set and shaft nut...

  • Page 50: Electric Diagram

    Electric diagram...

  • Page 51: Maintenance Log

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

  • Page 52: 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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