Danfoss ET9550 Operator's Manual
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Danfoss ET9550 Operator's Manual

Danfoss ET9550 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 ET9550 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 5.3.1 Prerequisites ..................30 5.3.2 Cutting individual hoses ..............31 5.3.3 Continuous cutting of small hoses (no return stroke limitation) ..32 5.4 Deactivation ....................33 5.5 Emergency stop ................... 34 5.6 Overload protection ..................34 5.7 Cleaning ...................... 35 5.8 Cleaning ......................

  • Page 7: About This Document

    About this document The "Cutting machine Danfoss ET9550" 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: Safety

    Safety 2.4.1 Working 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 15 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 16: Warning Signs On The Machine

    2.4.3 Warning signs on the machine Hand injury 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 owner.

  • Page 18: Machine Description

    Machine description Design and function Basic machine (1) Motor (2) Bending pin (3) Cutting plate (4) Foot pedal (5) Cut counter (6) Feed speed controller (7) Main power switch (8) Return stroke limitation (9) Feed fork (10) Knife (covered) (11) Knife protection (yellow) (12) Cover...
  • Page 19 The workpiece is positioned on the cutting plates (3) in front of the bending pins (2). During the cutting process, the cover (12) is closed and subsequently opened automatically. During cutting, the feed fork (9) is pneumatically driven forward and pushes the workpiece to- wards the knife (10).

  • Page 20: Technical Data

    Technical data Machine Dimensions L x W x H 820 x 760 x 815 mm Weight approx. 110 kg Noise level 80 dB(A)* Protection class IP 42 Operation mode S6-60% Function Hose feed Pneumatic Brake motor Extraction connection Ø 60 mm Cutting knife EM 6.2 TM G 350 x 3 x 30 mm Cutting knife EM 6.3...
  • Page 21 Electrical connection Power rating 4.6 kW 400 V – 50 Hz – 3Ph Connected voltage 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) Pneumatic connection...
  • 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

    Check the electric cables for damage. 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.

  • 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: Electrical Connection

    4.3.3 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 28: Connecting Compressed Air

    4.3.4 Connecting compressed air The compressed air connection must supply 7 bar. Provide a compressed air connection between the net and the compressed air maintenance unit (1). ATTENTION! Damage to the machine Contaminated compressed air may cause damage to the cutting machine.

  • Page 29: 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 30: 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 31: 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 32: Continuous Cutting Of Small Hoses (No Return Stroke Limitation)

    The cover (7) closes automatically. The feed mechanism moves forward. The cutting process is completed. Release the foot pedal. The feed mechanism moves backward. The cover opens automatically. Deactivate the machine at the power switch. Remove the workpiece. 5.3.3 Continuous cutting of small hoses (no return stroke limitation) WARNING! Cutting risk! There is a risk of cutting your extremities when cutting work-...

  • Page 33: Deactivation

    Deactivation Complete the cutting process. Deposit the workpiece outside the machine. Deactivate the power switch (1). Check the machine for contamination and outside damage. Check the cutting knives for damage and cracks. Remove dirt, dust and chips by using a vacuum cleaner. WARNING! Risk by bursting screens Workpieces may penetrate porous screens, which may result in...

  • Page 34: Emergency Stop

    Emergency stop In case of emergency In case of emergency, 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.

  • 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 Remount the cover plate.

  • 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 Check cutting knife for sharpness, cracks and breakouts; resharpen or replace the knife. Coating: To be checked (only TMC cutting knife). Bolted connections: To be checked and retightened, if re- quired. Machine: To be cleaned. Extraction line: To be cleaned. Safety equipment Knife protection: To be checked for function Press the knife protection on the outside edges towards the motor...

  • 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 workpiece outside the machine. Disconnect the machine from the power supply. Loosen the five bolts on the cover plate.

  • Page 40: Motor Brake Readjustment

    Remove the knife (1) and the washer (2) from the axle and posi- tion them carefully. Mount a new cutting blade- observe cutting direction. Position the washer (2) and tighten the nut (3). 10. Remount in the reverse order. ATTENTION! Risk of damage to machinery! If the directions of rotation of the motor and the knife do not match, there is a risk that the knife will be destroyed during cut-...
  • Page 41 The motor brake is located behind the black plastic cover (1) on the motor. Deactivate the machine on the power switch and secure it against unintentional restart. Remove nuts on the plastic cover and remove the plastic cover. Block the shaft using a hexagon key and turn the adjusting nut to the right using an open-end wrench.
  • Page 42 If the problems with the brake continue, immediately contact ser- vice department of the manufacturer.

  • Page 43: 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 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 (upgradable) Accessories Article code Hose guide, 2000 mm UHG 14 Extension, 1000 mm UHG 14 EXT Suction system UVC S36 Hose length measuring device UMS 4...

  • Page 47: Spare Parts List

    Spare parts list 9.2.1 Mechanical equipment Item Quantity Part code Designation 328.021.3 Frame 328.010.4 Feed fork 328.012.3 Cutting plate 328.006.3 Protective screen 320.111 Brake motor Foot pedal 329.009.4 Macrolon panel...
  • Page 48 Item Quantity Part code Designation 304.2001 Set of bending pins 328.036.4 Plastic guide 328.019.4 Feed gear 328.015.4 Toothed rack, long 328.037.4 Plastic guide, drive unit 328.018.4 Cylinder gear 328.017.4 Toothed rack, short 328.022.4 Gear shaft 328.053.4 Bearing case 328.014.3 Knife protection 328.059.3 Guide rail 307.010...

  • Page 49: Pneumatic Equipment

    9.2.2 Pneumatic equipment Item Quantity Article code Designation 808.300 Feed cylinder 104.2 Maintenance unit 808.500 Knife protection cylinder 808.400 Guide cylinder 808,068 5/2-way valve (feed) 808.059 5/2-way valve (knife protection) 808,003 Controller 0-2 bar 808.060 Flow control valve G1/4” 808.079 Shut-off valve G1/4”...

  • Page 50: Electric Equipment

    9.2.3 Electric equipment Item Quantity Article code Designation No figure VME 0134 Bolted connection + strain relief 8.11.240 Mounting rail 240mm 232.040 Power cable 8.06.002 Motor protection switch 800.021 Safety transformer 888.113 Undervoltage release: 888.114 Auxiliary switch 888.115 Carrier No figure 888,116 Turning handle 888.149...

  • Page 51: Wear Parts

    9.2.4 Wear parts Quantity Part code Designation TM G 350x3x30 Cutting knife with inclined slots TM C 350x3x30 Cutting knife, coated 320.118 Spare brake Soga (see motor nameplate) 320.116 Spare brake Seimec (see motor nameplate) 328.006.3 Protective screen 329.009.4 Macrolon panel 304.2001 Set of bending pins...

  • Page 52: Electric Diagram

    Electric diagram...

  • Page 54: Pneumatic Diagram

    Pneumatic diagram...

  • Page 55: Maintenance Log

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

  • Page 56: 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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