Danfoss ET9500 Operator's Manual
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Danfoss ET9500 Operator's Manual

Danfoss ET9500 Operator's Manual

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Summary of Contents for Danfoss ET9500

  • 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 ET9500 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 5.4 Deactivation ....................30 5.5 Emergency stop ................... 31 5.6 Overload protection ..................31 5.7 Cleaning ...................... 33 5.8 Cleaning ...................... 33 Maintenance ....................... 35 6.1 What you have to observe ................35 6.2 Maintenance schedule ................. 35 6.3 Knife replacement ..................37 6.4 Motor brake readjustment ................

  • Page 7: About This Document

    About this document The "Cutting machine Danfoss ET9500" 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 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. •...
  • Page 14 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 owner.

  • Page 17: Machine Description

    Machine description Design and function Basic machine (1) Motor (2) Bending pin (3) Cutting plate (4) Main power switch (5) Feed fork (6) Knife (covered) Knife protection (yellow) (8) Handle...
  • Page 18 The workpiece is positioned on the cutting plates (3) in front of the bending pins (3). During the cutting process, the handle (8) is moved downward, towards the cutting plate (3). During cutting, the feed fork (5) is moved forward by a chain drive and pushes the workpiece to- wards the knife (6).

  • Page 19: Technical Data

    Technical data Machine Dimensions L x W x H 745 x 690 x 430 mm Weight approx. 75 kg Noise level 80 dB(A)* Protection class IP 42 Operation mode S6-60% Function Hose feed Manual 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 20 Electric connection Connection power 4.6 kW 400 V – 50 Hz – 3 Ph 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)

  • 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 falling loads! Risk of injury from falling loads. • Do not stand under suspended loads. 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.
  • Page 23 Position the cutting plate flush with the table edge. Bolt the machine on the bench. 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: Extraction

    4.3.1 Extraction 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 sep- arator suitable for this purpose.
  • Page 25 Attach the adapter (2) to the extraction nozzle (1) of the ma- chine. Attach the angle adapter (3) to the adapter (2). Attach the spark extinguisher (4) to the angle adapter (3). Attach the metal hose to the spark extinguisher (4) and extrac- tion device (5).

  • Page 26: 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 27: 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 28: 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 29: 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 30: Deactivation

    Activate the machine at the main power switch (5). Move handle (1) steadily, slowly towards the cutting plate. The feed fork (2) moves forward. The cutting process is completed. Move handle (1) upwards to the starting position. The feed fork (2) moves backward. Deactivate the machine at the main power switch (5).

  • Page 31: Emergency Stop

    Polycarbonate screens are classified as wear parts by the Verein Deutscher Werkzeugmaschinenfabriken [German Machine Tool Builders' Association], since they lose their retention capacity due to environmental effects. Polycarbonate screens have to be re- placed 5 years after the construction of the machine (see year of construction) at the latest.
  • Page 32 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 33: 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 34 Remount the cover plate.

  • Page 35: 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 36 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 37: 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 38: 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 39 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 40 If the problems with the brake continue, immediately contact the manufacturer.

  • Page 41: 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 42: 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 43: 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 44: 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 45: Spare Parts List

    Spare parts list 9.2.1 Mechanical equipment Item Quantity Part code Designation 328.010.4 Feed fork 328.012.3 Cutting plate 320.111 Brake motor...

  • Page 46: Electric Equipment

    Item Quantity Part code Designation 329.009.4 Macrolon disc 304.2001 Set of bending pins 328.014.3 Knife protection 329.017.3 Tension rod 329.030.3 Hose feed 329.053.4 Guiding piece 329.020.4 Stop 329.025 Auto-spring 304.021 Pressure spring 329.019 Roller chain 329.042 Locking link 798.050010 Sleeve 329.040.4 Sticker EM6 329.1...

  • Page 47: Wear Parts

    Item Quantity Article code Designation 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 888.116 Turning handle 888.118 Axle 800.023 End supports 800.022 Fuse terminal 800.084 Protective conductor terminal 322.400 Rectifier No figure 530.217 Fine wire fuse...

  • Page 48: 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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Et9550

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