1. Manuals
  2. Brands
  3. FLETCHER Manuals
  4. Industrial Equipment
  5. Alfamacchine U200P
  6. Instruction manual

FLETCHER Alfamacchine U200P Instruction Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Document Code
U200P INSTRUCTIONS
EN
Name
FRAME ASSEMBLING MACHINE
ASSEMBLY OF FRAMES BY INSERTION OF METAL V-NAILS
Function
Model / Type
U200P
Serial number
Year of construction
2016
Manual Revision
PLEASE RETAIN FOR FUTURE REFERENCE
Rev.
01
INSTRUCTIONS MANUAL
TRANSLATION OF THE ORIGINAL INSTRUCTIONS (Keep for future reference)
TRANSLATION OF THE ORIGINAL INSTRUCTIONS (Keep for future reference)
Date saved
Date printed
30/06/2016
30/06/2016
EN
1

Advertisement

Table of Contents
loading

Related Manuals for FLETCHER Alfamacchine U200P

Summary of Contents for FLETCHER Alfamacchine U200P

  • Page 1 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 INSTRUCTIONS MANUAL Name FRAME ASSEMBLING MACHINE ASSEMBLY OF FRAMES BY INSERTION OF METAL V-NAILS Function Model / Type U200P Serial number Year of construction 2016 Manual Revision PLEASE RETAIN FOR FUTURE REFERENCE TRANSLATION OF THE ORIGINAL INSTRUCTIONS (Keep for future reference) TRANSLATION OF THE ORIGINAL INSTRUCTIONS (Keep for future reference)
  • Page 2 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 TRANSLATION OF THE ORIGINAL INSTRUCTIONS (Keep for future reference)

  • Page 3: Table Of Contents

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 TRANSLATION OF THE ORIGINAL INSTRUCTIONS INTRODUCTION TO USE ................................. 2 1.1. HOW TO CONSULT THIS MANUAL AND THE SYMBOLS ADOPTED ............... 2 1.2. WARNING - SAFETY ALERT DECALS (see figure) ..................... 2 1.3. TYPE OF USE AND CONTRAINDICATIONS ....................... 3 1.4.

  • Page 4: Introduction To Use

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 DANGER - WARNING BEFORE USING THE MACHINE PLEASE READ THIS MANUAL CAREFULLY SO THAT YOU BECOME FAMILIAR WITH THE MACHINE, ITS ENVISAGED USE AND ANY RISKS ASSOCIATED WITH IT. Keep the Use and Maintenance Manual in good condition: Remember, it is an integral part of the machine. Always refer to the manual to get best machine performance in maximum safety while performing the operations described therein.

  • Page 5: Type Of Use And Contraindications

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 1.3. TYPE OF USE AND CONTRAINDICATIONS. GENERAL WARNINGS The operator must read all the information in this manual carefully, paying special attention to the safety precautions listed in this chapter. It is also essential for the Operator to abide by the following warnings: · Always keep the machine and work area clean and tidy. · Arrange suitable containers for storing the workpieces to be processed and those that have already been completed. · NEVER use the machine when not in good psycho-physiological condition. · Always wear suitable workwear to avoid any hindrances and/or hazardous entanglement in machine parts. · Personnel must be authorized and trained beforehand on machine use by Alfamacchine technicians. · Wear all necessary personal protective equipment: safety footwear, gloves and protective glasses · The operator must wear personal protective equipment indicated in the Instruction Manual, in accordance with the operations to carry out. · Never remove or alter the dataplates affixed to the machine by the Manufacturer. · Keep fingers well away from the operating area. · Keep feet away from the pedal during machine adjustment operations.
  • Page 6 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 FORBIDDEN USE DANGER - WARNING FURTHERMORE IT IS PROHIBITED TO USE THE MACHINE IN AN INCORRECT MANNER, IN PARTICULAR: • never leave the loaded machine unattended • never use flammable, corrosive or toxic substances to clean the machine • never allow unauthorized personnel to use the machine • never smoke or use open flame equipment or handle incandescent material, unless adequate safety measures have been adopted • never activate or adjust the control and locking devices, such as knobs or similar devices, during machine operation or when not authorized to do so...
  • Page 7 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 PERSONNEL AUTHORIZED TO USE THE MACHINE This machine has been designed and manufactured to be used by qualified personnel with adequate training, experience and skills in accordance with the characteristics described below: Operators / Apprentices: • may be male or female; • must be aged 14 or over; • must have full use of both hands; • must have no physical or mental disabilities; • must know and fully understand the contents of the user manual.

  • Page 8: Technical Characteristics

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 SERVICE CONDITION USER LIMITS Special and additional prescriptions, not envisaged, may be requested for machines intended for: • outdoor use; • handling potentially explosive materials; • use in potentially explosive and/or flammable atmospheres; • use involving specific risks in the processing of specific materials; • use in mines; • use in refrigeration plants; • use at high temperatures;...

  • Page 9: Products Processed - Handled Or Generated

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 Material Recommended sharpness Soft woods and plastic transparent stick Medium wood brown stick Hard wood green stick Very Hard Wood and MDF red stick 1.5. PRODUCTS PROCESSED - HANDLED OR GENERATED The products handled by the machine described herein must be made up of wooden mouldings of various hardness, with multiple surface finishes, for the purpose of making frames for pictures, mirrors, display cases, cupboard doors etc.. The main technical characteristics of the products handled by the machine described herein are provided below. DESCRIPTION OF PRODUCTS HANDLED CHARACTERISTICS Minimum/maximum profile height 6 - 80 mm...

  • Page 10: Residual Risks

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 1.8. RESIDUAL RISKS For each risk, suitable instructions or prescriptions are given which the user must observe in order to avoid hazards affecting the machine operator, maintenance technicians, any exposed persons and the machine itself. Residual risk of finger crushing During the normal operating cycle and during maintenance, Operators are exposed to certain residual risks which, due to the nature of the operations could not be completely eliminated. - Finger crushing hazard in the operating area of the vertical clamp (A). Furthermore, it is to be pointed out that said finger crushing risks are present near each mobile element installed over the machine’s working bench. Consequently the operator and maintenance technician, as well as observing the instructions provided in this manual, must never place their fingers or any other part of the body in the zone indicated. What’s more, workers must never wear rings, wrist watches, jewellery, torn clothing, scarves, ties or any other loose clothing or personal accessories that may constitute a risk. Make sure sleeves fit snugly around wrists and keep long hair tied back. Residual risk due to the combustibility of the substances used in the machine and the products handled by the same To avoid the hazards resulting from: • the ignition of substances used in the machine; • residual risks associated with possible outbreaks of fire; the employer, in addition to training and adequately informing the machine operator and maintenance technician on such risks, must provide permanent fire protection systems in the vicinity of the machine control station. Said systems must be suitable for the types of material which could catch fire.

  • Page 11: Description Of Safety Functions

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 Residual risk caused by piloting the valves There is a residual risk for the maintenance technician, when the safety guards are open and the valve pilots are activated, in order to check (during troubleshooting procedures) the operation of the pneumatically operated mobile elements, when energy remains accumulated in the actuator cylinders. Consequently, when the aforementioned activities are performed, the maintenance technician must make sure that no exposed persons are found near the pneumatically controlled mobile elements and in any case said mobile elements must only be activated if strictly necessary for pinpointing operating faults. Residual risk due to the presence of accumulated energy inside the pneumatic actuator cylinders There is a residual risk for the maintenance technician when the machine is isolated from the compressed air network, due to the presence of accumulated energy inside the actuator cylinders, when mobile guards are open caused by the presence of closed- centre valves and/or tanks which remain pressurized.

  • Page 12: 1.10. Machine Description

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 1.10. MACHINE DESCRIPTION The U200P frame assembling machine has been designed to assemble every kind of frame. The U200P, with its simple and easy-to-use construction, can execute precise joins of any type of moulding using special steel V-nails. It can operate with normal V-nails, reinforced V-nails for very hard wood and special ALFAGRAF V-nails with “pulling power” of various heights. 1.11. MAIN MACHINE COMPONENTS The equipment listed below refers to standard machines. Consequently, any special supplies may have some different components to those listed. After removing the machine from the packaging, make sure the following accessories are present: • 1 head for 7-mm V-nails; • 1 head for 10-mm V-nails; • 1 Head for 12-mm V-nails; •...
  • Page 13 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 The vertical stopper unit is made up of the following main parts: (N) Punched rod - allows the operator to position the stopper at various heights based on the various frame profiles. (O) Screw for fastening and for rapid changeover of the mechanical stopper holder or the magnetic support; Stopper holder, which may be mechanical or magnetic depending on the type of accessories used. Click knob for blocking the column. Drilled rod support arm. Piston stem vertically activated by the pneumatic actuator.
  • Page 14 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 V-nail firing unit and magazine In the U200P machine, the magazine (E) can hold V-nails of different heights but only one V-nail height can be used at a time, depending on the nailing head installed. When the size of the V-nails is changed the nailing head must also be switched over to match the V-nails used. The V-nails are held in position by the V-nail pusher device (F). Head and L-block support are designed to guide the V-nails during the thrust action of the hammer and their insertion into the overlying mouldings.
  • Page 15 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 Alignment fences unit The alignment fences unit, positioned on the working bench, can slide along the assembly line of the firing unit and its position is adjusted by the operator. Fixed fences for 120° and 135° corners may also be installed in the fence support (A) for making frames with 6 and 8 sides respectively (available as optional accessories). Two-knob fence (optional) The fixed fence can be replaced with the two-knob model (C) which allows the user to adjust the tilt of the moulding stop in relation...

  • Page 16: Installation

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 INSTALLATION 2.1. STORAGE The machine, intended for indoor installation must be stored, if necessary, in well ventilated storage facilities and protected from dust. The delivered elements must remain in their original packing until the time of final installation. All parts of the machine subject to the risk of oxidation are protected with grease and protective sprays at the time of dispatch to prevent oxidation caused by weather conditions. In the case of prolonged inactivity the machine must be stored with all necessary precautions taken based on the location and expected storage times: 1. Store the machine in an enclosed place. 2. Protect the machine from impact and stress. 3. Protect the machine from humidity and excessive temperature differences (refer to the table below). 4. Do not allow corrosive substances to come into contact with the machine. 5. Check that the pack has not been damaged and that it is perfectly dry.

  • Page 17: Transport, Lifting And Handling

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 2.3. TRANSPORT, LIFTING AND HANDLING Dimensions, weight and handling of individual machine parts BOX DIMENSIONS Machine height ..........440 mm - 21 ⁄ 64in Machine depth .......... 500 mm - 11 ⁄ 16in Machine width .......... 660 mm - 63 ⁄ 64in Weight of the machine (including the packaging) a pprox. 35 kg - 88lbs DANGER – CAUTION • The machine must be transported to a position as close to the intended installation site as possible. Said site must be checked beforehand to obtain information about the necessary clearances and dimensions, including the essential space required for installation procedures. • It is strictly prohibited to lift loads over people. If persons are present in the area, lower the load and ensure everyone moves out of the way. 2.4. LIFTING AND HANDLING The U200P machine is shipped ready for use.
  • Page 18 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 .2.5. REMOVING THE PACKAGING Description of the packaging The machine may be shipped in a container or on a lorry. In both cases the same type of packing is envisaged which is suitable for guaranteeing the good condition and proper preservation of the machine during transport up to the time of delivery to the customer. The machine is shipped packed in a special box and protected against damage by polystyrene inserts. Maximum dimensions 660x440x500 (AxBxC). NOTE –It is advisable to keep the packaging in case it is needed to store or transport the machine at a later date. When storing the machine, never stack two machines packed on a pallet with shrink wrap.

  • Page 19: Preliminary Preparation And Adjustment Procedures

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 PRELIMINARY PREPARATION AND ADJUSTMENT PROCEDURES 3.1. PUTTING THE MACHINE INTO SERVICE 1) POSITION THE MACHINE ON THE TABLE OR ANOTHER HORIZONTAL WORKSURFACE 2) CONNECT THE PEDAL BY INSERTING THE AIR LINES IN THEIR CONNECTORS ON THE SIDE OF THE MACHINE. 3) CONNECT THE COMPRESSED AIR SUPPLY LINE.

  • Page 20: Assembly Of Separately Shipped Units

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 3.3. ASSEMBLY OF SEPARATELY SHIPPED UNITS DANGER – CAUTION All assembly activities concerning machine units supplied separately, include highly delicate operations which call for significant experience. Consequently they must be carried out exclusively by personnel appointed directly by the manufacturer or authorised by the same and, in any case, under the manufacturer's responsibility.

  • Page 21: Initial Start-Up And Use Of The Machine

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 INITIAL START-UP AND USE OF THE MACHINE DANGER - WARNING THE MACHINE MUST ONLY BE OPERATED BY AUTHORISED AND DULY TRAINED PERSONNEL WITH ADEQUATE TECHNICAL EXPERIENCE. MACHINE OPERATORS MUST BE AWARE OF THE FACT THAT KNOWLEDGE AND IMPLEMENTATION OF THE SAFETY RULES ARE AN INTEGRAL PART OF THEIR WORK.
  • Page 22 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 User’s compressed air production system The compressed air production system must be designed, installed and maintained in compliance with the applicable prescriptions indicated in the safety regulations in force. To high obtain quality compressed air, note that: • maintenance and operation of the compressors, the auxiliary systems and the primary systems must be in compliance with the manufacturers’ instructions and specifications • the lubricant must comply with the specifications given by the compressor manufacturer • the compressor or its suction line must be positioned in an area having the lowest possible level of pollution from vehicle exhausts, fumes exhaustion from industrial processes, etc. • a filter should be installed on the compressed air line as close as possible to the user point. Air quality: • To obtain the best possible performance and the maximum lifetime of the pneumatic system use compressed air having a dew point between +2°C and + 10°C. • use a separate air filter, installed as close as possible to the user point. Flush the line with compressed air before connecting it. For correct use of compressed air, in general terms, consult the following reference standards: • ISO 8573 – 1, this standard defines the industrial compressed air quality for general use without considering the quality of air at the compressor outlet. • The compressed air quality level for special applications must be based on the value resulting from a large number of measurements taken during a specific time period and in clearly defined operating conditions. For the required minimum pressure value, the nominal working pressure and the air consumption expressed as the average value for correct operation of the machine, refer to the heading “TECHNICAL CHARACTERISTICS”.

  • Page 23: Workstations And Operators' Tasks

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 4.2. WORKSTATIONS AND OPERATORS' TASKS The machine described herein is designed to be run by 1 operator suitably trained and instructed with regard to residual risks. The operator must have the same skills, in terms of safety, as the maintenance technicians and adequate professional competence. The normal work area of the operator and relevant tasks/assignments are: • the manual introduction/removal of mouldings onto the working bench, with the fixed safety guards closed and locked; • the manual loading of V-nails in the magazine, with the fixed safety guards closed and locked; • the adjustments and tooling of the key units (head, frontal clamp, alignment fences, etc.) needed to operate the machine, using the relevant tools, with the fixed guards closed and locked; • the manual removal of V-nails clogged in the magazine and/or nailing claw head, with the fixed safety guards closed and locked; • check operations (for example reading the data on the console panel and machine instrumentation). These are very simple tasks which can be carried out in total safety and clearly described in the Instruction Manual; • general monitoring of machine operation - for example checking the cleanliness of the machine, etc. In the event of a problem, the operator must not intervene, but simply call the Maintenance Service; • cleaning external and internal machine parts, and any other parts that may require cleaning (e.g. the upper/surrounding part of counter-rotating rollers) via the fixed safety guards, while these are closed and locked. Any cleaning of internal machine parts which requires the removal of the fixed guards must be performed by a qualified maintenance technician.

  • Page 24: Checks, Adjustments And Start-Up

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 4.3. CHECKS, ADJUSTMENTS AND START-UP All functions/operations pertaining to operating modes must always comply with safety measures and the prescriptions for the protection against residual risks. During normal production, the machine must only be used to process the products specified herein. During the working cycle, it is essential to comply with safety measures and prescriptions for the protection against residual risks 4.4. START-UP Before connecting the machine to the pneumatic system, you must first connect the control pedal. The three air lines connected to the pedal assembly must be inserted in the three connectors located on the right-hand side of the machine in the following order: 1) RED LINE in the connector on the outer side (1) 2) BLACK LINE in the intermediate connector (2) 3) TRANSPARENT LINE in the connector on the operator side (3) Inserting V-nails in the loader To load the V-nail magazine, proceed as follows:...
  • Page 25 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 Changing over the firing head for V-nail changeover. It is necessary to switch over the nailing head each time a different size V-nail is used. To replace the head proceed as follows: Loosen the firing head locking screw using a suitable wrench (the screw is on the opposite side to the V-nail magazine (1) · Lift the head upwards and out. · Draw the V-nail pusher back using the relative control cable located on the rear side of the machine’s working bench to make the magazine accessible (2). · Remove all the V-nails in the magazine (use the pencil magnet (3) if necessary). · Insert the new V-nails of the required height in the magazine (4) · Release the control cable and let the V-nail pusher move forward. · Insert the new head to match the height of the V-nails to be used (5). · Tighten the firing head locking screw. TRANSLATION OF THE ORIGINAL INSTRUCTIONS (Keep for future reference)
  • Page 26 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 V-nail firing head alignment NOTES Before proceeding with the operations provided below, disconnect the machine from the compressed air supply and disconnect the tube. Mechanical alignment of the V-nail firing head is necessary following: loosening caused by work operations, wear on components, jamming during firing, replacement of parts, maintenance. The parts which need to be aligned with one another are: head, L-block support, V-nail magazine and loader. To perform mechanical alignment, proceed as follows: 1. Undo the socket head screw securing the head to the L-block support and remove the head from the support. 2. Loosen the screws securing the L-block support to the firing unit. 3. Slacken the M5 screws on the two magazine locks.
  • Page 27 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 Adjustment and alignment of the mobile fence If it is not aligned, proceed as follows. 1. Move the transparent fence up to the mobile fence (A). Check 2. Turn the machine over and slacken the screws (B) relative that when the fence moves its bisector is aligned with the centre to the blocks (C) which lock the fence guide blocks to the of the V-nail firing head.
  • Page 28 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 Adjustment of V-nail insertion positions For correct positioning of the mouldings to be joined together, the U200P is fitted with a 90° fence. The fence may move forward or be drawn back (6) in order to correctly position mouldings of various sizes. The fence forward (8) and fence back positions can be fixed by locking it in the required position using the stopper clamps A-B (7). In this way the operator can easily use the U200P to insert V-nails with maximum precision in all the positions between the two mechanical stops (7 and 8). (A) This picture shows 4 V-nails inserted along the join between two mouldings;...
  • Page 29 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 Fixed fences, optional Replacing fixed fences with a two-knob mobile fence To replace the fence unit, proceed as follows: 1. Undo the 2 socket head screws (A). 2. Once the screws have been removed (A) the fixed fence of the fence unit can be removed. 3. To install new fences repeat the above steps in reverse order and tighten the 2 socket head screws. 4. If necessary remove the contact edges from the old fence and transfer to the new one if the latter is without. To do so, simply act on the 4 screws (B) shown in the figure. Fixed fences, optional 1. To vary the contact angle it is necessary to replace the fixed fence with one of the right angle. The fence for 90° joins (four-sided frame) is part of standard machine equipment. By installing the optional fence (C) the machine can be used to make 120° joins (six-sided frame). By installing the optional fence (D) the machine can be used to make 135° joins (eight-sided frame).
  • Page 30 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 Adjusting the height and replacing the vertical clamp stopper Interchangeable rubber stoppers: Soft (blue) Medium (yellow) Hard (black) Single stopper holder Magnetic stopper holder Magnetic support Round magnetic felt stopper. 1. To adapt the position of the stopper (E) to the thickness of the 2. To replace the stopper holder (F, G or H), you must unscrew frame, proceed as follows: the screw (I) which secures it to the rod and pull it downwards...
  • Page 31 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 3. In the case of a magnetic stopper holder, tighten the socket head screw (I). 4. In the case of a mechanical support, tighten the socket head screw (I). 5. Insert the interchangeable rubber stopper (E), depending on the required hardness, by inserting it into the stopper holder support. 6. Check the correct position of the stopper by positioning it like the 90° fence and tighten the fixing screw (l.). TRANSLATION OF THE ORIGINAL INSTRUCTIONS (Keep for future reference)
  • Page 32 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 Installation of interchangeable stoppers The interchangeable stoppers (E), based on work requirements, may be applied to: - Corner magnetic stopper holder; - Single stopper holder Install the stopper (E) for the required hardness in the stopper holder, positioning it under the slot and manually pressing it in place. To remove the stopper (E) simply pull it out with your hand by gently taking hold of one of the two sides.
  • Page 33 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 Adjusting the pressure of moulding clamping devices The procedure for adjusting the pressure of the vertical and front moulding clamping devices is described below. The work pressure must be suitable for the hardness of the mouldings to be joined. Adjust the clamping pressure in such a way as to avoid crushing or damaging the surface of the material to be joined, but ensuring that the thrust of the hammer for inserting V-Nails does not cause the moulding itself to rise. The harder the material to be joined, the greater the pressure that can be applied to the clamping devices is. To correctly assemble the mouldings, the operator must always check they do not rise when V-nails are being inserted. An excessively low work pressure may result in the incomplete insertion of the V-nail in the frame. The work pressure is adjusted by turning the pressure regulator knob (A) located on the working bench. The work pressure value can be seen on the pressure gauge (B). To alter the work pressure, proceed as follows: 1. Lift the knob by about 3-4mm. 2. Turn it clockwise to increase the pressure, or anticlockwise to reduce the pressure. 3. Press the knob to lock it back in place. The following operating pressure values are recommended: Pressione consigliata / Air Durezza / Hardness...
  • Page 34 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 SUGGESTIONS FOR MAKING PERFECT JOINS 1) V-nail types In order to ensure that the machine can make top quality joins using a wide variety of materials, different V-nails are available with different degrees of sharpness suitable for use with different hardness values and characteristics of the materials being handled. V-Nails can be divided up into the following categories: V-nail type Height mm 3mm (optional) 10mm 12mm 15mm it is advisable to carry out a check on the material in question for selecting the most suitable sharpness. 2) Stapling positions The following guidelines are designed to help you get the best results in terms of quality joins: - Avoid inserting V-nails close to the moulding edge. The minimum recommended distance from the outer edge is at least 10mm. - When creating a join with just one V-Nail, position the V-Nail on the centre line of the frame. - If you wish to insert 2 or more V-Nails for each join, it is advisable to insert the outer V-Nail at 1/3 from the outer edge and the inner V-Nail 1/4 from the inner edge. TRANSLATION OF THE ORIGINAL INSTRUCTIONS (Keep for future reference)
  • Page 35 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 Adjusting the working bench (IF OPTIONAL STAND PURCHASED) · The machine working bench can be tilted simply by changing the position of the screws responsible for fixing the machine to the stand in the uppermost position. This operation must be performed using one hand to counterbalance the machine and prevent the working bench from tipping toward the travel stop due to gravity. The machine can be set up as required in accordance with the following positions: Working bench tilted backward (2); Working bench horizontal (3); · Once adjustments have been made, tighten the screws securely to block the machine in the selected position. 4.5. WORKING CYCLE Checks to be performed before starting work After having correctly installed the machine as previously described, check that: · the mouldings to be joined are correctly positioned on the working bench. · the magazine holds V-nails which are suitable for the mouldings being joined; · the firing head is of the right size for the selected V-nails; · the adjustment of the vertical stopper is suitable; · vertical clamping is perfect when the profile is positioned and the pedal pressed halfway down, · adjustment of the V-nail insertion position is correct. · press the pedal all the way down to insert the V-nail.
  • Page 36 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 Make all the necessary regulations based on the dimensions of the mouldings and then: vertical stopper adjustment; Whenever the two-knob fence is being used, insert the first moulding on the right-hand side of the fence and then bring the left-hand moulding (error condition). The pedal has three positions: Position 1 – Stand-by Position 2 – Pressed halfway down to automatically activate the vertical clamping. Position 3 – Pressed all the way down commands the hammer for V-nail insertion. Release the pedal for the new V-nailing position and repeat the operation. 1. Taking care over the hazardous areas, use your hands to accompany the movement of the fences and the mouldings up to the desired V-nail insertion position.

  • Page 37: Maintenance, Troubleshooting And Cleaning

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 MAINTENANCE, TROUBLESHOOTING, AND CLEANING 5.1. MAINTENANCE TECHNICIAN REQUIREMENTS The term "maintenance" does not just cover periodical controls of normal machine operation, but also the analysis and consequent rectification of any of those problems which for any reason stop the machine from working properly or not at all. Specifically, personnel appointed to perform the servicing, cleaning, replacing of parts and troubleshooting, must work in compliance with the following aims: 1. limit the deterioration of wear parts. 2. reduce accidents to the absolute minimum. 3. reduce costs arising from faults. 4. limit the number and duration of interventions. 5. work in collaboration with the line operators to improve the efficiency of the plant.

  • Page 38: Tasks That Can Be Performed By The Operator

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 5.7. TASKS THAT CAN BE PERFORMED BY THE OPERATOR A list of all the periodical checks/inspections, adjustment and control operations and ROUTINE MAINTENANCE operations which can be carried out by the machine operator is provided below. The position of the machine components is shown in the layouts provided as an appendix to this manual. FREQUENCY CHECK METHODS AND RESULTS Before each shift Working area: The work station and all the parts outside the machine must be • must be clean and free cleaned and all dust and objects must be removed which could from dust impede correct operation and/or compromise the machine's original safety conditions.

  • Page 39: Tasks That Can Be Performed Only By Maintenance Technicians

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 5.8. TASKS THAT CAN BE PERFORMED ONLY BY MAINTENANCE TECHNICIANS The ROUTINE MAINTENANCE operations which must be performed by a maintenance technician are indicated below. The instructions concerning the replacement are not given in this manual and they must therefore be explicitly requested from the machine manufacturer, which reserves the responsibility for the replacement interventions. FREQUENCY CHECK METHODS AND RESULTS Every 1,000,000 V-nails used Check / replace: Replace every 1,000,000 V-nails used • Hammer Overturn the machine to gain access to the pneumatic equipment.
  • Page 40 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 It the hammer is worn out or chipped, proceed to replace the whole piston. The raised ends of the hammer must have marked edges to ensure correct insertion of the V-nail. Grease the hammer piston and the seals well then insert it in the special hole taking care not to pinch the lip seal. If insertion proves difficult, try removing the L-block support, head and V-nail loader. Note: position the hammer so that the high part of the piston has the two raised edges pointing towards the magazine. 10. Replace the cylinder and move it well up against the head. Secure in place with the 4 screws and reconnect the air lines. At the end of the operation check alignment of the V-nail firing head: magazine and head: reconnect the air supply to the machine and activate the hammer several times to make sure it moves correctly and that there are no mechanical hindrances.
  • Page 41 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 FREQUENCY CHECK METHODS AND RESULTS Every 5,000,000 Check / replace the "L" Proceed with disassembly by following the instructions in the heading V-nails inserted support block MECHANICAL ADJUSTMENTS / MAINTENANCE At least once a month All the parts inside the casings and in the machine housings where the motors are installed, must be kept clean and dry. Use suitable and normally available tools and equipment (e.g. vacuum cleaners and dry brushes to remove dust and absorbent cloths for removing moisture) to keep said areas of the machine in a suitable operating condition.

  • Page 42: Cleaning

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 5.9. CLEANING DANGER – CAUTION It is prohibited to manually clean, oil or grease moving machine parts and elements unless this is strictly necessary for some specific technical requirement. If this is the case all suitable measures must be taken to prevent hazards. Workers must be informed by means of clearly visible warning signs.
  • Page 43 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 ZONE, MODE AND METHODS THE WORKING BENCH AND THE FIRING HEAD must be kept clean from all residues of glues used to join the frames. Do not use water. Use a petroleum based cleaning product. THE V-NAIL MAGAZINE AND GUIDE must be kept clean from any residues and dust. Do not use water. Use a petroleum based cleaning product. • THE WORKPLACE AND THE CONTROL STATION must be kept clean and tidy. Remove all dust and dirt. An untidy workplace increases the risk of accidents. During cleaning operations, always use a dust mask and any other PPE prescribed for the type of operation being carried out and depending on the substances used for cleaning. Comply with the methods of use and use all the necessary PERSONAL PROTECTIVE EQUIPMENT SPECIFIED BY THE SUPPLIER OF SUCH SUBSTANCES.
  • Page 44 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 5.10. LUBRICATION During lubrication operations: 1. Avoid bringing oil and/or grease into contact with the skin. 2. During oil and/or grease changes use protective gloves. Both spent and fresh lubricants are highly polluting: for disposal of lubricants consult your lubricant dealer or contact a specific toxic waste disposal company. All lubrication operations must be performed: 1. after first cutting off all external energy supplies, 2. strictly observing the safety indications given in the “safety datasheets” provided with each individual lubrication product used. The lubrication operations which must be performed by maintenance technicians are indicated below. To obtain high performance and faultless operation, it is important to lubricate moving parts of the machine on a regular basis. The position of machine components which need lubricating is shown in the layout provided as an appendix to this manual. For the disposal of spent oil and grease, observe the relative legislation in force. Do not disperse spent oil in the environment. Consign it to specifically authorised collection centres. NOTES Fixed guards must be removed in order to gain access to some of the parts requiring lubrication. Fixed guards are identified by the following sign: Once lubrication operations have been completed, all the fixed guards must be refitted and secured in place.

  • Page 45: Troubleshooting And Release Of Moving Parts

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 TROUBLESHOOTING AND RELEASE OF MOVING PARTS If any of the moving parts becomes jammed, in order to release it in conditions of safety the machine operator must first stop the machine and then inform the persons in charge of maintenance, if he has not been authorised to release jammed parts beforehand. The following section describes operations for troubleshooting and releasing moving parts that can be performed by maintenance technicians. Before performing any work or investigations: 1. Install a sign indicating that maintenance is in progress on the machine 2. Make sure that the upstream and downstream connected machines do not constitute a source of danger or an impediment to the maintenance work; switch off said machines using the designated procedures. 3. Before restarting the machine, make sure there are no personnel still performing cleaning and /or maintenance operations on it. 4. For mechanical repair work, always seek the assistance of the manufacturer. 5. Always consult the machine manufacture in accordance with the methods specified on the initial pages of this manual. 6. Do not zero/reset the safety devices automatically by means of an external sequence without first checking and identifying the cause of the stoppage. By observing any types of information that the machine control system provides, machine faults can be identified and interpreted. All information devices (visual, audible) aimed at avoiding potential ergonomic hazards, with the relative explanations and the type of information the operator/s will receive are described in chapters 3 and 4. Depending on the type of information, action must be taken to eliminate the cause that led to/generated the visual or audible alarm signal. The PROBLEMS OR FAULTS which could lead to a MACHINE STOPPAGE are: PROBLEM / METHODS AND ANCILLARY NOTES...
  • Page 46 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 PROBLEM / METHODS AND ANCILLARY NOTES POTENTIAL CAUSE(S) FAULT When the pedal is pressed, the machine works Faulty or clogged valves properly, but - Remove oil and/or condensate when the pedal is - Replace the pedal valve. released, there is a - Replace the faulty control valves slight delay in the repositioning of the columns and/or...

  • Page 47: Reinstallation And Reuse

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 REINSTALLATION AND REUSE CAUTION - DANGER MOVING AND REINSTALLING THE MACHINE IN A DIFFERENT LOCATION ARE HIGHLY DELICATE OPERATIONS WHICH CALL FOR SIGNIFICANT EXPERIENCE. CONSEQUENTLY TO ENSURE THAT THE OPERATIONS ARE CARRIED OUT WITHOUT ANY RISKS FOR PERSONNEL OR THE MACHINE, THESE OPERATIONS MUST BE CARRIED OUT SOLELY AND EXCLUSIVELY BY PERSONNEL APPOINTED DIRECTLY BY THE MACHINE MANUFACTURER OR AUTHORISED BY THE SAME.

  • Page 48: Disposal

    Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 9.2. DISPOSAL DANGER - WARNING DISPOSE OF THE MACHINE COMPONENTS IN ACCORDANCE WITH OPERATING METHODS WHICH OBSERVE THE MAIN REGULATIONS GOVERNING SAFETY AND ENVIRONMENTAL PROTECTION IN THE COUNTRY OF DISPOSAL.
  • Page 49 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 TRANSLATION OF THE ORIGINAL INSTRUCTIONS (Keep for future reference)
  • Page 50 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 U series TAB.23 VERTICAL CLAMP GROUP - GRUPPO BLOCC. VERTICALE Alfamacchine 10.2016                  ...
  • Page 51 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 U200P TAB.35 HEAD GROUP ASSEMBLY - MONTAGGIO GRUPPO TESTA Alfamacchine 10.2016                   ...
  • Page 52 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 U200P TAB.37 PNEUMATIC COMPONENTS - COMPONENTI PNEUMATICI Alfamacchine 10.2016                     ...
  • Page 53 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 U200P TAB.38 FLOOR STAND - CAVALLETTO Alfamacchine 10.2016                      ...
  • Page 54 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 TRANSLATION OF THE ORIGINAL INSTRUCTIONS (Keep for future reference)
  • Page 55 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 TRANSLATION OF THE ORIGINAL INSTRUCTIONS (Keep for future reference)
  • Page 56 Document Code Rev. Date saved Date printed U200P INSTRUCTIONS 30/06/2016 30/06/2016 ALFAMACCHINE S.r.l. Via Curie Marie e Pierre, 3 - 47122 Forlì - FC Tel. +39-0543/783301 Fax +39-0543/783302 http://www.alfamacchine.com TRANSLATION OF THE ORIGINAL INSTRUCTIONS (Keep for future reference)

Table of Contents