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

Danfoss ET9600 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 3 EC / UK - Declaration of Conformity In accordance with EC Machinery Directive 2006/42/EC and UK-Sup- ply of Machinery (Safety) Regulations 2008. The following machine 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 UNIFLEX-Hydraulik GmbH Robert-Bosch-Strasse 50 - 52...

  • Page 4: Table Of Contents

    Contents About this document ................... 7 1.1 Target groups ....................7 1.2 Storage ......................9 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 5 Operation ......................33 5.1 What you have to observe ................33 5.2 Start ......................33 5.3 Work piece cutting ..................34 5.3.1 Prerequisites ..................34 5.3.2 Cutting individual hoses ..............35 5.3.3 Setting the return stroke ..............36 5.4 Stop ......................37 5.5 Overload protection..................

  • Page 7: About This Document

    About this document The "Cutting machine ET9650" is consistently designated as ma- chine in this Operation Manual. This Operation Manual includes important notes on how you oper- ate your machine/unit safely, properly and economically. Use not in compliance with the intended purpose may result in haz- ard to the operator's health and life and/or in the risk of damage to/the machine/unit.
  • Page 8 • national provisions, occupational safety regulations and appli- cable environmental protection regulations are fully complied with; • 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 hardcopy of the Operation Manual must always be kept at a designated place where the machine/unit is used.

  • Page 9: Storage

    Storage The Operation Manual is part of the machine/unit and must be kept near the machine/unit at all times. Upon disposal of the ma- chine/unit, the Operation Manual must also be handed over. Name plate The name plate is fixed near the power cable. Abbreviations cutting knife, plain cutting knife, with slots...

  • 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 follows: The signal word HAZARD identifies an imminent hazard resulting in HAZARD! serious injuries or death. This warning is supplemented by a trian- gular hazard symbol.

  • Page 11: Product-Specific Risks

    ➢ persons with a restricted capability for the operation of machines (e.g. under the influence of drugs, alcohol or narcotics) Use of the control in compliance with the intended purpose also in- cludes 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 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. 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...

  • 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) Swarf box (13) Hose feed...

  • Page 18: Accessories

    (14) 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 985 x 815 x 580 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 76 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 observed 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 installation site.

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

    Check the pneumatic hoses for damage and secure fitting. Train the operating staff and record training sessions in “Dec- laration 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 hazard 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

    Establish the compressed air connection between the network and the compressed air maintenance unit (1) using a pneu- matic hose Ø 8 mm (G ¼ “). 4.3.4 Electrical connection WARNING! Risk by electrical voltage! There is a risk of electrocution near the live parts! •...

  • Page 28: Adjusting The Blocking System

    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 29 Switch off the machine at the main switch and secure it against unintentional restart. The blocking system (2) is adjusted so that it secures the knife protection when the protective cover is open and can be mo- ved smoothly when the protective cover is closed. Turning anti-clockwise releases the blocking system earlier.

  • Page 31: Initial Operation

    4.3.6 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 32 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 bend- ing pin (2) and the hose feed (5).

  • Page 33: 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 ma- chine.

  • Page 34: 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 35: Cutting Individual Hoses

    • 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. • Do not reach into the working area of the cutting machine during operation.

  • Page 36: Setting The Return Stroke

    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 bend- ing pin (2) and the hose feed (5). Close protective cover (1).

  • Page 37: Stop

    Adjust the return stroke setting (1) by turning it to the desired position using a screwdriver. Turning the return stroke setting in a clockwise direction increases the return stroke path. Stop Complete the cutting process. Deposit the work piece outside the machine. Deactivate the main switch (1).

  • Page 38: Overload Protection

    Inform the fitter in case of damage or other irregularities. Overload protection The motor is protected against overload by a motor protection switch. 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.

  • Page 39: 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 40 Disconnect the metal hose from the spark arrester (2). Vacuum out the spark arrester (2). Mount the metal hose on the spark arrester (2).

  • Page 41: 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 regu- larly to ensure the troublefree use of the machine/unit. • Maintenance work may only be performed by qualified mainte- nance staff (machine/unit fitters).
  • Page 42 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 Chip box: emptying, cleaning...

  • Page 43: 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 44: 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 45 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. • Check and readjust the motor brake regularly. •...
  • Page 46 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. Block the shaft using a hexagon socket wrench and turn the adjusting nut to the right using an open-end wrench. Secure the plastic cover (5).
  • Page 47 If the problems with the brake continue, immediately contact the UNIFLEX Hydraulic Service desk: Tel. +49 (0)6039/9171-0...

  • Page 48: 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 49: 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 50: Consumables And Waste

    Consumables and waste Observe applicable national environmental protection and waste disposal regulations. Return consumables, e.g. oils, greases, test media, to supplier - they are hazardous waste. Also observe the information given on the safety data sheet.

  • Page 51: Annex

    Annex Individual machine/unit components may deviate in their features. Please indicate the serial number of the machine for spare part or- ders.

  • Page 52: Machine Overview

    Machine overview...

  • Page 54: Accessories (Upgradable)

    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 Hose length measuring device UMS 4 Spark extinguisher 330.050.3 Cutting knife, plain TM 400x4x30...

  • Page 55: Spare Parts List

    Spare parts list 9.3.1 Mechanical equipment - Chassis Item Quantity Part code Designation 323.135.0 Chassis 323.040.1 Electric drawer 323.116.3 Cover plate 323.051.3 Base plate...

  • Page 56: Mechanical Equipment - Knife Protection

    Item Quantity Part code Designation 323.139.3 U-profile 323.024.4 Path adjustment axle 323.026.4 Guidance 323.028.4 Guidance connection 323.107.3 Positioner 323.134.3 Spark extinguisher 323.122.3 Retaining tab 323.138.2 Chip box 1 Satz 304.2001 Set of bending pins TM C 400x4x30 Cutting knife, coated 233.111 Rubber-metal buffer 9.3.2 Mechanical equipment - Knife protection...
  • Page 57 Item Quantity Part code Designation 323.029.4 Guidance, front 323.020.4 Pin for knife protection 323.046.4 Fork of blocking bar 323.047.4 Guide sleeve 323.032.3 Blocker 323.035.4 Axle 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...

  • Page 58: Mechanical Equipment - Covers

    9.3.3 Mechanical equipment - Covers Item Quantity Part code Designation 323.019.0 Machine cover 323.014.1 Protective cover 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...

  • Page 59: Electric Equipment

    Item Quantity Part code Designation No pic- 3166 Red direction arrow ture No pic- 777.031 Power supply disconnection warning sign ture 9.3.4 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...

  • Page 60: Pneumatic Equipment

    Item Quantity Part code Designation No picture VME 0265 Fine wire fuse 323.204 Roller lever switch 307.010 Safety switch Electric motor with brake No picture 320.111 No picture 8.12.031 Mounted housing No picture 888.228 Socket insert Foot pedal No picture 8.00.030 Metal oxide varistor 9.3.5 Pneumatic equipment...
  • Page 61 Item Quantity Part code Designation No pic- Sound absorber 405.080 ture...

  • Page 62: Wear Parts

    9.3.6 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 63: Electric Diagram

    Electric diagram...

  • Page 64: Pneumatic Diagram

    Pneumatic diagram...

  • Page 65: Maintenance Log

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

  • Page 66: 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 un- derstood this Operation Manual completely. City Date Name...

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