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Alfamacchine U400S Instruction Manual

Semi-auto/pneumatic underpinner
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Function
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Year of construction
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PLEASE RETAIN FOR FUTURE REFERENCE
INSTRUCTIONS MANUAL
FRAME ASSEMBLING MACHINE
ASSEMBLY OF FRAMES BY INSERTION OF METAL V-NAILS
U400S (previous version MINIGRAF 44)
03

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Summary of Contents for Alfamacchine U400S

  • Page 1 INSTRUCTIONS MANUAL Name FRAME ASSEMBLING MACHINE Function ASSEMBLY OF FRAMES BY INSERTION OF METAL V-NAILS Model / Type U400S (previous version MINIGRAF 44) Serial number Year of construction Manual Revision PLEASE RETAIN FOR FUTURE REFERENCE...
  • Page 2 Fascicolo Tecnico costituito presso : ALFAMACCHINE S.R.L. Technical File drawn up by: ALFAMACCHINE S.R.L. Forlì ,...

  • Page 3: Table Of Contents

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 TRANSLATION OF THE ORIGINAL INSTRUCTIONS INDEX INTRODUCTION TO USE ................................. 2 1.1. HOW TO CONSULT THIS MANUAL AND THE SYMBOLS ADOPTED ............... 2 1.2. WARNING STICKERS - INDICATIONS (see figure) ....................2 1.3.

  • Page 4: Danger - Warning

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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.

  • Page 5: Permitted Use

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 PERMITTED USE 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.
  • Page 6 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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, •...

  • Page 7: User Limits

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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: •...

  • Page 8: Service Condition

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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;...

  • Page 9: Products Processed - Handled Or Generated

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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..

  • Page 10: Emission Of Airborne Noise

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 1.6. EMISSION OF AIRBORNE NOISE NOTE – The manufacturer declares, under his own responsibility, that the machine produces a continuous equivalent A-weighted sound pressure level of 72 dB. DANGER – WARNING:...

  • Page 11: Description Of Safety Functions

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 Residual risk of finger crushing With the adjustable polycarbonate guard in the high or low position, there is a residual risk of finger crushing, for operators and maintenance technicians, inside the slot on the working bench along the stroke of the V-nail shooting unit.
  • Page 12 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 Machine guards and safety devices GUARDS / TYPE OF SAFEGUARDED Ref. PROTECTIVE HAZARD DEVICES – POSITION Polycarbonate panel secured Adjustable guard to metal supports which can be adjusted by acting on the relative knobs, to prevent access to the stopper.

  • Page 13: 1.10. Description Of The Machine

    21/10/2022 1.10. DESCRIPTION OF THE MACHINE THE U400S FRAME ASSEMBLING MACHINE is a machine for producing wooden frames. More specifically it joins together the frame mouldings (which maybe pre-glued or dry) using metal V-nails. All operating phases such as: loading and unloading of the frame, clamping, head movement and nailing are completely manual.
  • Page 14 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 Working bench The working bench is the surface on which manual operations take place to move, clamp and join the frame mouldings and holds all the operator controls. It is made up of the following main parts:...
  • Page 15 21/10/2022 V-nail magazine and V-nail firing head In the U400S machine, the magazine can hold V-nails of different heights but only one V-nail size 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.
  • Page 16 Nailing head The nailing head ensures precision insertion of the V-nails in the frame. The nailing head used on the U400S machine (L) is different for every type of V-nail. On the machine the head is marked with a number (M) which indicates the height of the V-nails it can use.
  • Page 17 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 Head moving handle This device allows the operator to move the carriage which supports the V-nail firing unit to the point in which V-nails are to be inserted. Operation of the handle controls is obtained only after having pressed the pedal.

  • Page 18: Installation

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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.

  • Page 19: Transport, Lifting And Handling

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 2.3. TRANSPORT, LIFTING AND HANDLING Dimensions, weight and handling of individual machine parts MACHINE BODY Machine height ..........A = 1350 mm-53 in Machine depth ..........B = 600mm - 24’’...

  • Page 20: Removing The Packaging

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 2.4. 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...

  • Page 21: Preliminary Preparation And Adjustment Procedures

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 PRELIMINARY PREPARATION AND ADJUSTMENT PROCEDURES 3.1. POSITIONING Suitability of the floor – supporting surface The machine must be positioned on a solid, reinforced concrete foundation. The floor must have an adequate load bearing capacity to support the weight of the machine. The floor must be designed and prepared by the user.

  • Page 22: Assembly Of Separately Shipped Units

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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. These activities are...
  • Page 23 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 Installation of the bracket system for the wooden work surface (not supplied) The wooden work surface (not supplied) and the working bench must be aligned carefully so that the lower surface of the mouldings rest fully on the entire support surface when the double stopper presses down on the ends of the mouldings.
  • Page 24 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 Stand assembly Installation can be completed in a few simple steps as described below: 1. Proceed with assembly by joining the base (B) to the uprights 2. Join the base to the uprights using the 4 screws provided.
  • Page 25 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 3.4.2. Compressed air supply The compressed air supply must be maintained in compliance with the following technical prescriptions: • The compressed air supply must be of the type and intensity specified on the first page of the “pneumatic diagram”. If excessive pressure values are applied the components will be irreparably damaged.

  • Page 26: Initial Start-Up And Use Of The Machine

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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.

  • Page 27: Workstations And Operators' Tasks

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 4.1. 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.

  • Page 28: Start-Up

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 4.4. START-UP Before connecting the machine to the pneumatic system, you must first connect the control pedal. The three air lines which are 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).
  • Page 29 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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.
  • Page 30 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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: 1)Loosen the firing head locking screw using a suitable wrench.
  • Page 31 The alignment fences must be secured in position taking into account the linear movement of the head. To check correct positioning you can ask Alfamacchine to provide you with the transparent right-angle set square on which the height is shown by a serigraph line.
  • Page 32 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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 (A) to the thickness of the 2.
  • Page 33 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 Installation of interchangeable stoppers The interchangeable stoppers (A), based on work requirements, may be applied to: - Corner magnetic stopper holder; - Single stopper holder Installe the stopper (A) for the required hardness in the stopper holder, positioning it under the slot and manually pressing it in place.
  • Page 34 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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 front clamping pressure is limited to 2 bar. The work pressure must be suitable for the hardness of the mouldings to be joined.
  • Page 35 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 Adjusting the tilt of the workbench Depending on the operator’s needs, the workbench can be tilted. To carry out adjustments, proceed as follows: 1. Slacken the handle (A) located on one of the legs of the stand, under the working bench.
  • Page 36 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 Safety shield adjustment The machine is fitted with a transparent plastic safety shield designed to protect the operators hands from possible finger crushing accidents. To adjust the height of the safety shield, proceed as follows:...
  • Page 37 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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.

  • Page 38: Working Cycle

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 4.4. WORKING CYCLE DANGER – CAUTION During normal use, the machine must only process the products/materials indicated in this manual. Safety measures and the indications on residual risks must always be observed during machine operation.

  • Page 39: 4.4.1. Cycle Stop

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 4.4.1. CYCLE STOP To carry out the normal stop of the machine it is necessary to release the self-retained pneumatic pedal. DANGER - WARNING THE MACHINE MUST BE SWITCHED OFF AFTER USE.

  • Page 40: Maintenance Prescriptions

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 5.3. MAINTENANCE PRESCRIPTIONS DANGER - WARNING ALL THE MAINTENANCE, CLEANING AND PARTS REPLACEMENT MUST BE CARRIED OUT SOLELY AND EXCLUSIVELY WITH THE MACHINE DISCONNECTED FROM ALL POWER SUPPLIES. It is prohibited to perform any maintenance work on parts that are in motion.

  • Page 41: Tasks That Can Be Performed By The Operator

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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.

  • Page 42: Tasks That Can Be Performed Only By Maintenance Technicians

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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.
  • Page 43 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 It the hammer is worn out or chipped, Grease the hammer piston and the seals well then insert it in the special hole taking proceed to replace the whole piston.

  • Page 44: Adjustments / Maintenance

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 FREQUENCY CHECK METHODS AND RESULTS Every 5,000,000 Check / replace the Proceed with disassembly by following the instructions in the heading MECHANICAL V-nails inserted "L" support block ADJUSTMENTS / MAINTENANCE...

  • Page 45: Cleaning

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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. Cleaning operations which can be performed by maintenance technicians are indicated below. Normally, some cleaning operations can be performed by the machine runner; i.e., in the case of normal operations on the outside of the machine that call for the use of simple personal protective equipment..
  • Page 46 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 FREQUENCY ZONE - METHODS PERSONALE When necessary THE WORKING BENCH AND THE HEAD must be kept clean from all residues Also the operator of glues used to join the frames. Do not use water. Use a petroleum based cleaning product.
  • Page 47 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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.
  • Page 48 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 FREQUENCY METHODS AND RESULTS LUBRICATION At least once every Lubricate the hammer piston by following the instructions provided in the heading Maintenance technician six months ROUTINE MAINTENANCE. Lubricate the carriage guides located under the working bench.

  • Page 49: Troubleshooting And Release Of Moving Parts

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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.
  • Page 50 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 POTENTIAL CAUSE(S) PROBLEM / METHODS AND ANCILLARY NOTES FAULT When the button Replace the pressure regulator Faulty Pressure regulator is pressed, the pressure indicated on the gauge drops Replace the piping with one of greater diameter.

  • Page 51: Reinstallation And Reuse

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 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...

  • Page 52: Disposal

    © Copyright 2022 - ALFAMACCHINE S.r.l. Unless expressly authorized in writing by ALFAMACCHINE S.r.l., this manual nor any part of it, may be copied in any form, modified, transcribed, translated into any language, made available to third parties or in any way used in a manner which could have a negative impact on the interests of ALFAMACCHINE S.r.l..
  • Page 53 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 TABLE 0 - EXPLODED VIEW OF THE MACHINE TRANSLATION OF THE ORIGINAL INSTRUCTIONS (Keep for future reference)
  • Page 54 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 TABLE 25 - HEAD UNIT INSTALLATION Alfamacchine U400S TAB.25 HEAD GROUP ASSEMBLY - MONTAGGIO GRUPPO TESTA 10.2015 Numero Oggetto Titolo Quantità oggetto 714300015 GRANO STEI 6x6 UNI 5923 14.9 718100003 RONDELLA PIANA M6 UNI 6592 12.5x6 Z.B.
  • Page 55 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 TABLE 26 - VERTICAL CLAMP UNIT U400S TAB.26 VERTICAL CLAMP GROUP - GRUPPO BLOCC. VERTICALE Alfamacchine 10.2015            ...
  • Page 56  Document Code Rev. Date saved Date printed          U400S INSTRUCTIONS 21/10/2022 21/10/2022         TABLE 27 - ROD CLAMP      U400S TAB.27...
  • Page 57 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 TABLE 28 - COMPLETE EC SAFEGUARD Alfamacchine U400S TAB.28 CE SAFETY GUARD - PROTEZIONE CE COMPLETA 10.2015 #248950030 Numero Oggetto Titolo Quantità oggetto 710100001 VITE TCEI M4x6 UNI 5931 ZB 710100112 VITE TCEI M8x14 UNI 5931 8.8 Z.B.
  • Page 58 373400220 PIASTRINA ANTIROTAZIONE PROT. M44 334000170 PERNO PROTEZIONE M44 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 730160002 RACC.INN.RAP. FISSO L 5 MA.TUBO 4 215040 718100015 RONDELLA PIANA M6 UNI 6593 6x18 Z.B. 732540003 MICROVALVOLA 0ALF106.A TABLE 29 - AFC BRAKE UNIT...
  • Page 59 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 TABLE 30 - BALANCING CYLINDER Alfamacchine U400S TAB.30 BALANCE CYLINDER GROUP - CILINDRO BILANCIAMENTO 10.2015 Numero Oggetto Titolo Quantità oggetto 718100016 RONDELLA P.L. M8 x24 Z.B. 710100111 VITE TCEI M8x12 UNI 5931 8.8 Z.B.
  • Page 60 718100006 RONDELLA PN M12 UNI 6592 13x24 ZB Document Code Rev. Date saved Date printed 381300150 SUPPORTO CILINDRO BILANCIAMENTO M44 U400S INSTRUCTIONS 21/10/2022 21/10/2022 211130010 CILINDRO BILANCIAMENTO PNEUM. M44 720250033 OR 014/2050 S1,78 D12 NBR75 TABLE 31 - HANDLE BUTTON / END OF STROKE POSITIONS 730410005 RACCORDO RAPIDO ANGOLARE GIR.RL15 4 M5...
  • Page 61 Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 TABLE 32 - BV CYLINDER AND VALVES Alfamacchine U400S TAB.32 VC CYLINDER AND VALVES - CILINDRO BV E VALVOLE 10.2015 Numero Oggetto Titolo Quantità oggetto 225220020 BLOCCAGGIO VERTICALE M44 TAB.26...

  • Page 62: Pneumatic Diagram

    Document Code Rev. Date saved Date printed U400S INSTRUCTIONS 21/10/2022 21/10/2022 PNEUMATIC DIAGRAM    TRANSLATION OF THE ORIGINAL INSTRUCTIONS (Keep for future reference)
  • Page 64 ALFAMACCHINE S.r.l. Via Marie Curie e Pierre, 3 - 47122 Forlì - FC - Tel. +39-0543/783301 Fax +39-0543/783302 http://www.alfamacchine.com...

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Minigraf 44

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