Danfoss ET9650, Operator'S Manual

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Page 2: ...German Date of revision 2022 10 06 Version 1 0 Copyright by UNIFLEX Hydraulik GmbH Technical modifications reserved The reproduction distribution and utilization of this document as well as the communication of its contents to others without explicit authori zation are prohibited Offenders will be held liable for the payment of damages All rights reserved in the event of the grant of a patent util...

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Page 4: ...ch Strasse 50 52 D 61184 Karben The following standards codes and specifications have been applied EC Directive 2006 42 EC EMC Directive 2014 30 EC EN ISO 12100 2010 EN 60204 1 2018 UK Supply of Machinery Safety Regulations 2008 UK Electromagnetic Compatibility Regulations 2016 This declaration are invalid when the machine is modified or if unau thorized and unapproved third party components are u...

Page 5: ...sks in case of fire 13 2 4 Safety 13 2 4 1 Working area 13 2 4 2 Emergency stop 14 2 4 3 Warning signs on the machine 15 3 Machine description 17 3 1 Design and function 17 3 2 Accessories 18 3 3 Operation and display elements 19 3 4 Technical data 20 4 Transport and commissioning 23 4 1 Transport 23 4 2 Intermediate storage of machine unit 24 4 3 Commissioning 24 4 3 1 Extraction process for TM T...

Page 6: ...6 4 Motor brake readjustment 42 7 Troubleshooting 46 8 Decommissioning disposal 47 8 1 Dismantling 47 8 2 Recycling 47 8 3 Consumables and waste 48 9 Annex 49 9 1 Accessories upgradable 49 9 2 Spare parts list 50 9 2 1 Mechanical equipment Chassis 50 9 2 2 Mechanical equipment Knife protection 51 9 2 3 Mechanical equipment Covers 52 9 2 4 Electric equipment 54 9 2 5 Pneumatic equipment 55 9 2 6 We...

Page 7: ...n this Operation Manual The machine unit may only be operated by staff who has read the Operation Manual has understood it has been instructed in the operation of the machine unit and has signed in the Annex Figures may include accessories options Customer specific equipment may vary The product images shown are for reference only and may differ from the product delivered 1 1 Target groups The tar...

Page 8: ...achine unit fitters Machine unit fitters must be at least 18 years old and have completed training for the task i e they must have attended a specialist voca tional training A fitter must observe the instructions in the Operation Manual must inform the owner on failures and damage Operator An operator is a person charged with and instructed in the proper op eration of the machine unit by the owner...

Page 9: ...1 3 Name plate The name plate is fixed near the power cable 1 4 Abbreviations TM cutting knife plain TMG cutting knife with slots TMC cutting knife coated ...

Page 10: ...upplemented by a triangular hazard symbol The signal word ATTENTION identifies a potentially hazardous situa tion in which the product or property in the environment may be dam ages This warning is supplemented by a hazard symbol or a excla mation mark 2 2 Intended use This machine is intended for industrial use it is only suitable for cut ting pneumatic and hydraulic hoses up to a specific permis...

Page 11: ...rkpieces misuse of consumables and waste materials WARNING Risk for life and health Use not in compliance with the intended purpose imposes risks for life and health Consequences resulting from use for other than the intended purpose shall be under the sole responsibility of the owner Always use the machine in compliance with its intended pur pose 2 3 Product specific risks The machine unit is des...

Page 12: ...2 3 3 Risk imposed by pneumatic system Risks are imposed by all pneumatic lines and connections Pneu matic systems are subject to special safety provisions After the machine is deactivated the given and potentially haz ardous residual energy has to be considered Use correct hoses and hose clamps Only work in the permissible pressure range 2 3 4 Risks imposed by noise The noise level meter acc to I...

Page 13: ...th 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 2 4 Safety 2 4 1 Working area The working area is defined as the area all around the machine shaded Keep the working area free from trip hazards Use ducts for lines and cables Provide good illumination ...

Page 14: ...gency 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: ...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: ...sign 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 Hose feed ...

Page 18: ...witch 9 which starts the motor 7 and drives the cutting knife To perform the cutting procedure the foot pedal 6 is pressed which moves the work piece towards the cutting knife via the pneu matically driven hose feed 12 When the foot pedal 6 is released the hose feed 12 moves back into the starting position The control valve for feed speed 10 can be used to adjust the feed speed gradually according...

Page 19: ...3 3 Operation and display elements 1 Return stroke setting 2 Feed speed 3 Main switch emergency stop button ...

Page 20: ...ise level 85 dB A Protection class IP 42 Operation mode S6 60 Function Hose feed Pneumatic Brake motor Yes Extraction connection Ø 60 mm Cutting knife TM C 400 x 4 x 30 mm Work piece capacity Workshop SAE R13 SAE R15 2 Production SAE R13 SAE R1511 4 SAE R12 2 Industry 4 Max outside Ø 120 mm ...

Page 21: ...urrent of control circuit primary 0 48 kA Pneumatic connection Power rating 6 5 bar Air consumption Approx 25 Nl min Workbench Stable level workbench with a carrying capacity of approx 500 kg We recommend industrial flooring which meets the following structural requirements Permanent floor loading Approx 0 07 kg mm2 Floor carrying capacity Min 2500 kg m2 Floor quality B25 Evenness Max unevenness 5...

Page 22: ...mbient conditions Ambient temperature 5 o C 40 o C Air humidity 45 65 The data are theoretical computed values or values measured on a prototype Actual values may vary slightly depending on the ma chine ...

Page 23: ...be ob served during transport The machine may only be unloaded and transported by means of a lift truck or a crane When a crane is used for transport lifting gear with a sufficient length and lifting capacity has to be used The lifting gear must be attached to the lifting lug 1 For machine weight please refer to Technical data in Section 3 WARNING Danger from falling loads Risk of injury from fall...

Page 24: ...Mechanical damage The machine unit components may only be stored in closed rooms and under the following conditions temperature between 10 C and 35 C maximum air humidity 80 non condensating 4 3 Commissioning The machine is commissioned by the customer s fitter 1 Place the machine hanging on the lifting lug on the optionally supplied table 2 Position the cutting plate flush with the table edge 3 F...

Page 25: ...ponents might be flung out during the cutting process There is a risk of being injured Perform a cutting process in idle mode and without a work piece Check the machine for atypical noise 4 3 1 Extraction process for TM TMG cutting knife 1 Mount a metal hose for smoke and particle extraction to the extraction nozzle 1 We recommend an extraction fan with 100 mm water column and a capacity of 4 m mi...

Page 26: ...ark extinguisher after each use see Cleaning in Section 5 1 Attach the adapter 2 to the extraction nozzle 1 of the ma chine 2 Attach the angle adapter 3 to the adapter 2 3 Attach the spark extinguisher 4 to the angle adapter 3 4 Attach the metal hose to the spark extinguisher 4 and extrac tion device 5 We recommend an extraction fan with 100 mm water column and a capacity of 4 m min as well as a f...

Page 27: ...tion of compressed air ATTENTION Damage to the machine Contaminated compressed air may cause damage to the ma chine Only use clean oil free and water free compressed air The compressed air connection is located on the right side of the ma chine 1 Establish the compressed air connection between the network and the compressed air maintenance unit 1 using a pneumatic hose Ø 8 mm G ...

Page 28: ...tentional restart 2 Have the power cable of the machine connected to the local mains by a qualified electrician according to the regulations of the Electricity Board 3 Check the electric motor rotational direction according to the ar row Exchange outer cable phases of the connection if requi red ATTENTION Risk of damage to machinery Operating the motor in the wrong direction of rotation results in...

Page 29: ...ly be performed by qualified maintenance staff machine fitters If unusual noises can be heard switch off the machine im mediately and eliminate the cause Test run without work piece 1 Close protective cover 1 2 Switch on the machine using the main switch 3 3 Activate the foot pedal until the hose feed 5 has reached the end position ...

Page 30: ... Close protective cover 1 5 Set the feed speed 4 to a low to medium speed 6 Switch on the machine using the main switch 3 7 Activate the foot pedal until the work piece is cut completely 8 Loosen the foot pedal and wait until the hose feed 5 has re turned completely 9 Wait for about one minute until the cutting knife has cooled down 10 Repeat the cutting process nine times when cutting a work piec...

Page 31: ...ation of the working area of the machine During operation Observe the safety instructions on the machine Make sure that no other persons stay in the working area Each movement of the hand must be observed Eating drinking and smoking at the workplace is prohibited Wear close fitting clothes Do not wear watches or jewellery 5 2 Start 1 Check that there is no emergency stop situation 2 Activate the m...

Page 32: ...hine is operated wit hout hose prestressing Never cut without bending X Adjust the bending pin and the workpiece Prerequisites for a correct cutting process The bending pin position and the hose diameter are matched to each other 1 Large hose diameter large bolt distance 2 Small hose diameter small bolt distance ...

Page 33: ...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 Do not reach into the working area of the cutting machine during operation ...

Page 34: ...e on the cutting plate between the bending pin 2 and the hose feed 5 4 Close protective cover 1 5 Adjust the feed speed 4 to the middle of the scale picture A 6 Switch on the machine using the main switch 3 7 Activate the foot pedal until the work piece is cut completely 8 Loosen the foot pedal and wait until the hose feed 5 has re turned completely ...

Page 35: ...0 Remove the work piece 11 Check the cutting performance and adjust the feed speed 4 if necessary 5 3 3 Setting the return stroke To enable quicker working processes the return stroke setting can be used to adapt the return stroke to the work piece diameter 1 Adjust the return stroke setting 1 by turning it to the desired po sition using a screwdriver Turning the return stroke setting in a clockwi...

Page 36: ...amage and cracks 7 Remove contamination dust and chips using a vacuum Inform the fitter in case of damage or other irregularities 5 5 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 Starting the machine is only possib...

Page 37: ...e from all energy sources and secure it against switching on unintentionally Wear cut proof gloves ATTENTION Risk of damage to machinery If the machine is cleaned with a steam jet or compressed air dirt and water may ingress in the machine and cause serious da mage Do not use a steam jet to clean the machine Do not use compressed air to clean the machine ...

Page 38: ...e hose guide 5 If necessary remove the machine cover to gain better access to the hose guide 1 Release the four screws 4 of the machine cover 2 2 Lift up and remove the machine cover 2 using the strap grips 3 3 Vacuum the entire area 5 of the hose guide and hose feed 4 Attach the machine cover 2 5 ...

Page 39: ...on in Section 5 Use the lock to prevent the main switch from being switched on and also attach a sign Example text Machine unit out of service for maintenance work Do not switch on Welding flame cutting and grinding work on and in the ma chine unit and its environment must be approved in advance There is a risk of fire The machine unit must be cleaned from dust and inflammable substances Adequate ...

Page 40: ...s towards the motor with both thumbs wearing cutting protection gloves There must be a significant resistance X Warning signs on the machine Check legibility see Warning signs on the machine in Section 2 X Motor brake Motor check for function and readjust if necessary see Motor brake readjustment Sec tion 6 X Protective screens clean using a household window cleaner X Protective screens replace no...

Page 41: ... Always wear cut proof gloves when replacing the knives 1 Complete the cutting process 2 Deposit the work piece outside the machine 3 Disconnect the machine from the power supply 4 Open the protective cover 3 5 Release the four screws 10 of the machine cover 1 6 Lift up and remove the machine cover 1 using the strap grips 2 ...

Page 42: ... new cutting knife 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 ting Check the direction of rotation before starting the machine In the case of slotted cutting knives observe the cutting di rection The direction of rotation is to the right when viewing the...

Page 43: ...r 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 Do not continue using the machine if the brake is defective The motor brake is located behind the black plastic cover 5 on the motor 1 Deactivate the machine on the main switch and secure it against unintentional restart 2 Ope...

Page 44: ...come to a complete standstill 11 Check that the motor comes to a complete standstill within 10 seconds of being switched off 12 If the braking effect is insufficient repeat the process The motor brake must bring the motor to a standstill within 10 sec onds of it being switched off If this time is exceeded and it is still not possible to achieve this time despite repeated adjustment con tact the cu...

Page 45: ...ng effect and the temperature again 16 Attach the plastic cover 5 and tighten the nuts 17 Attach the machine cover 2 If the problems with the brake continue immediately contact the service department of the manufacturer ...

Page 46: ...if necessary Knife not centred Flange disc is not positioned correctly on the feather key Turn flange disc and insert it into the feather key Pneumatic feed is not working Compressed air supply dis connected Connect compressed air Air pressure too low Check air pressure and in crease if required Work piece is jammed in knife protection Deactivate the machine on the main switch and secure it agains...

Page 47: ...fety instructions see data sheet Wear personal protection equipment Do not eat drink or smoke in the working area and when handling consumables Ensure good ventilation 8 1 Dismantling This section describes activities to be performed by you as the opera tor to ensure the safe dismantling of the machine unit The machine unit may only be dismantled by entrusted and qualified staff Check the machine ...

Page 48: ...egulations have to be complied with 8 3 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 Also observe the information given on the safety data sheet ...

Page 49: ...tor 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 Cutting knife with inclined slots TM G 400x4x30 Cutting knife coated TM C 400x4x30 Bench TU Hose coiling reel UWT 2 2 Length measuring device for hose coiling reel UMS 4 514 1 Hose winder UAT 4 2 Hose winder USH 4 5 Quantity counter kit 323 1 P...

Page 50: ...nation 1 1 323 001 0 Chassis 2 1 323 040 1 Electric drawer 3 1 323 116 3 Cover plate 4 1 323 051 3 Base plate 5 1 323 006 3 U Profile 6 1 323 024 4 Path adjustment axle 7 1 323 026 4 Guidance 8 1 323 028 4 Guidance connection 9 1 323 107 3 Positioner 10 1 323 121 3 Extraction connection ...

Page 51: ...1 Rubber metal buffer 9 2 2 Mechanical equipment Knife protection Item Quantity Part code Designation 1 1 323 111 0 Knife protection 2 1 323 002 3 Hose feed 3 1 323 025 4 Switch bracket 4 1 323 029 4 Guidance front 5 1 323 020 4 Pin for knife protection 6 1 323 046 4 Fork of blocking bar 7 1 323 047 4 Guide sleeve 8 1 323 032 3 Blocker 9 1 323 035 4 Axle ...

Page 52: ...206 Adjusting ring 16 1 2 798 510007 798 610002 Pin EN 22340 Type B 8 x 30 Splint 17 1 798 310010 Hexagonal nut DIN EN ISO 4032 M8 18 1 798 110140 Countersunk screw with hexagon socket DIN EN ISO 10642 M8 x 30 19 2 798 220012 Adjusting washer DIN 988 8 x 14 0 5 9 2 3 Mechanical equipment Covers Item Quantity Part code Designation 1 1 323 019 0 Machine cover 2 1 323 014 1 Protective cover ...

Page 53: ...ding piece 8 1 322 054 Mushroom head handle 9 2 323 200 Telescopic rail 10 1 323 120 3 Eyebolt M12 11 2 501 068 Strap grip 12 1 323 105 3 Switch bracket 13 1 304 101 4 Knife sign 14 1 716 4 Hand injuries warning 15 1 3127 60 Mandatory Eye and Hearing Protection sticker 16 1 300 100 4 Cutting risk warning sign No pic ture 1 3166 Red direction arrow No pic ture 1 777 031 Power supply disconnection w...

Page 54: ...2 Securing clip 5 2 800 084 Protective conductor terminal 6 1 8 06 002 Motor protection switch 7 1 800 021 Safety isolating transformer 8 1 8 06 003 Auxiliary switch block No picture 2 VME 0265 Fine wire fuse 10 1 323 204 Roller lever switch 11 1 307 010 Safety switch No picture 1 320 111 Electric motor with brake No picture 1 8 12 031 Mounted housing ...

Page 55: ...de varistor 9 2 5 Pneumatic equipment Item Quantity Part code Designation 1 2 323 201 Pneumatic cylinder 2 2 323 202 Bracket for pneumatic cylinder 3 2 323 203 Fork head for pneumatic cylinder 4 1 322 050 Solenoid valve 5 1 322 406 Non return throttle valve 6 1 323 208 Maintenance unit No pic ture 1 405 080 Sound absorber ...

Page 56: ...sory 1 Kit 320 121 Spare parts kit Seimec Habasit Flange disc set and shaft nut 1 Piece 320 116 Spare brake Seimec see motor nameplate 1 Piece 320 118 Spare brake Soga see motor nameplate 1 Set 320 119 Spare flange set for motor 320 111 Soga 1 Piece 320 120 Spare shaft nut for motor 320 111 Soga 1 Piece 320 125 Fan for motor 320 111 1 Piece 320 126 Fan cover for motor 320 111 1 Set 304 2001 Set of...

Page 57: ...9 3 Electric diagram ...

Page 58: ...9 4 Pneumatic diagram ...

Page 59: ...9 5 Maintenance log Cutting knife Guide unit Extraction line Knife protection Motor brake Remark Date Signature ...

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Page 61: ... 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 Signature City Date Name Signature City Date Name Signature City Date Name Signature City Date Name Signature City Date Name Signature ...

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