Danfoss ET9700, Operator'S Manual

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Page 2: ...erman Date of revision 2022 10 11 Version 1 0 Copyright by UNIFLEX Hydraulik GmbH Technical modifications reserved The reproduction distribution and utilization of this document as well as the communi...

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Page 4: ...h 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 Machin...

Page 5: ...Risks in case of fire 14 2 4 Safety 15 2 4 1 Working area 15 2 4 2 Warning signs on the machine 16 3 Machine description 18 3 1 Design and function 18 3 2 Technical data 20 4 Transport and commissioni...

Page 6: ...he cutting knife 45 6 3 1 Replacing a resharpened cutting knife 47 6 4 Checking the motor brake 51 6 5 Motor brake readjustment 52 6 5 1 Motor brake variants 52 7 Troubleshooting 57 8 Decommissioning...

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Page 8: ...s of risks and haz ards in compliance with all notes included in this Operation Manual The machine unit may only be operated by staff who has read the Operation Manual has understood it has been instr...

Page 9: ...m and fighting means Free access to this equipment must be ensured personal protection equipment is worn safety footwear protec tion gloves and safety glasses Machine unit fitters Machine unit fitters...

Page 10: ...ept near the machine unit at all times Upon disposal of the machine unit the Operation Manual must also be handed over 1 3 Name plate The name plate is fixed near the power cable 1 4 Abbreviations TM...

Page 11: ...ING identifies a potentially hazardous situa tion which might result in serious injuries or death This warning is supplemented by a triangular hazard symbol The signal word CAUTION identifies a potent...

Page 12: ...isk These may include persons with physical or mental disabilities children and persons under age persons with a restricted capability for the operation of ma chines e g under the influence of drugs a...

Page 13: ...state of technology Nevertheless the machine unit may impose risks 2 3 1 Risks imposed by mechanical equipment Cutting risk A cutting risk exists during cutting and when the cutting knives are re plac...

Page 14: ...permissible pressure range 2 3 4 Risks imposed by noise The noise level meter acc to IEC 804 Class 2 was calibrated before measuring The operation of the machine causes noise emissions of 90 dB A at...

Page 15: ...2 4 1 Working area The working area is defined as the shaded area all around the ma chine see illustration Keep the working area free from trip hazards Use ducts for lines and cables Provide good ill...

Page 16: ...2 4 2 Warning signs on the machine Hand injury on the cover Crushing risk on the cover Cutting risk on the cutting knife Danger from electric current at the power supply line...

Page 17: ...Risk of eye injuries Wear safety goggles Risk of hearing damage Wear ear protection Illegible or missing warning signs must immediately be replaced by the operator...

Page 18: ...3 Machine description 3 1 Design and function 1 Protective cover 2 Catch bolt 3 Operation indicator lamp...

Page 19: ...es to the lowest position and pushes the work piece towards the cutting knife for cutting By releas ing the foot pedal 8 the cutting fork 9 moves back up to the start ing position The motor of the cut...

Page 20: ...ration mode S6 60 Function Hose feed Pneumatic Brake motor yes Extraction connection 100 mm Cutting knife Optional variant see Wear parts in Section 9 Annex TMC 520 x 4 x 40 mm Cut counter yes Feed fo...

Page 21: ...essed air connection 8mm OD snap in pneumatic tube connector Structural requirements Permanent floor loading Approx 0 07 kg mm2 Floor carrying capacity Min 2500 kg m2 Floor quality B25 Evenness Max un...

Page 22: ...ing loads shall be ob served during transport The machine unit may only be unloaded and transported by means of a forklift a lift truck or a crane When a crane is used for transport lifting gear with...

Page 23: ...forklift lift truck or crane at the desig nated points 2 and transfer it to the location of installation 4 2 Intermediate storage of machine unit If the machine unit cannot be mounted immediately upon...

Page 24: ...or Place the machine in a way so that it is easily accessible for main tenance work from all sides 3 Check the machine for damage 4 Check the electric cables for damage 5 Train the operating staff and...

Page 25: ...fe 1 Mount a metal hose for smoke and particle extraction to the ex traction nozzle 1 We recommend an extraction fan with 100 mm water column and a capacity of 4 m min as well as a filter element and...

Page 26: ...a spark extinguisher Clean the machine and spark extinguisher after each use see Cleaning in Section 5 1 Attach the spark extinguisher 2 to the extraction nozzle 1 of the machine 2 Attach the metal ho...

Page 27: ...nection 1 on the back of the ma chine 2 Check the pressure at the compressed air maintenance unit 2 and adjust to 7 bar if necessary The compressed air can be enriched with standard pneumatic oil thro...

Page 28: ...chine and secure it against switching on unintentionally 2 Have the power cable of the machine connected to the local mains by a electrically qualified person according to the regulations of the Elect...

Page 29: ...Switch on the main switch 4 Switch on the motor 5 Switch off the motor 6 While motor is coming to a standstill check the direction of rotation from the fan wheel 3 of the motor When looking at the fan...

Page 30: ...re 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 o...

Page 31: ...to the hose size 1 Switch off the main switch 2 Open protective cover 1 3 Release the quick fastener 3 by positioning it vertically 4 Pull the cutting fork 4 out of the cutting fork holder 2 5 Insert...

Page 32: ...without the aid of bending pins The bending pin and the hose have to be matched to each other Prerequisites for a correct cutting process The bending pin position and the work piece diameter are match...

Page 33: ...ing pin 2 at the appropriate location The bending pin position and the work piece diameter must be matched to each other Large work piece diameter large bending pin distance Small work piece diameter...

Page 34: ...4 3 Setting the cutting speed WARNING Cutting risk There is a risk of cutting your extremities when cutting work pieces Make sure that no extremities are in the working area behind the protective cove...

Page 35: ...s Only open the protective cover once the cutting knife has come to a complete standstill 8 Open protective cover 5 9 Remove the workpiece 10 Check the cross section 11 Adjust the speed setting 4 if n...

Page 36: ...stroke setting can be used to adapt the return stroke path of the cutting fork to the work piece diameter WARNING Cutting risk There is a risk of cutting your extremities when cutting work pieces Mak...

Page 37: ...tting plate 3 is large enough for the work piece to pass through 8 If necessary increase the return stroke setting 6 in increments 9 Repeat steps 4 7 until the opening is large enough 10 Switch off th...

Page 38: ...Manual return stroke Using the manual return stroke 1 the cutting fork can be returned to the uppermost position manually irrespective of the return stroke set ting 5 4 5 Cut counter...

Page 39: ...ng the guide rollers 2 Close the protection cover 3 Switch on the motor 4 Press the foot pedal until the cutting fork has reached the lowest position and cut the work piece 5 Release the foot pedal 6...

Page 40: ...ot pedal 6 Wait until the cutting fork has moved back 7 Remove the cut work piece 8 Feed in the remaining work piece and position as desired 9 Repeat steps 4 8 for all work pieces 10 Switch off the mo...

Page 41: ...screens which may result in damage to the face and body Check polycarbonate screens regularly and replace them at the specified intervals Polycarbonate screens are classified as wear parts by the Ver...

Page 42: ...king 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 ATTENTION Risk of damage to machine...

Page 43: ...n 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 cuttin...

Page 44: ...ges with both thumbs There must be a significant resistance X Protective cover check for function Close the protection cover Switch on the main switch The operation indicator lamp lights up Start the...

Page 45: ...cess 2 Deposit the workpiece outside the machine 3 Disconnect the machine from the electrical and pneumatic sup ply 4 Use a control cabinet key to open the rear maintenance door 5 and lift it out 5 Ho...

Page 46: ...e is a risk that the cutting knife will be destroyed during cutting Check the direction of rotation before switching on Observe the cutting direction The direction of rotation is to the left when view...

Page 47: ...esharpened cutting knife is 515 mm the height of the motor must be adapted to the outside diameter of the cutting knife It is recommended not to use cutting knives with a diameter smaller than 515 mm...

Page 48: ...sk If the position of the cutting knife is set too high the result will be insufficient protection and a significant risk of injuries to the hands There must always be a safety distance of at least 20...

Page 49: ...g knife and machine Make sure that all four height adjustment screws are equally adjusted Check that the cutting knife is straight 7 Tighten the locking screws 5 8 Use a suitable measuring aid to chec...

Page 50: ...k of damage to machinery If the outside diameter is set incorrectly this will result in damage to the cutting knife and machine If a new cutting knife is assembled the height of the motor also has to...

Page 51: ...otor checked and readjusted regularly Do not continue using the machine if the motor brake is de fective 1 Switch on the motor 2 Once the motor has reached full speed allow the motor to run for a furt...

Page 52: ...the right hand upper side cover 2 4 Adjust the motor brake according to the motor variant see Mo tor brake variants in Section 6 5 Assemble the side cover 2 and hose guide 1 in reverse order 6 5 1 Mo...

Page 53: ...not touch parts of the motor without sufficient protection WARNING Risk of injuries The fan wheel imposes a risk of serious injuries Only switch on the motor when the fan wheel cover is moun ted If p...

Page 54: ...to run for a further 30 seconds 7 Switch off the motor and measure the time taken for the motor to come to a complete standstill ATTENTION Risk of damage to machinery If the motor brake adjustment is...

Page 55: ...an open end wrench to turn the adjusting nut 4 clockwise by approx 30 30 0 1 mm 5 Lock the adjusting nut 4 with the locking washer 3 6 Attach the fan wheel cover 1 7 Switch on the motor 8 Once the mo...

Page 56: ...l result in increa sed wear and high heat generation Check that the time taken for the motor to come to a standstill is between 9 10 seconds 10 Check the time taken for the motor to come to a standsti...

Page 57: ...lug defective Check power plug and replace if required Motor defective Contact Service desk Cutting knife worn Check cutting knife for wear and replace if required Knife not centred Flange disc is not...

Page 58: ...ety 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 desc...

Page 59: ...gulations 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 supp...

Page 60: ...ose guide 2000mm UHG 14 Extension 1000mm UHG 14 EXT Suction system Adaptor UVC S36 777 061 Spark extinguisher 330 2 Cutting knife with inclined slots TM G 520x4x40 Cutting knife TM 520x4 5x40 CL Hose...

Page 61: ..._BD b1050 9 2 Spare parts list 9 2 1 Mechanical equipment Item Quantity Part code Designation 1 1 PJ_GLS1050 Front protective screen 2 2 501 071 Catch bolt 3 2 PJ_10 0410 04 Telescopic rail...

Page 62: ...Hold down large nominal widths 7 4 UJ_70 0410 23 Guide roller horizontal 8 2 UJ_70 0410 13 Guide roller vertical 9 1 UJ_70 0410 11 Protective plate cutting knife 1 set 2 pins 10 1 UJ_30 10 01 Oil pre...

Page 63: ...2 2 Pneumatic Item Quantity Part code Designation 1 1 PJ_40 10 05 Pneumatic cylinder 2 1 305 070 Throttle valve 3 1 UJ_40 50 02 Compressed air maintenance unit 4 1 UJ_40 50 19 5 3 way pneumatic valve...

Page 64: ...9 2 3 Electric equipment Item Quantity Part code Designation 1 1 888 641 Assistance switch 2 1 888 639 Motor protection switch 24 32 A 3 1 888 642 Contactor 24 V DV 4 1 888 645 Time block 0 1 30 s...

Page 65: ...elay 10 4 VME 0231 Microfuse 3 15 A delayed 500 V 11 1 888 648 Switching power supply 12 1 306 083 Brake motor 7 5 kW No pic ture 1 8 00 030 Metal oxide varistor No pic ture 1 306 089 Spare brake for...

Page 66: ...170 Motor stop button 4 1 UJ_20 30 171 Main Switch 5 1 UJ_20 30 166 Potentiometer 6 1 UJ_20 30 189 Button for raising the cylinder piston 9 2 5 Wear parts Quantity Part code Designation 1 TMC 520x4x40...

Page 67: ...9 3 Electric diagram...

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Page 70: ...9 4 Pneumatic diagram...

Page 71: ...9 5 Maintenance log Cutting knife Guide unit Extraction line Knife protection Motor brake Remark Date Signature...

Page 72: ...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 N...

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