User manual - Trick
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1. 180 E Hwy 14 PO Box 850 Philip SD 57567 0850 P 605 859 2542 e F 605 859 2499 User manual Universal pipe notcher Type AL100U 01 230 460 Volt 3 phase ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 1 of 29 cee ET Table of contents 1 0 0 9 6 Perera nennen eerder dee neerde elder verderen bel 4 11 Names oR Machine vei nn ennn ener ees 4 1 2 Warning inernet wei ei nod eee ad nde esate 4 1 3 Target group for each chapter nnee enneerenenneerenenverenenneeneneneenen een 4 VA SyMBOIS ns oer wee ieee eed ne ee ed a ed eee 4 1 5 Re ordering the user manual nnen ennverenenneerenenneerenenneerenenneenen eneen enen 4 1 6 Deficiencies in this user manual nnen en eneenenenneerenenneerenenneerenenne eeen enn 5 Ze MMMODUGH OM EE 6 2 1 A EE EEE 6 2 2 The manutactUr N ennen derden eneen ante ee ed eee 6 2 3 Machine identification nennen nereverrnerensennenenvanndeenennndteevnnnetee enne EEE 6 24 Function of the machine 2 s nnnetarneer indd nA ead aan dane 7 25 MACHINE Options 3 nmmr eere a a a aea a aa aaa 7 2 6 Liability ereinen a a a td eet aA 7 ZT ONE IE 7 2 8 Warani conditions eco mennie a E E E ERA 8 3 Salo FEQUIALIONS senorna A E E A 9 31 Safety provisions meenten EEA EE AE 9 sad Generalsin inen ernie a a eeen hd dln aaa 9 31 4 Emergeney StOp neren a E E AE RE 9 371 3 Safety SINGIAS nena2. M8 ev 8 12300 M8 000 25 1 Stempelveer 25 12 5x38 M090 00002 000 24 1 Pijp 04 00185 000 23 1 Zk moer M8 ev 8 01300 M8 000 22 1 Vik sluitr M8 ev zf 38130 M8 000 21 1 Zk tapbout M8x100 ev 8 8 01210 M8x100 000 20 1 Lagerhouder sam 04 00235 000 19 4 Vik sluitr M10 ev d2 3xd1 38210 M10 000 18 3 Zk tapbout M10x30 ev 8 8 01210 M10x30 000 17 1 Type AL43SH 8 5 x 8 cm A050 00024 000 16 1 Beschermglas 04 00059 000 15 3 Bzk vk schr M3x10 ev 8 8 07470 M3x10 000 14 3 Vik sluitr M3 ev zf 38130 M3 000 13 3 Zk moer M3 ev 8 01300 M3 000 12 1 Zk tapbout M8x25 ev 8 8 01210 M8x25 000 11 2 Vik sluitr M8 ev d2 3xd1 38210 M8 000 10 1 Boorbus DIN179A 8x16 G140 00002 000 9 1 Hefboom sam 04 00234 000 8 1 Schuifsupport sam 04 00232 000 7 1 Klem sam 04 00080 000 6 6 Vik sluitr M10 ev zf 38130 M10 000 5 2 Bzk ck schr M10x30 ev 8 8 07160 M10x20 000 4 2 Geleidingsas 04 00033 000 3 2 Pasring 0 3mm 8x14 38583 8x14 000 2 9 Vik sluitr M8 ev zt 38430 M8 000 4x tbv 04 00311 Zak sam 1 8 Zk tapbout M8x20 ev 8 8 01210 M8x20 000 4x tbv 04 00311 Zak sam Posnr Aantal Benaming Tek nr Rev Opmerking MATERIAAL TOLERANTIE Algemene toleranties volgens ISO 2768 2 TOL GEBIED m BEHANDELING Vormtoleranties volgens ISO 2768 1 TOL GEBIED m rent AL100U 01 400V 3 fase GET EPI DATUM _ 13 6 2007 SCHAAL 1 5 MAATEENHEID MM Blad 1 VAN 2 KOKER OPMERKING eel Ei ne gore WWW ALMI NL 0 MM 100 MM
3. Revision and revision date 2 20 09 2011 Page 2 of 29 6 2 Start UP rand dead den ansi Eede and ahead daze deter dba 26 6 35 OperatlOn siosana iaia aaia e a eenden tee e aaia aR 26 04 SAUTGOWN eich oti nee 27 Te Maimtenane8 ananda erdee eenen a ee 27 i Precautionary Measures nrd dante eener rer verekenen neer heee 27 T2 CheekpointSiernnmn a a aaa eera E haa renta ead 27 7 3 Replacement of components ananas eeen ensnenenenseeneerensneeenenseneenenseeenn ensen 28 8 TrOUDIG nr eerrnndsarnnaerer mates veneranda end cae este nase hee ae eelt 28 8 1 General information for trouble nanne enne eennenenneeerennernenereneer anneer ennen nnenenneenenn 28 8 2 Trouble indications and signals nnn eneen enneneeneenneenenenneeeenenneeeenenneeeen eneen 28 9 Disposal asisas ebde erde rade nete re derven 28 EU Declaration of Conformity for machines nnen enerenneee rennen eneeenneenennenn 29 Table 1 3 1 Overview of the target groups for each chapter nnn anneer eneen enen 4 Table 4 7 1 Other available grinding roller diameters ennn eneen eneen vennen ennen 22 Table 4 7 2 Overview of recommended grinding belts anneer ennen eneen 22 Table 7 2 1 Checkpoints and lubrication schedule nnen neee eneen ennenenen enen eenenen 27 Figure 2 3 1 Sample type plate with CE mark none en ennenneeenenenenennennseenenenenennen 6 Figure 2 3 2 Location of the type plate nnen neerenen
4. The grinding belt is enclosed in a housing that is only open on the front side at the location where the tube sections are notched For protection of the face the location at which the tube sections are notched is equipped with a transparent fold away shield The deburring area is equipped with a cover In order to allow the replacement of the grinding roller and or grinding belt the housing is equipped with a side cover The side cover must never be open or be opened when the grinding belt is in motion Only personnel that have received sufficient instruction may open safety shields to perform maintenance and or repairs Also refer to section 1 3 Target group for each chapter ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 9 of 29 Top cover deburring ion Transparent fold away A 1 shield for facial protection ty N __ ee en c 4 s ou Side cover Emergency stop Figure 3 1 1 Safety provisions ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 10 of 29 ec EEEN 3 2 Warning symbols on the machine The following warning symbols can be found on the machine For the location of the warning symbols on the machine see Figure 3 2 1 It is absolutely forbidden to remove the warning symbols or make them unreadable by any means Worn warning symbols must
5. also Figure 4 6 6 Figure 4 6 6 Adjustment of the grinding roller in relation to the grinding belt Turn bolt P in either direction until the misalignment has been corrected For a rough adjustment the grinding belt should be driven by hand by turning the drive roller on the motor shaft For fine adjustment the motor can be switched on ATTENTION First close the side cover See Figure 3 1 1 Comply with the safety regulations in section 3 3 ATTENTION After adjustment the two wingnuts of the support for the grinding roller see Figure 4 6 2 must be re tightened ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 21 of 29 ET 4 7 Technical data Type AL100U 01 Serial number Is indicated on the top of the clamp See Figure 4 7 1 Weight 190 kg Measurements Ixwxh 1450x1150x650 mm Motor Squirrel cage armature motor SG100L 21 3 kW suitable for supply voltage of 230 V or 460 V Motor speed 2895 rpm at 460V 50Hz 3420 rpm at 230V 60Hz The motor includes thermal protection and a switch with a no voltage coil Versions of motor Voltage 230 V switches and no voltage switch PKZM1 10 coils no voltage coil U PKZM1 230 Voltage 460 V switch PKZM1 6 no voltage coil U PKZM1 400 Belt speed 30 m s at 460V 50Hz 36 m s at 230V 60Hz Notching depth 20 76 mm Grinding roller For available grinding roller diameters see Table 4 7 1 Grind
6. amp nt tinnen ended 16 AOD SIODS ei cece rennen tenen enden len lee ader nanda te 17 4 6 6 Notching a tubing section anneer nennen neee veneneerenneneenennenernennen 17 4G Deb rrind urrern E ater EA 17 4 6 8 Exchange of the grinding belt nnn nennen neren enneneen ennen ennen 18 4 6 9 Exchange of the grinding roller anneer nennen neee ennnenrenseneneennen 19 4 6 10 Adjustment of the grinding roller and grinding belt nnen 20 Als Technical data eniinn nende nebe enden ekke aken andante add 22 5 Transport storage placement and initial setup nnnnnnn enen enneneneen eneen en ennenneeenenn 23 ol SCOPE OT delve rme eerernadtne venten hate lee cei edie te ad eed eurie ellende 23 D2 ASSEMDIY noren iiin nn a EEE ENEE edits elnaiel aia nace oe ade 23 9 3 Placement of the machine ace verrvene ven edeevsendedeerennkede rs anmenretdene senden edere 24 5 4 Connection of the power supply nnen en nenneeen en enen ennennenenenenenenneneneenenn 24 9 59 Transport and storage nasvearenere onnerne verveners andenevnnankd OEE EE EEA 25 5 6 Initial SSUP ere teresrnnnetertenendedke drente iten eels ertarhenn dende ee locegieidseaanesceceetaeelevvactuessaiea 26 6 OperatlOhmanmrendeteenerentoaetetttasnne eran enne a dna Bed aasde ea Eaa eee Rae 26 6 1 Operation IN generalen sanccion EEA deeded 26 ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG
7. and revision date 2 20 09 2011 Page 13 of 29 4 Description This chapter provides general information about the machine This chapter is intended for the owner the operator and the maintainer of the machine 4 1 General This user manual includes an appendix with an exploded view drawing with drawing number 3 1008 000 This drawing includes a parts list containing the name of each part 4 2 Construction of the machine The machine consists primarily of the components shown in Figure 4 2 1 Drive motor Tightening mechanism grinding bel Grinding roller Adjustment ae mechanism grinding roller Tube clamp Housing drive roller grinding roller and grinding belt Cross support Support pillar Grinding waste container ie Foot plate Figure 4 2 1 Construction of the machine ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 14 of 29 ET 4 3 Electrical supply For the electrical connection the machine is equipped with a 4 conductor supply cable without a plug The machine is equipped with a Euro voltage motor This means that the motor can be connected to a 230 Volt 3 phase or 400 Volt 3 phase supply with a tolerance of 10 When the machine is connected for the first time the voltage of the supply connection must be verified in comparison to the connection voltage indicated on the type plate and the correct
8. be replaced in a timely manner Pictogram 1 Read the user manual first Pictogram 2 Use of eye and hearing protection required Pictogram 3 Use of light respiratory protection required Pictogram 4 Use of safety gloves required O 0 Pictograms 1 through 4 Se gga a wt p Figure 3 2 1 Warning symbols on the machine ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 11 of 29 EEN 3 3 Safety regulations Although the machine satisfies the fundamental health and safety requirements of the European Union dangerous situations can always occur Always remain alert for possible dangerous situaitons Be careful of projecting portions of the machine Be careful with loose clothing and hair At a minimum the following safety regulations must be followed Never engage power to the machine if any person is in contact with the machine in a dangerous manner Never start the machine if any person is in contact with the machine in a dangerous manner During maintenance to the machine switch off the machine and disconnect the electrical plug Follow the warnings and indications on the machine For the explanation of the symbols see section 3 2 Before use of the machine close the side cover Close the top cover if deburring is not required Use the fold away shield to protect your face Wear close fitting clothin
9. grinding roller and or grinding belt Through intensive use the roller can become extremely hot To create the room that is necessary for exchange of the grinding belt the support must be moved as far as possible from the grinding roller with handle d Handle d is shown in Figure 4 5 1 To gain access to the grinding belt the side cover and the top cover must be opened The covers are shown in Figure 3 1 1 To remove the belt the tension on the belt must be released and the support for the grinding roller must be released The belt tension can be released by turning the hand crank counter clockwise The position of the belt tension device is shown in Figure 4 2 1 The belt tension mechanism with hand crank is shown in Figure 4 6 3 The support for the grinding roller can be released by loosening the wingnuts The support is shown in Figure 4 6 2 Adjust to 3 5 mm d during tensioning of the grinding belt Figure 4 6 3 Belt tensioning device ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 18 of 29 ET The grinding belt can now be removed Remove all remnants During installation of a new grinding belt the required direction of rotation for the belt must match that of the pulley An arrow is shown on both the inside of the belt and the pulley Begin by placing the new grinding belt on the side of the grinding roller For correct selection o
10. length stopper can be attached to these The stoppers are designed to ensure that a series of tubing sections with the same dimensions are notched to an equal depth The length stopper is not included with the machine and must be made by the user 4 6 6 Notching a tubing section After the tubing section has been clamped and the correct angle and stoppers are set up the slide with ball handle c must be positioned so the tubing section that is to be notched is moved toward the centre of the grinding roller Handle d is used to adjust the support perpendicular to the grinding roller By moving the support toward the grinding roller the tubing section can be notched Care must be given to ensure that the width of the notch does not exceed the width of the grinding belt 4 6 7 Deburring The top of the machine is equipped with a deburring table for deburring the notched tubing section See Figure 4 6 1 For deburring the top cover must be opened The cover is shown in Figure 3 1 1 Figure 4 6 1 Deburring table ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 17 of 29 ETT 4 6 8 Exchange of the grinding belt Before the grinding belt is exchanged the machine must be disconnected from the electrical supply by removing the plug connection from the mains supply Also read the safety regulations in section 3 3 Wear safety gloves during exhange of the
11. pillar 6 1 Ball handle in the support pillar 7 1 Handle in the support pillar 8 2 Grinding belt in the support pillar 9 1 Allen key 8 mm with handle 10 1 Set Attachment hardware in the support pillar 11 1 Power supply cable without plug 12 1 Set Grinding rollers and belts if ordered separately 13 1 User manual 14 1 exploded view drawing with drawing number 3 1008 000 5 2 Assembly For clarification of the procedures below see also Figure 5 2 1 Lifting eye Handle Grinding waste container M12 bolts Support pillar Foot plate Figure 5 2 1 Clarification of assembly ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 23 of 29 ET Remove loose components from the packaging Inside the support pillar you will find a box with any ordered grinding belts and grinding rollers the grinding waste container the ball handle the handle and the attachment hardware Remove the two attachment bolts with which the universal pipe notcher is attached to the bottom plate of the packaging Remove the wood screws with which the support pillar and foot plate are attached to the crate Remove the support pillar from the packaging and attach them together ATTENTION Inside the support pillar you will find a box with any ordered grinding belts and grinding rollers the grinding waste container the ball handle the handle and the attachment hard
12. 4 General description of the machine e e gt 5 Transport storage and setup ofthe machine 6 Operation of the machine 7 Maintenance ofthemachne T T gt 8 Trouble S S S e f 9 Disposal of the machine e Table 1 3 1 Overview of the target groups for each chapter 1 4 Symbols The safety and caution symbols shown below are used in this document The information indicated by this symbol warns you of potential problems Furthermore the symbol warns you that you can seriously injure yourself or that you can seriously damage the machine 1 5 Re ordering the user manual Extra copies of the user manual can be ordered from ALMI Machinefabriek BV of Vriezenveen When ordering indicate the document number and the number of copies The document number is indicated in the footer area ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 4 of 29 1 6 Deficiencies in this user manual This user manual was prepared with the greatest possible care Should you nonetheless find inaccuracies or deficiencies in the text notify ALMI Machinefabriek BV of the problem ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 5 of 29 FT 2 Introduction This chapter provides basic information about the machine and the accompanying user manual This cha
13. M10 ev bv 37420 M10 000 62 1 Zk tapbout M10x40 ev 8 8 01210 M10x40 000 61 1 Motor 230 400V 60Hz 3 fase 3kW E030 00002 000 60 3 Zk tapbout M10x25 ev 8 8 01210 M10x25 000 59 1 Scharnieras 04 00046 000 58 2 Sluitring 04 00049 000 57 1 Motorstoel sam 04 00095 000 56 1 Voet sam 04 00073 000 55 1 Zuil sam 04 00111 001 54 1 Almi sticker middel 14 8x4 6cm A050 00002 000 53 4 Bzk ck schr M6x16 ev 8 8 07160 M6x16 000 52 1 Plaat sam 04 00313 000 51 2 Vik sluitr M12 ev zf 38130 M12 000 2x tbv 04 00311 Zak sam 50 3 Zk tapbout M12x35 ev 8 8 01210 M12x35 000 2x tbv 04 00311 Zak sam 49 1 Deursluiting 04 00045 000 48 1 Klep sam 04 00236 000 47 1 Sticker zijklep 13x5 cm A050 00025 000 46 1 Steunas 04 00062 000 45 4 Zk tapbout M10x20 ev 8 8 01210 M10x20 000 44 1 Afvalbak 04 00056 000 43 2 Bzk ck schr M10x16 ev 8 8 07160 M10x16 000 42 1 Aanslag 04 00043 000 41 1 Zk tapbout M8x30 ev 8 8 01210 M8x30 000 40 1 Boorbus DIN179A 8x10 G140 00001 000 39 1 Kantelblok 04 00048 000 38 2 Moer 04 00064 000 37 2 Bzk st schr M5x6 45H ke 07840 M5x6 000 36 1 Drukveer d 3 2 DM 20 LO 105 M090 00006 000 35 1 Zk tapbout M12x30 ev 8 8 01210 M12x30 000 34 1 Vik sluitr M12 ev d2 3xd1 38210 M12 000 33 1 Spindel sam 04 00306 000 32 1 Hijsplaat 04 00063 000 31 1 Lageras sam 04 00309 000 30 1 Kap sam 04 00105 000 29 1 Grafietband 100mm 04 00068 000 28 1 Afdekplaat 04 00257 000 27 1 Inbussl dw greep slw8x100 M130 00001 000 26 1 Zk borgmoer
14. a E RAES 9 3 2 Warning symbols on the machine nnn nennneerenn neer ennennee rennen enneneenennen 11 3 3 Safety regulations cece eter ttre enneeerenenneerenenneerenenneereneneereneneeeenene eenen 12 3 4 The operator ee 12 3 5 The maintainer nnn nannnnneneeeenenennenennnenenenenenanneneeeenenenenannenenernnnenensnnennnnenn 12 3 6 Setup of the machine nnn ansnannrensennen ensen en ensneeenensnneenennenernennteernensteeen ennen 12 3 7 The noise emission of the machine nnn anneer enerennee rennen enne ennnenenneenenn 13 3 8 Maintenance of the machine nnn nanne ennnenenneerenneeneenerenneerenneeneneennnnenenneenenn 13 3 9 Summary of the safety regulations nnn eneen eneen ennereneerennneeneeeennnenenneenenn 13 4 Description eee 14 NT E E E E EE 14 4 2 Construction of the machine nanne eneen ennenenenenneeeen eneen enneneen eneen 14 4 3 Electrical supply eee 15 4 4 Safety provisions and warning symbols nnn ennen enneenensenneeeen eneen 15 4 9 Control and adjustments esiseinas ennei ASEE O AENEA EREA 15 46 OperatlOn zinnen a aaa a a aa AE RAE aAA EAEAN 16 4 6 1 Starting and stopping the grinding belt anneer ennen eeen 16 4 6 2 Drive for the grinding Delt 2 cccccseccceceeeccceceseneceseeeccecesuecceeesueedeceseeeceeedeease 16 4 6 3 Securing a tubing section nennen erneer ensenere venne neerennenennenneneen ennen 16 4 6 4 Angle adj stm
15. by declares that The universal pipe notchers With type numbers AL100 AL100U 01 AL100U 02 and AL150 in conformance with the machinery directive 2006 42 EG satisfy the requirements of the following other EU directives 73 23 EEC Low voltage direction as modified in the directive 93 68 EEC 2004 108 EG EMC directive as modified in directive 89 336 EEC and that the following European Standards have been applied NEN EN ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reduction NEN EN 60204 1 2006 Safety of machinery Electrical equipment of machines Part 1 General requirements Completed in Vriezenveen 1 november 2011 Signature gt l 2 J J Landhuis General Director ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 29 of 29 70 1 Schakelaar sam 04 00300 001 69 3 Bzk ck schr M6x10 ev 8 8 07160 M6x10 000 68 3 __ Vlk sluitr M16 ev zf 38130 M16 000 67 1 Zk moer M10 ev 8 01300 M10 000 66 1 Schuurband R929 100x2000 P36 A044 00003 000 65 1 Schuurband RX66 100x2000 P36 A044 00001 000 64 1 Poellie 04 00050 000 63 1 Vik sluitr
16. cated on the type plate The machine serial number The machine serial number is indicated on the top of the clamp See Figure 4 7 1 The part number The part number is indicated on the exploded view drawing provided with this user manual drawing number 3 1008 000 8 Trouble This chapter provides information about trouble and trouble indications This chapter is intended for the operator and the maintainer of the machine 8 1 8 2 General information for trouble When trouble occurs switch off the machine and contact your dealer or your own maintenance department Comply with the instructions in chapter 3 and the maintenance instructions in chapter 7 Trouble indications and signals The machine controls do not include trouble indications or other signals 9 Disposal This chapter provides information about the disposal of the machine This chapter is intended for the owner and the maintainer of the machine The machine must be disposed of in accordance with the legal requirements of the country in which it is used The owner is responsible for disposal of the machine ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 28 of 29 ET EU Declaration of Conformity for machines Directive 2006 42 EG art 6 sec 2 and Appendix II A Manufacturer ALMI Machinefabriek BV Address Wierdenseweg 82 86 Postcode and city 7671 JK Vriezenveen Here
17. d or grinding roller the adjustment of the grinding roller and the grinding belt must always be checked The centre of the grinding roller must be at the same height as the centre of the tubing and the belt may not run diagonally during operation Before the grinding roller is adjusted the machine must be disconnected from the electrical supply by removing the plug connection from the mains supply Also read the safety regulations in section 3 3 Wear safety gloves during adjustment operations Through intensive use the roller can become extremely hot Before adjustment the two wingnuts of the support for the grinding roller see Figure 4 6 2 must be loosened one turn ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 20 of 29 ET Adjustment of the centre height The height is adjusted as well as possible by the manufacturer If the centre of the tubing profile is not at the same height as the centre of the grinding roller the height of the grinding roller must be adjusted For more information see Figure 4 6 5 After loosening bolts R the height of the grinding roller can be adjusted After adjustment re tighten bolts R Figure 4 6 5 Adjustment of the centre height of the grinding roller Adjustment of the grinding roller in relation to the grinding belt For adjustment of the grinding roller in relation to misalignment of the grinding belt see
18. ection must be secured in the tubing clamp The tubing clamp is mounted on the cross support See Figure 4 5 1 The tubing clamp with V shaped side plates is suitable for clamping tubing with a diameter of 18 76 mm When the V shaped side plates are removed the tubing clamp can also be used to secure rectangular and square profile tubing In the case of rectangular and square profile tubing the centre of the tubing profile must be at the same height as the centre of the grinding roller To achieve the correct height of the tubing profile a fill block can be used under the tubing section The clamp can be secured with the clamp handle on the tubing clamp See Figure 4 5 1 4 6 4 Angle adjustment To adjust the angle Allen head bolt f must be loosened The scale divisions allow the correct angle to be set In relation to the grinding roller the clamp in adjustable from 90 to 30 degrees After adjustment the Allen bolts f must be re tightened ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 16 of 29 TT 4 6 5 Stops Under the cross support of the tubing clamp is a clamp block g with which a standard stopper can be adjusted See Figure 4 5 1 The stopper works to prevent the movement of the support toward the grinding roller The stopper can be secured with an Allen bolt The flat side of the clamp has two M8 threaded holes See Figure 4 5 1 A
19. ed over 5 5 Transport and storage The machine is delivered in a wooden crate The crate can be lifted and moved with a forklift Once the machine has been assembled it is sensible to lay the machine on a pallet when it must be moved or stored It can then be moved with a forklift For vertical lifting the machine is also equipped with a lifting eye This lifting eye can be used to set the machine upright ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 25 of 29 ED 5 6 Initial setup During first use and after exchange of the grinding belt and or grinding roller the adjustment of the grinding roller and the grinding belt must always be checked The centre of the grinding roller must be at the same height as the centre of the tubing and the belt may not run diagonally during operation For the adjustment procedures see the description in section 4 6 10 Once the machine is plugged into the mains supply the machine is ready for use 6 Operation This chapter provides information about the operation of the machine This chapter is intended for the operator and the maintainer of the machine 6 1 Operation in general The following is a description of regular operation Comply with the safety regulations in chapter 3 Operation is carried out using the controls and adjustments described in section 4 5 For additional information also see secti
20. f a grinding belt see section 4 7 ADVICE For a grinding roller with a diameter smaller than 30 mm use a grinding belt that has previously been used on a roller with a larger diameter A new grinding belt is very stiff and may break if used on a grinding roller with a small diameter After installing the new grinding belt the belt must be tensioned properly This can be done by turning the hand crank clockwise until the area between the ring and the plate is 3 5 mm See Figure 4 6 3 The tension is determined by the degree to which the spring is compressed Next the support for the grinding roller must be moved back to its original position and secured with the wingnuts See Figure 4 6 2 After exchange of the grinding belt any misalignment of the belt must be corrected For more information see section 4 6 10 4 6 9 Exchange of the grinding roller Before the grinding roller is exchanged the machine must be disconnected from the electrical supply by removing the plug connection from the mains supply Also read the safety regulations in section 3 3 Wear safety gloves during exchange of the grinding roller and or grinding belt Through intensive use the roller can become extremely hot Before the grinding roller is exchanged the grinding belt must be removed For more information see section 4 6 8 The grinding roller is held in place by two spring pressure retainers The grinding roller can be easily removed from the holde
21. f the machine As maintainer of the machine you must be aware of the information that is relevant for you Also refer to section 1 3 Target group for each chapter Always remain alert for possible dangerous situaitons Be careful of projecting portions of the machine Be careful with loose clothing and hair Never engage power to the machine if any person is in contact with the machine in a dangerous manner Never start the machine if any person is in contact with the machine in a dangerous manner During maintenance to the machine switch off the machine and disconnect the electrical plug Follow the warnings and indications on the machine For the explanation of the symbols see section 3 2 Before use of the machine close the side cover Close the top cover if deburring is not required Use the Lexan fold away shield to protect your face Wear close fitting clothing during grinding work Before grinding attach the workpiece securely No flammable materials may be present in the area surrounding the universal pipe notcher The grinding of pipes creates showers of sparks Wear safety gloves during grinding operations changing of the grinding roller and or grinding belt and during adjustment operations Through intensive use the roller can become extremely hot and as a result of grinding sharp burrs can be created ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision
22. g during grinding work Before grinding attach the workpiece securely No flammable materials may be present in the area surrounding the universal pipe notcher The grinding of pipes creates showers of sparks Wear safety gloves during grinding operations changing of the grinding roller and or grinding belt and during adjustment operations Through intensive use the roller can become extremely hot and as a result of grinding sharp burrs can be created Always think of the safety of yourself and others 3 4 The operator The machine may only be operated by personnel who are qualified to do so Personnel that have this qualification are referred to in the rest of this user manual as the operator As operator of the machine you must be aware of the information that is relevant for you Also refer to section 1 3 Target group for each chapter The operator is not permitted to perform operations that are not indicated to be intended for the operator Comply with the safety regulations in this user manual Do not deviate from the safety regulations This can result in danger 3 5 The maintainer Only personnel from the maintenance department who have received special training may carry out maintenance of the machine Personnel that have this qualification are referred to in the rest of this user manual as the maintainer As maintainer of the machine you must be aware of the information that is relevant for you Also refer to
23. ing belt Measurements Ixw 2000x100 mm 79 x4 The machine is delivered standard with 2 grinding belts type RX66 grit K36 For recommended grinding belts see Table 4 7 2 Noise emmission 83 87 dB A measured at a distance of 1 metre from the machine Figure 4 7 1 Location of serial number Range 20 60 mm diameter diameters increasing in steps of 2 mm Special diameters 76 mm 7 1 1 1 2 and 2 Other diameters between 20 and 76 mm Other diameters are available from your dealer upon request Table 4 7 1 Other available grinding roller diameters Grinding roller Stainless steel Aluminium diameter 20 through 40 mm 40 through 76 mm Table 4 7 2 Overview of recommended grinding belts ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 22 of 29 ET 5 Transport storage placement and initial setup This chapter provides information about the scope of delivery transport storage placement and initial setup of the machine This chapter is intended for the maintainer of the machine 5 1 Scope of delivery The machine is delivered in a wooden crate The following loose components are included in the scope of delivery part quantity description 1 1 Universal pipe notcher 2 1 Foot plate 3 1 Support pillar 4 2 Hex bolt with washer M12 5 1 Grinding waste container in the support
24. neer ARENAEN RANNAN KAAKAA RNA 7 Figure 3 1 1 Safety Provision S sac naer adt a N EA EAA deale advena dated ennn 10 Figure 3 2 1 Warning symbols on the machine nnen enen eneeeenennenerenenneeren eneen 11 Figure 4 2 1 Construction of the machine nnnnnenneenenenneerenenneerenenneerenenneenen eneen 14 Figure 4 5 1 Controls and adjustments nennen enen tiene eee enneerenenneerenenneerenenneeeenen 15 Figure 4 6 1 Deburring table iz nadar deerd benndert aaide KEERATA EE 17 Figure 4 6 2 Support for the grinding roller nnn ennen eneen ennneerenenneerenenneeren eneen 18 Figure 4 6 3 Belt tensioning device nnee enneerenenneerenennvereneneerenennveren eneen en 18 Figure 4 6 4 Exchange of the grinding roller nnn eneen ennenenneereneeenenneenneenennenn 19 Figure 4 6 5 Adjustment of the centre height of the grinding roller nnee 21 Figure 4 6 6 Adjustment of the grinding roller in relation to the grinding belt 21 Figure 4 7 1 Location of serial number nnn nnen enneennnerennerenenneneneerenneen enne eneneeenneenennen 22 Figure 5 2 1 Clarification of assembly nnn anneer ennn eeneerenneee nanne neneerenneen eneen eneeenneenennenn 23 Figure 5 2 2 Installation of the ball handle and handle nnen ennerenneenennen 24 Figure 5 4 1 Wiring connections in the connection compartment of the electrical motor 25 Appendix nnn ennen eenen enen ven enenene eneen EU Declara
25. nsparent shield above the grinding roller Check the presence and legibility of the warning symbols See section 3 2 Worn or removed symbols must be replaced Check for wear of the grinding roller bearings See also section 4 6 9 Check the operation of the tubing clamp bolts and screw threads used to secure and adjust a tubing section See also sections 4 6 3 4 6 4 and 4 6 5 Check the wear of the rubber coating on the drive roller The coating ensures the proper grip of the grinding belt to the drive unit See also section 4 6 2 Check the proper operation of the belt tensioning device See also section 4 6 8 Check the operation of the adjustment mechanism for the grinding roller See also section 4 6 10 Thoroughly clean the machine on a regular basis Check the mains cable for damage Monthly Monthly Every 6 months Every 6 months Every 6 months Every 6 months Every 6 months Monthly Monthly Table 7 2 1 Checkpoints and lubrication schedule 0 ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 27 of 29 ee ALMI 7 3 Replacement of components If the machine requires repair we recommend that you contact your dealer If you carry out repairs yourself you must only use original parts When ordering parts the following information must be provided The machine type number The machine type number is indi
26. nveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 24 of 29 ED If the voltages are not the same the adaptations described below must be made Open the connection compartment of the electrical motor and install the strips as shown in Figure 5 4 1 Replace the motor switch and the no voltage coil Section 4 7 shows what is required Replace the type plate of the machine The motor switch the no voltage coil and the type plate are available through your dealer 230 VOLT 460VOLT Brown Braun Brown Bruin Braun Bruin Black Schwarz Zwart Blue Blau Blauw m E Yellow green Yellow green Gelb grun Gelb grun Geel groen Geel groen Figure 5 4 1 Wiring connections in the connection compartment of the electrical motor Connect the wiring of the supply cable according to the correct diagram in Figure 5 4 1 Install a plug that matches your electrical outlet on the end of the cable After connection check the direction of rotation of the grinding belt The top surface must move toward the cross support ATTENTION First close the side cover See Figure 3 1 1 Comply with the safety regulations in section 3 3 If necessary exchange the concerned wires in the plug Route the cable to the electrical outlet in such a manner that it will not be tripp
27. odifications are made to the machine by others without instruction from ALMI in an incompetent manner non original parts are used the damage or defects are the result of connecting the machine in a manner other than intended incompetent use or failure to follow the regulations and instructions for use the deficiencies are the result of normal wear of the machine art 3 ALMI reserves the right to have work on the machine carried out by third parties during and after the warranty period ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 8 of 29 ET 3 Safety regulations This chapter provides information concerning the general safety regulations This chapter is intended for the owner the operator and the maintainer of the machine Read this chapter carefully before use of the machine and before carrying out repairs on the machine 3 1 Safety provisions 3 1 1 General For the exact location of the various provisions see Figure 3 1 1 It is absolutely forbidden to remove or disable the safety provisions 3 1 2 Emergency stop The machine is provide with an emergency stop The emergency shall break the electrical supply Unbreak the electrical supply by twisting the emergency stop counter clockwise the emergency stop jumps back in starting point After pushing of the emergency stop the grinding belt will standstill 3 1 3 Safety shields
28. on 4 6 1 Starting and stopping the grinding belt The switches for starting and stopping are on the right side of the support pillar See figure Figure 4 5 1 To start the machine push the green button To stop the machine push the red button ATTENTION Before the machine is started the side cover must be closed The side cover is shown in Figure 3 1 1 4 6 2 Drive for the grinding belt The grinding belt is driven by a Euro voltage motor This means that the motor can be connected to a 230 Volt 3 phase or 400 Volt 3 phase supply with a tolerance of 10 Before first use the voltage of the supply connection must be verified in comparison to the voltage indicated on the type plate For the electrical connection follow the instructions in section 5 6 A pulley with a rubber coating is mounted on the motor shaft The rubber coating in combination with the correct belt tension ensures the required grip of the grinding belt to the pulley Before putting tension on the grinding belt see section 4 6 8 The required direction of rotation is indicated on the pulley Consider this when making the electrical connection For the electrical connection follow the instructions in section 5 6 The direction of rotation is also indicated on the inside of the grinding belt This must match the arrow on the pulley Before installation of the grinding belt see section 4 6 8 4 6 3 Securing a tubing section For working the tubing s
29. on 4 6 the Operation of the machine 6 2 Start up Connect the machine to the mains supply if it is not already connected Check whether the correct grinding belt is installed For selection of the proper grinding belt see Table 4 7 2 Check the grinding belt for wear If it is necessary to replace the grinding belt see section 4 6 8 Check whether the correct grinding roller is installed The correct grinding roller is determined by the diameter measurement of the tubing sections that must be connected to one another For available grinding roller diameters see Table 4 7 1 lf it is necessary to replace the grinding roller see section 4 6 9 Check the adjustment of the grinding roller and the grinding belt The centre of the grinding roller must be at the same height as the centre of the tubing and the belt may not run diagonally during operation For the adjustment procedures see the description in section 4 6 10 Check whether the grinding waste container must be emptied 6 3 Operation Before securing rectangular or square profile tubing remove the side plates from the clamp If necessary use a fill block to maintain the correct centre height of the tubing section See also section 4 6 3 Secure the tubing section in the tubing clamp Set the proper angle Tighten the clamp Bring the tubing section toward the centre of the grinding roller Start the machine To do so push the green button on the m
30. otor switch Move the tubing section toward the grinding roller for notching The width of the notch must not exceed the width of the grinding belt To notch a series of tubing sections that have the same diameter and length the stoppers can be used For more information see section 4 6 5 After notching the tubing section it can be deburred on the deburring table at the top of the machine To do so open the top cover Stop the machine To do so push the red button on the motor switch ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 26 of 29 EEN 6 4 Shut down The machine can be shut down by removing the plug from the mains connection 7 Maintenance This chapter provides information about the maintenance of the machine This chapter is intended for the maintainer of the machine 7 1 Precautionary measures 7 2 Checkpoints Maintenance of the machine may only be performed if the machine if voltage free Comply with the safety regulations in chapter 3 The machine must regularly be checked according to the points in Table 7 2 1 Replace components as necessary See section 7 3 Item number Description Time interval 1 8 9 Check the presence and proper operation of safety shields See section 3 1 Check the operation of the closing mechanism for the side cover Check the visibility through the tra
31. pipeclamp Figure 2 3 1 Sample type plate with CE mark ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 6 of 29 EE For the location of the attached CE mark and type plate see Figure 2 3 2 lt Plate with CE mark Figure 2 3 2 Location of the type plate 2 4 Function of the machine The function of the machine is the notching and or deburring of the ends of tube sections It is not permissible to use the machine for any other purpose 2 5 Machine options There is no optional equipment that can be added to the existing version of the machine to change its function 2 6 Liability When injury or harm to persons or damage to the machine or products is the result of not following these operating and maintenance instructions ALMI Machinefabriek BV can not be held liable 2 7 Service For service contact your dealer or your own maintenance department ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 7 of 29 ET 2 8 Warranty conditions art 1 If within 12 months of delivery ALMI Machinefabriek BV is notified of deficiencies in the delivered machine that are caused by defects in materials or workmanship and is provided with the serial number and the original receipt ALMI will repair these defects art 2 All warranty obligations expire if repairs or m
32. plug must be installed For the electrical connection follow the instructions in section 5 6 4 4 Safety provisions and warning symbols The safety provisions and warning symbols are handeled in sections 3 1 and 3 2 4 5 Controls and adjustments For regular operation the machine has the following controls and adjustments The controls and adjustments are shown in Figure 4 5 1 Emergency stop Push button for stopping the grinding belt Push button for starting the grinding belt Ball wheel for adjusting support parallel to grinding roller Handle wheel for adjusting support perpendicular to grinding roller Clamp handle for securing workpiece Allen bolt for securing rotatable clamp using key with handle j Allen bolt for securing standard stopper using key with handle j Allen bolt for securing grinding belt using key with handle j Allen key 8 mm with handle for securing rotatable tubing clamp for securing standard stopper and for adjustment of grinding belt k Allen bolt for opening and closing side cover Mounting length stopper on flat side of clamp Fea mo9a90TD Controls and adjustments for changing and adjusting grinding belt and or grinding roller are described in sections 4 6 8 4 6 9 and 4 6 10 Figure 4 5 1 Controls and adjustments ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 15 of 29 ED 4 6 Operati
33. pter is intended for the owner the operator and the maintainer of the machine 2 1 The user Read this user manual carefully before use and before maintenance of the machine is carried out Only then is optimal safety ensured The machine may only be operated by qualified personnel The operator must read the chapters indicated in 1 3 carefully Maintenance of the machine may only be carried out by specially trained personnel from the maintenance department The maintainer must read the chapters indicated in 1 3 carefully 2 2 The manufacturer The manufacturer of the machine is ALMI Machinefabriek BV Wierdenseweg 82 86 7671 JK Vriezenveen The Netherlands T 31 0 546 561 353 F 31 0 546 564 465 2 3 Machine identification The machine is provided with the CE mark This is shown on the type plate See Figure 2 3 1 The CE mark indicates that this machine satisfies the fundamental health and safety requirements of the European Union Also refer to the warning in section 1 2 In addition to the CE mark the data indicated below is also shown on the type plate See also Figure 2 3 1 Name and address of the manufacturer Type indication Year of manufacture Serial number only reference Required supply voltage Motor speed Weight ALMI Machinefabriek B V Motor specifications Type AL100U 01 Voltage 400 Year of 2009 Hz 50 manufacture 4 min 2895 Serial no listed on the Weight 190 kg
34. r as shown in Figure 4 6 4 Never adjust the spring pressure retainers They have been properly adjusted by the manufacturer Clean recesses thoroughly Spring pressure retainers Bearings Supports for the grinding roller Figure 4 6 4 Exchange of the grinding roller ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 19 of 29 ET Before the new grinding roller is installed the recesses of the support for the grinding roller must be cleaned thoroughly This prevents clamping roblems Thereafter the new grinding roller can be installed The grinding belt can also be re installed For more information see section 4 6 8 For an overview of the available grinding roller diameters see section 4 7 ADVICE For a grinding roller with a diameter smaller than 30 mm use a grinding belt that has previously been used on a roller with a larger diameter A new grinding belt is very stiff and may break if used on a grinding roller with a small diameter ATTENTION The bearings that are mounted on the grinding roller must be handled with care because they can be easily damaged After exchange of the grinding roller any misalignment diagonal running of the belt must be corrected For more information see section 4 6 10 4 6 10 Adjustment of the grinding roller and grinding belt During first use see chapter 5 and after exchange of the grinding belt an
35. section 1 3 Target group for each chapter Comply with the safety regulations in this user manual Do not deviate from the safety regulations This can result in danger 3 6 Setup of the machine Make sure that the machine is setup and properly anchored on a flat horizontal floor during use Make sure there is sufficient lighting to allow the work to be performed in a safe and responsible manner ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 12 of 29 EEN 3 7 The noise emission of the machine The noise emission during grinding operations is 83 87 dB A measured at a distance of 1 metre The use of good hearing protection is required 3 8 Maintenance of the machine The machine must be in a sufficient state of repair that no dangerous situations can occur The troubleshooting chart is provided in chapter 7 If replacement is necessary use only original parts 3 9 Summary of the safety regulations __The machine may only be operated by personnel who are qualified to do so As operator of the machine you must be aware of the information that is relevant for you Also refer to section 1 3 Target group for each chapter The operator is not permitted to perform operations that are not indicated to be intended for the operator Only personnel from the maintenance department who have received special training may carry out maintenance o
36. tion of Conformity for machines Appendix nnn eenen nennen exploded view drawing with drawing number 3 1008 000 ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 11 AL100U 01 ENG Revision and revision date 2 20 09 2011 Page 3 of 29 ET 1 Foreword This foreword contains general information about and for this user manual 1 1 Name of machine The name of the machine is Universal pipe notcher 1 2 Warning Read this user manual carefully before use and before maintenance of the machine is carried out Only then is optimal safety ensured The machine may only be operated and maintained by personnel who have received special training There are moving parts on the machine For this reason the machine must always be switched off and the electrical supply must be disconnected before maintenance and or repairs are carried out Always be careful of the moving sharp and or protruding parts they can cause injury 1 3 Target group for each chapter This user manual is intended to provide information to the persons departments listed below the owner the operator the maintainer Next to the heading of each chapter is indicated for which of the groups described above the chapter is intended Table 1 3 1 provides an overview of the target groups for each chapter Chapter rite Owner Operator Maintainer Table of contents e 1 Foreword 2 Introduction 3 Safety regulations e
37. ware Remove the machine from the packaging To do so use the lifting eye Use the proper lifting equipment The machine weighs 200 kg Open the side cover of the machine Attach the machine to the support pillar using two M12 hex bolts Slide the grinding waste container under the machine Install the included ball handle on the front of the cross support Install the included handle under the cross support Ball handle Handle Figure 5 2 2 Installation of the ball handle and handle To test the direction of rotation and for adjustment during the initial setup also install a grinding roller and a grinding belt See sections 5 4 and 5 6 For the installation of the grinding belt and the grinding roller see sections 4 6 8 and 4 6 9 5 3 Placement of the machine Make sure that the machine is setup and properly anchored on a flat horizontal floor during use Make sure there is sufficient lighting to allow the work to be performed in a safe and responsible manner 5 4 Connection of the power supply For the electrical connection a 4 conductor supply cable without a plug is supplied with the machine The machine is equipped with a Euro voltage motor This means that the motor can be connected to a 230 460 Volt 3 phase supply with a tolerance of 10 The voltage of the supply connection must be verified in comparison to the connection voltage indicated on the type plate ALMI Machinefabriek B V Vrieze
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