User manual - Almi Machinefabriek
Contents
1. Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 18 of 27 4 6 11 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 Replacement of the hand wheel with a handle To replace hand wheel d with the provided handle the procedure below must be carried out For clarification also see sections Figure 4 5 1 Figure 4 6 7 and Figure 4 6 8 Removal of the spindle Position the slide as far as possible from the grinding roller Remove the hand wheel Push the slide as far as possible toward the rear Remove the slide from the backside Figure 4 6 7 Removal of the hand wheel and spindle Installation of the handle Remove the bolts and the spacer bushes on the bottom There is a spacer ring under the long spacer bush Install the handle in accordance with Figure 4 6 8 Make sure the spacer ring is reinstalled Figure 4 6 8 Installation of the handle ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 19 of 27 o 4 7 Technical data Type AL100U 02 Serial number Is indicated on the top of the clamp See Figure 4 7 12. 3 31 10 2014 Page 26 of 27 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 Hereby 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 2006 95 EG Low voltage direction as modified in the directive 73 22 EEG 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 4 november 2014 Signature l 0 J J Landhuis General Director ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 27 of 27
3. Safety regulations e e 4 General description of the machine e 5 Transport storage and setup of the machine 1 6 Operationofthemachine _ _ _ _ e e 7 Maintenance ofthe machine I l e 8 Trouble S S S e e 9 Disposal ofthe machine Cid e 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 ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 4 of 27 o 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 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 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 5 of 27 N 2 introduction This chapter provi
4. 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 g 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 g must be re tightened 4 6 5 Stops Under the cross support of the tubing clamp is a clamp block h 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 length stopper can be attached to these ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 14 of 27 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 No
5. 15 Figure 4 6 2 Support for the grinding roller cccccceccceeccceeeeeeeeeeeeecaeeseeeeeeeeeseeeeseesseeesueesaees 16 Figure 4 6 3 Belt tenSioning device cccccseecccseeeeceeeeeceeeeeneeeeeseeeeseaeeeseeeeseeeeesneeeseeeeseneeesens 16 Figure 4 6 4 Exchange of the grinding roller cccccccseeeceeeeeeeeeeeeceeeeeeeeeeeseeeesseeeeeaeeesaeeeesaes 17 Figure 4 6 5 Adjustment of the centre height of the grinding roller cccecceseeeeeseeeeeeeeeeeees 18 Figure 4 6 6 Adjustment of the grinding roller in relation to the grinding belt eee 18 Figure 4 6 7 Removal of the hand wheel and Spindle ccccccccseeeeeeeeeeeeeeeeeeeeeseeeeeseeeeesaes 19 Figure 4 6 8 Installation of the handle cc cccceccccseeeeseeeeeeeeeeeeeeeeseeeeeseeeeeseeeeeaeueesseeeesaeeeesaes 19 Figure 4 7 1 Location of Serial NUMDEL cccceecccceeeeeceeeeeeeeeeeaeeeesseeeeseeeeeseeseeseueesseeeeseneeesens 20 Figure 5 2 1 Clarification Of assembly ccceccccseeeeceeeeeeeeeeeeeeeeeaeeeesaeeeeseeeesaeeeeseneesseeeeseneeesees 21 Figure 5 2 2 Installation of the hand wheel and handle cccceceeeeeceeeeeeeeeeeaeeeeseeeeeseeeeesees 22 Figure 5 4 1 Wiring connections in the connection compartment of the electrical motor 23 iA 9 6 lt 1 5 8 eo ee eee ee eee eee eee ee ee eee EU Declaration of Conformity for machines POD ONIGIX cose sieiednenteedteavteenesevsnina
6. 2 Checkpoints The machine must regularly be checked according to the points in Table 7 2 1 Replace components as necessary See section 7 3 Check the presence and proper Monthly operation of safety shields See section 3 1 Check the operation of the closing mechanism for the side cover Check the visibility through the transparent shield above the grinding roller Check the presence and legibility of the Monthly warning symbols See section 3 2 Worn or removed symbols must be replaced 3 Check for wear of the grinding roller bearings See also section 4 6 9 Check the wear of the rubber coating on Every 6 months 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 Every 6 months tensioning device See also section 4 6 8 Check the operation of the adjustment Every 6 months mechanism for the grinding roller See ee also section 4 6 10 regular basis Check the mains cable for damage Monthly Table 7 2 1 Checkpoints and lubrication schedule 4 Check the operation of the tubing clamp Every 6 months bolts and screw threads used to secure and adjust a tubing section See also sections 4 6 3 4 6 3 and 4 6 3 go 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
7. 3 2 Warning symbols on the MACHING cccceecceseeeeeeeeeeeeeeeeseeeeeseeeesseeeesseeeeeseeeeseeeeess 9 Ja Gadlely TEQUIQUONS arises p ae a aes 10 OA TEOD OT ae E A OEE E EAE 10 3 9 The VAIN NOY eseisma EAE EE E EEE 10 3 6 Setup ofthe machine cccccccccecccceeeceseeceneecueeceecececsueeceueeseeesseeseueessueessueenaass 11 3 7 The noise emission of the machine ccccccccecccseeeceeeeceeeeceeeeseeeeseeeeseeeseeeesaeeesaees 11 3 8 Maintenance of the machine ccccccceeccceeeeceeeeseeeeaeeesaeeeseeeeseueeseeeeseeesaeeeseeeesaees 11 3 9 Summary of the safety regulations cccccccccseeeeeeeeeeceeeeeeeeeeeseeeeeeeueeeaeeessneeesaees 11 4 DESCHPUON eee ee ee ee eee 12 de STC oes seins A T enc aa EAEE seca TE patie misdaad wraps A A E E 12 4 2 Construction of the machine ccccccccssccceeeceeecceeecececeueesueecaeeseaeessueesseessaeeseas 12 Ao VOC UCAS UDO sosirii iaee ADEE TEREE A REE EEA RRE EAEE E AARE RA EEEE 12 4 4 Safety provisions and warning SYMDOIS ccccseececseeeeceeeeeseeeesaeeeesaeeeeeeeeeeseneeees 13 4 5 Controls and adjustments ccc ccccccceccceececeeeeceeeeseeeese cece eeseeeesaeeeseeseueeseueeseeeaes 13 DG CCRC eased ejereerstce EAE E E A A NEE A E 14 4 6 1 Starting and stopping the grinding belt cece ceeceeeeeeeeeeeeeeeseeeeseeeeaes 14 4 6 2 Drive for the grinding Delt cc eccccseececseeeeeeeeeeeeeeeeseeee
8. Warning symbols on the machine ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 9 of 27 CE 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 situations 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 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
9. 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 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 7 of 27 N 3 Safetyregulations 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 The grinding belt is enclosed in a housing that is only open on the front side at t
10. run diagonally during operation ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 17 of 27 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 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 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 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 ALMI Machinefabriek B V
11. 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 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 of 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 situations Be careful of projecting portions of the machine Be careful with loose clothing and hair Never e
12. 00114 amp 04 00115 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 belt Adjustment mechanism grinding Grinding roller roller Tube cl rm ube clamp ys amp a gt Nix me A Housing drive FNA J D roller grinding roller and grinding belt Cross support AT Grinding waste container o f Support pillar es Foot plate ed Figure 4 2 1 Construction of the machine 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 plug must be installed For the electrical connection follow the instructions in section 5 6 ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 12 of 27 N 4 4 Safety provisions and warning symbols The safety provisions and warning symbols are handled in sections 3 1 and 3 1 4 5 Controls and adjustment
13. 2014 Page 20 of 27 CD 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 pillar 6 1 Hand wheel 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 1010 000 5 2 Assembly For clarification of the procedures below see also Figure 5 2 1 Grinding waste container M12 bolts Support pillar Foot plate Figure 5 2 1 Clarification of assembly 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 hand wheel the handle and the attachment hardware Remove the two attachment bolts with which the universal pipe no
14. 96 io 6 gt 8 gt ee een er Oe eer nee eee E 23 IG MSE e en nr nen re Oe er a ne eee ee ee ee 23 O 912 62 6 CamEeet EN an er ae a ne en eee ne ne eee te eee eer 24 EE _ _ __ _ SE ___EoEoeqHEHEeaaeEEEEEEESgSe ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 2 of 27 tC 6 1 Operation in GENneral cccccccceecccceeceeeeeceeeeececeeececeeeeeseecesseeesseecesseecessueeeseneeesaees 24 ee VN E o E E EA ENE EAE E EEE AE 24 Ca ODO Oeean E EEE EEE E O E 24 E EE Ee eN y A E E A T T dade aved seus oveadses 24 la Maintenance ssniciesinaneriiei iiinn aii a an a ee ei a aa i a 24 7 1 Precautionary measures ccccccccssececesececeseeceeseeceeeeeceueeecsueeesaseeeeseecsaeeesegesensaess 24 Pe 61 gt 61 618 oa a a E E E e E ee een 25 7 3 Replacement of components ccccceeccceseecseeeceeeceeeceueeceueecaueesueeseaeecsueecseeesaaes 25 Os POUDO e ne ee a a a a a E 26 8 1 General information for trouble ccccccccseececeeeeeeeeeeeceeeeeseeeeeseueeeseeeesseeeeseneeesaees 26 8 2 Trouble indications and SIQMAlS cccccescccssscecceececeeecceeseecseseeceeeeeceseeensueeenaaess 26 lt D o e PTEE E E E AE EE sete E E E E A E E ee aseeeeeas 26 EU Declaration of Conformity for machines ccccceececeeeeceeeeceeeeaeeesaeeeseeeseuees
15. ON 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 section 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
16. User manual Universal pipe notcher Type AL100U 02 230 400 Volt 3 phase ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 1 of 27 o Table of contents T POWO rse EE EE E E E EE E EE EEEE E TEES 4 1 1 Name of machine cccccccccscccsnceceneeceeeecaeeecaeeceaeeceuceseueeceeesaeeceaeecaueeceeesseeseaeeseas 4 be N O e E Suan E E E 4 1 3 Target group for each Chaptel cccccccceseccssseeceeseeceeececeueeessueeeeaseesseseeseueeenseeseneas 4 bka MMOL a T E EA 4 1 5 Re ordering the user manual ccccceccceseeceeseecseseeceeeeceueeeceueeeseseeseeeeeceaeeeneueeeseas 5 1 6 Deficiencies in this user manual cece ceccceececeeeeceeeeseeeeseeeeseeeeseeeseeeseueesaeeeaeeeaes 5 2 IARC UNCC g PERNE A E A A cece N E E E T E 6 eM TACS a T sso en pee lates T E pee vn wanes aaa seesee eae 6 APS VU CN tape ne isn E E setae pee win anda ese nee seesee eee 6 293 Machpe identical essien aE E Ea 6 24 Function ofthe MACIING sssresscesicsrr rei E e E E T Z MaCS OPU ee E E E E E OE A EO ee 7 LO AD y eee A E E E A T Le o NVO a E E EE E EA T 2 0 Wanay COMMONS arcsin eae eian nia aE E Di N Ea a aNs 7 Ge Sa E GUIAUIOINS saa E E A eeatninseanel 8 ale S Dr ONS serea E E wceacaneaetasdoicweanee 8 784 ees e EE gt e N ee A NEE A E A E A T EE ee 8 312 EMMCIGCNCY SIOD sriain ea E 8 AL SAC SINCIOS cesnak a eE S 8
17. Weight 190 kg Measurements Ixwxh 1450x1150x650 mm Motor Squirrel cage armature motor SG100L 21 3 kW suitable for supply voltage of 230 V or 400 V Motor speed 2895 rpm at 400V 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 400 V switch PKZM1 6 no voltage coil U PKZM1 400 Belt speed 30 m s at 400V 50Hz 36 m s at 230V 60Hz Notching depth O20 676 mm Grinding roller For available grinding roller diameters see Table 4 7 1 Grinding belt Measurements Ixw 2000x100 mm 79 x4 The machine is delivered standard with 2 grinding belts 1 x type R929 and 1 x type R996 both grit K36 For recommended grinding belts see Table 4 7 2 Noise emission 83 87 dB A measured at a distance of 1 metre from the machine Figure 4 7 1 Location of serial number Range 20 76 mm diameter diameters increasing in steps of 2 mm Special diameters W Ya P 1 172 2 3 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 diameter T 36 36 Table 4 7 2 Overview of recommended grinding belts ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10
18. acture 2895 Serial no listed on the pipeclamp Weight 210 kg Figure 2 3 1 Sample type plate with CE mark ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 6 of 27 o For the location of the attached CE mark and type plate see Figure 2 3 2 _____ Type 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 cannot be held liable 2 Service For service contact your dealer or your own maintenance department 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 modifications are made to the machine by others without instruction from ALMI in an
19. 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 EE 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 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 ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 10 of 27 o 3 6 Setup of
20. des basic information about the machine and the accompanying user manual This chapter 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 02 Voltage Year of 2013 manuf
21. eeeeaeeeeaes 27 The universal pipe notchers cccccceccccscecesceceeeeceeeeceeececessueesueeseeeseueeseaeessaeess 2 Table 1 3 1 Overview of the target groups for each Chapter cccccccceecceceeceeseeeeeeeeseeeeeees 4 Table 4 7 1 Other available grinding roller diameters cccccceeeeeceeeeeeeeeeeeeeeesaeeeeseeeeeeaneeess 20 Table 4 7 2 Overview of recommended grinding Delts cccccceeccceeeeseeeeeeeseeeeseeeeseeeeseeeaes 20 Table 7 2 1 Checkpoints and lubrication SCNECUIE ccccccceeccceececeeeeeeeeeaeeeseeeesaeeeseeeeseeeeaes 25 Figure 2 3 1 Sample type plate with CE mMark cccccccccccceececeeeeeeeeseeeeseeeseeeeseeeeseeeseeesaeeees 6 Figure 2 3 2 Location of the type plate cc ceccceseccseseeeeeseeceaececeueeeseeeesaseeseaseeseaesesegesensaees 7 Fig re 3 1 1 Safety DIOVISIONS vic casicunasancwanmsdnnsdnaavestumnad ta tudnesanabnnsdapensanuaeniomaialuiannnsameseiaduauaceuas 8 Figure 3 2 1 Warning Symbols on the MACHING cccceccccseeeeceeeeeeeeeeeceeeeeseueeeaaeeeeaeeeesaeeeesanees 9 Figure 4 2 1 Construction of the machine ccccceecceceeeeeeeeeeeseeeeeeeeeeseeeeseeessueesseeessneeesaes 12 Figure 4 5 1 Controls and adjustments cccccecccceeeeeseeeeeeeeeeeaeeeeseeeeeseeeeeseeeeesueeeeeeeeseeeeesees 13 Figure 4 6 1 DEDUMING TADIC vaisesccuiscsnanenivdroraiseataenaceradtasadnusaxavansdatausaawaesboouatatuaannnailerseziaeauanaveld
22. eel a handle can be installed See section 4 6 11 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 ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 15 of 27 j Wha ill PTT tid meatier eli ite Adjust to 3 5 mm during tensioning of the grinding belt Figure 4 6 3 Belt tensioning device 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 of 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 s
23. exploded view drawing 230 Volt with drawing number 04 00115 7 9 6 lt 15 6 Ge ne ee ener exploded view drawing 400 Volt with drawing number 04 00116 ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 3 of 27 N 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 Table of contents e gt 1 Foreword S o e e o Introduction e gt e
24. gular 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 motor 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 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 Maintenance of the machine may only be performed if the machine if voltage free Comply with the safety regulations in chapter 3 ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 24 of 27 tt 7
25. he 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 Top cover deburring location Transparent fold away shield for facial protection Side cover Emergency stop Figure 3 1 1 Safety provisions ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 8 of 27 CE 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 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 Figure 3 2 1
26. ngage 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 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 11 of 27 oo 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 04
27. s For regular operation the machine has the following controls and adjustments The controls and adjustments are shown in Figure 4 5 1 k e a E Emergency stop Push button for stopping the grinding belt Push button for starting the grinding belt Hand wheel for adjusting support parallel to grinding roller Hand 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 Allen bolt for opening and closing side cover Mounting length stopper on flat side of clamp Controls and adjustments for changing and adjusting grinding belt and or grinding roller are described in sections 4 6 8 4 6 8 and 4 6 8 Figure 4 5 1 Controls and adjustments ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 13 of 27 o 4 6 Operation 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 ATTENTI
28. seeeeeseaeeesaeeeeseneeesees 14 4 6 3 Securing a tubing SECTION cccceecccseeeceeeeeceeeeceeueeceececseeeeseueeessaeeetaneesness 14 4 6 4 Angle adjustment scissasuinttiesiuneesusvandaaustmuaesaushnddanndnaaunerdvudasundwarteavdieGieasdewensweuendia 14 aS SE O 9 e E E E ne A A A E E eee nee A E E SS 14 4 6 6 Notching a tubing section cccceecccceeeeeceeeeeceeeeeeeeeeeseeeeeseeeeseaeeesaeeeeseeeeesees 15 AO DEDU eoa r E EA AAAA 15 4 6 8 Exchange of the grinding Delt ce ccceccceceeeeeeeeeeeeeeeeeseeeesseeeseeeeseeeesees 15 4 6 9 Exchange of the grinding roller cc ccceceeccceeeeeeeeeeeeeeeeeeseeeeeeaeeeseeeeeseneeenaes 17 4 6 10 Adjustment of the grinding roller and grinding belt cccccceeeeeeeeeeeeees 17 4 6 11 Replacement of the hand wheel with a Nandle ccccceccceeeeeeeeeeeeeeees 19 4 7 Technical Gels ce ttareeccaitasnnaeetesaseisadaana cons vances aancpuensbecdedataed ade aneceieese tee nannaa aai 20 5 Transport storage placement and initial setup 0 0 0 ceccceeceeeeeeeeeeseeeeseeeeaeeeeaeeesaeees 21 5 1 SCOR Of CSI OE aeciaii AAE E ES aA 21 De AS eE E A tsatosseceede waesaccsnsnacee 21 5 3 Placement of the MACHNING cccccscccssccceeeeceeecceeeccueeceuceceueecuessseeseueessueesseeenaass 22 5 4 Connection of the power SUPDIY ccccceccceeccceeeeee cece ceseeeeseeeeseeeeseeesseeseneeseeeesaees 22 oe immed B21 io 810 ques
29. tcher is attached to the bottom plate of the packaging ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 21 of 27 5 3 5 4 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 hand wheel the handle and the attachment hardware Remove the machine from the packaging To do so use the lifting eye Use the proper lifting equipment The machine weighs 190 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 hand wheel on the front of the cross support Handle installation Figure 5 2 2 Installation of the hand wheel 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 4 For the installation of the grinding belt and the grinding roller see sections 4 6 8 and 4 6 8 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
30. tching a tubing section After the tubing section has been clamped and the correct angle and stoppers are set up the slide with hand wheel d must be positioned so the tubing section that is to be notched is moved toward the centre of the grinding roller Hand wheel e 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 In place of the hand wheel a handle can be installed See section 4 6 11 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 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 exchange of the 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 hand wheel d Hand wheel d is shown in Figure 4 5 1 In place of the hand wh
31. the following information must be provided The machine type number The machine type number is indicated 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 04 00114 amp 04 00115 ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 25 of 27 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 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 3 8 2 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 12 AL100U 02 ENG Revision and revision date
32. tiff 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 ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 16 of 27 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 holder as shown in Figure 4 6 4 Never adjust the spring pressure retainers The
33. tion 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 section 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 rectan
34. to be performed in a safe and responsible manner Connection of the power 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 The voltage of the supply connection must be verified in comparison to the connection voltage indicated on the type plate 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 ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 22 of 27 5 5 5 6 The motor switch the no voltage coil and the type plate are available through your dealer 230 VOLT 400VOLT Brown Braun Brown Bruin Braun l Bruin Black Schwarz Zwart pa Black Schwarz Zwart Blue Blau Blauw Yellow green l Yellow green Gelb grun Gelb grun Geel groen Geelgroen Figure 5 4 1 Wiring connections in the connection compartment of the electrical motor Connect the supply cable wires according to the correct diagram in Figure 5 4 1 Install a plug that matches yo
35. ur 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 tripped over 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 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 ALMI Machinefabriek B V Vriezenveen Doc no 100287 HB 12 AL100U 02 ENG Revision and revision date 3 31 10 2014 Page 23 of 27 o 6 Opera
36. y 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 Before the new grinding roller is installed the recesses of the support for the grinding roller must be cleaned thoroughly This prevents clamping problems 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 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
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