en 100 notcher

CML International S.p.A.

USE AND MAINTENANCE INSTRUCTION MANUAL

(Rev. 00 dtd. 01/07/03)

TTUUBBEE NNOOTTCCHHIINNGG AANNDD GGRRIINNDDIINNGG MMAACCHHIINNEE AArrtt.. EENN110000

!!!WARNING Any use of the machine that does not conform with what is expressly written in this document immediately frees the MANUFACTURER

from any responsibility or warranty obligation.

DIRECTIVE 98/37/EC MACHINE DIRECTIVE Presidential Decree. 459/96

Directive 98/37/EC published on the European community Official Journal nr. L 207 of July 23, 1998. Presidential decree 459/96 published on the Official Journal nr. 209 of September 06, 1996

NOTE: CAREFULLY READ THIS MANUAL BEFORE INSTALLING AND STARTING THE MACHINE. KEEP THIS DOCUMENT FOR FUTURE REFERENCE.

CML International S.p.A. , Loc. Annunziata snc, 03030 Piedimonte S. Germano (FR), Italy


INDEX

TUBE NOTCHER DESCRIPTION...................................................................... 4 TECHNICAL SPECIFICATIONS........................................................................ 5 MACHINE EQUIPMENT...................................................................................... 6

ACCESSORIES SUPPLIED UPON REQUEST.................................................................... 6 WARRANTY ........................................................................................................... 7

WARRANTY CONDITIONS AND RESTRICTIONS.......................................................... 7 PRESCRIPTIONS................................................................................................... 8 OBLIGATIONS....................................................................................................... 9 MACHINE PREPARATION............................................................................... 10

CONNECTION TO POWER SUPPLY (230-400 VOLTS)................................................. 11 ABRASIVE BELT REPLACEMENT ................................................................ 12

DISMOUNTING...................................................................................................................... 12 ASSEMBLY ............................................................................................................................. 12 ABRASIVE BELT CHOICE.................................................................................................. 13

NOTES FOR A CORRECT USE ............................................................................................ 13 SKIDDING REGULATION ................................................................................ 14 WORKING ROLLER REPLACEMENT .......................................................... 15

WORKING ROLLER REPLACEMENT............................................................................. 15 PROTECTION AND SAFETY SYSTEMS........................................................ 17

RESIDUAL RISK LIMITATION ......................................................................................... 18 MACHINE USE .................................................................................................... 19

BUTT PROCESSING ............................................................................................................. 19 BASIC REGULATIONS ........................................................................................................ 19 STOP AND END OF NOTCHING PROCESS .................................................................... 19 NOTCHING OPERATION FOR A DIAMETER UNDER 76MM.................................... 19 DEBURRING........................................................................................................................... 20

TABLE 1................................................................................................................. 21 NOTCHING ADVICE.......................................................................................... 22

OVERVIEW............................................................................................................................. 22 ROLLER ARRANGEMENT ................................................................................................. 22 VICE POSITIONING ............................................................................................................. 22

MAINTENANCE .................................................................................................. 24 MACHINE CLEANING......................................................................................................... 24 WORKING ROLLER SUPPORTING BEARINGS............................................................ 24

TRANSPORTATION AND HANDLING .......................................................... 25 TRANSPORTATION ............................................................................................................. 25 PACKED MACHINE HANDLING....................................................................................... 25 INTERNAL HANDLING ....................................................................................................... 25

SCRAPS DISPOSAL ............................................................................................ 26 ECOLOGICAL INFORMATION......................................................................................... 26 INDICATIONS FOR A CORRECT WASTE DISPOSAL ................................................. 26

TAGS AND PLATES............................................................................................ 27 IDENTIFICATION PLATE EC MARKING....................................................................... 27 SAFETY SIGNALS................................................................................................................. 27


MACHINE CONFORMITY DECLARATION................................................. 28 NOISE RATING MEASUREMENT .....................................................................................28

TROUBLESHOOTING........................................................................................ 29 VICE GROUP........................................................................................................ 30 VICE MOTION GROUP ..................................................................................... 32 WORKING ROLLERS GROUP......................................................................... 34 SYSTEM DIAGRAMS ......................................................................................... 36 SPARE PARTS REQUEST.................................................................................. 39

- 4 Rev. 00


TUBE NOTCHER DESCRIPTION The tube notcher is a machine intended to notch, deburr and grind tubes and profiles. Main parts of the machine are:

1. Electrical panel integrated in the machine base.

2. Motorization and working rollers included in the machine body.

3. Piece holding vice.

Tube notcher main parts:

MOTORIZATION GROUP; ABRASIVE BELT (it allows to perform both, the notching itself and the

grinding of deburr formed on the tube after the notching phase); WORKING ROLLERS GROUP; VICE GROUP; VICE MOTION GROUP.

Picture 1

1 General switch

2 Vice group

3 Horizontal working area cover

4 Belt removal and maintenance cover

5 EC identification plate

1

2

5

1

4

3

- 5 Rev. 00


TECHNICAL SPECIFICATIONS The series number is included in the monobloc, as shown in figure 1 (part. 6) and represented in the following figure 2.

Figure 2

Electrical input: 220V - 400V Motor power: 3,7 kW Working speed: 2895 rpm (the motor) Dimensions (overall dim.): 15005001500mm Weight: 200 kg Noise rating: 7375 dB Abrasive belt dimensions (length x width):

2000mm100mm; 2100mm100mm.

Diameter of tubes that can be worked:

mm from 25mm to 76mm

inch gas 3/4, 1, 11/4, 11/2, 2, 21/2

inch 1, 11/4, 11/2, 2, 21/2, 3

- 6 Rev. 00

CML International S.p.A. Standard supply

MACHINE EQUIPMENT

The machine is equipped to notch and grind most commercial profiles.

The machine is equipped as illustrated in picture n.3:

Picture n.3

ACCESSORIES SUPPLIED UPON REQUEST Different diameters necessary for tube notching can be ordered, according to the limits of the

machine capacity.

M10 UNI 5931 + Flat Washer UNI 6592

M10x30 UNI 5739 + Grower UNI 1751 + Hexagonal nut M10

M8x20 UNI 5931 + Grower UNI 1751 + Flat washer DIN 6340

- 7 Rev. 00

CML International S.p.A. Warranty conditions

WARRANTY Every machine is carefully controlled and tested before shipment. Machine installation is under

customers responsibility, if qualified personnel is required for assistance and training, the cost

of the operation will be charged.

WARRANTY CONDITIONS AND RESTRICTIONS

1. Each tube notcher has a 24 month warranty effective from delivery date, against any components defect. The company reserves the right to request a copy of the sale invoice.

2. Defects must be notified to us within 2 months from the date the defect has been found. 3. Defects are checked on our premises, so every tube notcher must be sent, freight

prepaid, to our address or to authorized service centres. Any delivery will be rejected if not freight prepaid. If checking at customers premises is required, a cost for checking on site will be charged.

4. Warranty includes the defective components substitution or repair excluding labour cost. 5. Electrical parts are not included in the warranty in case of incompatibility with power

supply ( caused by overvoltage and / or atmospheric events ) 6. Operations performed under warranty may not extend warranty terms. 7. Warranty does not respond to damages caused by wear. 8. The warranty does not apply if damages are a result of incorrect handling or of a use that

does not conform with specifications described in this manual. 9. The warranty does not apply if the machine has been modified or tampered with. 10. The warranty certificate is invalid if dealer stamp with sales date is not included at the

bottom of this document and in the attached coupon. Furthermore, the part to be sent to us must be mailed within the 8 days following the invoice date.

11. The whole warranty falls into decline if: The machine has been repaired or maintained by personnel that has not been

authorized by CML International S.p.A.; Not original parts have been used; Damages or errors are due to connections not performed according to the using

instructions; Errors due to the machine wear

12. In no case the buyer can apply for compensation of damages . 13. The warranty does not include replacement even temporarily of the machine.

- 8 Rev. 00

CML International S.p.A. Prescriptions and obligations

PRESCRIPTIONS [ Use the machine without carefully consulting this manual. [ Get near to the roller when it is working. [ Place the tube on the vice with the belt in motion. [ Assemble or remove the roller with the machine in motion. [ Perform maintenance or repairing without switching off power supply. [ Modify electrical system. [ Have more than one person working on the same machine. [ Use the machine beyond the maximum capacity indicated in this manual. [ Use the machine for other than the use it was designed for. [ Assemble not original parts. [ Leave the machine unattended with the power on. [ Open side door when belt is in motion. [ Open the shutter in the deburring plane during the notching phase. [ Complete or partial fan removal. [ Lay objects on the machine.

FORBIDDEN

It is forbidden to operate manually with machine in motion

It is forbidden to leave the machine unattended when it is in motion

The use of the machine is forbidden to unauthorized personnel

- 9 Rev. 00

CML International S.p.A. Prescriptions and obligations

MANDATORY

OBLIGATIONS

! The tube notcher can only be used to deburr or notch tube or profile extremities. ! Before unpacking the machine, carefully read the manual. ! Make sure plug and cable are not damaged before plugging to power supply, substitute

them if necessary.

! Maintenance tasks on the machine not mentioned in this manual, can only be performed by qualified personnel.

! Unplug the machine from power supply before performing maintenance tasks. ! Make sure the piece is securely locked by the vice before performing any work. ! Always use protective goggles, gloves, anti-dust mask, protective earmuffs and all

individual protective devices required in the section Protection and safety systems.

! When a huge quantity of tubes are processed in a small amount of time, the front roller may become very hot, therefore protection gloves must be used to substitute it with other diameter rollers.

! To avoid the risk of fire, verify the compatibility with previous working residues, if any, since notching-grinding provoke sparks.

! Place the machine in a safety manner anchoring it to the floor. ! Always keep the front visual protection lowered during the working phase. ! Make sure the belt is thoroughly stretched and regulated to avoid skidding. ! Do not ever stop the machine when the material to be worked touches the belt. ! Do not ever start working on the belt edge, it may damage the belt. ! Make sure the notcher is unplugged before performing any type of control operation on

the fan.

! Spare parts must be requested to the manufacturer, since not original parts do not guarantee the machine perfect functionality and safety.

! At the end of the working phase it is mandatory to move the vice holder slide back to a certain safety distance, before performing the pipe dismounting operation.

Anyone who works on a machine tool must wear wrist buttoned shirts or jackets.

- 10 Rev. 00

CML International S.p.A. Machine preparation

MACHINE PREPARATION PREPARATION FOR ITS USE The machine is supplied disassembled and provided with screws for being assembled ( see following picture no.4 ) The following picture shows how to assemble the machine: Picture no. 4

- 11 Rev. 00

CML International S.p.A. Machine preparation

CONNECTION TO POWER SUPPLY (230-400 VOLTS)

!WARNING: Before connecting the machine to power supply verify the input tension to avoid risks for both, the operator and the machine.

The tube notcher has been manufactured according to the CEE, CEN and CENEL EC work safety norms in force. The machine is sold with a European voltage motor, this means that the motor can be connected to both 230 Volt, and 400 Volt triphase (tolerance 10%). Control the characteristics tag to verify if the machine is connected to the desired voltage. If this is not the case, open the motor contacts case and connect wires as indicated in figure 5:

use a star connection for a 400 Volt power supply; use a triangle connection for a 230 Volt power supply.

!WARNING: Don not ever operate on electrical contacts if the machine is connected to power supply.

STAR connection

TRIANGLE Connection

Figure 5

W2 U2 V2

U1 V1 W1

W2 U2 V2

U1 V1 W1

- 12 Rev. 00

CML International S.p.A. Abrasive belt replacement

ABRASIVE BELT REPLACEMENT

!WARNING: disconnect the tube notcher from power supply before performing any operation described in this section.

DISMOUNTING 1. Move the vice as far as possible to have a larger space to permit the belt insertion and

removal; 2. open lateral and upper doors; 3. rotate the hand wheel (A) counter-clockwise to loosen the belt tension and then release the

motor slide; 4. manually move the motor body forwards, against the working roller; 5. extract the abrasive belt.

!WARNING: Due the type of work, roller surfaces may reach high temperatures. For this reason the use of protective gloves is mandatory.

ASSEMBLY 1. Follow dismounting operations described on points 1, 2 and 3 of the previous paragraph; 2. place the abrasive belt, controlling that the arrow in the internal part of the belt coincides

with the running sense. Start the abrasive belt replacement from the side of the working roller;

3. move back the motor body stretching the belt manually; 4. use the hand wheel to stretch the belt, compensating efficaciously the lengthening suffered

by the belt with the passing of time; 5. cautiously start the machine to verify the belt skidding conditions (see Skidding

regulation section);

Figure 6 Use of protective gloves is mandatory

WARNING Switch off from power supply before opening the door.

- 13 Rev. 00

CML International S.p.A. Abrasive belt replacement

NOTE: For the accomplishment and creation of a new type of abrasive belt, contact technical

personnel.

ABRASIVE BELT CHOICE The tube notcher machine is supplied with 3 zirconium, cloth supported abrasive belts. If a different type of abrasive belt should be used, the following table includes useful indications on the grain and the abrasive type choice, according to the material to be worked. Information reported is not considered comprehensive, but an indicative information for the choice.

The abrasive material type depends on the material to be worked:

ABRASIVE MATERIAL TYPE

MATERIAL TO BE WORKED

Carbon steel Corundum Non ferrous materials and their alloys Carbon steel Steel alloy Ceramic corundum Casts iron

Non ferrous materials and their alloys Silicon carbide Casts iron (*) Carbon steel

Non ferrous materials and their alloys Zirconium Casts iron (*)

(*) it may vary depending on the characteristics of the abrasive considered.

The type of grain is a function of the hardness of the material to be worked. For low hardness materials a coarser grain and a low hardness abrasive is suggested. A finer grain and a harder abrasive is suggested for a harder material.

The dimension of the contact surface must be taken into consideration when making the choice:

For small surfaces use a coarse grain and a soft abrasive; For grater surfaces use a fine grain and a harder abrasive.

Notes for a correct use

When the abrasive belt is new, its suggested to make it rotate on the machine by itself for 5 minutes. This allows fibres to get settled increasing the belt working life.

For paper supported abrasive belts, when a working roller of a diameter under 30 mm is

used, its necessary to use an abrasive belts that has previously been used with a roller of a bigger diameter. Otherwise, the abrasive belt can be damaged, since when its new its fibre is excessively stressed on yielding. This problem is negligible for cloth supported belts.

- 14 Rev. 00

CML International S.p.A. Skidding regulation

SKIDDING REGULATION

!WARNING: The skidding regulation operation must be performed with the machine in motion, and therefore with every protection on.

!WARNING: Skidding regulation can be carried out by screwing or unscrewing very slowly the adjustment screw ( A ) ; an excessive regulation could make the belt collide against the roller support.

Skidding regulation is to be carried out after the belt has been inserted and already tensed, by following the below sequence: A) Rough ( approximate ) adjustment ( with machine switched off ): 1. Open the notching / grinding roll protection cover ( see

picture 1 fig. 7); 2. With left hand apply as much force as necessary to make

the belt rotate on the roller in the direction indicated in picture 1 fig. 7;

3. Screw or unscrew adjustment screw ( A ) in order to bring the belt in central position on roller;

4. Close all protection devices and switch machine on; B) Fine adjustment (with machine switched on):

1. With right hand screw or unscrew adjustment

screw ( A ) in order to correct eventual skidding;

2. Start machine up by pressing and MOTOR

switch;

3. Adjustment of eventual skidding;

4. Switch off machine by pressing STOP switch.

!WARNING: If belt skids a lot when machine starts up, switch immediately off the machine by pressing emergency button so as to avoid collision of belt against roller holding support.

1

2

Figure 7

A

- 15 Rev. 00

CML International S.p.A. Working roller replacement

WORKING ROLLER REPLACEMENT Before replacing the working roller, the abrasive belt must be removed according to the indications illustrated in the previous chapter. To remove the working roller see figure 8.

!WARNING: Unplug the machine from power supply before performing the working roller replacement operations.

WORKING ROLLER REPLACEMENT 1. Hold the roll by the hand and unscrew clockwise knurled hand wheel (A) ( fig. 8a ) ; 2. Remove roll ( Fig. 8b); 3. Repeat phase no.1 screwing knurled hand wheel (A) until end stop ; 4. After assembly proceed with belt regulation according to steps A, B on page 14 .

a b

Figure 8

N.B.= for rolls having small diameters, replacement can be effected without removal but

simply loosening belt ( phases 3 and 4 of working roller replacement section )

Use of protective gloves is mandatory. WARNING Unplug from power supply before opening

the door.

A

- 16 Rev. 00

CML International S.p.A. Working roller replacement

! WARNING: The notching grinding work leads the working roller to reach high temperatures. To avoid burning danger, the use of protective gloves is mandatory.

!WARNING: Bearings lateral supports must be cleaned with an air pistol after they have been dismounted.

NOTE: When a working roller of a diameter under 30 mm is used, its necessary to use an abrasive belts that has previously been used with a roller of a bigger diameter. Otherwise, the abrasive belt can be damaged, since when its new its fibre is excessively stressed on yielding. REMARK: We can supply different diameter rollers, consult Technical Specifications section for available dimensions.

Use of protective gloves is mandatory.

- 17 Rev. 00

CML International S.p.A. Protection and safety system

PROTECTION AND SAFETY SYSTEMS According to the safety norms in force its absolutely forbidden to remove or bypass any protection device during the machine use (Presidential decree nr. 547/1955, Directive nr. 89/392/EC, and successive, Presidential decree nr. 459/1996). Scrupulously follow this instructions manual during preparation, use, maintenance, or other operations. The machine is equipped with active and passive safety systems intended to minimize risks to which operators are exposed during the machine use or maintenance. Active safety:

low voltage command devices (24V); mushroom head button for the machine emergency stop; interlocked command buttons to avoid the roller starting with the fan off; micro-switch that stops the machine if the side mobile protection is open.

Passive safety:

lateral mobile protection for parts in motion; upper regulable sliding protection to avoid accidental contact with the abrasive belt; transparent regulable protection to protect against working filings drop; fastened protection for all live components.

!WARNING: It is forbidden to exclude in any way machine safety devices.

!WARNING: Do not ever operate on mobile organs when the machine is in motion.

!WARNING: Due to high temperatures reached by working filings, avoid their contact with inflammable material.

- 18 Rev. 00

CML International S.p.A. Protection and safety system

RESIDUAL RISK LIMITATION To face not eliminable residual risks due to the processing characteristics, the machine has been equipped with individual protection systems and informative indications on the correct machine use have been attached to it.

RISKS OF MECHANICAL NATURE TYPE OF RISK SAFETY DEVICE

Use of personal protection equipment is mandatory

Filings projection and/or working material fall danger

Abrasion danger Cutting danger

OTHER RISKS TYPE OF RISK SAFETY DEVICE

Coming in contact with high temperature surfaces danger

Use of personal protection equipment is mandatory

Falling danger

Use of non slip protective shoes is mandatory

Use of gloves is mandatory

Use of helmet is

Use of protective goggles is mandatory

Use of protective clothing is mandatory

Wear protective shoes

Use of protective mask is mandatory

Slippery floor, falling danger

Use of gloves is mandatory

Wear protective shoes

- 19 Rev. 00

CML International S.p.A. Machine use

MACHINE USE BUTT PROCESSING For butt processing we intend the processing made on the extremity of tubes to join them with different angles. Process consist in the material removal using a front working roller of a proper and desired diameter. The innovative technology used by the era tube notcher consists in moving forward the tube to be processed and automatically move it along the belt to increase its working life. Once the tube is locked and necessary regulations have been made rotating the advancement hand wheel, its possible to notice both, the tube advance of the desired quota in respect to the belt and the tube movement along the belt.

BASIC REGULATIONS Two regulations must be performed to obtain both movements. In the vice group (figure 9) of the machine, two vernier scales can be identified, one under the tube lock vice rotation plane regulated by the vice vernier scale, and the other in connection to the support vice regulated by the vernier scale for support vice. To obtain correctly the desired notches consult the following table, on which characteristic vice and support vice angles are reported for 0, 30, 45, 60 notching. STOP AND END OF NOTCHING PROCESS The machine is equipped with two stop commands, one to stop the machine under normal working conditions and the other for the emergency stop. At the end of the working drive it is mandatory to move longitudinally the slide back using the hand wheel, to place it at a proper safety distance before performing the tube dismounting operation.

NOTCHING OPERATION FOR A DIAMETER UNDER 76MM For tube notching up to 76 mm refer to the following table to set proper vice and support vice angles.

90 45 60 30

- 20 Rev. 00


DEBURRING

!WARNING: Only one person must operate on the machine.

!WARNING: Make sure the working roller has been covered with the proper regulable protection before starting the deburring process.

Residual burr removal from processed tubes or parts grinding may be done on the proper horizontal plane after the upper panel has been removed.

- 21 Rev. 00


TABLE 1

EN 100 NOTCHING CAPACITY 100MM WIDE BELT

Desired coupling Angle between horizontal tube and notched tube 90

60

45

30

TUBE OUTSIDE DIAMETER 0 30 45 60

(gas inch) (O.D. inch) (mm) Vice Vice

Support Vice Vice

Support Vice Vice

Support Vice Vice

Support

26,9 -6 6 21 9 30 15 35 25 1 25,4 -5 5 21 9 31 14 37 23

1 33,7 -9 9 18 12 25 20 24 36 1 31,75 -8 8 19 11 27 18 27 33

1 42,4 -14 14 15 15 18 27 NO NO 1 38,1 -11 11 16 14 22 23 NO NO

1 48,3 -19 19 12 18 14 31 NO NO 2 50,8 -22 22 11 19 11 34 NO NO

2 60,3 -33 33 7 23 3 42 NO NO 2 63,5 0 90 NO NO NO NO NO NO

2 76,1 0 90 NO NO NO NO NO NO 3 76,2 0 90 NO NO NO NO NO NO

HOW TO OBTAIN THE DESIRED ANGLE AND DEPTH OF NOTCH To obtain any desired notch, set the vice vernier scale and the vice support vernier scale at the settings indicated above. It is important to change the settings for each outside diameter of tube / pipe as indicated in the table above.

Vice Support Venier Scale

Venier scale for Vice

Vice

Vice Support

- 22 Rev. 00


NOTCHING ADVICE OVERVIEW The grinding-notching result depends on the quality of the material to be processed. According to the material type to be processed, different characteristic belts can be used. ROLLER ARRANGEMENT The roller must be well aligned on the machine and it must be in a correct position with respect to the abrasive belt, this will avoid excessive stress to the machine. The vice opening must be regulated to properly contain the tube. VICE POSITIONING Processing angles are reported on table 1 as a function of the joint angle and of the tube diameter. On process starting position the tube must touch the abrasive belt at about 5-6mm from the edge. Avoid starting the process on the edge of the belt sice it could be damaged. NOTE: For notching problems under non standard conditions, contact our project department. FRONTAL NOTCHING This process is oriented to the jointure of tubes at right angle ( T ), normally working with the roller included in the standard supply. To obtain this type of notching, regulate the tube holding vice, and the vice support according to table 1. For tubes having a diameter greater than 63,5mm operate in the following manner: 1. Dismount the dust collector drawer 2. Loosen lock screw ( A ) of support vice ( Fig. 10A); 3.Rotate clockwise support vice until aligned with base ( Fig. 10B); 5. Lock screw A; 6. Unscrew completely vice locking screw B ( Fig. 10A ); 7. Rotate anti-clockwise vice unitl hole C corresponds to hole D ( Fig. 10C-10D); 8. Lock screw B; 9. Operate vice through hand wheel

Support vice

BA D

C

A B C D

Picture 10

- 23 Rev. 00

CML International S.p.A. Maintenance

OBLIQUE NOTCHING This type of cut angle is used to perform coupling jobs between tubes at 90 not right angle. This process often generates confusion, since as you can notice in the figure a profile processed at 30 shows an angle of 60. This example shows that to perform a 30 coupling between two tubes, the material to be removed is of 30, leaving 60 of material on the tube. Follow instructions on table 1 !WARNING: always control that the diameter of the tube to be notched does not exceed the belt width

NOTCHING ANGLE

COUPLING ANGLE

- 24 Rev. 00

CML International S.p.A. Maintenance

MAINTENANCE MACHINE CLEANING Due to the type of process performed its necessary to clean the machine very often:

vice group; dust collection drawers;

to avoid compromising the correct performance of the machine with excessive accumulation of iron filings. Cleaning must be made using a proper aspirator and cleaning and scaling the front pre-filter.

!WARNING: Do not use any kind of lubricant. WORKING ROLLER SUPPORTING BEARINGS Its necessary to control often the status of working roller supporting bearings. Due to high rotation speed and to the presence of iron filings, bearings could get damaged or broken. Bearings must be cleaned with an air pistol.

!WARNING: Unplug machine from power supply before performing any maintenance operation.

!WARNING: In any case the use of original parts is suggested.

- 25 Rev. 00

CML International S.p.A. Transportation and handling

TRANSPORTATION AND HANDLING TRANSPORTATION The placement of the tube notcher machine on a normalized pallet is expected for its transportation. If transportation must cover a long distance, packing must be made impervious to atmospheric agents. Carefully load the machine and place it as illustrated in figure 11 to guarantee stability in case of sudden breaking. PACKED MACHINE HANDLING To handle the packed machine use lifting means, pallet truck or forklift of an adequate capacity, as shown in figure 12. Forks must be as long as the pallet or carton and of a proper capacity. INTERNAL HANDLING

The machine inside the packing is disassembled as shown in picture no.3 page 6 . Before assembling parts make sure to remove the machine from the pallet. Assemble machine and fix to the floor with screws supplied with machine. If machine needs to be moved in another working area after it has been assembled , lift up machine with lifting belts or disassemble and then reassemble machine. Before lifting the machine with the belts, make sure they are in excellent conditions and of an adequate strength to hold the machine weight: refer to the Technical Specifications section for the machine weight.

!WARNING: In case of unsteadiness do not try to hold manually the suspended machine. On the contrary, keep at a certain safety distance during lifting operations. If any anomaly arise during lifting and transportation operations, keep as far away as possible without taking any action manually.

Figure 11

Figure 12

- 26 Rev. 00

CML International S.p.A. Scraps disposal

SCRAPS DISPOSAL We recommend deactivating the machine, before proceeding to its demolition:

Disassembling its components; Removing its motor.

ECOLOGICAL INFORMATION The disposal of the tube notcher packing materials, substituted parts, lubricants, components or of the machine itself, must be performed respecting the environment, avoiding ground, water and air pollution. Its the duty of the machine owner to perform this operation conforming to norms in force in the country where the machine is used. INDICATIONS FOR A CORRECT WASTE DISPOSAL

Ferrous materials, aluminium, copper: are recyclable materials that must be taken to the proper authorized collecting centre.

Plastic and rubber materials: must be taken to a refuse disposal site or to the proper recycling centre.

- 27 Rev. 00

CML International S.p.A. Tags and Plates

TAGS AND PLATES IDENTIFICATION PLATE EC MARKING According to the norms in force (Directive nr. 89/392/EC and Presidential decree nr. 459/1996), the tube notcher has an identification plate with CE marking, where information on the machine characteristics that may be relevant to safety terms is included. Refer to this information in case of doubt. The plate is fastened to the machine where it can be easily seen and it is not removable. If the identification plate for any reason is damaged, immediately contact the manufacturer for its substitution. The plate attached to the machine is shown in figure 13.

!WARNING: Whoever tampers or removes the plate, can be prosecuted by law and frees the manufacturer from any machine warranty responsibility.

SAFETY SIGNALS Safety signals have been attached to the machine as shown in figure 14.

Figure 14 Figure 13

- 28 Rev. 00

CML International S.p.A. Attached documentation

MACHINE CONFORMITY DECLARATION (Directive nr. 89/392 CE, Attachment II, part A).

Manufacturer: CML International S.p.A. Address: 03030 Villa S. Lucia (FR), Italy Declares that: The Tube notcher machine, Series nr.________________ is: In conformity with the Machine Directive (Directive nr. 89/392 EC) conditions, as modified

with the legislation that transposes it; In conformity with conditions of the following EC directives:

directive 73/23/CEE regarding low voltage electrical material; directive 89/336/EEG regarding electromagnetic compatibility; directive 89/392/CEE regarding member countries approaching on machine legislation; directive 85/374/CEE regarding member countries approaching on legislation for

responsibilities for damages caused by defective products;

NOISE RATING MEASUREMENT TYPE OF MEASUREMENT NOISE RATING NOTE

WITHOUT PRESSURE 73 dB (A) ABRASIVE BELT FREE

DRIVE

WITH PRESSURE 75 dB (A) 2/3 LOAD

Measurements performed according to machine directives. Conclusion: the machine operator must use a noise protection helmet.

Made in __________ Date _____________

Signatorys name Sign _____________________________

- 29 Rev. 00

CML International S.p.A. Troubleshooting

TROUBLESHOOTING This paragraph helps determining and possibly resolving, some anomalies that may occur during the life of the tube notcher.

!WARNING: Immediately inform protection and safety means defects and deficiencies or any dangerous situation noticed.

Damages or failures caused by misuse or by a use of the machine other than the one foreseen in this use and maintenance manual. The technical service centre can help you by phone, fax or email to identify the failure if enough information is supplied:

Type of anomaly found; Detailed description of operations with anomaly found; Anomaly recurrence; Working environment conditions.

In any case, before calling we suggest to check if you can find a reference to the machine failure in the following table.

ANOMALIES DIAGNOSIS SOLUTION The machine doesnt turn on. Input cable is not plugged into power supply.

Verify if input cable is plugged to power supply.

The machine turns on, but rollers dont rotate.

A cable in the motor power supply box is disconnected.

Verify connections in the motor power supply box (refer to the Connection to power supply section.

- 30 - Rev. 00

CML International S.p.A. Structural parts

VICE GROUP

Pos. Q.ty Description 1 1 Vice base 2 1 Jaw shoulder 3 1 Mobile jaw 4 1 Left jaw 5 1 Clamp jaw plate 6 1 Female screw 7 1 Vice casing 8 1 Screw tr24x3 9 1 Bushing 10 2 Washer 11 1 Right jaw 12 4 Screw M8x20 uni 5933 13 3 Screw UNI 5931 M8x25

8.8 14 2 Screw UNI5931 M10x25

8.8 15 3 Screw UNI 5931 M10x30

8.8 16 3 Grower spring washer x M8

UNI 1751 17 5 Grower spring washer x

M10 UNI 1751 18 1 Seeger ring UNI 7435-20 19 1 Hand wheel GN 16151

GN300 78M10 SW

- 31 - Rev. 00

CML International S.p.A. Structural parts VICE GROUP

Upper view Lower view

- 32 - Rev. 00


VICE MOTION GROUP Pos. Q.ty Description 1 1 Vernier scale for vice 2 1 Vice support 3 2 Pin D. 20 4 1 Vice slide 5 1 Female screw 6 1 Screw 7 1 Bushing 8 2 Washer 9 1 Bushing 10 3 Washer 11 1 Pin 12 1 Locking nut 13 1 Vernier scale 14 1 Hand wheel GN300-78-

M10x25 SW 15 2 Spring washer x M10 UNI

1751 16 3 Spring washer x M6 UNI 1751 17 4 Bushing PAP 2020 P10 18 3 Screw T.C.E.I. UNI 5931

M6x16 8.8. 19 1 Flat washer x M10 UNI 6592 20 1 Screw T.C.E.I. UNI 5931

M10x20 8.8 21 1 Plate 5x5 L=25 UNI 6604-A 22 4 Scraper RS 20307 23 1 Hand wheel VR-140-FP+I 24 1 Selflocking nut M30x1,5 25 1 Seeger ring D22 UNI 7435 26 1 Screw T.C.E.I. M6x8 UNI

5931 8.8 27 2 Locking nut KM4 28 2 Screw UNI 5931 M10x45

8.8

- 33 - Rev. 00

CML International S.p.A. Structural parts VICE MOTION GROUP

- 34 - Rev. 00


WORKING ROLLERS GROUP

POS. DESCRIPTION 1 Protection cover 2 Spacer for selflocking nut 3 Selflocking nut M8 DIN 980 4 Bearings type 6000-Z 5 Spacer for berings 6 Conical shaft 7 Inner ring for bearings and small rolls type IR 12x16x16 8 Roll 9 Spring support pad 10 Spring washer 11 Threaded drum 12 Washer 13 Seeger ring for shaft D. 25 14 Grub screw M6 x 20 UNI 5925 Hexagonal nut M6 UNI 5589

16 Sliding hub 17 Support table 18 Screw T.C. M4x12 UNI 7687 with cruciform recess 19 Locking nut DIN 6332 + Panel DIN 6336 44 20 Shaft seeger ring D.15 21 Hexagonal nut M10 UUNI 1751 22 Spring washer x M10 UNI 1751 23 Screw TE M10x30 UNI 5739 24 Bushing for threaded drum 25 Seeger ring for D.26 hole

- 35 - Rev. 00


WORKING ROLLERS GROUP

1312

11

10

9

8

20

7

6

4

5

4

24

14

15

25

16

17

21

22

23

18

191

3

2

- 36 - Rev. 00

CML International S.p.A. System diagrams

SYSTEM DIAGRAMS

- 37 - Rev. 00


- 38 - Rev. 00


- 39 - Rev. 00


SPARE PARTS REQUEST To achieve a perfect identification of the part requested, please specify the following:

Model Type

Series Nr.

Subgroup

Part position nr.

Code nr.

Description

Quantity

Note: For electrical equipment request, please indicate the voltage in use.

en 100 notcher

Documents

machine use

machine equipment

machine preparation

correct use

italy cml international

abrasive belt replacement

working roller replacement

warranty obligation