CML International S.p.A.

USE AND MAINTENANCE INSTRUCTION MANUAL

(Rev. 2.1 dtd. 27/05/03)

TUBE NOTCHING AND GRINDING MACHINE

!!!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

CML International S.p.A.

INDEX

TUBE NOTCHER DESCRIPTION ...................................................................... 1 TECHNICAL SPECIFICATIONS........................................................................ 3 MACHINE EQUIPMENT...................................................................................... 4

PACKING CONTENTS: .......................................................................................................... 4 ACCESSORIES SUPPLIED UPON REQUEST.................................................................... 4

WARRANTY ........................................................................................................... 5
WARRANTY CONDITIONS AND RESTRICTIONS.......................................................... 5

PRESCRIPTIONS................................................................................................... 6 OBLIGATIONS....................................................................................................... 7 MACHINE PREPARATION................................................................................. 8 . .................................................................................................................................. 9

CONNECTION TO POWER SUPPLY (230-400 VOLTS)................................................. 10 COMMAND PANEL............................................................................................................... 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 PROCESS............................................................................................ 19 REAMINIG OPERATION FOR A DIAMETER UNDER 76MM..................................... 19 NOTCHING OPERATION FOR A DIAMETER OVER 76MM ...................................... 20 DEBURRING........................................................................................................................... 20 TABLE : PROCESSING CAPACITY 180mm BELT. NOTE: L.S. (SUPPLEMENTARY LEVER).............................................................................................. 21

NOTCHING ADVICE .......................................................................................... 22

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

MAINTENANCE .................................................................................................. 23
MACHINE CLEANING ......................................................................................................... 23 WORKING ROLLER SUPPORTING BEARINGS............................................................ 23 FRICTION CLUTCH REGULATION................................................................................. 23 ASPIRATOR FAN................................................................................................................ 24

TRANSPORTATION AND HANDLING .......................................................... 25

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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 STRUCTURAL PARTS ....................................................................................... 30 VICE GROUP........................................................................................................ 32 VICE MOTION GROUP ..................................................................................... 34
CONICAL COUPLE ...............................................................................................................36 INCLINED PLANE .................................................................................................................38 UPPER SLIDE .........................................................................................................................39 BOTTOM SLIDE.....................................................................................................................40

WORKING ROLLERS GROUP......................................................................... 43 SYSTEM DIAGRAMS ......................................................................................... 45 SPARE PARTS REQUEST.................................................................................. 49

CML International S.p.A.

Machine description

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. Filing aspiration system and electrical panel integrated in the machine base. 2. Motorization and working rollers included in the machine body. 3. Piece holding vice. Tube notcher main organs: MOTORIZATION GROUP; FAN (ASPIRATOR ); 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

10

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Machine description 6 7 8 9 10 EC identification plate Filing collection drawer Aspirator space Motorization group Aspirator

1 2 3 4 5

General switch Vice group Command panel Horizontal working area cover Belt removal and maintenance cover

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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: Motor power: Working speed: Dimensions (overall dim.): Weight: Noise rating: 220V - 400V 3,7 kW 2895 rpm (the motor) 15006001450 310 kg 7375 dB

Abrasive belt dimensions (length x width): 2000mm150mm; 2000mm180mm. Diameter of tubes that can be worked: inch gas inch mm 3/4, 1, 1, 11/4, 11/2, 11/4, 11/2, 2, 2, 21/2, 21/2, 3, 3, 31/2, 4. 31/2, 4.

from 25mm to 114mm

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Standard supply

MACHINE EQUIPMENT
The machine is equipped to notch and grind most commercial profiles.
PACKING CONTENTS:

BOTTOM FRAME WITH ASPIRATOR AND FILING COLLECTION DRAWER; MACHINE BODY; FOUR SPOKE HANDWHEEL FOR VICE CLOSURE AND TRANSVERSAL SLIDE MOTION; VICE DRIVING CRANK; SUPPLEMENTARY WORKING LEVER; M4, M5, M8 AND M10 ALLEN WRENCH; M17 FORK KEY 3 180mm ABRASIVE BELTS; FILING ASPIRATOR; 1 42 WORKING ROLLER; USE AND MAINTENANCE MANUAL; SAFETY MANUAL.
ACCESSORIES SUPPLIED UPON REQUEST

Different diameters necessary for tube notching can be ordered, according to the limits of the machine capacity.

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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.

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Prescriptions and obligations

PRESCRIPTIONS

FORBIDDEN

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.

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

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Prescriptions and obligations

OBLIGATIONS

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

! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! !

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.

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Machine preparation

MACHINE PREPARATION
PREPARATION FOR ITS USE The vice group is not assembled on the machine when it is delivered. It is inside the packing (A) (pic. 3-1). The procedure to follow to assemble the vice group and prepare the machine for its use is reported below.

1
DISINSERT

2 D B D

HINGE

C 5

Picture 3

1. Remove each part from its package (abrasive belts, working roller, front working supplementary lever and vice group); 2. remove the five hexagonal screws (B) ( pic.3-3 ); 3. extract pin (C) in the direction indicated in picture 3-3 4. lift the vice group (C) and place it as indicated in pic. 3-4 and re-insert pin (C); 5. rotate vice group until it fits onto the frontal part of the machine (pic. 3-5); 6. block the vice group to the machine with the five screws (A); 7. place the control panel inserting support tube into pin of vice hinge and tighten grub screw on the tube; 8. remove screws with which the tube notcher base is fastened to the pallet ( pic. 3-2 ) -8 Rev. 2.1

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Machine preparation

9. lift the machine from the pallet following instructions shown in the Transportation and handling section and place it in the working space; 10. verify if the working area is spacious enough and if the floor has the right characteristics to fix the pins on it; 11. anchor the machine to the floor using the four M12 screws ; 12. verify the power supply written on the machine. If input voltage is not correct, refer to the section Connection to power supply; 13. assemble a plug on the electrical input cable. After inserting the plug in the socket verify that the driving rolling rotation sense coincides with the direction indicated in the roller itself. If this is not the case, unplug the machine from power supply and invert the cable connection.

!WARNING: due to the considerable weight of the vice group, we strongly recommend
to use suitable lifting tools, ( pic. 3-5) respecting all safety rules in force.. .

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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 4: 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.

W2 U1

U2 V1

V2 W1

STAR connection

W2 U1

U2 V1

V2 W1

TRIANGLE Connection Figure 4

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Machine preparation

COMMAND PANEL

The tube notcher command panel has 4 buttons, as shown in figure 5: 1. 2. 3. 4. green button for motor starting; green button for aspirator starting; red button for motor and aspirator stop; red mushroom button for the emergency stop.

Figure 5 For safety reasons, aspirator and motor starting commands are interlocked, this means that the motor can not be started if the aspirator has not been started before. Every button in the command panel is identified by a pictogram and /or a written description for an intuitive interpretation of the function associated to the button itself. The correct starting and stopping procedures for an intuitive consultation are reported below: STARTING PROCEDURE: 1. push the aspirator starting button (2); 2. push the motor starting button (1). NORMAL STOPPING PROCEDURE: push the process stop button(3). EMERGENCY STOP: push the mushroom button (4). RESET AFTER AN EMERGENCY OPERATION: remove the cause that generated the emergency operation; execute a 90 rotation of the button (4) to unblock it; restart the machine. - 11 Rev. 2.1

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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
Switch off from power supply before opening the door.

Figure 6

Use of protective gloves is mandatory

!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); - 12 Rev. 2.1

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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 Corundum MATERIAL TO BE WORKED

Carbon steel Non ferrous materials and their alloys Carbon steel Ceramic corundum Steel alloy Casts iron Non ferrous materials and their alloys Silicon carbide Casts iron (*) Carbon steel Zirconium Non ferrous materials and their alloys 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.

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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 ) machine switched off ) adjustment ( with

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;
.1

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 ASPIRATOR and MOTOR buttons; 3. adjustment of eventual skidding; 4. switch off machine by pressing STOP button.

2 Figure 7

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

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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. 2. 3. 4. 5. 6. 7. 8.

Open the machine side door; loosen the regulation screw (A); loosen both screws (B) holding the working roller (C) still; remove the Allen head screw (D) using the Allen wrench supplied; remove both screws (B) and extract the plate (E) and the working roller (C); get the working roller to be used and insert it with a light pressure; re-assemble the plate (E); when assembly is completed regulate for skidding according to directions reported in the Skidding regulation section.

1 Figure 8

Use of protective gloves is mandatory.

WARNING Unplug from power supply before opening the door.

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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.

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.

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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.

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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 Use of gloves Use of Use of protective mandatory goggles is is mandatory helmet is
mandatory

Filings projection and/or working material fall danger Abrasion danger Cutting danger
Use of protective clothing is mandatory

Wear protective shoes

Use of protective mask is mandatory

OTHER RISKS TYPE OF RISK SAFETY DEVICE Use of personal protection equipment is mandatory
Use of gloves is mandatory

Coming in contact with high temperature surfaces danger

Falling danger

Use of non slip protective shoes is mandatory

Wear protective shoes

Slippery floor, falling danger

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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. 90 45 60 30

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 goniometric scales can be identified, one under the tube lock vice rotation plane (A), and the other in the back slide (B). The angle read on the vice plane indicates the angle that will be obtained at the end of the tube butt processing. The angle read on the guide indicates the longitudinal drive in function of the tube diameter and of the belt length. To obtain correctly the desired processing consult the two following tables, on which characteristic vice and guide angles are reported for 0, 30, 45, 60 processing.
STOP AND END OF PROCESS

B Figure 9

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.
REAMINIG OPERATION FOR A DIAMETER UNDER 76MM

For tube processing up to 76 mm refer to the following tables to set proper vice and back guide angles.

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Machine use

NOTCHING OPERATION FOR A DIAMETER OVER 76MM

To work on tubes over 76 mm the supplementary lever (L.S.) supplied with the machine must be used. To assemble it follow illustrations shown in figure 10: 1. 2. 3. 4. loosen locking handle (A); extract the roller holding pin (B); assemble the supplementary lever (L.S.) inserting the extremity (C) in the wedge; replace the roller holding pin and screw the locking handle.

Using the supplementary lever, the notching operation will be performed taking advantage only of the vice frontal advancement.

2 Figure 10

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.

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Machine use

TABLE : PROCESSING CAPACITY 180mm BELT. NOTE: L.S. (SUPPLEMENTARY LEVER)

Desired coupling Angle between horizontal tube and processed tube

VICE Inclination

90

60

45

30

vice (A) Inclination 30 45 guide (B) Rotation

60

Tube Diameter (inch gas) (inch) (mm)

1 1 1 1 1 1 2 2 2 2 3 3 3 3 4 4

26,9 25,4 33,7 31,75 42,4 38,1 48,3 50,8 60,3 63,5 76,1 76,2 88,9 88,9 101,6 101,6 114,3

3 3 3 3 5 4 5 5 6 7 9 9 11 11 12 L.S. L.S.

4 5 6 5 7 6 8 8 10 11 13 13 15 15 L.S. L.S. L.S.

6 6 8 7 10 9 11 12 14 15 17 17 20 20 L.S. L.S. NO

8 7 9 9 12 11 14 14 17 18 L.S. L.S. NO NO NO NO NO

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Machine use

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 tables 1 and 2 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 in a 0 position, regulate the longitudinal guide according to tables 1 and 2. Example. If the tube diameter is for example of , the vice inclination will be of 0 with a WEDGE rotation of 3 related to a transversal advancement of the slide. OBLIQUE NOTCHING This type of cut angle is used to perform coupling works between tubes at a 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, therefore, as reported in the previous tables, the reference axis for the rotation degrees will be the one of the working roller, this means of the tube on which the processed tube will be mounted.

!WARNING: Always control that the diameter of the tube to be

notched does not exceed the belt width

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Maintenance

MAINTENANCE
MACHINE CLEANING

Due to the type of process performed its necessary to clean the machine very often: vice group; aspiration conducts; 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.
FRICTION CLUTCH REGULATION

The Tube Notcher is supplied with a friction clutch which intervenes under heavy working conditions making the chain slip.The friction clutch is already well regulated. However, if it is necessary to regulate the friction again, follow the below procedure as illustrated in figure no. 11 : unplug the machine from power supply; place vice as in position illustrated in fig. 11 ; spot the plate (A) on lower part of machine (fig 11 seen from below), ; unscrew the two screws of the plate for decreasing friction action,; screw for increasing friction action

Figure 11 A

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Maintenance

ASPIRATOR FAN

For a better use of the fan (aspirator) under maximum safety conditions, motor bearings must be replaced after 10.000 hours of work. If abnormal noise and/or vibrations coming from the fan are noticed, immediately stop the machine (and the fan) and perform an accurate inspection of mechanical connections and of the rotor cleaning status and integrity. Make sure the machine on which the fan is connected is unplugged from power supply before performing any control, maintenance and/or replacement operation. CML International S.p.A. declines any responsibility for damages caused by an improper use of the fan, for a not fulfilment of periodical maintenance/replacement prescriptions and for the use of not original parts. Complete or partial remotion of the fan is forbidden.

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

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

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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

Figure 11

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

Figure 12

Use lifting belts for the internal handling of the tube notcher machine, attaching them as shown in figure 13.

!WARNING: 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

Figure 13

manually hold 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.

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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.

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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 14.

!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 15.

Figure 15

Figure 14

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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 WITHOUT PRESSURE WITH PRESSURE

NOISE RATING 73 dB (A) 75 dB (A)

NOTE ABRASIVE BELT FREE DRIVE 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 _____________________________

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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

Input cable is not plugged into Verify if input cable is plugged The machine doesnt turn on. power supply. to power supply. Verify connections in the The machine turns on, but A cable in the motor power motor power supply box (refer rollers dont rotate. supply box is disconnected. to the Connection to power supply section. Iron filings have partially Clean aspiration conducts Aspirator works, but it sucks obstructed the aspiration form any iron filings in weakly. opening and/or conducts . accumulated during process. Aspirator works, but it sucks Aspirator filter is obstructed. Change aspirator filter . in weakly.

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CML International S.p.A.

Structural parts

STRUCTURAL PARTS
POS. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Qty. 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 2 1 6 1 1 9 4 4 4 1 1 2 1 1 2 1 4 6 2 1 3 4 7 2 2 4 DESCRIPTION Base Inspection door Electrical panel door Filing collection drawer Fan holding chamber Equip holding structure Equip holding shelf Hinge support Hinge pin Shim washer Belt inspection door Sliding protection Visual protection Motor holding plate Turnbuckle guide Driving roller Motor washer Turnbuckle Spring hood Hinge M10 Knob Complete keyboard Triphase motor 400V-0,37kW-50Hz 2P-B5 Elastic washer x M10 UNI1751 T.C.E.I. Screw M10x25 UNI5931 Elastic washer x M8 UNI1751 T.C.E.I. Screw M10x30 UNI5931 Triphase motor 400V-4kW-50Hz Compression spring ID 17 thread D 5 P10 Plain washer X M6 UNI 6592 Screw T.E. M10x25 UNI5739 Aspirator MN502RD Seeger ring for ext. D30 UNI7435 Three spoke hand wheel VB 639/100 FP M16 Screw T.E. M8x25 UNI5739 Screw T.S.P.E.I. M6x16 UNI5933 Hexagonal nut M6 UNI5588 Hexagonal nut M16 UNI5588 Hexagonal nut M16 UNI5588 Screw T.E. M10x30 UNI5739 Plane washer for M10 burnished UNI6592 Screw T.C.E.I. M6x25 UNI6592 Plane washer for M30 UNI6592 Screw T.C.E.I. M8x35 UNI5931 - 30 Rev. 2.1

CML International S.p.A.

Structural parts

STRUCTURAL PARTS

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CML International S.p.A.

Vice Group

VICE GROUP
POS. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Qty. 1 1 1 2 1 1 1 1 1 2 1 1 1 1 3 4 2 1 5 11 8 8 4 1 4 2 DESCRIPTION Vice base Jaw shoulder Jaws support Jaws Vice closure plate Mobile jaw Vice case Nut screw Screw M30X3 Guides Vice guide Bushing Shim ring Stopper Screw T.C.E.I. M8X25 UNI 5931 Screw T.C.E.I. M8X20 UNI 5931 Elastic pin D6 L=35 UNI 6873 Screw T.C.E.I. M10X20 UNI 5931 Elastic washer X M10 UNI 1751 Elastic washer X M8 UNI 1751 Screw T.E. M6X14 UNI 5739 Elastic washer X M6 UNI 1751 Screw T.C.E.I. M10X30 UNI 5931 Screw T.C.E.I. M10X70 UNI 5931 Screw T.E. M8X25 UNI 5739 Blocking locknut KM5

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CML International S.p.A.

Vice Group

VICE GROUP

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CML International S.p.A.

Vice motion group

VICE MOTION GROUP

POS. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Qty. 1 2 1 2 1 1 4 2 1 1 1 2 2 1 1 2 3 1 1 8 3 2 2 4 1 3 1 2 2 1 2 1 1 1 DESCRIPTION Equip holding shelf Quill D16 Vice slide support Quill 25 Washer I15 E35 Washer Washer Shim ring Return pinion Stretching pin Reinforcing shelf Washer Tie Conical couple Handle. GN16151-GN300 78 Screw T.E. M10X20 UNI 5739 Elastic washer X M10 UNI 1751 Screw T.C.E.I. M14X55 UNI 5931 Handle GN16185-GN300 108 Hexagonal nut M8 UNI 5588 Elastic washer X M8 UNI 1751 Screw T.E. M6X14 UNI 5739 Elastic washer X M6 UNI 1751 Screw T.S.P.E.I. M8X20 UNI5933 PAP Bushing 1625 P10 Screw T.E. M8X25 UNI5739 Chain ISO 06B-1 pitch 3/8 Shaft seeger ring D16 UNI 7435 Plain washer X M8 UNI 6592 Screw T.C.E.I. M10X50 UNI 5931 Screw T.E. M8X35 UNI 5739 Inclined plane Bottom slide Upper slide

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CML International S.p.A.

Vice motion group

VICE MOTION GROUP

Upper slide

Conical couple Bottom slide

Inclined plane

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CML International S.p.A.

Vice motion group

CONICAL COUPLE

POS. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Qty. 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 2 1 2 2 2 1 6 2

DESCRIPTION Driving pinion Driving pin Gear wheel Z48 Gear wheel Z16 Spacer Washer Bushing Bushing Washer De25 Di12,1 Couple casing Driving shaft Driving axis support Upper cover Bottom cover Shim washer Knurled lock washer for M8 Screw T.C.E.I. M8X20 UNI 5931 Elastic washer X M8 UNI 1751 Rounded tang 5X5 L=40 UNI 6604 Screw T.E. M6X14 UNI 5739 Elastic washer X M6 UNI1751 Elastic quill D4X20 (spirol) UNI 6875 Screw T.S.P. CR. M3X5 UNI 6107 (Galvanized) Screw T.E. M8X16 UNI 5739

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CML International S.p.A.

Vice motion group

VICE MOTION CONICAL COUPLE GROUP

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CML International S.p.A.

Vice motion group

INCLINED PLANE

POS. 1 2 3 4 5 6

Qty. 1 2 1 8 2 8

DESCRIPTION Inclined plane Inclined plane wing Goniometer Elastic Washer X M8 UNI 1751 Screw T.S.P. CR M4X8 UNI 7688 (Burnished) Screw T.E. M8X20 UNI 5739

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CML International S.p.A.

Vice motion group

UPPER SLIDE

POS. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Qty. 1 1 1 1 1 1 1 1 1 2 4 4 4 1 4 1 1

DESCRIPTION Vice slide Vice holding slide front plate Vice holding slide rear plate Roller support Roller holding pin Washer Vice Goniometer Washer Auxiliary roller Screw T.S.P.E.I. M10X30 UNI 5933 Elastic washer X M10 UNI 1751 Screw T.C.E.I. M10X25 UNI 5931 PAP Bushing 1620 P10 Quill D8 X40 UNI 6334 A Scraper ring. RM2470 ref. 1622 Handle MR80 P M10X25 Ext. seeger ring. D17 UNI 7435

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CML International S.p.A.

Vice motion group

BOTTOM SLIDE

POS. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Qty. 1 2 1 1 4 4 4 4 2 2 2 2 2 2

DESCRIPTION Transversal slide Transversal resetting plate Chain break Clutch skid Elastic washer x M10 UNI 1751 Scraper ring. RM 2470 ref. 2535 PAP Bushing 2520 P 10 Screw T.C.E.I. M10x30 UNI 5931 Compression spring L= 20mm e 8,5 THREAD 1,5 P= 3 Cylindrical quill 10 x 50 UNI 6334 A Screw T.C.E.I. M5x40 UNI 5931 Washer x M5 UNI 6592 Screw T.C.E.I. M5x20 UNI 5931 Lock washer xM5 UNI 7064

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CML International S.p.A.

Vice motion group

VICE MOTION BOTTOM SLIDE GROUP

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CML International S.p.A.

Working Rollers Group

WORKING ROLLERS GROUP

POS. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Qty 1 1 1 1 1 1 1 1 1 1 1 2 4 6 2 2 2 1 1 1 1 7 1 1 2 2 2 2 1 2 2 DESCRIPTION Supporting shelf Connection Right side support Left side support Hinge pin Plate Upper plate Bottom plate Working roller 42,4 1 Gas Right side dust guard cover Left side dust guard cover Washer Screw T.E. M10X30 UNI 5739 Elastic washer for M10 UNI 1751 Elastic washer for M8 UNI 1751 Bearing type 6001-2Z (12x28x8) Int. seeger ring. D28 UNI 7437 Cylindrical Quill D8x25 UNI 1707 Screw T.C.E.I. M12x25 UNI 5931 Elastic busher for M12 UNI 1751 Screw T.C.E.I. M10x45 UNI 5931 Hexagonal nut M10 UNI 5588 Threaded bar M10 L=120mm Yellow spring MGSL 26x38 Screw T.S.P.E.I. M8x45 UNI 5739 Ext. seeger ring D15 UNI 7435 Plain washer for M14 UNI 6592 Screw T.C.E.I. M10x30 UNI 5931 Plain washer for M10 UNI 6592 Screw T.E. M8x25 UNI 5739 Screw T.C.E.I. M5x14 UNI 5931

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CML International S.p.A.

Working Rollers Group

WORKING ROLLER GROUP Fastening screws and supporting structure

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CML International S.p.A.

System diagrams

SYSTEM DIAGRAMS
DRAWING NR.1 220V

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CML International S.p.A.

System diagrams

DRAWING NR.2 220V

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CML International S.p.A.

System diagrams

DRAWING NR.1 400V

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CML International S.p.A.

System diagrams

DRAWING NR.2 400V

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CML International S.p.A.

Spare parts request

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.

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