En 180 Notcher

CML International S.p.A.

USE AND MAINTENANCEINSTRUCTION MANUAL

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

TTUUBBEE NNOOTTCCHHIINNGG AANNDDGGRRIINNDDIINNGG MMAACCHHIINNEE

®

!!!WARNINGAny use of the machine that does not conform with what is expresslywritten 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 – publishedon the European communityOfficial Journal nr. L 207 ofJuly 23, 1998.

Presidential decree 459/96 –published on the Official Journalnr. 209 of September 06, 1996

NOTE: CAREFULLY READ THIS MANUAL BEFORE INSTALLING ANDSTARTING 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...................................................................... 1TECHNICAL SPECIFICATIONS........................................................................ 3MACHINE EQUIPMENT...................................................................................... 4

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

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

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

CONNECTION TO POWER SUPPLY (230-400 VOLTS)................................................. 10COMMAND PANEL............................................................................................................... 11

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

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

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

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

BUTT PROCESSING ............................................................................................................. 19BASIC REGULATIONS......................................................................................................... 19STOP AND END OF PROCESS............................................................................................ 19REAMINIG OPERATION FOR A DIAMETER UNDER 76MM..................................... 19NOTCHING OPERATION FOR A DIAMETER OVER 76MM ...................................... 20DEBURRING........................................................................................................................... 20TABLE : PROCESSING CAPACITY 180mm BELT. NOTE: L.S.(SUPPLEMENTARY LEVER).............................................................................................. 21

NOTCHING ADVICE.......................................................................................... 22OVERVIEW............................................................................................................................. 22ROLLER ARRANGEMENT ................................................................................................. 22VICE POSITIONING ............................................................................................................. 22

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

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


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

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

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

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

TROUBLESHOOTING........................................................................................ 29STRUCTURAL PARTS ....................................................................................... 30VICE GROUP........................................................................................................ 32VICE MOTION GROUP ..................................................................................... 34

CONICAL COUPLE...............................................................................................................36INCLINED PLANE.................................................................................................................38UPPER SLIDE .........................................................................................................................39BOTTOM SLIDE.....................................................................................................................40

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

- 1 –Rev. 2.1

CML International S.p.A. Machine description

TUBE NOTCHER DESCRIPTIONThe 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

9

10

- 2 –Rev. 2.1

CML International S.p.A. Machine description

1 General switch 6 EC identification plate2 Vice group 7 Filing collection drawer3 Command panel 8 Aspirator space4 Horizontal working area cover 9 Motorization group5 Belt removal and maintenance cover 10 Aspirator

- 3 –Rev. 2.1


TECHNICAL SPECIFICATIONS

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

Figure 2

Electrical input: 220V - 400VMotor power: 3,7 kWWorking speed: 2895 rpm (the motor)Dimensions (overall dim.): 1500×600×1450Weight: ≅ 310 kgNoise rating: 73÷75 dB

Abrasive belt dimensions (length x width):

− 2000mm×150mm;

− 2000mm×180mm.

Diameter of tubes that can be worked:

inch gas 3/4”, 1”, 1”1/4, 1”1/2, 2”, 2”1/2, 3”, 3”1/2, 4”.

inch 1”, 1”1/4, 1”1/2, 2”, 2”1/2, 3”, 3”1/2, 4”.

mm from 25mm to 114mm

- 4 –Rev. 2.1

CML International S.p.A. 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 ø42 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.

- 5 –Rev. 2.1

CML International S.p.A. Warranty conditions

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

customer’s 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 anycomponent’s 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 ifnot freight prepaid. If checking at customer’s premises is required, a cost for checking onsite will be charged.

4. Warranty includes the defective component’s 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 tous 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.

- 6 –Rev. 2.1

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 tooperate manually withmachine in motion

It is forbidden to leave themachine unattended whenit is in motion

The use of the machine isforbidden to unauthorizedpersonnel

- 7 –Rev. 2.1

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, substitutethem if necessary.

! Maintenance tasks on the machine not mentioned in this manual, can only beperformed 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 allindividual 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 rollermay become very hot, therefore protection gloves must be used to substitute it withother 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 onthe fan.

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

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

Anyone who works on a machinetool must wear wrist buttonedshirts or jackets.

- 8 –Rev. 2.1

CML International S.p.A. Machine preparation

MACHINE PREPARATION

PREPARATION FOR ITS USEThe 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 itsuse is reported below.

1 2

3 4 5

Picture 3

1. Remove each part from its package (abrasive belts, working roller, front workingsupplementary lever and vice group);

2. remove the five hexagonal screws (B) ( pic.3-3 );3. extract pin (C) in the direction indicated in picture 3-34. 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 )

C

C

BDISINSERT

D

D

D

A

HINGE

- 9 –Rev. 2.1


9. lift the machine from the pallet following instructions shown in the Transportation andhandling 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 tofix 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. Ifthis is not the case, unplug the machine from power supply and invert the cableconnection.

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

.

- 10 –Rev. 2.1


CONNECTION TO POWER SUPPLY (230-400 VOLTS)

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

The tube notcher has been manufactured according to the CEE, CEN and CENEL EC worksafety norms in force. The machine is sold with a European voltage motor, this means that themotor can be connected to both 230 Volt, and 400 Volt triphase (tolerance ±10%). Control thecharacteristics tag to verify if the machine is connected to the desired voltage. If this is not thecase, 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 topower supply.

STAR connection

TRIANGLE Connection

Figure 4

W2 U2 V2

U1 V1 W1

W2 U2 V2

U1 V1 W1

- 11 –Rev. 2.1


COMMAND PANEL

The tube notcher command panel has 4 buttons, as shown in figure 5:

1. green button for motor starting;2. green button for aspirator starting;3. red button for motor and aspirator stop;4. red mushroom button for the emergency stop.

Figure 5

For safety reasons, aspirator and motor starting commands are interlocked, this means that themotor 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 foran 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.

- 12 –Rev. 2.1

CML International S.p.A. Abrasive belt replacement

ABRASIVE BELT REPLACEMENT

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

DISMOUNTING

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

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 thisreason 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 workingroller;

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

WARNINGSwitch off from power supply before opening the door.

- 13 –Rev. 2.1

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 CHOICEThe tube notcher machine is supplied with 3 zirconium, cloth supported abrasive belts. If adifferent type of abrasive belt should be used, the following table includes useful indications onthe grain and the abrasive type choice, according to the material to be worked. Informationreported is not considered comprehensive, but an indicative information for the choice.

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

ABRASIVE MATERIALTYPE

MATERIAL TO BE WORKED

Carbon steelCorundum Non ferrous materials and their alloysCarbon steelSteel alloyCeramic corundumCasts iron

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

Non ferrous materials and their alloysZirconiumCasts 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 lowhardness materials a coarser grain and a low hardness abrasive is suggested. A finer grainand 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, it’s suggested to make it rotate on the machine by itselffor 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 isused, it’s necessary to use an abrasive belts that has previously been used with a roller ofa bigger diameter. Otherwise, the abrasive belt can be damaged, since when it’s new itsfibre is excessively stressed on yielding. This problem is negligible for cloth supportedbelts.

- 14 –Rev. 2.1

CML International S.p.A. Skidding regulation

2Figure 7

SKIDDING REGULATION

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

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

Skidding regulation is to be carried out after the belt has been inserted and already tensed, byfollowing the below sequence:

A. – Rough ( approximate ) adjustment ( withmachine 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 tomake the belt rotate on the roller in the directionindicated in picture 1 fig. 7

3. Screw or unscrew adjustment screw ( A ) in order tobring 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 “ ASPIRATOR” and“MOTOR”” buttons;

3. adjustment of eventual skidding;4. switch off machine by pressing “STOP” button.

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

.1

- 15 –Rev. 2.1

CML International S.p.A. Working roller replacement

WORKING ROLLER REPLACEMENT

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

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

WORKING ROLLER REPLACEMENT

1. Open the machine side door;2. loosen the regulation screw (A);3. loosen both screws (B) holding the working roller (C) still;4. remove the Allen head screw (D) using the Allen wrench supplied;5. remove both screws (B) and extract the plate (E) and the working roller (C);6. get the working roller to be used and insert it with a light pressure;7. re-assemble the plate (E);8. when assembly is completed regulate for skidding according to directions reported in the

“Skidding regulation” section.

1 2Figure 8

Use of protective gloves is mandatory.WARNING

Unplug from power supply before openingthe door.

- 16 –Rev. 2.1

CML International S.p.A. Working roller replacement

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

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

NOTE: When a working roller of a diameter under 30 mm is used, it’s necessary to use anabrasive belts that has previously been used with a roller of a bigger diameter. Otherwise, theabrasive belt can be damaged, since when it’s new its fibre is excessively stressed on yielding.

REMARK: We can supply different diameter rollers, consult Technical Specifications sectionfor available dimensions.

Use of protectivegloves ismandatory.

- 17 –Rev. 2.1

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

PROTECTION AND SAFETY SYSTEMS

According to the safety norms in force it’s absolutely forbidden to remove or bypass anyprotection device during the machine use (Presidential decree nr. 547/1955, Directive nr.89/392/EC, and successive, Presidential decree nr. 459/1996). Scrupulously follow thisinstructions manual during preparation, use, maintenance, or other operations.

The machine is equipped with active and passive safety systems intended to minimize risks towhich 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 contactwith inflammable material.

- 18 –Rev. 2.1

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 beenequipped with individual protection systems and informative indications on the correct machineuse have been attached to it.

RISKS OF MECHANICAL NATURETYPE OF RISK SAFETY DEVICE

Use of personal protection equipment ismandatory

− Filings projection and/or workingmaterial fall danger

− Abrasion danger− Cutting danger

OTHER RISKSTYPE OF RISK SAFETY DEVICE

− Coming in contact with hightemperature surfaces danger

Use of personal protection equipment ismandatory

− Falling danger

Use of non slip protective shoes ismandatory

Use of glovesis mandatory

Use ofhelmet is

Use of protectivegoggles ismandatory

Use ofprotectiveclothing ismandatory

Wearprotectiveshoes

Use ofprotective maskis mandatory

Slippery floor, falling danger

Use of glovesis mandatory

Wear protectiveshoes

- 19 –Rev. 2.1

CML International S.p.A. Machine use

MACHINE USEBUTT PROCESSINGFor butt processing we intend the processing made on the extremity of tubes to join them withdifferent angles.

Process consist in the material removal using a front working roller of a proper and desireddiameter.The innovative technology used by the era® tube notcher consists in moving forward the tubeto be processed and automatically move it along the belt to increase its working life. Once thetube is locked and necessary regulations have been made rotating the advancement hand wheel,it’s possible to notice both, the tube advance of the desired quota in respect to the belt and thetube movement along the belt.

BASIC REGULATIONSTwo regulations must be performed to obtain bothmovements. In the vice group (figure 9) of the machine, twogoniometric scales can be identified, one under the “tubelock vice” rotation plane (A), and the other in the “backslide“ (B). The angle read on the vice plane indicates theangle that will be obtained at the end of the tube buttprocessing. The angle read on the guide indicates thelongitudinal drive in function of the tube diameter and of thebelt length. To obtain correctly the desired processing consultthe two following tables, on which characteristic vice andguide angles are reported for 0°, 30°, 45°, 60° processing.

STOP AND END OF PROCESSThe machine is equipped with two stop commands, one tostop 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 thehand wheel, to place it at a proper safety distance before performing the tube dismountingoperation.

REAMINIG OPERATION FOR A DIAMETER UNDER 76MMFor tube processing up to Ø 76 mm refer to the following tables to set proper vice and backguide angles.

B

A

Figure 9

90° 45° 60° 30°

- 20 –Rev. 2.1


NOTCHING OPERATION FOR A DIAMETER OVER 76MM

To work on tubes over Ø 76 mm the supplementary lever (L.S.) supplied with the machine mustbe used. To assemble it follow illustrations shown in figure 10:

1. loosen locking handle (A);2. extract the roller holding pin (B);3. assemble the supplementary lever (L.S.) inserting the extremity (C) in the wedge;4. replace the roller holding pin and screw the locking handle.

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

1 2 3Figure 10

DEBURRING

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

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

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

- 21 –Rev. 2.1


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

Desired couplingAngle between horizontal tube and processed tube

90 60 45 30

VICE Inclination

“vice” (A) Inclination0° 30° 45° 60°

Tube Diameter

(inch gas) (inch) (mm)

“guide” (B) Rotation

¾” 26,9 3° 4° 6° 8°1” 25,4 3° 5° 6° 7°

1” 33,7 3° 6° 8° 9°1” ¼ 31,75 3° 5° 7° 9°

1” ¼ 42,4 5° 7° 10° 12°1” ½ 38,1 4° 6° 9° 11°

1” ½ 48,3 5° 8° 11° 14°2” 50,8 5° 8° 12° 14°

2” 60,3 6° 10° 14° 17°2” ½ 63,5 7° 11° 15° 18°

2” ½ 76,1 9° 13° 17° L.S.3” 76,2 9° 13° 17° L.S.

3” 88,9 11° 15° 20° NO3” ½ 88,9 11° 15° 20° NO

3” ½ 101,6 12° L.S. L.S. NO4” 101,6 L.S. L.S. L.S. NO

4” 114,3 L.S. L.S. NO NO

B

A

- 22 –Rev. 2.1


NOTCHING ADVICEOVERVIEWThe grinding-notching result depends on the quality of the material to be processed. Accordingto the material type to be processed, different characteristic belts can be used.

ROLLER ARRANGEMENTThe roller must be well aligned on the machine and it must be in a correct position with respectto the abrasive belt, this will avoid excessive stress to the machine. The vice opening must beregulated to properly contain the tube.

VICE POSITIONINGProcessing angles are reported on tables 1 and 2 as a function of the joint angle and of the tubediameter. On process starting position the tube must touch the abrasive belt at about 5-6mm fromthe 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 NOTCHINGThis process is oriented to the jointure of tubes at right angle ( T ), normallyworking with the roller included in the standard supply. To obtain this typeof notching, regulate the tube holding vice in a 0° position, regulate thelongitudinal guide according to tables 1 and 2.

Example.If the tube diameter is for example of ¾ , the vice inclination will be of 0°with a “WEDGE” rotation of 3° related to a transversal advancement of theslide.

OBLIQUE NOTCHINGThis type of cut angle is used to perform coupling works between tubes at anot right angle. This process often generates confusion, since as you cannotice in the figure a profile processed at 30° shows an angle of 60°. Thisexample shows that to perform a 30° coupling between two tubes, thematerial to be removed is of 30°, leaving 60° of material on the tube,therefore, as reported in the previous tables, the reference axis for therotation degrees will be the one of the working roller, this means of the tubeon which the processed tube will be mounted.

!WARNING: Always control that the diameter of the tube to benotched does not exceed the belt width

- 23 –Rev. 2.1

CML International S.p.A. Maintenance

MAINTENANCE

MACHINE CLEANINGDue to the type of process performed it’s necessary to clean the machine very often:

− vice group;− aspiration conducts;

to avoid compromising the correct performance of the machine with excessive accumulation ofiron 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

It’s necessary to control often the status of working roller supporting bearings. Due to highrotation 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 workingconditions making the chain slip.The friction clutch is already well regulated. However, if it isnecessary to regulate the friction again, follow the below procedure as illustrated in figureno. 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 actionFigure 11

Below view

A

- 24 –Rev. 2.1

CML International S.p.A. Maintenance

ASPIRATOR – FAN

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

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

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

- 25 –Rev. 2.1

CML International S.p.A. Transportation and handling

TRANSPORTATION AND HANDLING

TRANSPORTATION

The placement of the tube notcher machine on a normalizedpallet is expected for its transportation. If transportation mustcover a long distance, packing must be made impervious toatmospheric agents. Carefully load the machine and place it asillustrated in figure 11 to guarantee stability in case of suddenbreaking.

PACKED MACHINE HANDLING

To handle the packed machine use lifting means, pallet truck orforklift of an adequate capacity, as shown in figure 12. Forksmust be as long as the pallet or carton and of a proper capacity.

INTERNAL HANDLING

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

!WARNING: Before lifting the machine with the belts,make sure they are in excellent conditions and of anadequate strength to hold the machine weight, refer to theTechnical Specifications section for the machine weight.

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

Figure 11

Figure 12

Figure 13

- 26 –Rev. 2.1

CML International S.p.A. Scraps disposal

SCRAPS DISPOSALWe 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 orof the machine itself, must be performed respecting the environment, avoiding ground, water andair pollution.It’s the duty of the machine owner to perform this operation conforming to norms in force in thecountry 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. 2.1

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 machinecharacteristics that may be relevant to safety terms is included. Refer to this information in caseof 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 itssubstitution. The plate attached to the machine is shown in figure 14.

!WARNING: Whoever tampers or removes the plate, can be prosecuted by law and freesthe 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

- 28 –Rev. 2.1

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 modifiedwith 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 _____________

Signatory’s nameSign

_____________________________

- 29 –Rev. 2.1

CML International S.p.A. Troubleshooting

TROUBLESHOOTINGThis paragraph helps determining and possibly resolving, some anomalies that may occur duringthe life of the tube notcher.

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

Damages or failures caused by misuse or by a use of the machine other than the one foreseen inthis use and maintenance manual.

The technical service centre can help you by phone, fax or email to identify the failure if enoughinformation 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 failurein the following table.

ANOMALIES DIAGNOSIS SOLUTION

The machine doesn’t turn on. Input cable is not plugged intopower supply.

Verify if input cable is pluggedto power supply.

The machine turns on, butrollers don’t rotate.

A cable in the motor powersupply box is disconnected.

Verify connections in themotor power supply box (referto the “Connection to powersupply” section.

Aspirator works, but it sucksin weakly.

Iron filings have partiallyobstructed the aspirationopening and/or conducts .

Clean aspiration conductsform any iron filingsaccumulated during process.

Aspirator works, but it sucksin weakly. Aspirator filter is obstructed. Change aspirator filter .

- 30 -Rev. 2.1

CML International S.p.A. Structural parts

STRUCTURAL PARTSPOS. Qty. DESCRIPTION

1 1 Base2 1 Inspection door3 1 Electrical panel door4 1 Filing collection drawer5 1 Fan holding chamber6 1 Equip holding structure7 1 Equip holding shelf8 1 Hinge support9 1 Hinge pin10 2 Shim washer11 1 Belt inspection door12 1 Sliding protection13 1 Visual protection14 1 Motor holding plate15 2 Turnbuckle guide16 1 Driving roller17 1 Motor washer18 1 Turnbuckle19 2 Spring hood20 1 Hinge21 6 M10 Knob22 1 Complete keyboard23 1 Triphase motor 400V-0,37kW-50Hz 2P-B524 9 Elastic washer x M10 UNI175125 4 T.C.E.I. Screw M10x25 UNI593126 4 Elastic washer x M8 UNI175127 4 T.C.E.I. Screw M10x30 UNI593128 1 Triphase motor 400V-4kW-50Hz29 1 Compression spring ID 17 thread D 5 P1030 2 Plain washer X M6 UNI 659231 1 Screw T.E. M10x25 UNI573932 1 Aspirator MN502RD33 2 Seeger ring for ext. D30 UNI743534 1 Three spoke hand wheel VB 639/100 FP M1635 4 Screw T.E. M8x25 UNI573936 6 Screw T.S.P.E.I. M6x16 UNI593337 2 Hexagonal nut M6 UNI558838 1 Hexagonal nut M16 UNI558839 3 Hexagonal nut M16 UNI558840 4 Screw T.E. M10x30 UNI573941 7 Plane washer for M10 burnished UNI659242 2 Screw T.C.E.I. M6x25 UNI659243 2 Plane washer for M30 UNI659244 4 Screw T.C.E.I. M8x35 UNI5931

- 31 -Rev. 2.1

CML International S.p.A. Structural parts

STRUCTURAL PARTS

- 32 -Rev. 2.1

CML International S.p.A. Vice Group

VICE GROUP

POS. Qty. DESCRIPTION1 1 Vice base2 1 Jaw shoulder3 1 Jaws support4 2 Jaws5 1 Vice closure plate6 1 Mobile jaw7 1 Vice case8 1 Nut screw9 1 Screw M30X310 2 Guides11 1 Vice guide12 1 Bushing13 1 Shim ring14 1 Stopper15 3 Screw T.C.E.I. M8X25 UNI 593116 4 Screw T.C.E.I. M8X20 UNI 593117 2 Elastic pin D6 L=35 UNI 687318 1 Screw T.C.E.I. M10X20 UNI 593119 5 Elastic washer X M10 UNI 175120 11 Elastic washer X M8 UNI 175121 8 Screw T.E. M6X14 UNI 573922 8 Elastic washer X M6 UNI 175123 4 Screw T.C.E.I. M10X30 UNI 593124 1 Screw T.C.E.I. M10X70 UNI 593125 4 Screw T.E. M8X25 UNI 573926 2 Blocking locknut KM5

- 33 -Rev. 2.1

CML International S.p.A. Vice Group

VICE GROUP

- 34 -Rev. 2.1

CML International S.p.A. Vice motion group

VICE MOTION GROUP

POS. Qty. DESCRIPTION1 1 Equip holding shelf2 2 Quill D163 1 Vice slide support4 2 Quill 255 1 Washer I15 E356 1 Washer7 4 Washer8 2 Shim ring9 1 Return pinion10 1 Stretching pin11 1 Reinforcing shelf12 2 Washer13 2 Tie14 1 Conical couple15 1 Handle. GN16151-GN300 7816 2 Screw T.E. M10X20 UNI 573917 3 Elastic washer X M10 UNI 175118 1 Screw T.C.E.I. M14X55 UNI 593119 1 Handle GN16185-GN300 10820 8 Hexagonal nut M8 UNI 558821 3 Elastic washer X M8 UNI 175122 2 Screw T.E. M6X14 UNI 573923 2 Elastic washer X M6 UNI 175124 4 Screw T.S.P.E.I. M8X20 UNI593325 1 PAP Bushing 1625 P1026 3 Screw T.E. M8X25 UNI573927 1 Chain ISO 06B-1 pitch 3/8”28 2 Shaft seeger ring D16 UNI 743529 2 Plain washer X M8 UNI 659230 1 Screw T.C.E.I. M10X50 UNI 593131 2 Screw T.E. M8X35 UNI 573932 1 Inclined plane33 1 Bottom slide34 1 Upper slide

- 35 -Rev. 2.1


VICE MOTION GROUP

Bottom slide

Upper slide

Conical couple

Inclined plane

- 36 -Rev. 2.1


CONICAL COUPLE

POS. Qty. DESCRIPTION1 1 Driving pinion2 1 Driving pin3 1 Gear wheel Z484 1 Gear wheel Z165 1 Spacer6 2 Washer7 1 Bushing8 1 Bushing9 1 Washer De25 Di12,110 1 Couple casing11 1 Driving shaft12 1 Driving axis support13 1 Upper cover14 1 Bottom cover15 1 Shim washer16 2 Knurled lock washer for M817 2 Screw T.C.E.I. M8X20 UNI 593118 1 Elastic washer X M8 UNI 175119 2 Rounded tang 5X5 L=40 UNI 660420 2 Screw T.E. M6X14 UNI 573921 2 Elastic washer X M6 UNI175122 1 Elastic quill D4X20 (spirol) UNI 687523 6 Screw T.S.P. CR. M3X5 UNI 6107 (Galvanized)24 2 Screw T.E. M8X16 UNI 5739

- 37 -Rev. 2.1


VICE MOTION – CONICAL COUPLE GROUP

- 38 -Rev. 2.1


INCLINED PLANE

POS. Qty. DESCRIPTION1 1 Inclined plane2 2 Inclined plane wing3 1 Goniometer4 8 Elastic Washer X M8 UNI 17515 2 Screw T.S.P. CR M4X8 UNI 7688 (Burnished)6 8 Screw T.E. M8X20 UNI 5739

- 39 -Rev. 2.1


UPPER SLIDE

POS. Qty. DESCRIPTION1 1 Vice slide2 1 Vice holding slide front plate3 1 Vice holding slide rear plate4 1 Roller support5 1 Roller holding pin6 1 Washer7 1 Vice Goniometer8 1 Washer9 1 Auxiliary roller10 2 Screw T.S.P.E.I. M10X30 UNI 593311 4 Elastic washer X M10 UNI 175112 4 Screw T.C.E.I. M10X25 UNI 593113 4 PAP Bushing 1620 P1014 1 Quill D8 X40 UNI 6334 A15 4 Scraper ring. RM2470 ref. 162216 1 Handle MR80 P M10X2517 1 Ext. seeger ring. D17 UNI 7435

- 40 -Rev. 2.1


BOTTOM SLIDE

POS. Qty. DESCRIPTION1 1 Transversal slide2 2 Transversal resetting plate3 1 Chain break4 1 Clutch skid5 4 Elastic washer x M10 UNI 17516 4 Scraper ring. RM 2470 ref. 25357 4 PAP Bushing 2520 P 108 4 Screw T.C.E.I. M10x30 UNI 59319 2 Compression spring L= 20mm øe 8,5 THREAD ø 1,5

P= 310 2 Cylindrical quill ø 10 x 50 UNI 6334 A11 2 Screw T.C.E.I. M5x40 UNI 593112 2 Washer x M5 UNI 659213 2 Screw T.C.E.I. M5x20 UNI 593114 2 Lock washer xM5 UNI 7064

- 41 -Rev. 2.1


VICE MOTION – BOTTOM SLIDE GROUP

- 43 -Rev. 2.1

CML International S.p.A. Working Rollers Group

WORKING ROLLERS GROUP

POS. Qty DESCRIPTION1 1 Supporting shelf2 1 Connection3 1 Right side support4 1 Left side support5 1 Hinge pin6 1 Plate7 1 Upper plate8 1 Bottom plate9 1 Working roller φ42,4 − 1” ¼ Gas10 1 Right side dust guard cover11 1 Left side dust guard cover12 2 Washer13 4 Screw T.E. M10X30 UNI 573914 6 Elastic washer for M10 UNI 175115 2 Elastic washer for M8 UNI 175116 2 Bearing type 6001-2Z (12x28x8)17 2 Int. seeger ring. D28 UNI 743718 1 Cylindrical Quill D8x25 UNI 170719 1 Screw T.C.E.I. M12x25 UNI 593120 1 Elastic busher for M12 UNI 175121 1 Screw T.C.E.I. M10x45 UNI 593122 7 Hexagonal nut M10 UNI 558823 1 Threaded bar M10 L=120mm24 1 Yellow spring MGSL 26x3825 2 Screw T.S.P.E.I. M8x45 UNI 573926 2 Ext. seeger ring D15 UNI 743527 2 Plain washer for M14 UNI 659228 2 Screw T.C.E.I. M10x30 UNI 593129 1 Plain washer for M10 UNI 659230 2 Screw T.E. M8x25 UNI 573931 2 Screw T.C.E.I. M5x14 UNI 5931

- 44 -Rev. 2.1

CML International S.p.A. Working Rollers Group

WORKING ROLLER GROUP

Fastening screws and supporting structure

- 45 -Rev. 2.1

CML International S.p.A. System diagrams

SYSTEM DIAGRAMS

DRAWING NR.1 – 220V

- 46 -Rev. 2.1



- 47 -Rev. 2.1



- 48 -Rev. 2.1



- 49 -Rev. 2.1

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.

En 180 Notcher

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