Danfoss ET9500 User manual

Imprint
Manufacturer:
UNIFLEX-Hydraulik GmbH
Robert-Bosch-Strasse 50-52
D-61184 Karben
Germany
Phone: [phone] / 91 71 - 0
Fax: [phone] / 91 71 - 181
This Operating Manual of the machine is a translation; the origi-
nal is in German.
Date of revision:2022-10-05
Version: 1.0
© Copyright by UNIFLEX-Hydraulik GmbH
Technical modifications reserved.
The reproduction, distribution and utilization of this document as well
as the communication of its contents to others without explicit authori-
zation are prohibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant of a patent, util-
ity model or design.

EC / UK - Declaration of Conformity
In accordance with EC Machinery Directive 2006/42/EC and UK-Sup-
ply of Machinery (Safety) Regulations 2008.
The following machine
Danfoss ET9500
was developed, designed and manufactured in compliance with EC
Directive 2006/42/EC and UK-Supply of Machinery
(Safety) Regulations 2008, in the sole responsibility of
UNIFLEX-Hydraulik GmbH
Robert-Bosch-Strasse 50 - 52
D-61184 Karben
The following standards, codes and specifications have been applied:
•EC Directive 2006/42/EC
•EMC Directive 2014/30/EC
•EN ISO 12100: 2010
•EN 60204-1: 2018
•UK-Supply of Machinery (Safety) Regulations 2008
•UK-Electromagnetic Compatibility Regulations 2016
This declaration are invalid when the machine is modified or if unau-
thorized and unapproved third-party components are used without
our prior approval.
Entity authorised for documentation: Uniflex-Hydraulik GmbH, Tech-
nical Documentation Dept.
Karben, 04.10.2022
Managing Director Harald von Waitz

Contents
1About this document .......................................................................................... 7
1.1 Target groups ............................................................................................... 7
1.2 Storage.........................................................................................................8
1.3 Name plate ...................................................................................................9
1.4 Abbreviations................................................................................................9
2Safety instructions............................................................................................ 10
2.1 Presentation of warnings ............................................................................ 10
2.2 Intended use............................................................................................... 10
2.3 Product-specific risks.................................................................................. 11
2.3.1 Risks imposed by mechanical equipment........................................ 11
2.3.2 Risks imposed by electricity............................................................. 12
2.3.3 Risks imposed by noise................................................................... 12
2.3.4 Risks in case of fire.......................................................................... 12
2.4 Safety.......................................................................................................... 13
2.4.1 Working area................................................................................... 13
2.4.2 Emergency-stop .............................................................................. 13
2.4.3 Warning signs on the machine ........................................................ 15
3Machine description.......................................................................................... 17
3.1 Design and function.................................................................................... 17
3.2 Technical data ............................................................................................ 19
4Transport and commissioning......................................................................... 21
4.1 Transport .................................................................................................... 21
4.2 Intermediate storage of machine/unit.......................................................... 22
4.3 Commissioning ........................................................................................... 22
4.3.1 Extraction......................................................................................... 24
4.3.2 Extraction process for TMC cutting knife......................................... 24
4.3.3 Electrical connection........................................................................ 26
5Operation ........................................................................................................... 27
5.1 What you have to observe.......................................................................... 27
5.2 Start............................................................................................................ 27
5.3 Work piece cutting ...................................................................................... 28
5.3.1 Prerequisites.................................................................................... 28
5.3.2 Cutting individual hoses................................................................... 29

5.4 Deactivation.................................................................................................30
5.5 Emergency stop...........................................................................................31
5.6 Overload protection.....................................................................................31
5.7 Cleaning ......................................................................................................33
5.8 Cleaning ......................................................................................................33
6Maintenance.......................................................................................................35
6.1 What you have to observe...........................................................................35
6.2 Maintenance schedule.................................................................................35
6.3 Knife replacement........................................................................................37
6.4 Motor brake readjustment............................................................................38
7Troubleshooting.................................................................................................41
8Decommissioning, disposal..............................................................................42
8.1 Dismantling..................................................................................................42
8.2 Recycling.....................................................................................................42
8.3 Consumables and waste .............................................................................43
9Annex..................................................................................................................44
9.1 Accessories (upgradable)............................................................................44
9.2 Spare parts list.............................................................................................45
9.2.1 Mechanical equipment .....................................................................45
9.2.2 Electric equipment............................................................................46
9.2.3 Wear parts........................................................................................47
9.3 Electric diagram...........................................................................................48
9.4 Maintenance log..........................................................................................51
9.5 Declaration of qualified staff ........................................................................52

1 About this document
The "Cutting machine Danfoss ET9500" is consistently designated as
machine in this Operation Manual.
This Operation Manual includes important notes on how you operate
your machine/unit safely, properly and economically.
Use not in compliance with the intended purpose may result in hazard
to the operator's health and life and/or in the risk of damage to/the
machine/unit. Consequently, please only use the machine/unit
•in good order and condition,
•in accordance with its intended purpose,
•in a safety-conscious manner, with awareness of risks and haz-
ards,
•in compliance with all notes included in this Operation Manual.
The machine/unit may only be operated by staff who
•has read the Operation Manual,
•has understood it,
•has been instructed in the operation of the machine/unit, and
•has signed in the Annex.
Figures may include accessories/options. Customer-specific
equipment may vary.
The product images shown are for reference only and may differ
from the product delivered.
1.1 Target groups
The target groups of this Operation Manual are:
Owner
An owner is a natural person or entity using the device himself/her-
self/itself, or on whose behalf the device is used. An owner may ap-
point a representative to exercise the owner's rights and obligations.
The owner has to make sure that
•national provisions, occupational safety regulations and applica-
ble environmental protection regulations are fully complied with;

•persons working on the machine/unit are adequately qualified;
•persons working on the machine/unit are suitable for operating
the machine/unit;
•the Operation Manual has been read and understood. One hard-
copy of the Operation Manual must always be kept at a desig-
nated place where the machine/unit is used.
•persons working on the machine/unit are aware of potential
risks;
•the operating staff is familiar with the location as well as with op-
erating the fire alarm and fighting means. Free access to this
equipment must be ensured.
•personal protection equipment is worn (safety footwear, protec-
tion gloves and safety glasses).
Machine/unit fitters
Machine/unit fitters must be at least 18 years old and have completed
training for the task, i.e. they must have attended a specialist voca-
tional training.
A fitter
•must observe the instructions in the Operation Manual;
•must inform the owner on failures and damage.
Operator
An operator is a person charged with and instructed in the proper op-
eration of the machine/unit by the owner or the otherwise contractu-
ally obliged person.
The operator
•must observe the instructions in the Operation Manual;
•must inform the owner on failures and damage.
•must not perform and maintenance or repair work on the ma-
chine/unit.
1.2 Storage
The Operation Manual is part of the machine/unit and must be kept
near the machine/unit at all times. Upon disposal of the machine/unit,
the Operation Manual must also be handed over.

1.3 Name plate
The name plate is fixed near the power cable.
1.4 Abbreviations
TM cutting knife, plain
TMG cutting knife, with slots
TMC cutting knife, coated

2 Safety instructions
2.1 Presentation of warnings
Warning notes in the Operation Manual warn against risks involved
with the handling of the machine/unit. Risk levels are identified as fol-
lows:
The signal word HAZARD identifies an imminent hazard resulting in
serious injuries or death. This warning is supplemented by a triangu-
lar hazard symbol.
The signal word WARNING identifies a potentially hazardous situa-
tion, which might result in serious injuries or death. This warning is
supplemented by a triangular hazard symbol.
The signal word CAUTION identifies a potentially hazardous situa-
tion, which might result in light injuries. This warning is supplemented
by a triangular hazard symbol.
The signal word ATTENTION identifies a potentially hazardous situa-
tion, in which the product or property in the environment may be dam-
ages. This warning is supplemented by a hazard symbol or a excla-
mation mark.
2.2 Intended use
This machine is intended for industrial use; it is only suitable for cut-
ting pneumatic and hydraulic hoses up to a specific permissible dia-
meter, see “Technical Data” in Section 3.
Intended purposes include:
•Single user workplace for one person only
•Manual input and retrieval
•Operating temperatures between 5 °C and 40 °C
•Operation in a closed operation room
•The machine must not be operated by persons not capable of
operating the machine without any risk. These may include:
➢persons with physical or mental disabilities;
➢children and persons under age;
HAZARD!
WARNING!
CAUTION!
ATTENTION!

➢persons with a restricted capability for the operation of ma-
chines (e.g. under the influence of drugs, alcohol or narcot-
ics)
Use of the control in compliance with the intended purpose also inclu-
des compliance with the instructions in this Operation Manual.
Use for other than the intended purpose
Any other use is considered as being not in compliance with the in-
tended purpose, in particular:
•Design modifications of the machine
•Use in explosive environments
•Use of impermissible cutting knives
•Cutting of inflexible workpieces
•misuse of consumables and waste materials.
WARNING!
Risk for life and health!
Use not in compliance with the intended purpose imposes risks
for life and health. Consequences resulting from use for other
than the intended purpose shall be under the sole responsibility
of the owner.
•Always use the machine in compliance with its intended pur-
pose.
2.3 Product-specific risks
The machine/unit is designed in accordance with the latest state of
technology. Nevertheless, the machine/unit may impose risks:
2.3.1 Risks imposed by mechanical equipment
Cutting risk
A cutting risk exists during cutting and when the cutting knives are re-
placed.
•Take care and wear cut-proof protective gloves when cutting
and replacing knives.

Risk of squeezing
There is a risk of squeezing on the moving parts.
Tilting hazard
The risk of tilting mainly exists while the machine is being trans-
ported.
•Observe the machine's centre of gravity during transport.
2.3.2 Risks imposed by electricity
There is a risk of electrocution near the live parts!
•Work on electric systems may only be performed by qualified
electricians or instructed and trained persons under the supervi-
sion of a qualified electrician.
•Deactivate the machine/unit and secure it against unintentional
restart before maintenance.
2.3.3 Risks imposed by noise
The noise level meter acc. to IEC 804, Class 2, was calibrated before
measuring.
The operation of the machine causes noise emissions of 90 dB(A) at
the workplace. Noise protection is required.
Higher noise emissions may occur when other machinery is simulta-
neously used at the workplace. The machine owner must provide for
appropriate protection, e.g.
•instruct staff to wear ear protection;
•provide information/instructions on risks
•identify hazardous areas
•provide health monitoring
2.3.4 Risks in case of fire
The operating staff has to be familiar with the location as well as with
operating the fire alarm and fighting means. Free access to this
equipment must be ensured.

Use extinguishing powder in case of fire.
2.4 Safety
2.4.1 Working area
The working area is designed as the area 1 metre all around the ma-
chine (shaded).
•Keep the working are free from trip hazards.
•Use ducts for lines and cables.
•Provide good illumination.
2.4.2 Emergency-stop
The machine is fitted with an emergency-stop button.

Immediately activate the emergency-stop function (1) in cases of
emergency.
Remedy the cause of the emergency stop first before re-starting the
machine.

2.4.3 Warning signs on the machine
Cutting risk
on the cutting knife
Danger from electric current
at the power supply line
Risk of eye injuries
Wear safety goggles

Risk of hearing damage
Wear ear protection
Illegible or missing warning signs must immediately be replaced by
the owner.

3 Machine description
3.1 Design and function
Basic machine
(1) Motor
(2) Bending pin
(3) Cutting plate
(4) Main power switch
(5) Feed fork
(6) Knife (covered)
(7) Knife protection (yellow)
(8) Handle

The workpiece is positioned on the cutting plates (3) in front of the
bending pins (3). During the cutting process, the handle (8) is moved
downward, towards the cutting plate (3). During cutting, the feed fork
(5) is moved forward by a chain drive and pushes the workpiece to-
wards the knife (6). The knife is driven by the motor (1). Move the
handle (8) back to the starting position after cutting; the feed fork will
move back. The cut counter (option) counts the number of completed
cutting processes and can be reset by activating the pushbutton.
Accessories
The machine may be fitted with accessories. A list of the available ac-
cessories is included in the Annex, Section "Accessories".

3.2 Technical data
Machine
Dimensions L x W x H
745 x 690 x 430 mm
Weight
approx. 75 kg
Noise level
80 dB(A)*
Protection class
IP 42
Operation mode
S6-60%
Function
Hose feed
Manual
Brake motor
Yes
Extraction connection
Ø 60 mm
Cutting knife EM 6.2
TM G 350 x 3 x 30 mm
Cutting knife EM 6.3
TM C 350 x 3 x 30 mm
Cut counter:
Optional
Workpiece capacity
Workshop SAE R13 &
SAE R15
2"
Production SAE R13 &
SAE R15
11/4“
SAE R12
2"
Industry
3"
Max. outside
Ø 95 mm

Electric connection
Connection power
4.6 kW
Connected voltage
400 V –50 Hz –3 Ph
Back-up fuse
20 A delayed
Short circuit current lk3p
6,7 kA
Short circuit current lp3p
9,7 kA
Full load current of circuit
16,5 kA
Full load current of
control circuit (primary)
0,48 kA
Workbench
Solid, plane workbench with a
carrying capacity of
approx. 500 kg
We recommend industrial flooring meeting the following struc-
tural requirements
Permanent floor loading
Approx. 0.07 kg/mm2
Floor carrying capacity
Min. 2500 kg/m2
Floor quality
B25
Evenness
Max. unevenness 5 mm/m
Inclination
max. 5 mm/m
Ambient conditions
Ambient temperature
5 oC –40 oC
Air humidity
45 % –65 %
The *data are theoretical/computed values, or values measured on a
prototype. Actual values may vary slightly, depending on the ma-
chine.