ORIGINAL INSTRUCTIONS
Contents
1. Fig 2 B TYPE 1 Fig 2 TYPE Fig 2 D TYPE 3 A A B g 6 k A CABLE A CABLE A CABLE B HOOK B HOOK B HOOK C ROLLER C ROLLER C BELT D EYEBOLT D HANGER Fig 2 TYPE 4 Fig 2 F TYPE 5 A CABLE A LIFTING DEVICE B 11M254 Edition 01 Revision 07 2 14 GENERAL SECTION MACHINE INSTALLATION By T TECHNICAL DATA j i i MACHINE MODEL E CUT OFF MACHINE a 1 OVERHEAD TRAVELING CRANE Lal Lu 1 du OR CRANE 4 4 4 1 LIFTING TYPOLOGY 215 md WEIGHT T r 7000 Kg TECHNICAL DATA MACHINE MODEL ELECTRIC CABINET OVERHEAD TRAVELING CRANE OR CRANE LIFTING TYPOLOGY TYPE 1 WEIGHT 800 Kg TECHNICAL DATA MACHINE MODEL CONTROL BOARD OVERHEAD TRAVELING CRANE OR CRANE LIFTING TYPOLOGY TYPE 2 WEIGHT 190 Kg 11M254 Edition O1 Revision 07 2 15 GENERAL SECTION MACHINE INSTALLATION hy As for the lifting and transport of the cases containing accessories or parts or the plant the same rules listed at the beginning of this chap2. Saw drive Saw carriage drive Cuts per minute Direction of operation Cold Saw 1 5 mm Electro mechanical Mechanical pneumatically actuated Electric motor with variable speed converter Elecric motor through pinion and rack MAX 25 min on 6 meters lenght tubes Right to Left Mill pass line from floor 1000 mm Voltage 480 V 60 Hz 11M254 Edition 01 Revision 07 2 10 GENERAL SECTION MACHINE INSTALLATION 2 4 MACHINE INSTALLATION 241 TRANSPORT AND HANDLING WARNING SKILLED PERSONNEL TRAINED FOR THIS TYPE OF OPERATIONS MUST CARRY OUT HANDLING AND LIFTING OPERATIONS In order to facilitate transport operations and depending on requirements MTM transports its machines either assembled or disassembled into their parts All the machine mechanical parts are protected using protective paints and or protective oil before shipping them Instead electrical parts are protected with plastic films and bags containing dehydrating salts are put inside The load is then fastened by means of ropes and belts ATTENTION MAKE SURE THAT WHERE THE BELTS ROPES TOUCH THE MACHINE SUITABLE PROTECTIONS OF THE CONTACT SURFACE ARE PLACED IN ORDER NOT TO DAMAGE IT The plant accessories regardless of the means of transport used are generally packed in wooden cases lined with shock resistant blister polyethylene sheets In case of transport by sea dehydrating salt bags will a
3. TETT TETTIE ee duh dud TEE Tm 18 2 61 SETTING UP ADJUSTMENTS a m E Te s IB 2 6 2 ADJUSTMENT DURING PRODUCTION ssssssleele 2 18 27 INSTRUCTIONS FOR MACHINE 5 TI bd 2 19 EX 2 19 272 DESCRIPTION OF OPERATING 5 2 19 273 ACOUSTIC NOIS PRODUCED BY TH MACHINE pad bag A 27 4 SAFETY PRECAUTIONS 2 2l 27 5 SAFETY SIGNS ON MACHINES peed pd Be 276 SOFTWARE SAFETY PRECAUTIONS 2 ir Y een Hiab a Foe gos 2 24 27 7 SAFETY PROTECTIONS pg ee ene quid d 278 RESTRICTIONS OF USE sess ehe wama as d dile Pide dd das pedesque s utin 27 2 7 9 PREVENTION OF RISKS CAUSED BY MOBILE ELEMENTS 2 27 2 710 MACHINE SAFE OPERATION PRR iach asas asa B 27 2 711 PRECAUTIONS TO BE ADOPTED DURING THE OPERATION 2 28 11M254 Edition 01 Revision 07 1 1 MAIN TABLE OF CONTENTS Pag 28 MAINTENANCE REQUIREMENTS 2 29 2 81 SPECIAL MAINTENANCE 2 29 29 TROUBLE SHOOTING REI I iSi EPIS 2 30 210 REPAIR AND REPLACEMENT OF PART
4. Beside the above a user manual for video operation inclusive of Fault finding System is supplied together with the electrical documentation If at the end of these operations the problem is not solved the customer shall contact MTM by sending the enclosed TECHNICAL SERVICE see chapter 2 13 1 TECHNICAL SERVICE form giving a brief and clear description of the malfunctioning or trouble 11M254 Edition 01 Revision 07 GENERAL SECTION REPAIR AND REPLACEMENT OF PARTS 21 0 REPAIR AND REPLACEMENT OF PARTS The repair and replacement of the parts will be agreed upon case by case B with the MTM offices For this purpose refer to the chapters 2 13 INTERVENTION REQUEST TECHNICAL SERVICE pag 2 34 and 2 14 WARRANTY pag 2 37 11M254 Edition O1 Revision 07 e 3l GENERAL SECTION MOVING THE MACHINE Ey ell MOVING MACHINE SETTING THE MACHINE OUT OF SERVICE Before moving the machine the user should have removed all the material being processed on the line After this operation he will disconnect the machine from all the distribution networks electric power water air oil etc Due to the high technological content of the machine all the above operations must be carried out by skilled personnel trained for this purpose ell2 DISASSEMBLE AND PACKAGE Before being moved the machine must be disassembled and packed in order to avoid damages that may compromise its
5. ORIGINAL INSTRUCTIONS FLYING CUT OFF MACHINE TYPE A071 CS Manufacturer OFFICINE M T M S P A Serial number 11M254 Building year 2011 EMT TUBE MILLS experience your innovation La riproduzione del presente manuale vietata OFFICINE M T M S P A di seguito denominata MTM si riserva il diritto di apportare in qualsiasi momento le modifiche che ritenesse necessarie per il miglioramento della macchina This manual copying is forbidden OFFICINE M T M S P A hereinafter referred to as MTM reserves the right of making the changes needed for the improvement of the machine in any moment La reproduction de ce manuel est interdite OFFICINE M T M S p A ci dessous appel e se r serve le droit d apporter tout moment les modifications retenues comme n cessaires pour am liorer la machine La reproducci n del presente manual est prohibida OFFICINE M T M S P A en adelante se reserva el derecho de aportar en cualquier momento las modificaciones que considere necesarias para el mejoramiento de la m quina M T M MANUAL DATA Edition 01 Revision 07 Date 07 2012 MAIN TABLE O
6. 3251 0 COMPRESSED AIR PRESSURE SWITCH Description Operation Adjustments It is used to control a suitable air pressure 5 6 bar in the pneumatic system By a pressure switch equipped with an mechanical switch placed on the entry main unit It is possible to adjust the operating threshold of pressure switch operating on the adjusting screw placed on the pressure switch itself 3251 OIL LUBRICATION MOTOR PUMP Description Commands Operation Adjustments Controls Its purpose is to lubricate all flying cut off movement parts Lubrication command 15 automatically operated according to the cutting cycles Lubrication frequency can be set by video 1 cycle every 150 cuts By electric motor Working calibration is pre set on design and it is carried out by means of a proper regulator placed on the pump Pressure is shown on a pressure gauge There is a visual and electrical control of the tank level Pressure switch controls the lubrication is carried out In case the pressure switch does not recognize the lubrication occurred an alarm 15 generated on the operator screen 11M254 Edition 01 Revision 07 1 FLYING CUT OFF MACHINE AO7I CS FUNCTION AND ADJUSTMENTS Wi G 326 PROTECTION TUNNEL OPTIONAL Its purpose is to protect the operator during machine working cycles 3261 OPENING CLOSING MOVEMENT Description The protection must be opened when the machine is stopp
7. FUNCTION AND ADJUSTMENTS 3257 VICE CLOSING Description Commands Operation Adjustments Its purpose is to block the tube during the cutting phase Manual mode see 2 72 DESCRIPTION OF OPERATING MODES pag 2 19 by means of a push button placed on the control board Automatic mode see 2 72 DESCRIPTION OF OPERATING MODES pag 2 19 according to the working cycle sequences By means of pneumatic cylinders operated from the network pressure Control solenoid valves are placed on control block on the vices Pressure can be adjusted depending on the tube to be produced 325 8 VERTICAL MOVEMENT OF ENTRY AND EXIT VICE PILOT GUIDES Description Operation Its purpose is to align the tube containing ferrules The movement is made by means of a mechanical adjustment to be carried out by the proper wrench on the micrometer screw 325 9 PUMP FOR THE LUBRICATION OF COLD CUTTING UNIT GUIDES AND CARRIAGE GUIDES Description Commands Operation Adjustments Controls Its purpose is to lubricate guides of cutting unit carriage and linear actuator Lubrication command 15 automatically operated according to the cutting cycle By a pneumatic solenoid valve In order to operate the Dropsa pump fill the tank with grease see grease list and purge air from the mill pipes Operate manually the ON OFF pneumatic solenoid valve continually till to the ball sliding blocks are filled w
8. CUT OFF CARRIAGE WITH CUTTING UNIT AND VICES Its purpose is to support and guide the cutting unit during the flying cut off longitudinal movement see Pos 8 on Fig 3 A 3241 LIMIT SWITCHES OF FLYING CUT OFF OPENING PROTECTION NO CUSTOMER FURNITURE Description Commands Operation Their purpose is to control the flying cut off protection is closed during the operation phases By means of two electromechanical limit switches If the protection is open the plc commands the quick stop of the profiling mill and cut off machine only they were running otherwise any quick stops occur The opening of one protection stops the flying cut off automatic run and the blade run but not the flying cut off jog run When the operator closes the protection the plc control the reset of the limit switch Then the operator carries out a normal profiling mill reset in order to restore the profiling mill run consents including also safety relay reset of the protections 11M254 Edition 01 Revision 07 FLYING CUT OFF MACHINE AO7I CS FUNCTION AND ADJUSTMENTS Ey 325 CUTTING UNIT Its purpose is to move the cold saw blade depending on tube position and type see Pos 7 on Fig 3 A 225 CUTTING MOVEMENT Description Its purpose is to move the blade with a pre set penetration angle 15 Commands Manual mode see 2 72 DESCRIPTION OPERATING MODES pag 2 19 by a selector place
9. ROUTINE AND SPECIAL MAINTENANCE OPERATIONS DESCRIBED BELOW MUST BE CARRIED OUT WITH THE MACHINE STOPPED AND DISCONNECTED For the operations relevant to the machine maintenance refer to the specific technical forms of each machine and to the specific documentation relevant for each part equipment and accessory supplied with the machine At the end of the maintenance operations and before starting the machine it is mandatory to check that all the safety devices installed by MTM or by the customer have been restored and that the general safety standards are complied with 281 SPECIAL MAINTENANCE Special maintenance operations can be carried out by both MTM and customer personnel If these operations are carried out by the customer at the end of the maintenance operations and in any case before starting the machine it is mandatory to check that all the safety devices installed by MTM have been restored and that the general safety standards are complied with 11M254 Edition 01 Revision 07 2 29 GENERAL SECTION TROUBLE SHOOTING Ey 29 TROUBLE SHOOTING The electronic equipment fitted on the machines produced by MTM includes a Fault finding Diagnostic System This diagnostic system is described to the personnel in charge during the machine installation and personnel training phase At the end of the machine testing phase the personnel in charge is able to carry out all fault finding diagnostic operations
10. all the dangerous situations have been evaluated considering the different aspects of the operator machine relation the possible machine states the reasonable and expected use b Protection measures On the basis of the analysis in point a protections have been studied and designed A protections from transmission mobile components B protections from mobile components involved in working In both cases protection consists of fixed mobile and electronic devices The machine is fitted with devices for the protection of the operator from the risks deriving from noise and vibrations c Use information The machine is fitted with danger and warning signs and operating instructions d Personal means of protection MTM has taken into account that the operators controlling the machine are always equipped with the following personal protection devices helmet ear protectors glasses accident preventing shoes overall e The indication of some written procedure the users must apply 11M254 Edition O1 Revision 07 eee GENERAL SECTION INSTRUCTIONS FOR MACHINE USE By 27 5 SAFETY SIGNS ON THE MACHINES For a more efficacy safety action some accident prevention plates 3 concerning specific safety rules danger conditions obligations prohibitions have been fixed on the machines In some specific case the application of these signs is referred to the present safety regulations SIGNS GIV
11. forms concerning the machines making up the line are included in the present manual 272 DESCRIPTION OF OPERATING MODES The plant in question has two operating modes manual mode and automatic mode 2721 MANUAL MODE The operator may decide to work in manual mode for the following reasons fine tuning of the machine resolution of any problems when operating in automatic cycle 2722 AUTOMATIC MODE The machine must always work in automatic mode The operator has only to check the potential problems see the video pages 11M254 Edition 01 Revision 07 2 19 GENERAL SECTION INSTRUCTIONS FOR MACHINE USE Ey 27 3 ACOUSTIC NOISE PRODUCED BY THE MACHINE During design the lowering of the noise threshold has been especially evaluated However the requirements deriving from the machine normal operation do not allow its complete soundproofing by suitable acoustic insulating materials Therefore the operator will have to wear ear protectors The system noise changes as the test position changes Measurements carried out with the machine operating without tube in production differ from the ones carried out with the tube on line With the tube in production the noise is very high and the operators will have to wear ear protectors The level of acoustic pressure hereinafter described has been detected on a machine identical to the one object of this manual under normal operating conditions and during the produ
12. of information regarding the all plant with particular regard to safety and handling The following sections however describe the individual machines of the plant in detail Each section is divided up into topics each topic describing a series of operations in full The general table of contents constituent section 1 lists all the topics covered in the whole manual The numbering of the pages of each section is independent and consists in a progressive number preceded by the number of the section to which the page belongs e g 2 5 is page n 5 of section 2 This manual is intended for use by the personnel in charge of the installation use maintenance and demolition of the machine and is related to the technical life of the machine subsequent to its manufacture and sale In the event the machine is subsequently transferred to a third party for any reason sale free loan or any other reason the machine must be handed over complete with all the documents The information contained in this manual is not intended as a substitute for the knowledge and experience possessed by the customer using the machine who is fully responsible for the performance of the operations for which the machine was purchased Before starting any operation on any unit the person in question must have at least read the whole manual and subsequently given greater attention to the topic relating to the work to be performed This manual contains copyr
13. or alternatively according to the previous agreements with MTM and to its authorisations The great technological content of this machine does not allow the user to intervene in the above mentioned operations excepted that in the presence of AUTHORIZED ENGINEERS or alternatively according to the previous agreements with MTM and to its authorisations 11M254 Edition 01 Revision 07 2 16 GENERAL SECTION PERSONNEL TRAINING Ey 25 PERSONNEL TRAINING During the machine installation the personnel selected by the customer will be trained in the machine use We recommend to select the skilled personnel in advance taking into account that in relation to the its great technological level the machine must be operated by skilled personnel having a great experience in using similar machines The personnel training ends when the plant is started unless otherwise agreed in this case reference will be made to the order confirmation subscribed by both parties This phase is defined by the starting report where the names of the people trained in the machine use will be listed 2 17 11M254 Edition 01 Revision 07 GENERAL SECTION MACHINE ADJUSTMENT Wi 26 MACHINE ADJUSTMENT For machine adjustments are meant all the adjustments to be carried out to obtain the maximum machine operating performance They are subdivided into Setting up adjustments Adjustment during production 261 SE
14. regular operation to the detriment of the personnel safety Disassembly and packing operations must be carried out by skilled personnel trained for this purpose In particular for packing modalities make reference to the chapter 2 4 7 TRANSPORT AND HANDLING pag 2 11 213 TRANSPORT Transport operations must be carried out by skilled and suitably trained personnel For modalities make reference to the chapter 2 4 7 TRANSPORT AND HANDLING pag 2 11 214 INSTALLATION Installation operations must be carried out by skilled and suitably trained personnel When the machine is moved from the original seat where MTM authorised technical personnel had installed and tested it any form of warranty and responsibility of the Manufacturer fails If the user requests the intervention of MTM authorised technical personnel for the machine installation in the new site the warranty validity will be agreed with MTM and will start from the commissioning and testing report date 11M254 Edition 01 Revision 07 GENERAL SECTION DEMOLITION OF THE MACHINE Ey 2 2 DEMOLITION OF THE MACHINE MTM machines are mainly made of recyclable materials If the machine owner decides to demolish it he will verify that demolition is made according to the environment protection policies and programs of the country where the machine is installed In particular the owner will recycle all the reusable parts personally or thr
15. 1 Revision 07 WARNINGS FLYING CUT OFF MACHINE TYPE CS 2 38 WARNINGS O Operator will periodically e clean the carriage sliding guides and the rack removing any chips and foreign matters e check e centralised lubrication pump cycle e wear condition of carriage wheels sliding guides and all of all equipment and cables inside the chain 11M254 Edition 01 Revision 07 OFFICINE M T M S PA via Palladio 36 30038Spinea Venezia Italy tel 39 041 5089611 fax 39041999611 info mtmtubemills com www mtmtubemills com
16. 54 Edition 01 Revision 07 2 27 GENERAL SECTION INSTRUCTIONS FOR MACHINE USE 27 PRECAUTIONS BE ADOPTED DURING THE OPERATION 27 RECOMMENDED PROCEDURE THE PHYSICAL BARRIERS ARRANGED ON THE MACHINE LAYOUT MUST NEVER BE REMOVED DURING THE MACHINE OPERATION Should they be removed due to technical problems all the possible measures able to highlight the danger we suggest using danger signs placed on the control board minimise the resulting danger It is advisable to stop the machine by removing the power keys The access means to the production area adjustment and maintenance points are designed and realised to ensure the safety of operators carrying out these operations anyway operators must always be previously trained Those operations must always be carried out with the machine stopped Barriers must be re fitted in their normal position as soon as the reasons making necessary their temporary removal are expired ACCESS TO THE MACHINE DURING ITS OPERATION IS FORBIDDEN EXCEPT IN THE SUITABLY ARRANGED AREAS AND HOWEVER IT IS RESERVED TO THE TRAINED AND SKILLED PERSONNEL ONLY 272 DESCRIPTION OF THE PROTECTION DEVICES INSTALLED As for the protection devices installed make reference to the specific technical forms of the single machines 11M254 Edition 01 Revision 07 2 28 GENERAL SECTION MAINTENANCE REQUIREMENTS 28 MAINTENANCE REQUIREMENTS ALL THE MACHINE
17. F CONTENTS I MAIN TABLE OF CONTENTS pag l MAIN TABLE OF CONTENTS 1 1 2 GENERAL SECTION FOREWAR C PERI sess 2 1 22 INTRODUCTION u uy zu Sasa si usss Abeta bates 2 eel PRESENTATION OF THE MANUAL Vidi dd Bd TL bug deed COMPONENTS IDENTIFICATION sa eee 2 8 MANUFACTURER RR AU UR RARE 2 8 224 COMPONENTS TECHNICAL FEATURES od 23 GENERAL DESCRIPTIONS TECHNICAL SPECIFICATIONS 2 10 231 TECHNICAL DATA GR weed lots 2 10 24 MACHINE INSTALLATION TU TUE TDI awe TUI d 24l TRANSPORT AND HANDUING decd EORR e qb exe 4 2 I 24 2 UFTING AND HANDLING RULES TEET E a ie ana 243 UFTING TYPOLOGY ADR ede OB ee ces yd ee kas quod 2 244 MACHINE UNPACKING 4 2 6 24 5 MACHINE STORAGE BEFORE START UP 2 6 2 4 6 INSTALLATION AND CONNECTIONS 0 0 2 6 25 PERSONNEL TRAINING yu d ass 2 17 2 6 MACHINE ADJUSTMENT
18. HNICAL SERVICE Type Serial Number Year of Manufacture a FAULT LOCATION Fault occurred on Had any inconvenient faults already occurred before YES If so at what frequency When the fault has occurred what was the material being processed and which were its characteristics TUBE Outer diameter min mm STRIP Width min mm Thickness min mm COIL Diameter inn mm Weight SPEED Speed max max max out max max Detailed description of how and in what part of the line the fault has occurred possible make reference to and enclose the parts of the drawings supplied with the machine mm mm mm Kg m min Has the machine been regularly maintained and cleaned according to MTM specifications Regular lubrication and greasing YES Regular cleaning of sliding parts YES Roll sliding check YES Which environmental conditions may have contributed to the fault NO NO NO 11M254 Edition 01 Revision 07 GENERAL SECTION INTERVENTION REQUEST TECHNICAL SERVICE B Which measures have been temporarily adopted to continue production Suggestions of the department foreman b INTERVENTION REQUEST With reference to the description in point a FAULT LOCATION we request the intervention of your engineers at our location according to the modalities and the
19. ICAL FEATURES The machine manufactured by MTM consists of Flying cut off machine type A71 CS Cut off entry guide Metering wheel Pneumatic and lubrication unit Electric cabinet Control board 11M254 Edition 01 Revision 07 GENERAL SECTION INTRODUCTION Ey 1 Flying cut off machine type A71 CS 2 Cut off entry guide 3 Metering wheel 4 Pneumatic and lubrication unit 5 Electric cabinet 6 Control board 7 Protection tunnel optional Fig 2 A General view of the machine 11M254 Edition 01 Revision 07 2 9 GENERAL SECTION GENERAL DESCRIPTIONS TECHNICAL SPECIFICATIONS 23 GENERAL DESCRIPTIONS TECHNICAL SPECIFICATIONS 231 TECHNICAL DATA 231 MATERIAL SPECIFICATIONS Material to be processed Max tensile strength Type of production Tube diameter Thickness Final tube Length Carbon steel 550 N mm Round Square and Rectangular tube MIN 3 MIN 026 156 MIN 4 0 m MAX 8 0 m 2312 MAIN TECHNICAL FEATURES Mechanically predisposed speed MAX 150 m min Cutting process Cutting tollerance Cutting head movement Tube clamping
20. ING ORDERS Entry forbidden to Donot smokeanddo Entryforbidden to Do notuse water to unauthorised notuseflames pedestrians extinguish the flames Entry forbidden to Do not smoke Non drinkable water trucks andi TOrk ERS Do not touch Do not remove protection devices Fig 2 G Signs giving orders 11M254 Edition O1 Revision 07 2 GENERAL SECTION INSTRUCTIONS FOR MACHINE USE By WARNING SIGNS AAAA Non ionogenig Attention to falls AAAA 1 In absence of a specific high temperature control Fig 2 H Warning signs 11M254 Edition 01 Revision 07 2 23 GENERAL SECTION INSTRUCTIONS FOR MACHINE USE Ey COMPULSORY SIGNS Breathing protection is compulsory Face protection is Safety gloves are compulsory Eye protection is compulsory Waming with possible additional sign Safety footwear is compulsory Safety helmets are Ear protection is compulsory Individual protection against falls is compulsory Body protection is compulsory Compulsory path for pedestrian Lifting point Fig 2 1 Compulsory signs 27 6 SOFTWARE SAFETY PRECAUTIONS Software installed on personal computers of the control boards is tested and controlled by MTM before delivery in order to avoid presence of any virus MTM is not responsible for any virus present in the system and recommends that the customer provides its computer systems with
21. L OPTIONAL YEN MS redis 33 OPERATION et eint PERRO A MIO 3 14 331 TOOL REPLACEMENT 3 15 34 BUSH REPLACEMENT ON THE RACK SUPPORT 3 16 35 RACK REPLACEMENT t aa au 3 7 36 INSTALLATION RR CUP haw 0 3 61 FOUNDATIONS 3 18 3 62 ELECTRIC INSTALLATION TT TOMTOM TY eM 2 3 48 37 LUBRICATION C FERES ss rus s 3 19 3 74 CUT OFF MACHINE 3 19 372 METERING UNIT cdd a WORT OH 38 WARNINGS TEETH ON 3 23 11M254 Edition 01 Revision 07 l 2 FOREWARD GENERAL SECTION 2 e GENERAL SECTION el FOREWARD This manual is a guide for the correct and safe use of the machine and for its rational maintenance For this reason we specify that the personnel operating the machine will always be identified in this manual depending on the operations to be carried out as 2nd grade operator skilled authorised equipped informed operator The constant compliance with the standards contained in this manual ensures best performances cost effective operation and machine lo
22. N and pos O Take off the rack pos G and carry out the replacement At the end of the replacement carry out in the opposite the assembly At the end of the assembly carry out the alignment of the new rack NOTE THE BUSHES MUST HAVE WITHOUT EXCESSIVE STRESSES A HOLE WITH TOLERANCE FROM 0 08 TO 0 12 MM TO GUARANTEE A GOOD GUIDE FOR THE RACK IT CAN WORK UP TO 0 50 MM OF CLEARANCE IT IS NEED TO VERIFY THE ANOMALY OF NOISE AND CUTTING TOLERANCE 11M254 Edition 01 Revision 07 3 17 FLYING CUT OFF MACHINE TYPE AO7I CS INSTALLATION 36 INSTALLATION Before sending the machine MTM will send the lay out showing the arrangements of the foundation and floors and the connections to the distribution networks for power requirements electric power water air oil etc Installation connections and testing must only be carried out under the control of MTM TECHNICAL ASSISTANCE PERSONNEL or alternatively in accordance to the previous agreements with MTM and after its authorisation ONLY SKILLED PERSONNEL TRAINED FOR THIS TYPE OF OPERATION MUST CARRY OUT INSTALLATION OPERATIONS IN ALL THE HEREAFTER DESCRIBED OPERATION THE OBLIGATIONS IMPOSED TO THE OPERATOR OF USING IF NECESSARY OR EXPECTED THE INDIVIDUAL PROTECTION EQUIPMENT E G SHOES GLOVES GLASSES EAR PROTECTORS OVERALLS ETC HAVE BEEN TAKEN I
23. NTO ACCOUNT 361 FOUNDATIONS After having checked the correct execution of foundation according to the layout provisions the operator will position the flying cut off machine as expected using the suitable lifting means see the chapter concerning 2 4 2 LIFTING AND HANDLING RULES pag 2 13 The machine levelling plates will have to be positioned on the base resting points paying attention that the adjustment screw is positioned on the plate The anchor bolts will be fitted with the suitable fastening and adjustment nuts The work axis will be perfectly aligned to the line according to the layout provisions and the machine will be leveled using the adjustment screws After having checked that the cut off machine is perfectly aligned the log bolts have to be fitted with cement When the set has occurred the log must be fastened only after having checked the perfect alignment with the adjusting screws 36 2 ELECTRIC INSTALLATION The flying Cut Off Machine is equipped with electric cables cut at measure numbered and connected to the proper boxes connecting the control board and the main cabinet passing though the ducts During the profiling mill positioning the cables will have to be introduced in the relevant ducts paying great attention in order to avoid damages The cables have to be brought towards the control panel thought the ducts The connection to control panel must comply with the instructions contained in th
24. NTRIC MOVEMENT OF VERTICAL ROLLERS ON MACHINING AXIS Description It concentrically aligns the vertical rollers according to the width of the profile Operation The shift is obtained by a mechanical adjustment using the handwheel on the micrometric screw 11M254 Edition 01 Revision 07 3 4 FLYING CUT OFF MACHINE AO7I CS FUNCTION AND ADJUSTMENTS Ey 323 FLYING CUT OFF MACHINE GEAR UNIT The purpose of the gear unit is to transmit longitudinal movement to the carriage by means of rack and pinion see Pos 9 on Fig 3 A 3231 MOTOR Description Motor can rotate in manual or automatic mode both clockwise and counterclockwise Manual mode see 2 72 DESCRIPTION OPERATING MODES pag 2 19 its purpose is to make the carriage rotate at pulses and at low speed during tube introduction and adjustment Automatic mode see 2 72 DESCRIPTION OF OPERATING MODES pag 2 19 controls and commands the movement of the carriage according to working cycle set by the flying cut off electronic command system Commands The clockwise and counterclockwise rotation is obtained by means of selectors placed on the cut off machine control board Adjustments Manual rotation speed is set during project phase while the automatic one depends on the line production speed see metering unit Controls The electric motor is controlled by an encoder The carriage movement is fitted with two electromechanical limi
25. OPEN 33 1 JAWS AND VICE PILOT GUIDES Depending on the tube to be produced it will be necessary to insert the jaws and relevant pilot guides by loosening the special fastening screws Then the entry and exit guides and the entry tube adjuster will be re aligned 3312 BLADE REPLACEMENT To correctly replace the blade follow the operation hereafter described by jog speed place the carriage in the suitable position for the blade change opening on protection stop the motor running remove the keys from the blade replacement safety and auxiliary services selector switches on the flying cut off control board open the tunnel protection open the protection carter remove the blade locking unit replace the blade by checking the operating direction of the teeth according to the blade rotation see arrow on carter lock the blade by the nut and close the cover by proper handwheel close the tunnel protection insert the keys of blade replacement safety selectors and of auxiliary services 11M254 Edition O1 Revision 07 3 15 FLYING CUT OFF MACHINE TYPE CS BUSH REPLACEMENT ON THE RACK SUPPORT 34 BUSH REPLACEMENT ON THE RACK SUPPORT BUSH DETAIL CUT OFF MACHINE END SIDE GEAR UNIT SECTION CARRIAGE SIDE Fig 3 D Bus
26. PERATURE FROM 25 55 UP 70 FOR NOT MORE THAN 24H 11M254 Edition 01 Revision 07 e le GENERAL SECTION MACHINE INSTALLATION By 24 2 LIFTING AND HANDLING RULES MTM machines including their related general electric boards are fitted with adequate lifting connections and or eyebolts which are integral part of the machine and designed according to its weight In order to lift and handle the machine safely observe the following recommendations DO NOT STAND OR PASS UNDER SUSPENDED LOADS AND IN THE AREAS WHERE SAID LOADS ARE LIKELY TO FALL EVEN WHEN TRANSLATION MOVEMENTS ARE NOT CARRIED OUT The lifting and transport equipment must only be used by authorised personnel the lifting and transport equipment must be adequate to the load characteristics shape and volume as well as to the operating conditions the efficiency of the equipment and in particular ropes metal cables chains hooks must be checked and possible irregularities must be pointed out the carrying capacity of the equipment must be complied with check that the equipment and load path is free from any obstacle check that the operating station allows perfect visibility make sure that the loads are correctly slung preventing the ropes from sliding on both the load and the hook and preventing them from slipping on sharp edges bends with small radius of curvature and multiple torsion en
27. S TETTE 2 MOVING THE MACHINE AN PENT TT DUE ene 211 SETTING THE MACHINE OUT OF SERVICE 2 32 212 DISASSEMBLE AND PACKAGE MNT PEOR Tort 2 32 BAS TRANSPORT 2 32 21 4 INSTALLATION m TTC TNT m R 2 32 DEMOLITION OF THE MACHINE T T aeri 2 33 213 INTERVENTION REQUEST TECHNICAL SERVICE 2 34 2131 TECHNICAL SERVICE ele 2 35 214 WARRANTY TT TROP TTE errr 2 37 215 ORIGINAL SPARE PARTS beet TET 2 38 216 LIST OF TECHNICAL DOCUMENTS CONCERNING THIS MANUAL 2 39 3 FLYING CUT OFF MACHINE TYPE CS meld 34 DESCRIPTION 3 2 32 FUNCTION AND ADJUSTMENTS 3 2 321 FLYING CUT OFF METERING UNIT TOM aaa ak E TERI 3B 2 322 INFEED CENTRING UNIT 3 4 323 FLYING CUT OFF MACHINE GEAR UNIT 3 5 32 4 FLYING CUT OFF CARRIAGE WITH CUTTING UNIT AND VICES 3 7 32S CUTTING UNIT L u br 326 PROTECTION TUNNE
28. TEMPERATURE AMBIENT AIR TEMPERATURE NOT EXCEEDING 35 FOR A 24H PERIOD HUMIDITY lt 8096 WITHOUT CONDENSE HEIGHT lt 1000 M A S L ATTENTION IF THE MACHINE SHOULD BE MOVED FROM THE ORIGINAL SITE WHERE IT HAS BEEN INSTALLED AND TESTED BY MTM AUTHORISED TECHNICAL PERSONNEL CLIMATE PARAMETERS MAY CHANGE CAUSING MALFUNCTIONING 27 9 PREVENTION OF RISKS CAUSED BY MOBILE ELEMENTS When designing its machine MTM pays special care to the prevention of risks that may arise from their use Prevention is considered by MTM with special care as its machines are NOT mass produced MTM machines are projected designed and manufactured according to the customer s technical specifications That is the reason why MTM each time projects and installs special risk protection Besides MTM has projected the protections in accordance with the standards listed in paragraph 2 7 FOREWARD pag 2 1 2710 MACHINE SAFE OPERATION During the machine design phase has checked the risks and dangers the operator can be subject to On the basis of the carried out analysis devices signs procedures and any other measure considered necessary for safety purposes have been provided In its evaluation MTM has also considered that the operator in compliance with the general safety standards uses the following individual protection devices overall accident preventing shoes glasses ear protectors helmet gloves 11M2
29. TRODUCTION 2213 UNITS OF MEASUREMENT INTERNATIONAL SYSTEM SI Basic SI units Length meter Mass kilogram Time second Electric current ampere Thermodynamic temperature kelvin Angular measure radian SI derived units Strength newton Pressure pascal Energy joule Power watt Voltage volt Frequency hertz Capacitance farad Electrical resistance ohm kg rad Pa 11M254 Edition 01 Revision 07 GENERAL SECTION INTRODUCTION tera giga mega kilo hecto deca deci centi milli micro nano pico SI prefixes 10 2 109 106 103 102 101 10 1 10 2 10 3 10 5 10 9 10 12 1 000 000 000 000 1 000 000 000 1 000 000 1 000 100 10 0 1 0 01 0 001 0 000 001 0 000 000 001 0 000 000 000 001 11M254 Edition 01 Revision 07 GENERAL SECTION INTRODUCTION Ey 222 COMPONENTS IDENTIFICATION The machine model is shown on the nameplate located on the upper right corner of the Main Electric Cabinet It bears the following data MANUFACTURER OFFICINE M T M S P A MACHINE MODEL FLYING CUT OFF MACHINE TYPE A071 CS SERIAL NUMBER 11M254 YEAR OF CONSTRUCTION 2011 223 MANUFACTURER The machine described this user s manual and the models deriving from it are manufactured and sold by Officine M T M S P A 1h via Palladio 36 30038 Spinea Venezia Italy tel 39 041 5089611 fax 39 041 999611 www mtmtubemills com 224 COMPONENTS TECHN
30. TTING UP ADJUSTMENTS They are the ones made during machine testing and installation or in case of operation restoring after a period of stop The machine setting up adjustment is only carried out by MTM personnel or alternatively according to the previous agreements with MTM and to its authorisations It is carried out in collaboration with the personnel operating the machine which will provide the data concerning the production specifications to MTM engineers 26 2 ADJUSTMENT DURING PRODUCTION They are carried out and repeated by the trained personnel according to the requirements resulting from the machine normal use As for the latter ones make reference to the technical forms concerning each machine SKILLED PERSONNEL TRAINED IN THIS TYPE OF OPERATIONS ONLY MUST CARRY OUT ADJUSTMENT OPERATIONS 11M254 Edition 01 Revision 07 2 18 GENERAL SECTION INSTRUCTIONS FOR MACHINE USE Ey 27 INSTRUCTIONS FOR MACHINE USE All the above operations are controlled through sophisticated electronic equipment consisting of electric panels control boards monitoring systems and control boxes Operators trained by MTM engineers see chapter 2 5 PERSONNEL TRAINING pag 2 17 control all the operating modes above described 271 MACHINE USE Personnel trained in its use can only operate the machine The machine control operations are described in detail in the enclosed User s manual for the supervisor The technical
31. a suitable antivirus program The antivirus program will have to be installed by a skilled engineer and to be considered reliable it will have to be continuously updated Back up copies of the operative programs is supplied together with the electric documentation 11M254 Edition 01 Revision 07 2 4 GENERAL SECTION INSTRUCTIONS FOR MACHINE USE 277 SAFETY PROTECTIONS Each MTM machine is fitted with protections in order to avoid injuries and damages to the health of the operators PROTECTIONS ARE DESIGNED ACCORDING TO THE STANDARDS LISTED IN PARAGRAPH FOREWORD AS FOR PERIMETRAL PROTECTIONS MTM HAS IDENTIFIED DURING DESIGN PHASE POSSIBLE RISKS AND DANGERS THAT MAY OCCUR TO USERS IN CASE OF NON INSTALLATION AND HAS INFORMED CUSTOMER OF THOSE OCCURRENCES ATTENTION IN DESIGNING AND MANUFACTURING THE PROTECTIONS DESCRIBED BELOW THE OBLIGATIONS IMPOSED TO THE OPERATOR IF NECESSARY OR EXPECTED THE INDIVIDUAL PROTECTION EQUIPMENT E G SHOES GLOVES GLASSES EAR PROTECTORS OVERALLS HELMET ETC HAVE BEEN TAKEN INTO ACCOUNT E G SAFETY SHOES GLOVES EYEGLASSES HEADSETS OVERALLS HELMET ETC In more details the machine must be equipped with 2771 FLYING CUT OFF MACHINE a A device for immediate stopping of the line named Pipe jamming device is located at the cropper entry point This device consists of a steel ring in which the pipe to be cut slides and which is activ
32. ated when the pipe abandons the normal sliding location and touches the ring b The cropper must also be equipped with a mechanical protection named tunnel constructed by the customer which can be opened to prevent access to the cutting operation zone The protection must have interlocking devices which are tripped when the protection is opened thus preventing the system from operating IF PROTECTION IS NOT PROPERLY CLOSED THE MACHINE MUST NOT BE OPERATED 1 Protection tunnel optional Fig 2 J Protection tunnel 11M254 Edition 01 Revision 07 2 25 GENERAL SECTION INSTRUCTIONS FOR MACHINE USE Wi 2772 ADDITIONAL PROTECTIONS In addition to the above protections MTM machines are equipped with a Safety devices Fast stop push buttons installed on the control boards b Warning signs and notices located on the machine sides THE OPERATOR IS OBLIGED TO USE THE INDIVIDUAL PROTECTION DEVICES 11M254 Edition 01 Revision 07 2 26 GENERAL SECTION INSTRUCTIONS FOR MACHINE USE Ey 27 8 RESTRICTIONS OF USE This machine must only be used in compliance with the working schemes envisaged by the Manufacturer and described in detail by this manual and its enclosures According to the machine operating site as per order confirmation the climate parameters to be complied with are the following AMBIENT AIR UNDER OPERATING CONDITIONS FROM 5 C 40
33. be used If not specified the bearings are life long pre lubricated Maintenance notes are indicated in the technical sheets of SALES MATERIAL CATALOGUES SECTION Fig 3 G Pumps CENTRALIZED LUBRICATION OF VICES AND RACK ELECTROPUMP MOBIL oil type VACTRA OIL N 2 15 It Centralized lubrication of vices and rack The pump is pre set during the inspection It is foreseen a working cycle of 1 sec each 15 cuts Check every month the lubricant arrives at the different uses The tank is fitted with a minimum level sensor Add oil when needed For pump technical features see manual enclosed to documentation See SALES MATERIAL CATALOGUES SECTION Q 2 CENTRALISED LUBRICATION OF CARRIAGE WHEELS AND ACTUATOR PNEUMATIC PUMP grease type GR MU EP00 2 Kg Centralised lubrication of carriage wheels and actuator Pump is pre set during test phase and it is foreseen a greasing each 3800 cuts The tank is fitted with a minimum level sensor Add oil when needed For pump technical features see manual enclosed to documentation See SALES MATERIAL CATALOGUES SECTION 11M254 Edition 01 Revision 07 FLYING CUT OFF MACHINE TYPE CS LUBRICATION GEAR UNIT OF CUTTING UNIT MOBIL oil type MOBILGEAR 629 4 5 It 5 The first oil change must be carried out after 600 hours of operation then ever
34. costs you will communicate us by fax Stamp and signature 11M254 Edition 01 Revision 07 GENERAL SECTION WARRANTY B 214 WARRANTY However as they are not mass produced but manufactured upon Generally MTM machines guaranteed for 6 months i customer s specifications the warranty will have to be defined in the order For this reason make reference to the Contract Order confirmation subscribed by both parties as far as warranty conditions are concerned 11M254 Edition O1 Revision 07 2 87 GENERAL SECTION ORIGINAL SPARE PARTS 215 ORIGINAL SPARE PARTS MTM equipment is made up of special machines therefore some of its components are not in the warehouse or cannot be found in a short time To order spare parts needed for a correct machine working please contact the MTM SPARE PARTS DEPARTMENT HOLDING GOOD THE WARRANTIES IS NOT RESPONSIBLE OF THE PLANT IDLE PERIODS AND LACK OF PRODUCTION DUE TO UNAVAILABILITY OF SPARE PARTS MTM 1 NOT RESPONSIBLE FOR DAMAGES DUE TO USE OF NOT ORIGINAL SPARE PARTS 11M254 Edition 01 Revision 07 e 38 GENERAL SECTION LIST OF TECHNICAL DOCUMENTS CONCERNING THIS MANUAL Bh 216 LIST OF TECHNICAL DOCUMENTS CONCERNING THIS MANUAL Assembly drawings of all the machine groups with the list of all MTM CY drawings and of all the market components u
35. ction of steel tubes and profiles at the speed of 130 m min For measuring the real level of acoustic pressure a noise meter mod DELTA OHM HD8701 having the following characteristics has been used Measure range Autorange 40 130 dB Frequency Response Weighted mean A Being the machine very long and the working position variables The acoustic pressure level has been measured at 1 m from the surface of the machine and at 1 60 m height above the ground near the working areas listed below The actual measurement of the acoustic pressure level carried out during production is the following Cut off machine area 80 dB 11M254 Edition 01 Revision 07 e eo GENERAL SECTION INSTRUCTIONS FOR MACHINE USE 27 4 SAFETY PRECAUTIONS THE MANUFACTURER IS NOT RESPONSIBLE FOR DAMAGES TO PEOPLE OR OBJECTS RESULTING FROM NON COMPLIANCE WITH THE SAFETY STANDARDS SKILLED PERSONNEL EXPERIENCED IN THE USE OF SIMILAR MACHINES MUST OPERATE THE MACHINE The machine can be considered safe if it has been designed to be used adjusted maintained dismantled and eliminated in its expected use conditions without causing injuries or damages to health In order to achieve this aim MTM has adopted the following measures a Reduction of risks starting from design During design the expected use space and time restrictions have been taken into consideration The dangers have been identified and
36. d on the flying cut off control board Automatic mode see 2 72 DESCRIPTION OF OPERATING MODES pag 2 19 the movement is carried out during the cutting cycle Operation By means of a electric motor operated by proper converter A gear unit controls the drive of cold sawing process Adjustments Up and down cutting speed can be optimised by video settings on the profiling mill and cut off machine control board Controls Cutting strokes and speeds are controlled by a closed loop contro that permits to set the various parameters of the three cutting steps For more details refer to the HMI user s manual In addition the motor is fitted with a temperature control Two electromechanical switches control the mechanical extra strokes in case of anomalies of the control system 3252 MOTOR PUMP FOR GEAR UNIT LUBRICATION OF CUTTING UNIT Description Its purpose is to lubricate the cutting unit gearbox Commands Lubrication command is automatically operated before the blade motor start Operation By electric motor ATTENTION EVERY DAY CHECK THE GOOD OPERATING OF MOTOR PUMP AND INSTALLATION EVERY MONTH CHECK THE INSTALLATION MAINLY THE POINTS WHERE THE OIL COMES IN 11M254 Edition 01 Revision 07 3 8 FLYING CUT OFF MACHINE TYPE CS FUNCTION AND ADJUSTMENTS 3253 BLADE GEAR UNIT Description Commands Operation Adjustments Controls Its purpose is to rotate the blade according to
37. e wiring diagrams concerning the machine 11M254 Edition 01 Revision 07 3 18 FLYING CUT OFF MACHINE TYPE CS LUBRICATION By 37 LUBRICATION Lubrication is very important for ensuring the regular operation of MTM P machines and as a result of this prevents malfunctioning which may cause safety problems Therefore the hereafter provided instruction must be complied with ATTENTION HOWEVER WE RECOMMEND CAREFULLY READING OF THE SPECIFIC DOCUMENTS ENCLOSED 371 CUT OFF MACHINE I Fig 3 F Lubrication points For lubrication and maintennace refer to the manual enclosed with the CARRIAGE LONGITUDINAL MOVEMENT MOTOR GY documentation See SALES MATERIAL CATALOGUE 11M254 Edition 01 Revision 07 3 19 FLYING CUT OFF MACHINE AO7I CS LUBRICATION BLADE MOTOR Check that the mechanical and electrical installation specifications are complied with Read on the data plate term dates for bearing lubrication and for the grease to
38. ed whereas working operations are needed i e blade change The protection must be closed after finishing working operations and then start the production Operation The opening is made in manual way Controls 2 electromechanical limit switches controls the protection closure 11M254 Edition O1 Revision 07 3 13 FLYING CUT OFF MACHINE TYPE AO7I CS OPERATION 33 OPERATION ATTENTION IN ALL THE HEREAFTER DESCRIBED OPERATION THE OBLIGATIONS IMPOSED To THE OPERATOR OF USING IF NECESSARY OR EXPECTED THE INDIVIDUAL PROTECTION EQUIPMENT E G SHOES GLOVES GLASSES EAR PROTECTORS OVERALLS ETC HAVE BEEN TAKEN INTO ACCOUNT WITH THE MACHINE STOPPED BEFORE STARTING ANY OPERATION ON THE FLYING CUT OFF IT IS COMPULSORY TO EXTRACT THE KEY OF BLADE CHANGE SECURITY SELECTOR ON THE CONTROL BOARD Flying cut off preliminary set up operations consist of protection opening carter protection opening blade assembly and protection carter closure assembly and alignment of jaws vices and entry and exit pilot guides flying cut off entry tube adjusting device blade positioning depending on tube diameter by video settings protection closing 11M254 Edition 01 Revision 07 3 14 FLYING CUT OFF MACHINE AO7I CS 3 3 TOOL REPLACEMENT ALL THE HEREAFTER DESCRIBED OPERATIONS ARE TO BE CARRIED OUT WITH THE MACHINE STOPPED MOTORS OFF AND PROTECTION
39. eel 5 Upper metering wheel 6 Vertical rollers CW1 4 1 cil 2 solenoid valve energized V A gt lt a n Fig 3 B Metering unit It is used to detect speed and forwarding of flying cut off tube order to i control automatic operation of the flying cut off The group is positioned in the ending area of the sizing base before the cut off machine 321 DETECTION TUBE SPEED ENCODER Description Its purpose is to detect the tube speed and forwarding in the flying cut off machine Operation An encoder supplies a frequency proportional to the tube speed 11M254 Edition 01 Revision 07 FLYING CUT OFF MACHINE TYPE AO7I CS FUNCTION AND ADJUSTMENTS 3212 VERTICAL MOVEMENT OF LOWER CONTRAST Description Operation Its purpose is to align the lower contrast wheel to the line under tube position The movement is made by means of a mechanical adjustment to be carried out by proper wrench on the adjusting screw 1 Fig 3 B 3213 VERTICAL MOVEMENT OF UPPER METERING WHEEL Description Commands Operation Adjustments Its purpose is to align the metering whee
40. h replacement on the rack support CUT OFF MACHINE END SIDE 1 Loose the screws and take away the upper side of the rack guide jacket support pos C 2 Loose the fastening screws of the rack guide jacket D away the 2 bush semi shells pos E 3 Take away the rack guide jacket enough to loose the screws and take CARRIAGE SIDE 4 Take off the cover pos dust cover pos H Take away the 2 bush semi shells pos and replace if needed the 6 the end of the replacement carry out in the opposite the assembly 11M254 Edition 01 Revision 07 3 16 RACK REPLACEMENT FLYING CUT OFF MACHINE TYPE CS 2 35 RACK REPLACEMENT Fig 3 E Rack replacement Loose the screws and take away the upper side of the rack guide jacket support pos C Loose the fastening screws of the rack guide jacket pos D and disconnect the rubber tubes of the lubrication system from the pipe fittings fixed on the rack guide jacket Take off the rack guide piston pos by loosing the nut pos To disconnect the rack pos from the support pos I take out the screws pos K In the support of rack locking unit there are the centering plugs Release the cover pos M of the gear unit by loosing the screws pos
41. ight information and cannot be furnished to third parties even in part for any purpose and in any form without MTM s prior written consent MTM hereby declares that the information contained in this manual is consistent with the technical and safety specifications of the machine the manual refers to A true copy of this manual is filed in the machine s technical folder which is kept at MTM s offices MTM shall not recognize any documents which have not been produced released or distributed by MTM 11M254 Edition O1 Revision 07 GENERAL SECTION INTRODUCTION 221 GRAPHIC CONVENTIONS In order to make the topics more immediately comprehensible graphic and typographic symbols and conventions have been adopted throughout the manual and are described below THE NOTES CONTAIN IMPORTANT INFORMATION AND ARE HIGHLIGHTED ALONGSIDE THE TEXT THEY REFER TO THE CAUTION INSTRUCTIONS INDICATE THOSE PROCEDURES WHERE FAILURE TO FULLY COMPLY THEREWITH MAY RESULT IN DAMAGE TO THE MACHINE OR OTHER EQUIPMENT CONNECTED TO IT THE DANGER INSTRUCTIONS INDICATE THOSE PROCEDURES WHERE FAILURE TO FULLY COMPLY THEREWITH MAY RESULT IN DAMAGE OR INJURY TO THE OPERATOR OR OTHER PEOPLE NEARBY Warning Attention I Burn hazard cy Texts to be read with particular care i O Addresses contacts 4 Uh A Information regarding the packaging of the various compo
42. ith grease After these operations excite the pneumatic solenoid valve with pressure at 6 bar for five second cycle each 3800 cuts See enclosed diagram Fig 3 C Lubrication diagram L14AF 03 pag 3 11 Calibration is made during general set up and it is carried out by means of a proper regulator placed on the pump Pressure is shown on a pressure gauge The installation is divided in two pumping elements with sized capacities There is a visual and electrical control of the tank level The control generates an alert warning on the operator screen 11M254 Edition 01 Revision 07 3 10 FLYING CUT OFF MACHINE TYPE AO7I CS FUNCTION AND ADJUSTMENTS 8 5 m r T is I 11 Kf Y E TE N E N E Ld cH E H d N Lj 5 REASE ACIP Fig 3 Lubrication diagram L14AF 03 11M254 Edition 01 Revision 07 3 11 FLYING CUT OFF MACHINE AO7I CS FUNCTION AND ADJUSTMENTS
43. l to the upper tuber position The wheel is operated by a pneumatic cylinder and controlled by proper pneumatic selector placed on site By a pneumatic cylinder pos 2 in Fig 3 B The speed and the descent pressure can be optimised by means of regulators placed near the cylinder 3214 CONCENTRIC MOVEMENT OF VERTICAL ROLLERS ON MACHINING AXIS Description Operation It concentrically aligns the vertical rollers according to the width of the profile The shift is obtained by a mechanical adjustment using the handwheel on the micrometric screw pos 3 in Fig 3 B 3215 JAMMING TUBE SENSOR Description Operation Adjustments Its purpose is to stop the profiling mill in case the tube entering the flying cut off machine goes out of rolls containment jamming bending and shift The tube contact is detected by means of a steel ring connected with a relevant electric circuit The ring diameter must be adequate to the diameter of the tube being produced 11M254 Edition 01 Revision 07 FLYING CUT OFF MACHINE TYPE CS FUNCTION AND ADJUSTMENTS Wi 322 INFEED CENTRING UNIT It is used to contain the profile during machining before entry into the cropper see Pos 1 in Fig 3 A 322 GROUP VERTICAL MOVEMENT Description It is used for aligning the horizontal roller in the line under pipe position Operation By mechanical adjustment of the micrometric screw with a spanner 3222 CONCE
44. lso be used In addition MTM makes custom made packaging on customer s requests or due to special requirements size or material fragility Machines are loaded in bulk on both boxes and containers After the arrival at the customer s premises the machines and cases will have to be handled very carefully using equipment having a carrying capacity adequate to the weight to be lifted and handled both indoor and outdoor If the anchoring instructions are not complied with there is the risk that the machine or the case overturns or falls see lifting diagrams in the following chapter The described solutions also apply in case the machine or parts of it are lifted or handled by the customer or in case of future movements For the cases the standard transport modalities apply Two different transport solutions can be adopted to deliver the machine to the user namely a Truck The machine is loaded on low bed or standard trucks always covered by tarpaulin which must ensure the protection of the load against atmospheric agents We recommend to always check the covering tarpaulin integrity 11M254 Edition O1 Revision 07 2 11 GENERAL SECTION MACHINE INSTALLATION By b Ship The machine is loaded on board 40 20 open top containers B d wooden boxes coated with tarpaper and lined with nylon We recommend to always check the covering tarpaulin integrity TRANSPORT TEM
45. nents Operation to be performed by qualified personnel for assistance on electrical equipment Texts containing information of particular relevance 11M254 Edition 01 Revision 07 2 3 GENERAL SECTION INTRODUCTION Eh Information on transportation by truck Information on transportation by ship Information on transport and handling Danger suspended load 5999 E Information regarding adjustment procedures Information regarding acoustic noise Ear protection is compulsory Body protection is compulsory Machine downtime Information regarding the machine fixing to the floor CEOE Lubricant loading Information regarding greasing lubrication Pressure greasing Manual greaasing rege 11M254 Edition 01 Revision 07 2 4 GENERAL SECTION INTRODUCTION EN CCW COUNTER CLOCK WISE rotation of the horizontal screw CW CLOCK WISE rotation of the horizontal screw CW CLOCK WISE rotation of the vertical screw S CCW COUNTER CLOCK WISE rotation of the vertical screw ee CW CLOCK WISE rotation of the component COUNTER CLOCK WISE rotation of the component Vertical movement of the component Horizontal movement of the component 2212 TYPOGRAPHIC CONVENTIONS Wording Used to indicate reference to figures chapters or topics other than the in italics current ones 11M254 Edition O1 Revision 07 2 5 GENERAL SECTION IN
46. ng life and avoids common causes of accidents which may occur during work or maintenance In designing and manufacturing the machine the obligations imposed to the operator of using if necessary or expected the individual protection equipment e g shoes gloves glasses ear protectors overalls etc have been taken into account This manual is an integral part of the machine and therefore the personnel operating and maintaining the machine must be enabled to easily make reference to it at any time The descriptions and pictures provided in this manual are not binding MTM reserves the right of making the changes that may be convenient for improvement purposes without undertaking to update these documents For further clarifications contact MTM offices which are available for any useful information 11M254 Edition 01 Revision 07 El GENERAL SECTION INTRODUCTION 22 INTRODUCTION 221 PRESENTATION OF THE MANUAL CN NOTE A ON RECEIVING THE MACHINE BEFORE PROCEEDING TO ASSEMBLE OR MOVE READ THE USER GUIDE AND MAINTENANCE MANUALS CAREFULLY This manual contains instructions on how to handle install maintain operate adjust the machine question The manual is made up of various sections in booklet form each of which covers a series of topics subdivided into chapters and paragraphs which deal with a precise application of the plant Section 2 GENERAL SECTION contains a series
47. ough specialised companies respecting the environment Special care will be paid in recovering and recycling oil grease emulsions and all the other strongly polluting elements needed for the machine normal operation The owner or the demolisher will also disassemble the machine by dividing the pieces on the basis of the classification provided for in the country where the demolition is made and sending them to authorised disposal and recycling centre THE DEMOLITION MUST BE MADE ACCORDING THE RUBBISH ELIMINATION REGULATIONS IN FORCE IN THE STATE WHERE THE MACHINE IS USED 11M254 Edition 01 Revision 07 2 33 GENERAL SECTION INTERVENTION REQUEST TECHNICAL SERVICE Ey 2 13 INTERVENTION REQUEST TECHNICAL SERVICE In the presence of any machine fault it is necessary to comply with the B following instructions Make reference to the Supervisor s manual in the chapters relevant to Fault Finding Make reference to the specific technical forms of the single machines If the problem cannot be eliminated do not attempt any other operation and Contact the MTM Assistance Service Fill and send by fax the enclosed module TECHNICAL SERVICE see chapter 2 13 1 TECHNICAL SERVICE pag 2 35 briefly and clearly describing the malfunctioning of the functional inconvenient 11M254 Edition 01 Revision 07 e 34 GENERAL SECTION INTERVENTION REQUEST TECHNICAL SERVICE 2131 TEC
48. sed T Drawings of wear parts Technical forms and catalogues of the main market materials Hydraulic and pneumatic diagrams Electric and electronic diagrams Supervisor s manual 11M254 Edition O1 Revision 07 2 39 FLYING CUT OFF MACHINE AO7I CS 2 3 FLYING CUT OFF MACHINE AO7I CS 7 1 Tube guide support infeed centring unit _ 8 2 Metering wheel cr ME 3 Pneumatic and lubrication unit 4 Electric cabinet 5 Control board 6 Protection tunnel optional 7 Cutting head unit 8 Carriage unit 9 Gear unit Fig 3 A Flying cut off machine general view 11M254 Edition 01 Revision 07 3 1 FLYING CUT OFF MACHINE TYPE AO7I CS DESCRIPTION Ey 24 DESCRIPTION This machine allows cutting tubes according to customer specifications and being perfectly synchronized with the profiling mill 32 FUNCTION AND ADJUSTMENTS 321 FLYING CUT OFF METERING UNIT 1 Screw for vertical movement of lower contrast wheel 2 Pneumatic cylinder for vertical movement of upper metering wheel 3 Handwheel for concentric movement of vertical rollers 4 Lower contrast wh
49. speeds set by cutting parameters Run and stop are operated by means of suitable buttons placed on flying cut off control board By electric motor Blade motor is fitted with a speed regulator inverter The inverter allows changing motor speed from about 700 to 3000 rpm Revolution number can be set by video on the control board Motor is controlled by the inverter 325 4 ENTRY EMULSION FOR CUTTING BLADE Description Commands Operation It feeds the blade lubrication nozzles by means of a solenoid valve The solenoid valve run and stop is automatically commanded by the blade run and stop By solenoid valve 325 5 ENTRY EMULSION FOR VICE CLEANING Description Commands Operation It feeds the two entry and exit vice manifolds by means of solenoid valve Vice cleaning is automatically carried out at each cutting cycle By solenoid valve 325 6 ENTRY LUBRICATION FOR CUTTING BLADE OPTIONAL Description Commands Operation Controls It feeds the lubrication nozzles of the blade through a solenoid valve The start and stop of the solenoid valve are obtained automatically with the descent command of the blade Through solenoid valve placed on the lubrication panel An electric level sensor monitors the presence of oil in the tank The sensor generates an alert warning on the operator screen 11M254 Edition 01 Revision 07 FLYING CUT OFF MACHINE AO7I CS
50. sure the means and load stability ensure that the hook does not stick to fixed structures place the hooks in a barycentric position and do not pull slantwise to avoid dangerous oscillations when the load is lifted from the resting surface make sure that where the belts ropes touch the load suitable protections are placed in order not to damage these surfaces ift the load first as high as to check if it is balanced then lift it at regular speed to the height needed to safely pass over all the obstacles which may be found along the route slowly place the load on suitable resistant supports and make sure that it cannot overturn after loosening the slings remove possible slings from the hook and lift it as high as to prevent the danger of knocking it THESE OPERATIONS HAVE NOT BEEN CORRECTLY CARRIED OUT THERE IS STILL THE RISK THAT THE MACHINE CASES AND ELECTRIC BOARD OVERTURN OR FALL IN ANY CASE MTM DECLINES ANY RESPONSIBILITY IT IS RECOMMENDED THAT SKILLED PERSONNEL TRAINED FOR THIS TYPE OF OPERATIONS CARRY OUT HANDLING AND LIFTING OPERATIONS 11M254 Edition 01 Revision 07 2 13 GENERAL SECTION MACHINE INSTALLATION Some drawings showing the anchoring points of the lifting equipment and the weights of each machine are given here below REMAINING RISK CHECK ALL LIFTING EQUIPMENT ENSURE THE HOOKS ARE SUITABLE TO THE CAPACITY AND EFFICIENT 243 LIFTING TYPOLOGY
51. t switches forward and backward emergency that stop the run in both directions delimiting the carriage working area The limit switches must never be moved They are positioned during the general set up 3232 CARRIAGE RETURN SENSOR Description Its purpose is to command the carriage return during the automatic operation cycle Commands By means of an inductive sensor Operation It establishes the carriage inversion point in the automatic operation cycles Flying cut off carriage will go back according to a dimension previously set on video This dimension practically set the working stroke 11M254 Edition 01 Revision 07 3 5 FLYING CUT OFF MACHINE AO7I CS FUNCTION AND ADJUSTMENTS 3233 HYDRAULIC DECELERATORS Description Their purpose is to stop the carriage in case it goes beyond the emergency limit switches Operation By means of a hydraulic closed circuit placed inside the decelerator Adjustments There are not adjustments ATTENTION IN ORDER TO AVOID THRUSTS WHICH CAN CAUSE DAMAGES TO THE MOTOR DECELERATORS AND THE WHOLE MECHANICS WHEN THE CARRIAGE GOES IN EMERGENCY AGAINST THE DECELERATORS THE RACK HAS TWO LINES ONE PER SIDE WITHOUT TEETH THIS ALLOWS THE CARRIAGE GOING AGAINST THE DECELERATORS AT IDLE SPEED IT IS NOT PUSHED BY THE MOTOR 11M254 Edition 01 Revision 07 3 6 FLYING CUT OFF MACHINE AO7I CS FUNCTION AND ADJUSTMENTS 324 FLYING
52. ter apply SKILLED PERSONNEL TRAINED FOR THIS TYPE OF OPERATIONS MUST CARRY OUT HANDLING AND LIFTING OPERATIONS 244 MACHINE UNPACKING The machine parts and the cases containing accessories or plant parts must be unpacked with care according to good technique standards avoiding damages and faults that may compromise the machine good operation THEREFORE WE RECOMMEND THAT SKILLED PERSONNEL TRAINED FOR THIS TYPE OF OPERATIONS CARRY OUT UNPACKING OPERATIONS MTM is not responsible for problems in installing the machine caused by damages occurred during the transport handling and unpacking of the machine and of all its parts 24 5 MACHINE STORAGE BEFORE START UP When arriving by the customer and before start up the machine must be stored by the MTM authorised technical personnel in premises ensuring its protection from bad weather from the atmospheric agents and from any cause or external agent which may damage it e g chemical agents dust shocks etc In particular ATTENTION STORAGE TEMPERATURE FROM 25 C 55 C UP TO 70 C FOR NOT MORE THAN 24H 246 INSTALLATION AND CONNECTIONS Before sending the machine MTM will send the layout showing the arrangement of the bases and the connections to the distribution networks for power requirements electric power water air oil etc The installation connections and testing must only be carried out under the control of MTM TECHNICAL ASSISTANCE PERSONNEL
53. y 4000 hours They do not require special maintenance Only the periodic control of lubricant level and to restore it if needed DECELERATOR Q 6 For optimum use and maintenance refer to the ACE instructions given in the i documentation SALES MATERIAL CATALOGUES SECTION LINEAR ACTUATOR 7 Grease type GR The screw lubrication is centralized by DROPSA pump The bearings should be manually lubricated by grease nipple positioned on the carriage For a good operation and use of the machine please clean carriage i slideways and rack from chips and impurities Periodically check centralised lubrication pump cycle pneumatic pump cycle for cutting guide lubrication wear condition of the blade carriage and cutting unit slideways 11M254 Edition O1 Revision 07 FLYING CUT OFF MACHINE AO7I CS LUBRICATION By 372 METERING UNIT Fig 3 H Metering unit It is advisable to periodically check the wear condition of contact wheels i pos A and contrast wheels pos B 11M254 Edition 0
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