Betriebsanleitung

Instructions
Notice d’instructions

EV 834
Eckenverputzautomat
Corner cleaning machine
Ebavureuse d’angles
Originalbetriebsanleitung
 Safety regulations
Always disconnect the machine from the pneumatic network and
electrical power supply before carrying out repair work, maintenance work
and servicing work of any nature.
Switch off the electrical master switch and lock it to prevent it being
switched back on again!
Switch off the pneumatic master switch, depressurise the machine and
lock it to prevent it being switched back on again!

Electrical and pneumatic systems must not be changed!

Organisational measures
The user must provide the required personnel safety equipment.
All safety devices fitted must be inspected regularly before starting work.
The user is responsible for correct insertion of the profiles into the machine.

Protective equipment
• All protective equipment must be fitted correctly and must be in operable
condition each time before placing the machine into operation.
• Protective equipment may be removed only
- after the machine has stopped and
- after the machine has been safeguarded against being placed back into
operation.

Informal safety measures

The operator has to prepare operating instructions.
Please always have the Manual ready at hand near to the machine's place of use.
In addition to the Manual, the generally valid and local regulations on accident
prevention and environmental protection must be available for inspection and must
be followed.
All safety and danger information on the machine must be kept in a legible
condition.
Never operate machine under the influence of drink or drugs, as such situations
reduce the operator’s discernment and alertness.

Personnel training
Only trained and instructed personnel may work on the machine.

Machine control
Only instructed personnel are permitted to operate the control.

Safety measures during normal operation

Please operate the machine only when all safety devices are fully operable.
Before switching the machine on, please ensure that no one can be endangered as
the result of the machine starting up.
Inspect the machine at least once per shift for outwardly visible damage and for
operability of the safety devices.

Dangers resulting from electrical power

Have work on the electrical power supply system carried out only by a qualified
electrician.

Clean the machine regularly

 EV 834

1 Safety information
General
information Please note the information in the Manual
• A knowledge of the fundamental safety regulations is absolutely essential for
safely working with this machine and trouble-free operation of the machine.
• This Manual contains the most important safety information which you will need
to operate the machine safely.
• The Manual, in particular the Safety Information, must be followed by all
persons working on the machine.
• Moreover, please comply with the rules and regulations on accident prevention
applicable to the place of use.

User Obligations of the user

The user is obliged to allow only persons who comply with the conditions below to
work on the machine:
• persons who are familiar with the regulations regarding work safety and
accident prevention and who have been instructed in operating the machine.
• persons who have read, understood and confirmed by their signature the
Chapter on Safety and the warning information on this Manual.
The user must check, at regular intervals, that the personnel are working on the
machine in safety-conscious manner.

Personnel Obligations of the personnel

Persons entrusted with working on the machine are obliged, before starting work,
• to follow the regulations on work safety and accident prevention and
• to read the Chapter on Safety and the warning information in this Manual and
confirm, with their signature, that they have understood this information.

Using the
machine Dangers when using the machine
®

The corner cleaning machine has been constructed on the basis of the
state of the art and the recognised technical safety rules. The machine may be
used
• only for the intended application and
• only in perfect, safe working order.
Improper use of the machine may pose risks to the life and limb of the user or third
parties or may cause damage to the machine or other valuables.
Faults and malfunctions which could impair safety must remedied immediately.

Manual 1-1
EV 834

Use as
intended Use as intended
®

The only intended use of the corner cleaning machine is cleaning

window sashes and window frames made of PVC or plastics similar to PVC.
Any other use or use over and above this is not considered as use as intended.
®

cannot be held responsible for damage, loss or injury resulting

therefrom.
Use as intended also includes
• compliance with all information in the Manual and
• carrying out scheduled inspection and maintenance work.
® ®

Please use only original tools or tools approved by which

withstand the anticipated loading in accordance with EN 847-1.

Warranty and
liability Warranty and liability
Our “General Terms of Sale and Delivery” always apply. The user will have been
made aware of these Terms at the latest since conclusion of the Contract.
The warranty covers the supplied machine with all parts. We provide warranty
inasmuch as we opt to replace or repair, free of charge, defects on
machines/components demonstrably attributable to manufacturing errors or
defective materials despite correct handling and compliance with the User Manual.
We are unable to accept claims under warranty and liability claims in relation to
personal injury or damage to property if these claims are attributable to one or
more of the following causes:
• use of the machine not as intended
• incorrect assembly, commissioning, operation and/or maintenance of the
machine
• operation of the machine if safety devices and protective equipment items are
defective and/or inoperable
• not following the information in the Manual in relation to transport, storage,
installation, commissioning, operation, maintenance and setting of the machine
• arbitrary design modifications to the machine without authorisation
• arbitrary modifications to the drive conditions without authorisation
(power rating, speed,…)
• inadequate inspection of the machine components subject to wear
• repairs carried out incorrectly
• disasters and catastrophes resulting from the action of foreign bodies or force
majeure.
The information in this publication is reviewed regularly and any required
corrections are incorporated in the subsequent editions.
We would be very grateful to receive any suggestions and improvement proposals
you may have.
This document may not be reprinted, duplicated or translated, even in extract form,
®

without the prior written consent of .

®

constantly endeavour to improve their products and thus reserve the

right to make technical modifications without any prior announcement whatsoever.

1-2 As per 09/03

 EV 834

2 Safety regulations

Symbols and
signs Explanation of symbols and signs used
The following words and symbols are used to indicate danger in the Manual:

Danger
This symbol indicates imminent danger to the life and
limb of personnel.
DANGER
If this information is not followed, this will result in
serious detriment to health or even life-threatening
injury.

Warning
This symbol indicates a possible imminent danger to
the life and limb of personnel.
WARNING
If this information is not followed, this may result in
serious detriment to health or even life-threatening
injury.

Caution
This symbol indicates a possibly dangerous situation.

Not following this information may lead to slight injury

CAUTION or damage to property.

Note
This symbol indicates information, tips on use and
useful information.

This information helps you to make best possible use

of the machine’s functions.

Manual 2-1
EV 834

Symbols and
signs Explanation of symbols and signs used
The following symbols are attached to the machine:

Caution: High voltage

This symbol indicates an imminent danger to the life
and limb of personnel as the result of electric-shock
hazard.

Control ON
The key identified with this symbol switches the
machine's control on.

Motor ON
The key identified with this symbol switches the
cutter motor on.

Motor OFF
The key identified with this symbol switches the
cutter motor off.

Switchover
Manual cutter selection / Profile
distinguishing system
The 2-position selector switch identified with this
1 2 symbol allows you to switch over between the
automatic profile distinguishing system at cutter
positions 1 and 2 and manual cutter selection.

Position "1" : Manual cutter selection

1 2
Position "2" : Profile distinguishing
system
Frame 1 / Sash 2

Cutter selection
This 4-position selector switch allows you to select
between the four cutters.

1 2 3 4 Position "1" : Cutter 1

Position "2" : Cutter 2
Position "3" : Cutter 3
Position "4" : Cutter 4

2-2 As per 09/03

 EV 834

Cleaning knives
This 4-position selector switch allows you to activate
and deactivate the cleaning knives mutually
independently.
0 1 2 3
Position "0" : Both knives off
Position "1" : Bottom knife on
Position "2" : Top knife on
Position "3" : Both knives on

The following symbols and signs are used in the Manual and on the machine:

Eye-protectors
This symbol indicates that you must wear a pair of
protective goggles to protect your eyes (against swarf
and dust).

Hand protectors
This symbol indicates that you must wear a pair of
protective gloves to protect your hands (when
changing the cutters).

Caution: Risk of crush injury!

This symbol indicates a directly imminent risk of
injury (risk of crush injury) to the hands! Do not place
your hands into the work area during a work
sequence!

Caution: Risk of injury!

This symbol indicates a directly imminent risk of
injury as the result of the rotating tools!
Switch off the cutter motor and ensure that it has
stopped before detaching the side cowl!

Manual 2-3
EV 834

2.1 Organisational measures

The user must provide the required personnel safety equipment.
All safety devices fitted must be inspected regularly before starting work.
The user is responsible for correct insertion of the profiles in the machine.

2.2 Protective equipment

• All protective equipment must be fitted correctly and must be in operable
condition each time before placing the machine into operation:
- the lockable safety master switch which protects the machine against
unintentional or unauthorised operation,
- the front, vertically adjustable safety guard prevents persons placing their
hands into the machine during the work sequence either unintentionally or
in unauthorised manner.
- Always keep the lateral safety guards locked.
Only authorised personnel with key or tool are permitted to detach the lateral
safety guards.
• Protective equipment may be removed only
- after the machine has stopped and
- after the machine has been safeguarded against being placed back into
operation.
• If optional accessories are supplied, the protective equipment must be attached
correctly by the user.

2.3 Informal safety measures

Please always keep the Manual ready at hand near to the machine’s place of use.
In addition to the Manual, the generally valid and local regulations on accident
prevention and environmental protection must be available for inspection and must
be followed.
All safety and danger information on the machine must be kept in a legible
condition.

2.4 Personnel training

Only trained and instructed personnel may work on the machine.
The scope of authority of each member of staff must be clearly stipulated in
respect of installation / assembly, commissioning, operation, setting, maintenance
and repair.
Trainees may be allowed to work on the machine only under the supervision of an
experienced member of staff.

2.5 Machine control

Only instructed personnel are permitted to operate the control.

2-4 As per 09/03

 EV 834

2.6 Safety measures during normal operation

Please operate the machine only when all safety devices are fully operable.
Before switching the machine on, please ensure that no one can be endangered
as the result of the machine starting up.
Inspect the machine at least once per shift for outwardly visible damage and for
operability of the safety devices.

2.7 Dangers resulting from electrical power

Have work on the electrical power supply system carried out only by a qualified
electrician.
Inspect the machine’s electrical equipment regularly. Repair loose connections and
defective cables immediately.
Always keep the switch cabinet locked. Access to the switch cabinet may be
allowed only to authorised personnel with key or an appropriate tool.
When carrying out work on electrically live components, please always have a
second person standing by to switch off the master switch if necessary.

2.8 Dangers resulting from the pneumatic system

• The operating pressure of the machine is 7 bar.

• Have work carried out on the compressed air network only by a qualified
specialist.
CAUTION

When connecting the pneumatic energy, there is a possible risk of injury owing to
sudden movements of machine components if the lateral safety guards have been
detached.

WARNING

Always wear a pair of protective goggles when working on the milling spindles
since, otherwise, swarf could endanger your eyes.

Manual 2-5
EV 834

2.9 Points posing a particular danger

Tools Mechanical danger as the result of tearing and cutting:

- when changing the profiling cutters and grooving knives

Before carrying out work on the milling spindles, please set the master switch on
the switch cabinet to position "0", i.e. switch it off.
Safeguard the master switch with a padlock to prevent it being switched back on
again.
DANGER

Switch off the cutter motor and ensure that it has stopped before detaching the
side cowl!

Always wear protective goggles when working on the cutters since, otherwise,
swarf could endanger your eyes.

Always wear protective gloves when changing the cutters in order to avoid the
possibility of injury.

Clamping
cylinders Mechanical danger resulting from crushing:
- when clamping the workpiece

The clamping cylinders are clamped pneumatically when the two limit switches in
the feed-in zone are actuated.

This means that there is a residual risk posed to unauthorised persons placing
DANGER their hands into the machine.

Tools,
Workholding
fixtures Mechanical danger resulting from crushing, cutting and impact:
- during the work sequence

The automatic work sequence is started when the two limit switches in the feed-in
zone are actuated.

This means that there is a residual risk posed to unauthorised persons placing
DANGER their hands into the machine.

2-6 As per 09/03

 EV 834

2.10 Maintenance, servicing and fault-clearance

• Conditioning unit
(see also Chapter 7)
• The guide shafts must be cleaned and oiled as required.

2.11 Design modifications to the machine

No modifications, attachment work or conversion work may be carried out on the
machine without the manufacturer’s approval. This also applies to welding work on
load-bearing components.
No conversion work may be carried out without the prior written consent
®

of .
Machine components which are not in perfect working order must be replaced
immediately.
®

Please use only spare parts and parts subject to wear.

The manufacturer is unable to accept claims under warranty if spare parts and
®

parts subject to wear not manufactured by are used.

2.12 Cleaning the machine and waste disposal

Lubricants and other materials used must be handled correctly and disposed of
correctly, in particular
- when working on the lubrication systems and devices and
- when cleaning with solvents.

2.13 Noise emission of the machine

The sustained sound pressure level emitted by the machine is dependent on the
profiles to be machined and on the tools used. Please refer to the Annex
(Chapter A), Noise emission values, for further information.

Since the sustained sound pressure level is > 80 dB(A), the operating personnel
must be provided with appropriate safety equipment in order to prevent hearing
impairment.

2.14 Copyright
®

retains copyright to this Manual.

This Manual is intended only for the user and his personnel.
It contains instructions and information which may not be duplicated or distributed
in any other way, either entirely or in part.
Violations of this clause constitute a criminal offence against which legal action
may be taken.

Manual 2-7
EV 834

2-8 As per 09/03

 EV 834

3 Transportation and storage

The machine is transported on pallets.

3.1 Packaging
The machine is packed in a plastic film.

Machine type Gross weight Net weight

EV 834 approx. 610 kg approx. 590 kg

Storage of the
machine Please note the following when storing the machine for a long
period:
• store the machine only in dry rooms,
• choose a type of packaging suitable for storage (protective film) or leave the
machine in the original packing.

Even though most components are provided with a protective coating, the
machine must be thoroughly cleaned before placing it into operation since it is not
possible to carry out milling with soiled supporting surfaces.

3.2 Scope of delivery

Please check that the machine consignment is complete so that the
®

corner cleaning machine can be installed correctly on customer

premises:

• Corner cleaning machine EV 834

• Accessories
- 1 set of grooving knives
- Support arms
- Conditioning unit
- Set of spanners
- Manual

Cutters are not included in the scope of delivery.

They must be ordered separately.

Manual 3-1
EV 834

3.3 Transportation instructions

3-2 As per 09/03

 EV 834

4 Technical data

4.1 Machine data

Designation: Corner cleaning machine
Type: EV 834
Serial number: See rating plate

4.2 Connection data

Electrical: Voltage
Current See electrical circuit
max. back-up fuse diagram for the precise
Connected load connection data.
Compressed air: 7 bar

4.3 Performance and operating data

Frame size max.: Unlimeted
Frame size min.
Outside: 290 x 290 mm (Profile width 40 mm)
Inside: 160 x 160 mm (Profile width 70 mm)
Profile height max.: 200 mm
Profile height min.: 25 mm
Profile width max.: 140 mm
Cutter diameter max.: 260 mm
Power output: 2500 W
Spindle speed: 3400 r.p.m.
Diameter of milling
spindle: 32 mm
Air consumption per
working cycle: 100 l

4.4 Dimension and weights

Machine type Length / Depth / Height Weight
[mm]
EV 834 980 x 1690 x 1670 approx. 590 kg

Manual 4-1
EV 834

4.5 Ambient conditions

4.5.1 Noise

Since the sustained sound pressure level is > 80 dB(A), the operating personnel
must be provided with appropriate safety equipment to prevent hearing
impairment.

The noise emission of the machine is dependent on the profiles to be machined

and on the tools used.

Please refer to the Noise emission values in the Annex.

4.5.2 Temperatures

Permitted ambient influences

The machine must be installed in a dry location protected against frost and
subzero temperatures.

The permitted ambient temperatures are between 10 °C and 30 °C.

Additional cooling of the electrical and electronic components will be required at

temperatures above 30 °C.

Temperatures during operation:

- During operation, the room temperature should not drop below +12 °C and
- should not exceed +26 °C.

These temperatures comply with the EC Workplace Directive.

Ensure that there is adequate intake and extract ventilation!

4-2 As per 09/03

 EV 834

5 Installation, assembly and commissioning

Supplier’s
personnel Safety information

• Ensure that no electrical cables or pneumatic lines are damaged when lifting
the machine with a fork-lift truck.

• Do not use machine components to climb onto the machine!

WARNING
Keep all grips and handles in clean condition.

• Electrical cables must be correctly laid and installed.

The cross-section, length and quality of the cables must comply with local
regulations.

• Before switching the machine on, please ensure that no one will be
endangered by the machine operating.

5.1 Installation location and place of use

User Structural requirements which the user must comply with before
installing the machine:

Please make sure that the base surface / floor has an adequate load-bearing
capacity before installing the machine. Please note our information on weight of
the machine.

DANGER

The foundation plan on page 5-2 shows the maximum space required by the
machine.
The installation location of the machine must be flat and level.

Subsequent extensions to the machine (stops and roller conveyors…) should be

also be borne in mind when selecting the location for the machine.

When installing the machine, please ensure that you comply with the legally
prescribed minimum clearances.

The clearance between machine rear panel and building wall or other machines
DANGER must be at least 0.5 m.

The machine must be installed in dry, and if applicable, heated rooms.

The permitted ambient temperature range is +15°C to +35°C.

Manual 5-1
EV 834

5.1.1 Foundation plan

5-2 As per 09/03

 EV 834

5.2 Unpacking the machine

Ensure that no electrical cables or pneumatic lines are damaged when lifting the
machine with a fork-lift truck.

Secure the machine so that it cannot slip of the forks.

DANGER

If the machine is delivered on a pallet:

• Remove the outer packaging.
• Check that the consignment is complete.
• Release the transport safety device securing the machine to the pallet.
• Lift the machine from the pallet with a fork-lift truck.
• Position the machine at the scheduled installation location.

Manual 5-3
EV 834

5.3 Installing the machine

• Position the machine at the scheduled installation location.

• Use a spirit level to check that the machine is precisely horizontally.
• Align the machine with the support feet precisely horizontally.

Visual
inspection Please inspect the machine for any signs of corrosion (screws or bolts) and,
®

should you detect corrosion, please inform the Servicing Department.

Please clean the machine before placing it into operation.

5.4 Connecting the electrical power and compressed air supply

• Electrical cables must be correctly laid and installed. The cross-section,

length and quality of the cables must comply with local regulations.

• Work on the electrical system may be carried out only by qualified specialists.
DANGER
Please always follow the regulations of the local electrical power supply
company.

5.4.1 Electrical system

Before connecting the machine to the mains, please:
• check that the cross-sections of the cables laid comply with the system's
technical data (see electrical circuit diagram)
• check that the milling spindles turn in the correct direction.
When connecting the electrical cable, insert it into the machine base and through a
free screwed gland into the switch cabinet.
Make the connection to the electrical mains.

5.4.2 Pneumatic system

Connection The connection to the
compressed air network
must be made at the
compressed air
conditioning unit.
This is located on the left-
hand side of the machine
base.
This compressed air
connection must supply dry
air at a sustained, constant
pressure of 7 bar.

5-4 As per 09/03

 EV 834

5.5 Machine

5.5.1 Operating controls

The most imporant operating controls of the machine are as follows:

Master switch
The master switch is used to disconnect and connect the machine from and to the
electrical power supply.

EMERGENCY-STOP button
These buttons are located on the operating panel. Pressing the button disconnects
the entire machine from the electrical power supply. The button must be turned in
order to release it (this releases the lock).

Operating panel
The following operating controls can be found on the front panel, above the feed-in
zone:

Cutter motor ON

Cutter motor OFF

Switchover:
"1" : Manual cutter selection
"2" : Profile distinguishing system
1 2

Cutter selection
Position "1" : Cutter 1
Position "2" : Cutter 2
Position "3" : Cutter 3
Position "4" : Cutter 4

EMERGENCY-STOP button

Cleaning knives:
"0" : Both knives off
"1" : Bottom knife on
"2" : Top knife on
"3" : Both knives on

Manual 5-5
EV 834

Operating controls on the switch cabinet

The following operating controls are located on the switch cabinet:

Control ON:

Master switch

5-6 As per 09/03

 EV 834

6 Operation

Only personnel instructed in the appropriate procedures may be allowed to set

the parameters for processing.

The safety devices of the corner cleaning machine must be inspected every day.
DANGER

6.1 Operating principle of the corner cleaning machine

The corner cleaning machine allows you to process welded plastic window sashes
and frames (at an angle of 90°).
The welding beads are cleaned resp. grooved simultaneously on the upper side
and underside of the profiles. The cleaning knives at the top and bottom and the
profiling cutters for the outer contour can be switched on and off.
The profiling cutters for machining the outer contour are all driven simultaneously
by the cutting motor via V-belts. The cutters are positioned by swivelling a turntable
which accommodates the milling spindles and are then fixed in psition. The
turntable is swivelled and the milling spindles are locked pneumatically.
The cutters can be selected by means of an entry on the keypad.
The sliding table with the cutters is traversed towards the workpiece pneumatically.
The cleaning arms with the cleaning knives are traversed towards the workpiece
pneumatically.
Feed-in mechanism movement is performed pneumatically.
The workpiece is clamped pneumatically via two vertical clamping cylinders.

Manual 6-1
EV 834

6.2 Settings and components

Always recheck clamping levers and clamping screws after setting to ensure that
they are clamping firmly and reliably after carrying out adjustment work of any
nature.

WARNING

6.2.1 Conditioning unit

The conditioning unit consists of two

components:
Pressure reducing valve (C + E) with
pressure gauge
Water separator (F + H)

Pressure reducing valve

The machine's operating pressure is set
to 7 bar as follows:
Lift the twist grip (C) until it disengages
audibly.
Set the pressure at the pressure gauge
(E):
- Turning clockwise: Increases the
pressure
- Turning couter-
clockwise: Decreases the
pressure

Re-engage the twist grip after setting.

Water separator
See Chapter 7.1.1, Conditioning unit

6-2 As per 09/03

 EV 834

6.2.2 Workholding fixture with profile distinguishing

The pneumatic workholding fixture reliably fixes the workpiece in position and thus
guarantees clean, neat machining.
The profile distinguishing system is used to activate the profile-specific outer
contour cutter positions 1 and 2.

You can use the 2-position selector switch to choose between "Manual cutter
1 2
selection" and automatic "Profile distinguishing system" . If this switch
1 2
is set to Position "2" , cutter positions 1 and 2 are activated fully
automatically via a reed contact sensor on the left-hand clamping cylinder.

A height-offset clamping
element which
distinguishes between
frame and sash is attached
to this clamping cylinder.
Consequently, a frame
cutter must always be
Clamping assigned to cutter position
cylinders 1 and a sash cutter must
always be assigned to
cutter position 2.

Clamping
element, left

Clamping
element, right

Manual 6-3
EV 834

Setting the clamping cylinders

The clamping cylinders must be positioned so that the profile cannot tipp over.

The left-hand clamping cylinder must be set precisely to the relevant window
sash profile so as to ensure reliable clamping and to correctly distinguish
between the profiles.
CAUTION

The clamping cylinders can be set through the slots in the cylinder mounting plate.

Cylinder Adjusting the clamping

mounting cylinders:
plate - Undo the four securing
screws of the relevant
clamping cylinder.
- Set the clamping cylinder
to the required position.
- Retighten the securing
screws.

Securing
screws

The left-hand clamping

cylinder must be set
precisely to the window
Clamping
sash profile to be
element of the
machined.
left-hand
clamping
cylinder

Clamping The sash profiles must be

element inserted into the machine
so that the wide profile side
contacts the tabletop.
Sash profile

Tabletop

6-4 As per 09/03

 EV 834

6.2.3 Cutter assignment and cutter selection

In the 2-position selector switch (Switchover: Manual cutter selection / Profile

distinguishing system) is set to Position "1" (Manual cutter selection), the cutter
assignment (frame or sash) is free. The cutter can be selected via the 4-position
selector switch (Cutter selection).
1 2
If the 2-position selector switch is set to Position "2" (Profile distinguishing
system), a frame cutter must be assigned to cutter position 1 and a sash cutter
must be assigned to cutter position 2.

Cutter positions 3 and 4 can be selected only via "Manual cutter selection" .

6.2.4 Profiling cutters

How a routing cutter set is put together depends on the particular profile.

Stop for the cutting depth

The relevant stop screw is positioned automatically by swivelling the stop plate
depending on cutter selection.
A stop screw is assigned to each cutter.
The stop screws are set at the works to a basic ø of 80 mm and may be readjusted
only if absolutely necessary, e.g. after grinding the routing cutters.
Should the routing cutters be ground, ensure that the diameters of the individual
routing cutters of a routing cutter set always have the same tatio with respect to
each other.

The screw can be adjusted

Stop after slackening the lock
Cutter 1 nut.
The cutter stroke is
reduced if the screw is
Stop
screwed out of the plate.
Cutter 2
The cutter stroke is
increased if the screw is
Stop screwed into the plate.
Cutter 3 You must retighten the lock
nut after making the
Stop adjustment.
Cutter 4

Manual 6-5
EV 834

The stops for the routing depth are set to a basic ø of 80 mm.
Consequently, the smallest routing cutter ø of a routing cutter set must be 80 mm.
The largest routing cutter ø may not exceed 260 mm.

Zero setting on basic ø 80 mm

(The feed cylinder is moved to stop position in this illustration.)

6-6 As per 09/03

 EV 834

6.2.5 Height-adjustable metal guard

The height-adjustable metal guard must be set so that the distance between
metal guard and upper edge of profile is maximum 5 mm with the frame fitted.

CAUTION

Correctly adjusting the

guard plate makes it
possible to prevent persons
placing their hands into the
machine either
unintentionally or in
unauthorised manner
during the work sequence.
Clamping Release the right-hand and
lever left-hand clamping lever
and the guard plate can
then be moved up or down
in the slots.
Firmly retighten the
clamping levers after height
adjustment.

Manual 6-7
EV 834

6.2.6 Profile feed-in mechanism

The frame resp. sash to be

machined and which has
been inserted by the
operator is fed into the
corner cleaning machine
via the feed-in unit.
The adjustable feed-in
arms allow percise feed-in
and optimum matching to
Feed-in arms
the profile structure.
The feed-in arms can be
adjusted in the slots of the
right-hand and left-hand
mounting brackets after
slackening the cheese-
head screws.

Mounting
bracket

Cheese-head
screw

6.2.7 Support arms

The adjustable support

arms allow optimum
matching to the frame resp.
sash size.

The support arms can be

swivelled towards the
inside or outside after
slackening the hexagon
nut.
The support arms can be
Hexagon bolt locked in position by
tightening the hexagon nut.
Hexagon nut

6-8 As per 09/03

 EV 834

6.2.8 Chip blow-off system

The nozzles of the chip

blow-off system should
always be aimed at the two
Nozzle
limit switches.

Contact face,
limit switch

6.2.9 Wipers

There are wipers, one between spindle 1 and 2 and one between spindle 3 and 4,
beneath the table so as to keep the running surface of the rotary table free of dirt
and swarf.

The height of these must

be set so that the side
plates are only just above
the baseplate.
However, the plates may
not contact when they turn.

Wipers
Securing In order to set them, undo
screws the two front securing
screws, set the wiper in the
slots to the appropriate
height and retighten the
securing screws.
Wiper plate

Manual 6-9
EV 834

6.2.10 Valve bank

The machine features a

valve bank. It is located at
the right-hand side of the
switch cabinet in the
Valve bank machine.

Please refer to the circuit

diagram for the valve
assignment and control
assignment.

6-10 As per 09/03

 EV 834

6.3 Fitting and changing the tools

6.3.1 Fitting and changing the profile cutters

Always switch off the master switch on the switch cabinet by setting it to
position "0" and lock it with a padlock to prevent it being switched back on again
before carrying out work of any nature on the milling spindle!

DANGER

Always wear protective gloves when changing the profiling cutters.

The profiling cutters can be changed as follows:

Clamping - Counter the spindle with
screw the supplied open-end
Spacer sleeve spanner.
- Slacken the clamping
screw with the sluppied
Profiling
chuck spanner.
cutter
- Detach the spacer sleeve
from the spindle.
Spacer disc
- Detach the profiling cutter
from the spindle.
- Change the spacer disc
beneath the profiling
cutter.
Chuck
spanner - Fit the new profiling cutter
on to the spindle.
- Fit the related spacer
Spindle
sleeve onto the spindle.
- Screw the clamping
screw onto the spindle
and tighten it with the
chuck spanner.

Open-end
spanner

Always change the entire set of tools (spacer sleeve + profiling cutter + spacer
disc).
CAUTION

Manual 6-11
EV 834

6.3.2 Fitting and changing the grooving knives

The double-edges grooving knives can be turned through 180° about their
longitudinal axis and can thus be used on both sides.

The grooving knives are clamped with two grub screws in their guide in the blade
holder.
The grooving knife can be changed as follows:

Upper cleaning arm

Grub screws

Grooving
knife, upper
cleaning arm

- Undo the grub screws

(access can be gained to
the grub screws from the
Recess
top through the recess in
the upper cleaning arm).
- Pull the old grooving knife
Grub screw out of the guide.
- Slide the new grooving
knife into the guide and
align it.
- Retighten the grub
screws.

6-12 As per 09/03

 EV 834

Bottom cleaning arm

Grooving
knife, bottom
cleaning arm

Grub screws
- Undo the grub screws
(access can be gained to
the grub screws from
below through the recess
in the bottom cleaning
Grub screws arm).
- Pull the old grooving knife
out of the guide.
- Slide the new grooving
knife into the guide and
Recess
align it.
- Retighten the grub
screws.

Manual 6-13
EV 834

6.4 Work sequence

Never work without the protective equipment and never work without the material
being properly clamped.

DANGER

Work sequence with profile distinguishing system switched on

1. Switch on the master switch.
2. Press key ("Control ON").

3. Set the 2-position selector switch ("Manual cutter selection / Profile

1 2
distinguishing system") to position "2" .
Cutter positions 1 and 2 are activated automatically.

4. Set the 4-position selector switch ("Cleaning knife") to the required

position.

5. Press key ("Motor ON").

6. Insert the workpiece with the first outer corner to be machined into the feed-in
zone in such a manner that it contacts the stop faces and so that the limit
switches are actuated.
The workpiece is then clamped and the automatic work sequence commences.
7. When the work sequence is complete, repeat the procedure until all outer
corners have fully machined.

8. Key ("Motor OFF") switches off the cutter motor.

Work sequence with manual cutter selection

1. Switch on the master switch.
2. Press key ("Control ON").

3. Set the 2-position selector switch ("Manual cutter selection / Profile

distinguishing system" to position "1" .

4. Set the 4-position selector switch ("Cutter selection") to the required

position.

5. Set the 4-position selector switch ("Cleaning knife") to the required

position.

6. Press key ("Motor ON").

7. Insert the workpiece with the first outer corner to be machined into the feed-in
zone in such a manner that it contacts the contact faces and so that the limit
switches are actuated.
The workpiece is then clamped and the automatic work sequence commences.
8. When the work sequence is complete, repeat the procedure until all outer
corners have been fully machined.

9. Key ("Motor OFF") switches off the cutter motor.

6-14 As per 09/03

 EV 834

Work sequence without outer contour machining

1. Press key ("Motor OFF").

2. Set the 4-position selector switch ("Cleaning knife") to the required

position.
3. Insert the workpiece with the first outer corner to be machined into the feed-in
zone in such a manner that it contacts the stop faces and so that the limit
switches are actuated.
The workpiece is then clamped and the automatic work sequence commences.
4. When the work sequence is complete, repeat the procedure until all outer
corners have been fully machined.

If you wish to abort a work sequence once it has been started, you must press the
EMERGENCY-STOP button.
If the EMERGENCY-STOP switch is pressed, the motor switches off, the units
return to Home position and the workholders open.

6.5 Faults and malfunctions

Fault Possible cause Remedy

Cutter does not turn
- Motor does not operate
- Rough surface during outer
contour machining
- Rough surface during
cleaning
- No mains power supply
- Cutter is blunt
- Grooving knife is blunt
- Check mains connection
- Check fuses
- Exchange cutter
- Turn the grooving knife
through 180° or change it

Manual 6-15
EV 834

6-16 As per 09/03

 EV 834

7 Maintenance, servicing and cleaning

• Work on the electrical system and pneumatic system may only be carried out
by a qualified specialist.

• Before carrying out maintenance work or cleaning work of any nature, please
DANGER
lock the machine to ensure that it cannot be switched back on again by
unauthorised persons. Always disconnect the machine from the electrical
power supply and pneumatic network.

• Please always follow the mandatory directives and legislation when carrying
out maintenance and cleaning work of any nature.

• Adjustment work must be carried out by authorised personnel.

7.1 Maintenance and servicing

7.1.1 Conditioning unit

The water separator must be drained regularly since this could otherwise result in
discharge disturbances.

WARNING

In order to drain the water separator,

you must push the black screw union
(H) beneath the sight glass (F) up
until the sight glass is empty.

Manual 7-1
EV 834

7.1.2 Checking and tensioning the V-belts

The V-belt tension should be checked every six months as follows and the V-belt
should be re-tensioned if necessary:

Checking:
- Remove the cover.
- Check the V-belt tension
Securing by pressing your thumb
screws agaist the V-belt
(it should be possible to
deflect the V-bet by
approx. 10 mm).
Adjusting nut

Threaded
spindle

Re-tensioning:
- Slacken the four securing screws on the motor bracket.
- The V-belt can be tensioned by pulling the motor bracket back.
Adjustment can be performed using the threaded spindle with the adjusting nut.
The lock nut on the opposite housing wall must be slackened beforehand.
Retighten the lock nut after adjustment.
- Retighten the four securing screws on the motor bracket.

The V-belts between milling spindle 1 and milling spindle 2 resp. between milling
spindle 3 and milling spindle 4 can be re-tensioned by adjusting the relevant idler
pulley.
In order to do this, slacken the securing screws of the pulley mount on the
turntable. Adjust the pulleys in the slots of the pulley mount. It is absolutely
essential that the securing screws be firmly retightened again after adjustment.

7.1.3 Lubrication
Clean all guide shafts monthly with an oil-soaked cleaning cloth.

7-2 As per 09/03

 EV 834

7.1.4 Maintenance

Components Maintenance work

Pneumatic system
- Lines - Visually inspect for cracks and porous points.
- Screw unions - Check that unions are firmly tightened and check
for leaks.
- Water separator - Check the water level and drain if necessary.
- Check for leaks.
Electrical system
- Cables - Visually inspect for damage.
- Screwed glands - Check that the screwed glands are firmly tightened.
Clamping cylinders - Check for leaks.
- Inspect clamping buffers for damage.
V-belts - Visually inspect for damage
(if damage has occurred, exchange immediately!).
- Check the belt tnsion and retension the belts
if necessary.

7.2 Cleaning work

Clean the entire machine with compressed air after each shift.
When fitting or replacing cutters, please clean the parts to be fitted in order to
remove swarf and dust residue.
Clean the machine surface frequently with a non-corrosive cleaning agent in order
to remove lubricant and dust deposits.

7.3 After-sales service

If necessary, our After-Sales Service Department can assist you.
You can contact us at the address below:

Address:
®

Maschinenfabrik
elumatec GmbH
Pinacher Str. 61
D 75417 Mühlacker

Telephone:
Switchboard: +49 (0) 70 41 / 14-0
After-Sales Service: +49 (0) 70 41 / 14-250
Fax: +49 (0) 70 41 / 14-280

Manual 7-3
EV 834

7-4 As per 09/03

 EV 834

8 Spare parts list and list of parts subject to wear

Manual 8-1
EV 834

8-2 As per 09/03

 EV 834

A Annex

A.1 Electrical circuit diagram

A.2 Pneumatic circuit diagram

A.3 Noise emission values

Manual A-1
EV 834

A-2 As per 09/03

 EV 834

Noise emission values

elumatec Corner cleaning machine Type: EV 834

The workplace–specific emission value LpA, determined in accordance with

DIN EN ISO 11202, supplemented by CEN -TC 142, is as follows:
Idling ..........69,6 dB(A)
Operating noise ..........80,4 dB(A)
The measurement uncertainty constant K is 4 dB (A).

The following supplements, stipulated by CEN - TC142, have been allowed for
in order to obtain an accuracy class better than 3 dB:
− The ambient correction factor K3A is ≤ 4 dB
− The difference between background noise sound pressure level and noise
sound pressure level at each measuring point is ≥ 6 dB

Allowing for ISO 7960, Sections 0 to 4, the machine-specific measurement

conditions were as follows:
Cutter: 95 mm x 65 mm Teeth: 4 n=3400 rpm.
Workpiece: PVC - profile
Microphone position: 1m away at central position in front of the machine at a
height of 1,5m.

Note
The values specified above are emission values and thus do not necessarily also represent
safe workstation values. Since there is no correlation between emission values and
workstation values, these figures cannot be used reliably to determine whether or not further
precautions are necessary. Factors which may influence the currant workstation value include
the duration of exposure, the characteristics of the work room or area, other noise source, the
number of machines and other neighbouring influences. The reliable workstation values may
also vary from country to country. However, the above information is intendend to allow the
user to better estimate potential danger and risk.

Noise emission values

 Artikelnummer Bezeichnung 1 Bezeichnung 2
8341080001Z ETK EV 834
041160303 Proximity sensor M8‐plug SME‐8M‐ZS‐24V‐K0.06‐M8‐SA
041160634 Connecting cable 3‐pol. M8 5m NEBU‐M8G3‐K‐5‐LE3, GD
041213801 Silencer G1/8 L=35,9mm U‐1/8 (plastic)
041215603 Rod clevis SG‐M20x1,5
041216007 Manometer d=40mm 16bar G1/8 MA‐40‐16‐1/8
0412170228 Cylinder D16 S185 DSNU‐16‐185‐P‐A
0412170280 Cylinder D80 S320 DNC‐80‐320‐PPV‐A‐SA236145A
041217066 Cylinder D20 S10 DSNU‐20‐10‐P‐A
0412171134 2/2‐Start valve 60%p HEL‐D‐MINI‐SA2355556A
041219022 PE converter 3,7bar 2,5m 2x0,75 rising NO
070108203Z Clamping lever M6x15, size 1 (4 pieces)
070108204Z Clamping lever M6x15, size 1 (8 pieces)
070108205Z Clamping lever M6x15, size 1 (12 pieces)
070123001 Hinged spray head
070164912 Contactor 24V= 4kW 3H1B LP1‐K0910BD3
070216000 Manometer 0‐10bar DIA40 G1/8 111.40.10, KZ8813
072160314 Motor protec. switch 6‐10A GV2‐ME14
076108201Z Illuminated press button green
078218300 Air reservoir f. SK‐1/4 semiautom. PL16996 ‐H
079108206Z Emergency stop button
079108207Z P
Press button black
b tt bl k
079108212Z Service unit 1/4 left
101162703 Fuse terminal 6,3x32 600V10A WK4/THSi6,3x32U
103165004 Power pack NTG 30‐24‐5 24VDC/5A
104108215Z Fuse 6,3x32 2A 500V slow (10 pieces)
104160310 Main switch 25A VCD‐0 emergency shoutdown
104160609 Solenoid valve plug 180° LED+ protec. circuit, 2,5m 3x0,75
104166107 5/2 Direct. control valve 1/8 24Vdc, S9 581‐1/8, pulsed
104166108 5/2 Direct. control valve 1/8 24Vdc, spring‐b., S9 581RF‐1/8
104166110 5/3 Direct. control valve 1/8 24Vdc, S9 581RFG‐1/8
105100300Z Snap switch
133160301 Cylinder proximity switch RS‐S KL3046 with plug, make
150166101 3/2 Direct. control valve 1/8 24Vdc, S9 381RF‐1/8‐NG
250217103 5/2 Direct. control valve 1/8 pneum., pulsed, S9 561‐1/8
605830001 Ball bearing 6006 DDU  DIN 625 grease: AV2S, d30 D55 L13
834101150Z Safety position switch
834101151Z Safety position switch
834102050Z Ball bearing
834102051Z Cylinder D50 H200
834169250Z Illuminated press button
834169251Z Selector switch head
834261301 Distance washer D45 d32 L0,2
834261302 Distance washer D45 d32 L0,5
834261303 Distance washer D45 d32 L1
834261304 Distance washer D45 d32 L5
834261305 Distance washer D45 d32 L10
834261306 Distance washer D45 d32 L30
834382101 Keyway cutterbar 2,8x0,5 for chamfer