Nogval B22 ZERO Operation Manuals

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MANUAL BEVELLING AND

DEBURRING SYSTEM B22

ZERO

Ord.no. 27 220

Operation manual for the device

SUBJECT TO CHANGE

C. Borges Blanques nº 38 P.I. La Borda 08140 Caldes de Montbui (Barcelona) Tel.: 0034 93 865 35 68 E-mail: info@nogval.com

MAQUINARIA NOGVAL S.L.

Contents:

General information

Machine description B22 ZERO

Identification data

Reference standards

Tests

Warranties

Safety regulations

Technical specifications

Accessories

Machine equipment

Control elements B22 ZERO

Use

Bevel angle adjustment

Setting the bevel height - reduction

Bevelling

Machining 0° - FACING

Pipe bevelling

Additional handle

Replacement of indexable inserts

Replacement of milling head – tools

Maintenance and operation

Spare parts

List of spare parts

19 - 25

Read the operation manual carefully prior to use

1. General information

Thank you for purchasing one of our machines, and we hope that you will be fully satisfied.

This guide provides instructions for the installation, adjustment, operation and maintenance of the machine B22 ZERO in compliance with valid safety standards.

The information and data contained in this document subject to changes due to further improvement of machinery. To eliminate any doubts, when differences are detected, please contact N.KO Machines.

Never perform any operation on the machine before you read the instructions in the manual and understand them. Major part of accidents that happen in the workplace are due to the fact that the guidelines and recommendations contained in the manual are not complied with.

The graphic symbols used in the manual are intended to emphasize the important information regarding the safety and operation of the machine.

Attention :

Information important for the personal safety of the operating staff.

Important:

Instruction that needs to be observed to ensure the proper function of the machine.

2. Machine description B22 ZERO

Machine B22 ZERO is designed solely for the activities below: B22 ZERO is designed solely for bevelling, fetch fettling, and the removal of material layer on the workpiece edge occurred during the sheet metal removal by soldering – i.e. FACING. To be performed solely on metal materials in the workshop in the production hall. This includes manual and manually managed machine. The main feature of the machine

is the ability to machine flat and shaped workpieces, profiles, and tubes. The machining angle can be changed without the necessity to use any tools. Use the machine in the environment protected from rain, snow, and other adverse weather conditions.

3. Identification data

The identification data of machine B22 ZERO are listed on the label placed on the motor unit.

3.1. Reference standards (CE Declaration of Conformity)

3.2 Device construction as regards safe operation

Device B22 ZERO fulfils the below statements:

• The tools are constructed and covered to ensure sufficient protection from random contact with life parts.

• The tools in case of common load do not reach excessive temperatures.

• The tool cover provides sufficient level of protection from moisture in compliance with the tools’ classification.

• The tools are constructed in such way the fire hazard, mechanical damage with negative effects on safety or

injury from electrical current was eliminated at the highest achievable level due to abnormal activity.

• The handles are shaped and placed in such way to minimize the hazard of accidental hand contact of the

user with rotary parts.

• The tools have sufficient mechanical solidity and it is constructed to be resistant to rough treatment which

can be expected during common use.

• The parts used for the provision of required level of protection from moisture cannot be removed without the

tool.

• The tools construction does not include asbestos.

• Parts difficult to remove which provide required level of protection from electrical current injury, from

moisture, and from contact with moving parts are reliably attached and resistant to mechanical load which occurs during common use.

• The handles, buttons, grips, levers, and similar parts are reliably attached to prevent releasing during

common use, if such release could cause danger.

• Parts conducting current and other parts where corrosion could cause hazards, are resistant to corrosion.

• The shafts of the control buttons, grips, levers, and similar parts are not live parts.

• The conductors are protected to prevent the contact with burrs, cooling ribs, etc. which could cause damage

to the insulation of conductors.

• The openings in the metal with passing insulated conductors are fitted with bushing, they are smooth and

with well rounded edges.

• The conductors are effectively protected from contact with moving parts.

• The internal lines and electrical connections between various parts of the tools are sufficiently protected or

covered.

• For indoor lines there are no aluminium conductors. Winding is not considered to be internal line.

• The parts comply with the safety requirements defined in the respective standards IEC within the scope

efficient for the application of the standards.

• If the parts include indicated work characteristics, the conditions for the use of the parts in the tools must

comply with this marking, unless special exception is defined.

• The tools do not include:

- switches or automatic control devices in the moving supplies, RCD are permitted;

- the devices which in case of the tools defect activate the safety device in fixed electrical line;

- thermal fuses which can be again set to the original state by soldering.

• The external parts from non-metal material, part from insulating material which maintain live parts including

the electrical connections in the defined position, and parts from thermoplastic material providing additional insulation or reinforced insulation which in case of damage could cause the tools incompliant with the requirements of the standard, must be sufficiently resistant to heat.

• The tools do not emit hazardous radiation and it does not represent toxic or similar hazard.

4. Tests

The machine for edges bevelling is tested in our test room.

During that test, the correct function of bevelling sheets and profiles by different types and sizes, are tested.

5. Warranties

The B22 ZERO is provided by the seller with a guarantee that the article shall not feature any material and production defects for a period of 12 months following the delivery date.

The machine is provided with a 12-months' guarantee from the delivery date for the faultless function of the article and the materials used.

The seller undertakes to make sure that any potential warranty defects are removed free of charge and without undue delay so that the buyer is able to use the article the way they desire. Should the buyer claim liability for warranty-unrelated defects, it shall reimburse the seller for any expenses associated with that.

The manufacturer considers the guarantee invalid if:

• the machine is improperly used.

• used in conflict with national or international standards

• improper installation

• Defective supply of compressed air or its adverse quality

• severe shortcomings in maintenance

• unauthorised modifications or interventions

• other than the original or unapproved parts and accessories by the

manufacturer are used for that model;

• full or partial failure to follow the instructions in this manual

• extraordinary events, natural disasters or the like.

6. Safety regulations

Attention :

In order to prevent the injury observe the below instructions

Inspect the machine for mechanical and other damage prior to use. Stroj uvádějte do provozu jen v případě, že není nijak poškozen přívodní napájecí kabel. Check the supply cord regularly. In case of damage have it replaced in an authorised service shop authorised to perform the such repairs. Contact your supplier.

Personal protection from injury During the work use safety goggles, solid work footwear, hearing protection, suitable head cover, e.g. safety helmet.

• Connect the machine in electrical network solely if the machine is in off position.

• Prior to each use, check the device and supply cord for damage. Do not use the

machine in case of any damage.

• Do not use the machine in humid environment and protect from high

moisture.

• Ensure good lighting at the workplace to prevent the risk of potential injury or

eyesight damage.

• Caution, the tool (milling machine) is sharp with the risk of injury. During the

replacement use safety gloves, never touch the tool which moves.

• The machined material must always be fastened and horizontal. Optimum

workpiece height is 900 mm above ground.

• Pay attention to the supply cable during work. It should be loosely placed on the

ground outside the worked material and other sharp objects.

• After work, disconnect equipment from the electricity supply.

• Do not overload the machine motor. The machine operates better if not

overloaded.

• During work, hold the device by both hands.

• Attention is drawn to the injury hazard with hot metal shavings.

Attention :

During work, hold the device by both hands. The switch must be within the reach of left hand of the machine operation employee, see figure 6.0.1.

Fig. 6.0.1

Important:

In case of damage have the machine repaired in an authorised service shop authorised to perform the repairs. For more information on, contact your supplier.

7. Technical specifications

Bevel angle

Infinitely adjustable within the range from 0° to 60°

Bevel width

0 to 20 mm < 400N/mm2 - 0 to 16 mm > 400N/mm2

Machining width for FACING

22mm

Motor

Electric 400V 1,1 kW / 50Hz, 480V 1,3kW / 60Hz, 3x 220V 1,1kW / 60Hz

Motor power

1,1kW (400V) / 1,3kW (480V)

Revolutions

2850 rpm (50Hz) / 3420 rpm (60Hz)

Weight

19.5 kg

Number of indexable inserts

10 pcs

8. Accessories

Milling head STANDARD (incl. inserts, screws)

29 201

Milling head PREMIUM for stainless steel (incl. inserts, screws)

29 202

Cutting plates STANDARD

29 203

Cutting plates PREMIUM for stainless steel and head 29 202

29 205

Adapter for tube and pipe bevelling

29 204

Additional handle

29 206

9. Machine equipment

Unpack the machine from the cardboard and check if the machine is ok and free from damage. If necessary contact the seller. Machine B22 ZERO is supplied with required tools for the operation without the connection socket. It is necessary to assemble the respective socket according to the standards and regulations of the respective country.

10. Control elements B22 ZERO

Fig.10.0.1

Main switch

Reduction size control rosette

Reduction size scale for 60° and 50°

Reduction size indicator for 60° and 50°

Handrail

Left scale for setting the bevel angle

Bevel angle arresting

Reduction size indicator for 45° and 30°

Reduction size scale for 45° and 30°

Reduction size setting arresting

Right scale for setting the bevel angle

11. Use

Attention :

During the adjustment operation, wear gloves and other personal protective equipment. The operations must be carried out on the machine at rest and after disconnecting from the power supply.

11.1. Bevel angle adjustment

• Disconnect the machine from electricity supply.

• Release the setting arresting lever (fig.10.0.1 position G)

• By gradual tilting of rulers set the required machining angle. You can reduce

the value on the angle setting scale (fig.10.0.1 position F and K).

• After setting, re-fasten the arresting lever (fig.10.0.1 position G).

11.2. Bevel height adjustment

• Disconnect the machine from electricity supply.

• Release the setting arresting lever (fig.10.0.1 position J)

• Turn the rosette (fig.10.0.1 position B) for setting the reduction size. Actual setting is

displayed on the scales on both electrical wiring sides (fig.10.0.1 position I and C) by means of composite indicators (fig.10.0.1 position H and D) The scale is used for

orientation reading of the bevel height value (dimension A fig.11.2.2) for angles 30°, 45° onone and 50° and 60° on the other bonnet side (fig.11.2.1). Setting for other

angles must be estimated.

• After setting, re-fasten the arresting lever (fig.10.0.1 position J).

11.2.1

Important:

Maximum bevel width for machine B22 ZERO - 20mm (dimension P fig.11.2.2). It is necessary to be aware that the scales (fig. 10.0.1 pos.I and C and fig.

11.2.1) are for setting the bevel height (dimension A fig.11.2.2) Maximum possible reduction can be achieved solely in more reductions. It depends on the bevel angle and material solidity. We recommend performing the test.

Start with lower reduction and gradually increase the value until the work with the machine is comfortable and the plates can achieve gradually reduction without increased vibrations. In order to achieve the maximum machining regardless the bevel we recommend proceeding according to table (fig. 11.2.2).

We recommend administering the work log for recording the measured value and the machining procedure.

Fig. 11.2.2

Chip no.

max P

Bevel height A

Number of recommended reductions

30°

20mm

17mm

3 reductions

45°

20mm

14mm

4 reductions

50°

20mm

13mm

4 reductions

60°

20mm

10mm

5 reductions

Important:

The machine was constructed for the preparation of welded surfaces. Machining accuracy is within limit +/-1mm. The condition for reaching the satisfactory results is a perfect preparation of the material edges. Unfortunately the material is often burned or cut. The inaccuracy shall be reflected on the resulting accuracy and quality of machining.

Important:

If it is difficult to machine the bevel within the recommended number of steps, we recommend dividing the process to more chips. The reason can be the wear of the cutting inserts or worse machining properties of material.

11. 3. Bevelling

Important:

The device can be used solely if it is fitted with the original indexable inserts supplied by our supplier, i.e. the device manufacturer. It includes four-sided indexable inserts (order no. 29 203). The device can be fitted with 10 pieces of indexable inserts. We do not recommend using other than original inserts.

• Connect the machine to electricity supply.

• Attach the adjusted machine on the material side in such way the horizontal and

vertical guiding bar is in contact with material.

• Grip the machine in the handle area and start gradually shifting from the right to the

left (fig. 11.3.1). Be aware that at the start of machining when the vertical and horizontal bars are not in contact with material with the whole length, the machine is more susceptive to vibrations. and it is less stable. Proceed with care. The same effect occurs at the end of the material during the machine extraction from the reduction.

• Slowly move the machine to the material until you feel the milling machine is in

reduction. CAUTION!!! The rebound is possible at this moment, be careful.

• Shift the machine alongside material constantly, using only such speed the

milling machine was able to remove material in the set chip profile. Otherwise, the milling machine will be pushed out from the material and the bevel will be unequal.

Fig.11.3.1

11. 4. Machining the material edge under angle 0° - FACING

• Set the working angle 0° on the machine

• Fit the milling machine outside the working zone in order to prevent contact.

with material at the moment of loading the machine on sheet metal. Proceed according the chapters 11.2

• Connect the machine to electricity supply.

• Fit the machine on material at any part of its length. Horizontal and vertical guiding

bar must be in contact with material at its whole length.

• Switch on the machine and slowly turn the bevel size setting (fig.10.0.1 position B)

with the control rosette to bring the milling machine closer to the material. At the moment you hear the contact of the milling machine with material occurred, stop turning the rosette (fig.10.0.1 position B) and secure the position with the arresting lever (fig.10.0.1 position J).

• Remove the machine from the material. Now release the arresting lever

(fig.10.0.1 position J) and set the required depth of machining with the rosette (fig.10.0.1 position B). It commonly set to 1-2mm. The setting size must be estimated. There is no scale. Set the machining size when the machine can be safely shifted alongside the material.

• Attach the machine on the material side in such way the horizontal and

vertical guiding bar is in contact with material (fig.11.4.1.).

• Grip the machine in the handle area and start gradually shifting from the right to the

left. Be aware that at the start of machining when the vertical and horizontal bars are not in contact with material with the whole length, the machine is more susceptive to vibrations and generally less stable. Proceed with care. The same effect occurs at the end of the material during the machine extraction from the reduction (fig.11.4.1.).

• Slowly move the machine to the material until you feel the milling machine is in

reduction. CAUTION!!! The rebound is possible at this moment, be careful.

• Shift the machine alongside material constantly; using only such speed the milling

machine was able to remove material in the set machining depth. Otherwise, the milling machine will be pushed out from the material and the machining shall be unequal.

Fig. 11.4.1

Attention :

During work, wear gloves and other personal protective equipment.

The maintenance operations must be carried out on the machine at rest and after disconnecting from electricity supply.

Important:

The shift during machining is always from right to the left.

Attention :

The device operators must hold the device with both hands. When the milling machine starts machining, the rebound is possible! Hold the device solidly and set only such bevel size to keep the machine under control. The switch must be within the reach of left hand of the machine operation employee, see figure

6.0.1.

11.5 Tube and pipe bevelling

Machine B22 is constructed for machining the tubes and pipes from minimum diameter Ø150mm. It is provided by a special tube preparation which must be assembled on the machine. Order no. 29 204. Assemble the preparation on the machine instead of horizontal ruler, as follows:

• Disconnect the machine from electricity supply.

• Unscrew 4 socket head screws (fig.11.5.1 position B) and disassemble the

basic horizontal ruler (fig.11.5.1 position A)

• Instead assemble the device on the tubes (fig.11.5.1 position C). Use original socket

head screws.

Fig. 11.5.1

The preparation adjustment procedure on the tubes and bevelling the tubes:

• Release both arresting levers of the preparation rolls position adjustment on

the tubes (fig.11.5.2 position N) and set the suitable position according to the diameter of worked tube in such way the machine touches the tube periphery with the rulers and both rolls at the same time.

• Setting the bevel size and perform the machining angle according to former

chapters 11.1 and 11.2

• Connect the machine to the electricity supply and switch on the main

switch (fig.10.1.1 position A)

• Fit the machine on the tube in position according to the figure (fig.11.5.2 and

11.5.3) and apply gradual pressure to press the material in full profile of the set machining. Pay attention to the rebound!

• Start shifting the machine around the tube clockwise so both guiding rolls and

the centres of both rulers are in permanent contact with the tube. Otherwise, the bevel shall not be balanced.

Fig. 11.5.2

Fig. 11.5.3

Attention :

During the adjustment operation, wear gloves and other personal protective equipment. The operations must be carried out on the machine at rest and after disconnecting from the power supply.

11.6 Use the additional handle

It is possible to buy additional handle to the machine to improve the ergonomics of the machine and achieve higher production rate. The work with the machine is also more comfortable. The handle is always assembled under the machine safety frame screws (fig.11.6.1 position A) and it can be assembled in four positions to enable simple work with the machine in every position, see fig. 11.6.1.

Fig. 11.6.1

12. Machine maintenance:

12.1 Replacement of indexable inserts and milling machine

Important:

Work solely with sharp and not damaged indexable inserts. It prevents the machine damage. If the cutting inserts are worn or damaged, they must be replaced.

Important:

Replacement of indexable inserts:

• Disconnect the machine from electricity supply.

• Set the machine into the vertical position on the motor fan cover.

• Completely unscrew the arresting lever for the reduction size setting (fig. 12.1.1

position J) and extract the screw completely from the machine.

• Dismantle the whole set of the machine bonnet.

• Attach the wrench (fig. 12.1.2 position A) release individual plates (fig. 12.1.2 position

B) and replace it with new ones.

• Reset the machine in the opposite

process Fig. 12.1.1

Fig. 12.1.2

Dismantling the milling head (tool):

• Disconnect the machine from electricity supply.

• Set the machine into the vertical position on the motor fan cover.

• Completely unscrew the arresting lever for the reduction size setting (fig. 12.1.1

position J) and extract the screw completely from the machine.

• Dismantle the whole set of the machine bonnet (fig. 12.1.1)

• Attach the side wrench to secure the milling machine against turning. (Fig. 12.1.3

position M)

• Attach the socket head screw and release and completely unscrew the

attachment screw (fig. 12.1.3 position L)

• Remove the milling machine from the shaft with hand or suitable

removal preparation. Fig. 12.1.3

12.2 Maintenance and cleaning

Machine B22 ZERO is a very simple construction and it does not require complicated maintenance. Keep the machine, mechanical moving parts, threads, and tools clean.

Work solely with sharp and not damaged and complete tools.

Important:

The moving parts, threads, and rolls must be gradually cleaned using compressed, and must be preserved (greased).

Attention :

When using compressed air for cleaning, wear safety goggles and never use a pressure exceeding 2 bar.

13. Spare parts and electric connections

Orders of spare parts shall contain the following information:

• machine type;

• serial number;

• Description of required part and its number

• quantity.