User manual spindle moulder F 3 e-classic...when using, maintaining or repairing the machine. Attention! Risk of material damage! The machine must be inspected immediately upon arrival.

Keep this manual handy and in good condition for continual reference!

Dok.ID: 503010-907_02 • Englisch • 2015-09-04

User manual

spindle moulderF 3 e-classic

(Translation)

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Spindle moulderF 3 e-classic

Note: Year of constructionThe machine number of this machine will be printed on the cover sheet of this operating manual. The final two digits of the machine number show the year of construction of this machine.e.g. XXX.XX.XXX.14 -> Year of manufacture 2014

Important Notices!Please note, that depending on the model of the machine, not all described functions are present, or additional functions and buttons are available (e.g. machines with special functions).

For the safety of all personnel, it is necessary to study this manual thoroughly before assembly and operation. This manual must be kept in good condition and should be considered as part of the machine. Furthermore, the manual must be kept to hand and within the vicinity of the machine so that it is accessible to operators when using, maintaining or repairing the machine.

Attention! Risk of material damage! The machine must be inspected immediately upon arrival. If the machine has been damaged during transport, or if any parts are missing, a written record of the problems must be submitted to the forwarding agent and a damage report compiled. Also be sure to notify your supplier imme-diately.

© Felder KGKR-FELDER-STR 1A-6060 Hall in Tirol

Tel. +43 (0) 5223 45 0 90Fax. +43 (0) 5223 45 0 99

E-Mail: [email protected]: www.hammer.at

HAMMER A product of the FELDER GROUP!

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Table of contents

1 General .......................................................................................................... 61.1 Symbol legend ...............................................................................................................61.2 Information about the manual ..........................................................................................61.3 Copyright ......................................................................................................................61.4 Liability and warranty .....................................................................................................71.5 Warranty notice .............................................................................................................71.6 Spare parts ...................................................................................................................71.7 Disposal ........................................................................................................................7

2 Safety ............................................................................................................ 82.1 Intended use ..................................................................................................................82.2 Manual contents ............................................................................................................82.3 Making changes and modifications to the machine.............................................................82.4 Responsibilities of the operator .........................................................................................92.5 Personnel requirements ....................................................................................................92.6 Work safety ..................................................................................................................92.7 Personal protective equipment ........................................................................................102.8 Machine hazards .........................................................................................................102.9 Other risks ..................................................................................................................112.10 Battery safety instructions ............................................................................................11

3 Technical specifications .................................................................................. 123.1 Dimensions and weight .................................................................................................123.2 Operation and storage conditions ..................................................................................133.3 Electrical connection .....................................................................................................133.4 Drive motor .................................................................................................................133.5 Chip extraction ............................................................................................................133.6 Particle emission ..........................................................................................................143.7 Noise emission ............................................................................................................143.8 Tools ..........................................................................................................................15

4 Transport, packaging and storage ................................................................. 164.1 Safety instructions ........................................................................................................164.2 Transport inspection ......................................................................................................164.3 Packaging ...................................................................................................................164.4 Storage .......................................................................................................................174.5 Transport .....................................................................................................................17

4.5.1 Transport locking device .................................................................................................. 174.5.2 Transport with a crane ..................................................................................................... 184.5.3 Transport with a forklift truck............................................................................................. 184.5.4 Transport with a pallet jack .............................................................................................. 19

A product of the FELDER GROUP!

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5 Setup and installation ................................................................................... 205.1 Safety instructions ........................................................................................................205.2 Floor space requirement ................................................................................................205.3 Positioning and levelling the machine ..............................................................................215.4 Adjust the system handwheel .........................................................................................215.5 Chip extraction ............................................................................................................225.6 Electrical connection .....................................................................................................23

6 Assembly ..................................................................................................... 246.1 Overview F 3 e-classic ..................................................................................................246.2 Operation and display elements.....................................................................................246.3 Data plate ...................................................................................................................256.4 Safety devices .............................................................................................................26

6.4.1 Safety break switches ...................................................................................................... 266.4.2 Spindle moulder guard attachment .................................................................................... 266.4.3 Automatic braking system ................................................................................................ 27

7 Making adjustments and preparations - Spindle moulder unit ......................... 287.1 Safety instructions ........................................................................................................287.2 Adjusting the moulding height ........................................................................................287.3 Spindle moulder fence .................................................................................................29

7.3.1 Spindle moulder fence „220“ (Standard) ........................................................................... 297.3.2 Multi-adjustment system for the moulder fence (Option) ........................................................ 307.3.3 Spindle moulder guard attachment .................................................................................... 31

7.4 Safety bar guides (Option) ............................................................................................327.5 Tool changer ...............................................................................................................33

7.5.1 Prepare to change tooling ................................................................................................ 337.5.2 Mounting/removing/changing the spindle moulder tool ...................................................... 347.5.3 Prepare the machine to operate ........................................................................................ 35

7.6 Determining/adjusting the speed....................................................................................367.6.1 Establishing/setting the speed .......................................................................................... 367.6.2 Maximum spindle resiliance (rotation limit) ......................................................................... 377.6.3 Adjusting the moulder spindle rotation ............................................................................... 38

7.7 Sink the spindle moulder ...............................................................................................39

8 Operation - Spindle moulder unit .................................................................. 408.1 Safety instructions ........................................................................................................408.2 Switching on the machine / Switching off the machine / Emergency-stop ............................418.3 Working techniques ......................................................................................................42

8.3.1 Work stations ................................................................................................................. 428.3.2 Authorised working techniques ......................................................................................... 428.3.3 Prohibited working techniques .......................................................................................... 428.3.4 General procedures for authorised working techniques ........................................................ 438.3.5 Moulding long sides and profiles ...................................................................................... 438.3.6 Insert moulding ............................................................................................................... 448.3.7 Curve moulding .............................................................................................................. 458.3.8 Moulding with a high velocity spindle ............................................................................... 468.3.9 Moulding with a power feeder ......................................................................................... 47

Table of contents

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9 Service ......................................................................................................... 489.1 Safety instructions ........................................................................................................489.2 Maintenance schedule ..................................................................................................489.3 General maintenance instructions ...................................................................................49

9.3.1 Belt tension .................................................................................................................... 499.3.2 Cleaning and lubrication ................................................................................................. 49

9.4 Maintenance work - Spindle moulder unit ........................................................................509.4.1 Greasing height spindle and height guide .......................................................................... 50

10 Faults ......................................................................................................... 5210.1 Safety instructions ......................................................................................................5210.2 What to do if a fault develops .....................................................................................5210.3 What to do after rectifying the fault ..............................................................................5210.4 Faults, causes and repairs ...........................................................................................53

11 Annex ........................................................................................................ 5411.1 Declaration of Conformity F 3 e-classic .........................................................................54

Table of contents

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1 General

1.1 Symbol legend

Important technical safety instructions in this manual are marked with symbols.These instructions for work safety must be followed.

In all these particular cases, special attention must be paid in order to avoid accidents, injury to persons or material damage.

Attention! Risk of material damage!This symbol marks instructions which, if not observed, may lead to material damage, functional failures and/or machine breakdown!

Warning! Risk of injury or death!This symbol marks instructions that must be followed in order to avoid harm to one‘s health, injuries, perma-nent impairment or death!

Warning! Danger! Electric current!This symbol warns of potentially dangerous situations relating to electric current. Not observing the safety instructions increases the risk of serious injury or death. All electrical repairs must be carried out by a qualified electrician!

General

1.2 Information about the manual

This manual describes how to operate the machine properly and safely. Be sure to follow the safety tips and instructions stated here as well as any local accident prevention regulations and general safety regulations.Before beginning any work on the machine, ensure that the manual, in particular the chapter entitled “Safety” and the respective safety guidelines, has been read in its

entirety and fully understood. This manual is an integral part of the machine and must therefore be kept in the direct vicinity of the machine and be accessible at all times. If the machine is sold, rented, lent or otherwise transferred to another party, the manual must accompany the machine.

1.3 Copyright

This manual should be handled confidentially. It is designated solely for those persons who work on or with the machine. All descriptions, texts, drawings, photos and other depictions are protected by copyright and other commercial laws. Illegal use of the materials is punishable by law.

This manual, in its entirety or parts thereof, may not be transferred to third parties or copied in any way or form, and its contents may not be used or otherwise communicated without the express written consent of the manufacturer. Infringement of these rights may lead to a demand for compensation or other applicable claims. We reserve all rights in exercising commercial protection laws.

Note:This symbol marks tips and information which should be observed to ensure efficient and failure-free operati-on of the machine.

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1.4 Liability and warranty

The contents and instructions in this manual have been compiled in consideration of current regulations and state-of-the-art technology as well as based on our know-how and experience acquired over many years. This manual must be read carefully before commencing any work on or with this machine. The manufacturer shall not be liable for damage and/or faults resulting from the dis-regard of instructions in the manual. The text and images do not necessarily represent the delivery contents. The images and graphics are not depicted on a 1:1

scale. The actual delivery contents are dependent on custom-build specifications, add-on options or recent technical modifications and may therefore deviate from the descriptions, instructions and images contained in the manual. Should any questions arise, please contact the manufacturer. We reserve the right to make technical modifications to the product in order to further improve user-friendliness and develop its functionality.

1.5 Warranty noticeThe guarantee period is in accordance with national guidelines. Details may be found on our website, www.felder-group.com

1.6 Spare parts

If unauthorised spare parts are fitted into the machine, all warranty, service, compensation and liability claims against the manufacturer and their contractors, dealers and representatives shall be rejected.

Use only genuine spare parts supplied by the manufac-turer.

1.7 Disposal

If the machine is to be disposed of, separate the compo-nents into the various materials groups in order to allow them to be reused or selectively disposed of. The whole structure is made of steel and can therefore be dis-mantled without problem. This material is also easy to dispose of and does not pol-

lute the environment or jeopardise public health. Interna-tional environmental regulations and local disposal laws must always be complied with.

General

Attention! Risk of material damage!Non genuine, counterfeit or faulty spare parts may result in damage, cause malfunction or complete break-down of the machine.

Note: The original spare parts that have been authorised for use are listed in a separate spare parts catalo-gue, enclosed in the documentation package supplied with the machine.

Attention! Used electrical materials, electronic components, lubricants and other auxiliary substances must be treated as hazardous waste and may only be disposed of by specialised, licensed firms.

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2 SafetyAt the time of its development and production, the machine was built in accordance with prevailing technological regulations and therefore conforms to industry safety standards.However, hazards may arise should the machine be operated by untrained personnel, used improperly or em-ployed for purposes other than those it was designed for. The chapter entitled “Safety” offers an overview of all the important safety considerations necessary to optimise

safety and ensure the safe and trouble-free operation of the machine.To further minimise risks, the other chapters of this manual contain specific safety instructions, all marked with symbols. Besides the various instructions, there are a number of pictograms, signs and labels affixed to the machine that must also be heeded. These must be kept visible and must not be removed.

2.1 Intended useThe machine described in this manual is intended solely for processing wood and similar machinable materials. Machining materials other than wood is only permitted with the express written consent of the manufacturer. Operational safety is guaranteed only when the machine is used for the intended purposes.The term “proper use” also refers to correctly observing

the operating conditions as well as the specifications and instructions in this manual.The machine may only be operated with parts and original accessories from the manufacturer.

2.2 Manual contentsAll those appointed to work on or with the machine must have fully read and understood the manual before commencing any work. This requirement must be met even if the appointed person is familiar with the operation of such a machine or a similar one, or has been trained by the manufacturer.Knowledge about the contents of this manual is a prere-

quisite for protecting personnel from hazards and avoi-ding mistakes so that the machine may be operated in a safe and trouble- free manner. It is recommended that the operator requests proof from the personnel that the contents of the manual have been read and understood.

2.3 Making changes and modifications to the machineIn order to minimise risks and to ensure optimal perfor-mance, it is strictly prohibited to alter, retrofit or modify the machine in any way without the express consent of the manufacturer.All the pictograms, signs and labels affixed to the

machine must be kept visible, readable and may not be removed. Pictograms, signs and labels that have become damaged or unreadable must be replaced promptly.

Safety

Attention! Any use outside of the machine‘s intended purpose shall be considered improper and is therefore not permitted. All claims regarding damage resulting from improper use that are made against the manufactu-rer and its authorised representatives shall be rejected. The operator shall be solely liable for any damage that results from improper use of the machine.

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2.4 Responsibilities of the operator

This manual must be kept in the immediate vicinity of the machine and be accessible at all times to all persons working on or with the machine. The machine may only be operated if it is in proper working order and in safe condition. The general condition of the machine must be controlled and the machine must be inspected for visible defects every time before it is switched on. All instruc-tions in this manual must be strictly followed without reservation.Besides the safety advice and instructions stated in this manual, it is necessary to consider and observe local

accident prevention regulations, general safety regula-tions as well as current environmental stipulations that apply to the operational range of the machine.The operator and designated personnel are responsible for the trouble-free operation of the machine as well as for clearly establishing who is in charge of installing, servicing, maintaining and cleaning the machine. Machines, tools and accessories must be kept out of the reach of children.

2.5 Personnel requirementsOnly authorised and trained personnel may work on and with the machine. Personnel must be briefed about all functions and potential dangers of the machine. “Spe-cialist staff“ is a term that refers to those who – due to their professional training, know-how, experience, and knowledge of relevant regulations – are in a position to assess delegated tasks and recognise potential risks. If the personnel lack the necessary knowledge for wor-king on or with the machine, they must first be trained. Responsibility for working with the machine (installation, service, maintenance, overhaul) must be clearly defined and strictly observed. Only those persons who can be expected to carry out their work reliably may be given permission to work on or with the machine. Personnel

must refrain from working in ways that could harm others, the environment or the machine itself. It is absolu-tely forbidden for anyone who is under the influence of drugs, alcohol or reaction-impairing medication to work on or with the machine. When appointing personnel to work on the machine, it is necessary to observe all local regulations regarding age and professional status. The user is also responsible for ensuring that unauthorised persons remain at a safe distance from the machine. Personnel are obliged to immediately report any irregu-larities with the machine that might compromise safety to the operator.

2.6 Work safetyFollowing the safety advice and instructions given in this manual can prevent bodily injury and material damage while working on and with the machine. Failure to observe these instructions can lead to bodily injury and damage to or destruction of the machine. Disregard of the safety advice and instructions given in this manual

as well as the accident prevention regulations and gene-ral safety regulations applicable to the operative range of the machine shall release the manufacturer and their authorised representatives from any liability and from all compensation claims.

Safety

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2.7 Personal protective equipment

When working on or with the machine, the following must be strictly observed:

Protective clothesSturdy, tight-fitting clothing (tear-resistant, no wide sleeves, no jewellery (rings, bracelets, necklaces, etc.)).

Persons with long hair who are not wearing a hairnet are not permitted to work on or with the machine!

It is prohibited to wear gloves while working on or with the machine.

When working on or with the machine, the following must always be worn by personnel:

Protective footwearTo protect the feet from heavy falling objects and prevent sliding on slippery floors

Hearing protectionTo protect against loss of hearing

2.8 Machine hazardsThe machine has undergone a hazard analysis. The design and construction of the machine are based on the results of this analysis and correspond to state-of-the-art technology.The machine is considered operationally safe when used

properly.Nevertheless, there are some remaining risks that must be considered.The machine runs at high electrical voltage.

• Before carrying out any maintenance, cleaning and repair work, switch off the machine and ensure that it can not be accidentally switched on again.

• When carrying out any work on the electrical equip-ment, ensure that the voltage supply is completely

isolated.• Do not remove any safety devices or alter them to

prevent them from functioning correctly.

Safety

Warning! Danger! Electric current!Electrical energy can cause serious bodily injury. Damaged insulation materials or defective individual compo-nents can cause a life-threatening electrical shock.

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General safety rules:• Be wary of sharp edges to avoid cutting yourself, in

particular when changing the tooling.• Risk of injury due to ejected work pieces and parts of

work pieces (e.g. branches, chips).• Risk of injury from workpiece kickback.• Hearing damage as a result of high noise levels.• Risk of damage to health from dust especially when

working hard woods.• Risk of injury through being crushed, cut, caught,

wound up or sliced.

depending on the equipment:• Contact with the rotating saw blade and/or the

scoring unit can cause an injury.• Danger of injury due to contact with the rotating moul-

der tool.• Risk of injury if come in contact with the rotating

cutterblock (Drilling tool).• Risk of injury from ejected tool pieces (e.g. cutting

pieces).• Therefore, never stand directly in the cutting line of the

saw blade whilst it is operating (in machining or idling mode)

2.9 Other risks

2.10 Battery safety instructions

Batteries are required for some models of this machine (according to design).

• Swallowing batteries is a health hazard. Keep batteries out of reach of children. Seek medical care immediately if you have swallowed a battery.

• Liquid can leak from the battery if it is used inap-propriately. This can result in skin irritation. Avoid contact with the liquid. However if contact does oc-

cur, wash the liquid off with plenty of water. Should the liquid come into contact with the eyes, rinse immediately with water for 10 minutes and seek medical care.

• Do not throw the batteries into fire or expose them to high temperatures. Risk of explosion.

• Remove the batteries from the machine once they have run out. This prevents the risk of damage resul-ting from battery leaks.

• Do not dispose of used batteries in domestic waste. Dispose of the batteries in an environmentally friend-ly manner.

Safety

Warning! Risk of injury or death!

Warning! Risk of injury!Even if the safety measures are complied with, there are still certain associated risks that must be considered when working on the machine:

Attention! Risk of material damage!

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D C1

B

C2

E

A

F


Machine Spindle moulder F 3 e-classic Length A 830 mm Length: Machine table B 1000 mm Overall width C1 775 mm Overall width C2 110 mm Machine table width D 550 mm Working height (approx.) E 888 mm Total height F 1350 mm Net weight *) 330 kg

Machine including packaging Length x Width 1470 x 1160 mm Height 1200 mm Weight (approx.)* 300 kg

*) with average-sized equipment

3 Technical specifications

3.1 Dimensions and weight

Technical specifications

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Alternating-current motor Three-phase current motor Motor voltage 1x 230 V 3x 400 V Motor frequency 50/60 Hz 50/60 Hz System of protection IP 55 IP 55

Motor power S6-40 %*) 3 kW 3 kW

*) S6 = operation under load and intermittent service; 40% = relative operating factor

3.2 Operation and storage conditions

3.3 Electrical connection


3.4 Drive motor

The actual values can be found on the data plate.

Operating/room temperature +10° to +40°C Storage temperature –10° to +50 °C

mains voltage according to specification plate ±10% Safeguarding see circuit plan Power supply cord (H07RN-F) 3x2,5 mm²/ 5x2,5 mm² Triggering characteristic C (D*)

*) if starting up is slow, caused by large swinging masses

3.5 Chip extraction

Spindle moulder fence

Dust extraction outlet, Ø 120 mm Min. air speed 20 m/s Min. vacuum 470 Pa Min. volume flow (at 20 m/s) 814 m³/h

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88 93

80 85


3.7 Noise emission

The specified values are emission values and therefore do not represent safe workplace values. Even though a relationship exists between particle emission and noise emission levels, an inference cannot be made about whether additional safety measures need to be imple-mented. Factors which can significantly affect the emis-sion level that presently exists at the workplace include duration of the effect, characteristics of the workspace, and other ambient influences. The permissible workplace

values may also differ from country to country. Neverthe-less, this information is provided to help the operator bet-ter assess hazards and risks. Depending on the location of the machine and other specific conditions, the actual noise emission values may deviate significantly from the specified values.


3.6 Particle emission

The working areas of this machine comply to BGI 739-1 and are classed as dust reduced.

The maximum concentration level of 2 mg/m³ of inhala-ble dust in the air will not be exceeded.

This only applies if the conditions that are specified in the section >Extraction< are adhered to.

See chapter entitled >Setup and installation<

Note:

To keep the noise emission as low as possible, always use sharpened tools and operate the machine at the correct speed.

Ear protection must always be worn; however, such protection cannot be considered a substitute for properly sharpened tools.

All values in dB(A) and with a measurement uncertainty factor of 4 dB(A).

Idle Working Sound power level (EN ISO 3746) Workplace emissions values (EN ISO 11202)

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Only use spindle moulder tools,• which have a max. authorised rotation speed higher than that of the spindle moulder• which conform to DIN EN 847-1 standards and• which are marked with „MAN“!

3.8 Tools

Note: We recommend that only original HAMMER tools are used (HAMMER catalogue).


Warning! Risk of injury!Never exceed the maximum speed indicated on the tool!

Table opening (Ø) 180 mm Spindle moulder-Ø max. Spindle moulder guard 230 mm Slot guard 275 mm Spindle-Ø Standard 30 mm Option 1 High velocity spindle Option 2 1 inch constant rotation 3000/6000/8000/10000 min-1 Speed High velocity spindle 14000 min-1 Spindle height above table (Usable height) 100 mm

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4 Transport, packaging and storage

4.1 Safety instructions

Transport, packaging and storage

4.2 Transport inspection

Upon arrival, inspect the shipment to ensure that it is complete and has not suffered any damage.If any transport damage is visible, do not accept the deli-very or only accept it with reservation. Record the scope of the damage on the transport documents/delivery note. Initiate the complaint process.

For all defects that are not discovered upon delivery, be sure to report them as soon as they are recognised as damage claims must be filed within a certain period, as granted by law.

4.3 Packaging

If no agreement has been made with the supplier to take back the packaging materials, help to protect the environ-ment by reusing the materials or separating them according to type and size for recycling.

Note: Help preserve the environment!Packaging materials are valuable raw materials and in many cases they can be used again or expediently reprocessed or recycled.

Attention! Dispose of the packaging materials in an environmentally friendly way and always in accordance with local waste disposal regulations. If applicable, contract a recycling firm to dispose of the packaging mate-rials.

Warning! Risk of injury!There is a risk of injury as a result of falling parts while transporting, loading or unloading the machine.

Attention! Risk of material damage!The machine can be damaged or destroyed if it is subjected to improper handling during transport.

For this reason the following safety instructions must be observed:

• Never lift loads over a person.• Always move the machine with the utmost care and

caution.• Only use suitable lifting accessories and hoisting

devices that have a sufficient load-carrying capacity.• Never lift the machine by its protruding parts (e.g.

sliding table).• Consider the machine‘s centre of gravity when trans-

porting it (minimise the risk of it tipping over).• Take measures to prevent the machine from slipping

sideways.• Ropes, belts or other hoisting devices must be

equipped with safety hooks.

• Do not use torn or worn ropes.• Do not use knotted ropes or belts.• Ensure that ropes and belts do not lie against sharp

edges.• Transport the machine as carefully as possible in order

to prevent damage.• Avoid subjecting the machine to shocks.

When transporting the machine overseas, ensure that the packaging is airtight and that a desiccant is added to protect the metal parts against corrosion.

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The machine is partly assembled when delivered on the pallet

The machine is mounted to the pallet with transport brackets.

Remove the transport brackets before moving the machi-ne to the installation location

The machine can be transported with a crane, forklift, pallet jack or rolling carriage.

!Transport brackets

4.5.1 Transport locking device

Fig. 4-1: Transport locking device

4.5 Transport

4.4 Storage

Keep items sealed in their packaging until they are assembled/installed and be sure to observe the stacking and storage symbols on the outside of the packaging.

Store packed items only under the following conditions

• Do not store outdoors.• Store in a dry and dust-free environment.• Do not expose to aggressive substances.• Protect from direct sunlight.• Avoid subjecting the machine to shocks.• Storage temperature: -10° to +50° C.• Maximum humidity: 60 %.• Avoid extreme temperature fluctuations (condensation

build-up).• Apply a coat of oil to all bare machine parts (corrosi-

on protection).

• When storing for longer than 3 months, apply a coat of oil to all bare machine parts (corrosion protection). Regularly check the general condition of all parts and the packaging. If necessary, refresh or re-apply the coat of anti-corrosive agent.

• If the machine is to be stored in a damp environment, it must be sealed in air-tight packaging and protected against corrosion (desiccant).


Attention! Risk of material damage!Transport the machine according to the enclosed transport and assembly instructions!The machine must not be lifted by the work table, sliding table or base! Ropes, belts and chains may only be fastened to the base of the machine.

Note:The transportation width is well under 1000 mm. This makes it possible to transport the machine through doorways.

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4.5.2 Transport with a crane

Fig. 4-2: Transport with a crane

Only use belts or chains to transport the machine

Thread the belts or chains through the cutout holes in the machine frame

!Belts

4.5.3 Transport with a forklift truck

Move the truck‘s forks so that they fit into the holes in the machine frame.

!Cutout hole in the machine frame

Fig. 4-3: Transport with a forklift truck


Attention! Risk of material damage!The machine must not be lifted by the work table, sliding table or base! Ensure that the lifting gear used has an adequate capacity and that the load is secured against lateral slippage!

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90 x 90 mm70 x 70 mm

40 x 40 mm

950 x 750 x 25 mm

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4.5.4 Transport with a pallet jack

Fig. 4-4: Transport with a pallet jack

Use a loading platform similar to the one depicted in the picture opposite to unload from the pallet.

1. Push the forks under the gaps in the machine frame.2. Unload the machine from the pallet with the fork

carriage truck.

!Cutout hole in the machine frame"Unloading ramp


Attention! Heavy dead weights can easily cause an injuryDepending on the equipment, two or three additional helpers may be necessary when unloading.

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5 Setup and installation


• Before assembling and installing the machine, check to make sure it is complete and in good condition.

• Keep the work area orderly and clean. Components and tools that are not put in their correct place or put away may be the cause of accidents!

• Ensure that there is sufficient space to work around the machine. If there is not sufficient distance bet-

ween the machine and neighbouring machines, walls or other solid objects, larger workpieces could pose a risk during the sawing process.

• Install the safety equipment according to the instructions and check that it functions properly.

5.2 Floor space requirement

Fig. 5-1: Space requirements/Measurements

Installation site requirements:• Operation/room temperature: +10° to +40° C• Ensure that the work surface is sufficiently stable and

has the proper load-bearing capacity• Provide sufficient light at the workstation• Ensure there is sufficient clearance for or from

neighbouring workstations

To operate and maintain the machine, leave a min. of 2000 mm space all around the machine.

Setup and installation

Attention! Risk of material damage!Only operate the machine in ambient temperatures from +10°C to +40°C. If the instructions are not followed, damage may occur to bearings.

Warning! Risk of injury! An incomplete, faulty or damaged machine can lead to serious physical injury or equipment damage. Only assemble and install the machine if the machine and its parts are complete and intact.

Warning! Risk of injury! Improper assembly and installation can lead to serious physical injury or equipment damage. For this reason, this work may only be carried out by authorised, trained personnel who are familiar with how to operate the machine and in strict observance of all safety instructions.

Warning! Danger! Electric current!Work on electrical fittings may only be carried out by qualified personnel and in strict observance of the safety instructions.

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1. Transport the machine to the installation site as instructed in the “Transport“ chapter and the enclo-sed transport or installation instructions.

2. Position the machine with the aid of a spirit level to ensure that the machine functions precisely and operates smoothly.

If the floor is uneven, use blocks to level the machine.

!bubble level"blocks

Fig. 5-3: Floor mounting

3. If necessary, the machine can be bolted down to the floor with the transport brackets.

4. Remove the oxidation protective layer from all blank machine parts.

!Transport brackets

5.4 Adjust the system handwheel

The display clocks may need readjusting after transporta-tion.To set the indicator precisely, open the clamping screw and remove from the handwheel. Turn it until the mea-sured value of a previously processed workpiece is precisely displayed.Reinsert the indicator into the handwheel and carefully tighten the clamping screw.

!Digital readout"Clamping screwFig. 5-4: System handwheel

5.3 Positioning and levelling the machine

Fig. 5-2: Positioning the machine


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5.5 Chip extraction

Warning! Risk of injury! Vacuum hose must be flame-resistant and must conduct electricity! Be sure to use only genuine HAMMER vacuum hoses!

Note: As a rule, all units must be vacuumed during use. A time delayed socket is available as an accessory.

• In addition, the vacuum performance must be sufficient to achieve the required negative pressures and an air speed of 20 m/s at the connector. (see “Technical data”)

• Check the air speed before putting the machine into operation for the first time and after essential changes.

• The dust extractor setup must be controlled before the machine is put into operation for the first time. Check for obvious defects on a daily basis and the efficiency on a monthly basis.

• The dust extractor must be connected to the machine in such a manner that it runs in unison with the machine.

• The dust extraction hoses must be electrically conduc-tive and grounded to prevent electrostatic build up.

• Use dust extractors with reduced dust emission to clean dust from the machine.

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5.6 Electrical connection

Note: Do not open the machine‘s switch box unless you have the express consent of the HAMMER service de-partment Violating this stipulation shall render the right to make claims under the warranty null and void.

Note: The machine‘s power cable is delivered with an open cable end, i.e. without a plug.The operator is responsible for fitting the machine‘s power cable with a suitable plug in accordance with any country’s specific regulations.

Attention! Risk of material damage!The machine must be secured with an automatic fuse

Attention! Risk of material damage!Before hooking up the machine to the power supply, compare the specifications on the data plate with those of the electrical network. Only hook up the machine if the two sets of data correspond to each other. The electri-cal outlet must have the appropriate socket (for a three-phase alternating current motor, CEE).

Electrical connection requirements• The machine must be earthed with electrical

conductors.• The voltage fluctuations in the mains supply may not

exceed ±10 %.• The switch cabinet must be fitted with a circuit

breaker (DIN VDE 0641). Number of terminals: 3 (three phase current motors)

• The unit must only be used in TN-Systems (neutral connected to earth)! (only 3x400V)

• Power supply cable H07RN-F at least 5x 2,5 (rotary-current motor) or 3x 2,5 (alternating-current motor).

• Safeguarding/Power supply cord: see “Technical data”

• The power supply cable must be protected against damage (e.g. armoured conduit).

• The power supply cable must be laid in such a way so it does not overbend or chafe and there is no risk of tripping over it.

1. Preselect the required rotating direction with the selec-tor switch - Switch on and let the machine run briefly.

2. While the motor is running, check its direction of rotation.

3. Should a change in the direction of rotation be necessary, switch the two phases on the power cable.


Fig. 5-5: Direction of the Motor rotatation

Warning! Danger! Electric current!

Work on electrical fittings may only be carried out by qualified personnel and in strict observance of the safety instructions.

Checking the loop impedance and the suitability of the overcurrent protective device must take place at the location where the machine is to be commissioned!

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44

576369

3944

50

42

47

3000

6000

8000

1000

0

756759 7352 65

5242

inch mm

345

5,56

88,51011

7

12

80100125140160

200220250280

180

300

Ø

1500

0

! " # $ %


Control panel!Green push button - spindle moulder unit ON"Red push button - machine OFF

(= Warning light - Anti-clockwise rotating spindle moulder)

#Forward and reverse run switch$Spindle moulder height adjustment (Handwheel)%Indicator window - Spindle rpm

6 Assembly

6.1 Overview F 3 e-classic

Assembly

Fig. 6-1: Overview

Fig. 6-2: Control panel F 3 e-classic

6.2 Operation and display elements

!Main switch (depending on the equipment)"Control panel#Machine table$Spindle moulder fence%Extraction port with diameter 120 mm&Controls - Spindle moulder unit/Doors

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PH: HZ: A:

Baujahr / year of construction / ANNEE DE CONSTR.:

KW:

V:

NR.:

TYPE :

XXX-XXX/XX-XX

XXXXXXXX

20xx

A-6060 HALL in Tirol, KR-Felder-Straße 1Austria, Tel. +43 (0) 5223 58500Fax +43 (0) 5223 56130, [email protected] www.hammer.at

3 50 X.X400

X.X S1


6.3 Data plate

The specifications plate is mounted on the side of the machine.

!Data plate

Fig. 6-3: Layout of the data plate

The data plate displays the following specifications:• Model designation• Machine number• Voltage• Phases• Frequency• Power• Power supply• Year of construction• Manufacturer information

Fig. 6-4: Data plate

Assembly

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Assembly

Assembly / Adjusting:See chapter entitled >Making adjustments and prepara-

tions<

Screw the spindle moulder guard onto the spindle moulder fence cover with screws and washers.

The vertical pressure shoe and/or the horizontal pressure spring have to be adjusted.

!Spindle moulder guard attachment

6.4 Safety devices

6.4.1 Safety break switches

Fig. 6-5: Close the door

6.4.2 Spindle moulder guard attachment

Warning! Risk of injury!The spindle moulder fence should always be equipped with the spindle moulder guard to avoid injuries!

Fig. 6-6: Spindle moulder guard attachment

Your machine is equipped with safety break switches. The machine only runs when the end switch in the inside of the machine frame is engaged by the locking device.

Close the door and lock with the screw.

!Doors"Thumb screw

27


6.4.3 Automatic braking system

Your machine is equipped with an automatic braking unit. The brake is a maintenance-free DC braking unit. All necessary adjustments are done ex factory.

Please contact the FELDER KG service department, if pro-blems or a fault- function should occur!

Assembly

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Adjusting the moulding height:1. Switch the machine off and ensure that it cannot be

switched on again.2. Adjust the moulding height with the handwheel

• Clockwise: higher• Anti-clockwise: lower

3. To compensate the threaded spindle, set the mould-ing height always from low to high.

Note: Important accessoriesThe digital clock is built into the height adjustment system handwheel.Exact adjustments to one tenth of a millimeter are possi-ble with the digital display..

See the HAMMER catalogue for other accessories and dust extraction equipment.

! Spindle moulder height adjustment" Digital display

7 Making adjustments and preparations - Spindle moulder unit


• Before beginning any maintenance work on the machine, switch it off and secure it against acciden-tally being switched on again.

• Before commencing any work with the machine, inspect it to ensure that it is complete and in technically good condition.

• Ensure that there is sufficient space to work around the machine.


• Install the safety equipment according to the instructions and check that it functions properly.

Making adjustments and preparations

Warning! Risk of injury! Improper adjustment and setup work can lead to serious physical injury or material damage. For this reason, this work may only be carried out by authorised, trained personnel who are familiar with how to operate the machine and in strict observance of all safety instructions.

Warning! Risk of injury!Adjustments to the machine or tool replacement may only be conducted once the machine has stopped.

7.2 Adjusting the moulding height

Fig. 7-1: Adjusting the moulding height/moulding angle

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Assembling:1. The spindle moulder guard has to be mounted.

Mount if required2. Position the spindle moulder fence onto the machine

table so that both thumb screws can be screwed into the threaded holes.

3. Screw the thumb screw in tightly.4. Attach the dust extraction hose Ø120 mm

!/ "Thumb screw#Spindle moulder fence$Machine table%Threaded holes&Spindle moulder guard attachment

Adjusting the spindle moulder fence:1. Loosen the thumb screw 1.2. Adjust the spindle moulder fence3. Tighten the thumb screw 1.4. Fine adjust the spindle moulder fence:

Turn the knurled handle until the position has been reached.

The setting is displayed on the scale.5. Loosen the thumb screw 2.

Move the spindle fence plates to the left and/or to the right into the required position.Tighten the thumb screw 2.

/Dust extraction accessories Ø120 mm(Knurled handle)Spindle fence platesBLScale


7.3 Spindle moulder fence

Warning! Risk of injury!The spindle moulder guard has to be mounted - Mount if required

Note:The spindle moulder fence „220“ is appropriate for spindle moulder tools with a diameter up to 220 mm. The spindle fence plates are each 320 mm long.

Fig. 7-2: Assembling the spindle moulder fence

Fig. 7-3: Adjusting the spindle moulder fence

7.3.1 Spindle moulder fence „220“ (Standard)

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7.3.2 Multi-adjustment system for the moulder fence (Option)

1. i.e. the shaper fence retains all of its settings when removed and reinstalled.

2. When setting the fence on the machine table, you position the guide piece so the bolts fit into the holes in the machine table.

!Bolts"Guide piece#Holes

Note:The fine adjustment for the outer tool diameter is used for the fine adjustment of the complete shaper fence in relation to the outer tool diameter. It has an automatic repeat function

Note:To ensure that the settings remain unchanged after removing and remounting the shaper fence, you have to compensate for play in the fitting bolt by always applying light pressure backwards on the depthadjustable straightedge when setting.

3. After opening the outer tool diameter clamping screw, adjust the shaper fence roughly in relation to the outer tool diameter.

4. Tighten the outer tool diameter clamping screw. 5. Now you can fine adjust the entire shaper fence to

the outer tool diameter via the handwheel. 6. On scale, you can directly read the outer tool diam-

eter to which the rigid straightedge is set.7. After adjusting, tighten the shaper fence to the ma-

chine table via the clamping bolts.

!Circle of cut clamp screw"Scale#Handwheel


Fig. 7-4: MULTI-Fine adjustment system

Fig. 7-5: Fine adjustment for outer tool diameter

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7.3.3 Spindle moulder guard attachment

Warning! Risk of injury!The spindle moulder fence should always be equipped with the spindle moulder guard to avoid injuries!

Assembly:1. Loosen the thumb screw.2. Fold the spindle moulder fence lid to the back.3. Screw the spindle moulder guard onto the spindle

moulder fence cover with screws and washers.4. Tilt the spindle moulder fence lid and the mounted

spindle moulder guard to the front.5. Screw the spindle moulder fence lid on tightly with

the thumb screws.

!Thumb screws"Screws / Washers#Spindle moulde fence cover$Spindle moulder guard attachment

Adjusting:The vertical pressure shoe and/or the horizontal pressure spring have to be adjusted.1. Loosen the appropriate thumb screw.2. Move the spindle moulder guard along the rod

and/or into the required position.3. Tighten the thumb screw.

!Rod"Thumb screw#Pressure spring$Pressure shoe


Fig. 7-6: Spindle moulder guard attachment

Fig. 7-7: Set the spindle moulder guard attachment

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7.4 Safety bar guides (Option)

Note: It is recommended to use safety bar guides (Accessories) when moulding profiles. This ensures a continu-ous work supporting block which means increased safety and better results.

Assembly/Disassemble:See assembly instructions „Safety bar guides“

Moving:1. Switch the machine off and ensure that it cannot be

switched on again.2. Loosen the clamping screw.3. Slide the safety bar guide upwards.4. Tighten the clamping screws.5. Check whether the spindle moulder tool is running

freely. The spindle moulder tool must not touch the safety bar guides.

6. Check whether the guides are parallel to the ma-chine table.


!Clamping screws"Safety bar guides#Spindle fence plates

Fig. 7-8: Safety bar guides

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Warning! Risk of injury!Adjustments to the machine or tool replacement may only be conducted once the machine has stopped.Switch the machine off at the main switch.

7.5.1 Prepare to change tooling


Warning! Risk of injury!Be wary of sharp edges to avoid cutting yourself, in particular when changing the tooling.

7.5 Tool changer

Fig. 7-9: Prepare to change tooling

1. Loosen the thumb screw 1. (2 x)2. Tilt the spindle moulder fence cover and the

assembled spindle moulder guard to the back.3. Loosen the thumb screw 2.4. Pull the guides as far apart as possible.5. Position the spindle moulder right at the top.

!Thumb screw 1"Thumb screw 2#Spindle moulde fence cover$Spindle fence plates

34

min 3 mmmax 8mm

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Warning! Risk of injury!minimum tightening torque:: 30 Nm!

Note:We recommend that only original HAMMER tools are used (HAMMER catalogue).See technical data for the authorised milling tools.

7.5.2 Mounting/removing/changing the spindle moulder tool


Required tools:• Allen key 8 mm• Fork wrench 22 mm

1. Prepare to change tooling.2. Hold the spindle moulder cap tight with the fork

wrench.3. Loosen the socket head cap screw with an allen key.4. Remove the spindle moulder cap and collar.5. Remove the spindle moulder tooling when changing

or removing the tools.6. Remove dust and shavings from the spindle moulder.

7. Changing or mounting tools: Place the spindle moulder tool as low as possible

onto the spindle moulder so as to avoid vibrations

Place as many spindle collars as are required to achieve sufficient clamping space (approx. 8 mm) between the spindle moulder cap and the spindle moulder.

Tool removal: Mount all the spindle collars. Take note that there is sufficient clamping space (approx. 8 mm) between the spindle moulder cap and the spindle moulder.

8. Fit on the spindle moulder cap and socket head cap screw

9. Screw in the socket head cap screw with the allen key and tighten.

!Socket head cap screw"Spindle moulder cap#Spindle moulder collar$Spindle moulder%Spindle moulder tooling

Fig. 7-10: Spindle moulder

Fig. 7-12: Incorrect tooling fitting

Fig. 7-11: Installing the spindle moulder tool

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1. Close as much of the table opening with backing rings as possible.

2. Adjust the guides according to the tooling.3. Tilt the spindle moulder fence lid and the mounted

spindle moulder guard to the front.4. Screw the spindle moulder fence lid on tightly with

the thumb screws.5. Determining/adjusting the speed6. Close the door7. Switch machine on.

!Backing rings"Spindle fence plates#Spindle moulde fence cover$Thumb screws%Doors

7.5.3 Prepare the machine to operate

Warning! Risk of injury!Pay attention to the correct rotational direction of the spindle moulder tool!The workpiece to be machined, should only be moulded against the rotation direction!


Note: The moulding tool only operates if the break switch, inside the machine frame, is not actuated!Close the door and lock with the screw.

Fig. 7-13: Prepare the machine to operate

Fig. 7-15: Incorrect direction of rotation Fig. 7-14: Note the direction of rotation!

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7.6.1 Establishing/setting the speed

7.6 Determining/adjusting the speed

Warning! Risk of injury! / Risk of material damage!Stay within correct cutting speed guidelines:• smaller 40 m/s - Kickback risk • larger 75 m/s - Tool breakage risk

Warning! Risk of injury! / Risk of material damage!Do not exceed the limit value obtained from the diagram!


1. Using the sticker on the chassis cover, set the correct spindle rotation on the machine. The cutting speed should always be between 40 and 75 m/s.

2. Check the maximum spindle resiliance (limit revolution) in the diagrams on the following pages.3. Set the obtained spindle speed.

!Tool diameter [mm / inch]"Blade velocity [m/s]#Spindle speed [min-1]

Fig. 7-16: Establishing/setting the speed

37

1

2

3

4

5

6

7

8

9

100 125 150 175 200 225 250 275 300

nmax

(x 1

000)

ø 25 / 25,4 mm

10

20

30

50

80

100

mm

ø mm

1

2

3

4

5

6

7

8

100 125 150 175 200 225 250 275 300

9

ø 30 / 35 mmø 31,75 mm

10

20

30

50

80

100

mm

ø mm

nmax

(x 1

000)

2

3

4

5

6

7

8

9

100 125 150 175 200 225 250 275 300

ø 40 mm

10

20

30

50

80

100

mm

nmax

(x 1

000)

ø mm

2

3

4

5

6

7

8

9

100 125 150 175 200 225 250 275 300

ø 50 mm

30

50

80

100

mm

nmax

(x 1

000)

ø mm


7.6.2 Maximum spindle resiliance (rotation limit)

1. Calculate minium rotation speed (boundary value) depending on the tool diameter and length of cut using this diagram.

2. Using the sticker on the chassis cover, set the correct spindle rotation on the machine.3. Set the obtained spindle speed.

Warning! Risk of injury! / Risk of material damage!Do not exceed the limit value obtained from the diagram!


Fig. 7-17: Diagrams - Maximum spindle load

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Warning! Risk of injury!The machine has to be switched off when carrying out any work on the machine!Switch the machine off at the main switch.

1. Switch off the main switch.2. Push the lock to the top.3. Open the door with the screw.4. Loosen the belt-tensioning screw.5. Place the belt around the point where the belt pulley

diameter becomes smaller: Reducing speed:• First change the motor belt.Increasing speed:• Place the belt around the spindle moulder first.

6. Tighten the drive belt tensioning screw.7. Close the door again and tighten the screw.

!Motor pulley"Belt-tensioning screw#Belt$Spindle moulder%Doors

7.6.3 Adjusting the moulder spindle rotation


Fig. 7-18: Set the speed

Attention! Risk of material damage! Do not over-tension the drive belt!Stop turning the belt-tensioning screw once the drive belt is tensioned sufficiently, enabling it to transmit power effectively.

39

!

ø 125

ø 180

max 85 mm

ø 220

max 20 mm



7.7 Sink the spindle moulder

Attention! Risk of material damage! Ensure that the tool turns freely.

The spindle moulder can be lowered in a 90° positi-on under the table for tools with a max. diameter of 180 mm when the tool is clamped and the backing rings are removed.

The spindle moulder can be lowered 20 mm under the table at a 90° position if the tooling diameter is not more than 220 mm and the tooling is chucked and the ba-cking rings are removed.

Fig. 7-19: Sink the spindle moulder

40

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8 Operation - Spindle moulder unit

Before starting work:• Before commencing any work with the machine,

inspect it to ensure that it is complete and in technically good condition.



• Ensure that all safety devices have been installed properly.

• Adjustments to the machine or tool replacement may only be conducted once the machine has stopped.

• Only clamp authorised tools to the machine.• Pull the clamping lever of the moulder spindle tight.• Adapt the speed to the tooling• Only work with sharp tools. This reduces the kick-

back risk especially with slotted blades• Install the dust extraction system according to the

instructions and test its function.• Only machine workpieces that can be safely placed

on the machine and guided.• Carefully inspect workpieces for foreign matter (nails,

screws) which might impair processing.• Ensure that the tool turns freely.• Pay attention to the correct rotational direction of the

spindle moulder tool• Before switching on the machine, always check to make

sure that there are no other persons in the immediate vicinity of the machine.

During operation:• When changing to another workpiece or if a

malfunction occurs, first switch off the machine and then secure it against being switched on again accidentally.

• Do not switch off, circumvent or decommission protective and safety devices during operation.

• Risk of injury from ejected tool pieces (e.g. cutting pieces).

When working on or with the machine, the following must be strictly observed:• Persons with long hair who are not wearing a hairnet

are not permitted to work on or with the machine!• It is prohibited to wear gloves while working on or

with the machine.

When working on or with the machine, the following must always be worn by personnel:• Sturdy, tight-fitting clothing (tear-resistant, no wide

sleeves, no jewellery (rings, bracelets, necklaces, etc.)).

• Protective footwear - To protect the feet from heavy falling objects and prevent sliding on slippery floors

• Hearing protection - To protect against loss of hea-ring

Note: Accessories:Support long workpieces with additional surface equipment (e.g. Table extensions, roll supports). Keep tools for handling short and narrow workpieces close at hand. (e.g.: Pushing Grip)


Operation

Attention! Risk of material damage!Only operate the machine in ambient temperatures from +10°C to +40°C. If the instructions are not followed, damage may occur to bearings.

Warning! Risk of injury! Improper operation may lead to severe physical injury or material damage. For this reason, this work may only be carried out by authorised, trained personnel who are familiar with how to operate the machine and in strict observance of all safety instructions.

41

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Fig. 8-1: Switching on moulding aggregate

Switching on the machine1. Connect the machine to the main power supply.2. If available: unlock the main switch and switch on

(position "I").3. Set the mode switch onto the following settings

• "Spindle moulder anti-clockwise rotation" setting or • "Spindle moulder clockwise rotation" setting.

With alternating-current motors4. Press and hold down the green push button.5. Release the push button once the machine has rea-

ched the maximum rotational speed.With a three-phase current motor6. Hold down and then release the green push button.

Switching off the machine:1. Push and release the red push button.2. If available: switch off the main switch (position “0”)

and secure.3. Disconnect the machine from the main power supply.

Emergency-stop:(depending on the equipment)• Hold down the red push button• Press the EMERGENCY-STOP button.

The machine is stopped automatically.Release the EMERGENCY-STOP button by turning it.

!Main switch"Mode switch#Green push button - spindle moulder unit ON$Set the mode switch onto the following settings

Clockwise rotating spindle moulder%Red push button - machine OFF&EMERGENCY STOP button (Option)

8.2 Switching on the machine / Switching off the machine / Emergency-stop

Operation

Attention! Risk of material damage!Improper operation may cause damage to the machine. Do not activate the green push button whilst the machine is in operation!

Warning! Risk of injury due to insufficient preparation!It is only permitted to switch on the machine if, for the work at hand, the required preconditions are fulfilled and any preliminary work is completed. Therefore, the adjusting, fitting and operating instructions (see the corresponding chapters) must be read before switching on the machine.

42


Operation

Fig. 8-2: Work stations/Work positions

Warning! Risk of injury! Danger from ejected tools or workpiece parts

8.3.2 Authorised working techniques

8.3.3 Prohibited working techniques

8.3.1 Work stations

8.3 Working techniques

• Risk of injury due to ejected workpieces and workpi-ece parts (e.g. cutting tools, branches, trimmings).

• Always work from right to left in front of the machine.• Exception: For special operations (e.g. curve moul-

ding with clockwise spindle moulder rotational direc-tion), work from left to right.

The following working techniques are allowed with the moulder unit:

• Profile and long side moulding (using the spindle moulder fence)• Insert moulding• Curved mouldings (using the Curve Shaping Device)• Using a high velocity spindle• Using a power feeder

Generally prohibited using the spindle moulder unit are the following working techniques:

• Any procedure excluding the use of a spindle moulder fence or a curved spindle moulder fence• Synchronous moulding (the rotational moulding direction corresponds to that of the feeding direction)• Use of higher speed, and/or a larger diameter than appears in the speed diagram• Slotting with circular saw blades• Use of tools with larger tool bores by using drill sleeves

43

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8.3.5 Moulding long sides and profiles

Note: Numerous profiles are possible when combining the height adjustment with the diverse moulding cutter heads and profile knifes. Moulding profiles corresponds to moulding long sides.

Warning! Risk of injury! Only mould profiles if using safety guides! Use a push stick or push block at the end of the workpiece.

1. Take note of general procedures for authorized working techniques.

2. Set the detachable spindle fence guide exactly on the diameter of the spindle moulding tool.

3. Set the depth of cut with the feeding spindle fence guide.

4. Set the moulding height and/or moulding angle. Set the spindle moulder guard attachment.

5. Press the workpiece against the fence and spindle table and feed past the spindle moulder tool with fingers and thumbs balled into a fist.

6. If you are not going to continue working, switch off the machine and secure it against being turned on again accidentally.

!Outfeed fence guide"Infeed fence guide

Fig. 8-3: Moulding profiles

8.3.4 General procedures for authorised working techniques

Operation

1. Switch the machine off before starting to machine.2. Ensure there are sufficient extension options

(accessories).3. Keep handling auxiliaries at hand:

(Tools and Accessories catalogue)• Pushing stick; wood with holding magnets• Pushing stick; plastics• Push grip

4. If required, and depending on the previous machine use:• Assemble the spindle moulder tool.• Mount the spindle moulder guard.

5. Adjusting the moulding height.6. Extraction system must be connected.7. Only switch on the spindle moulder once the

workpiece has been positioned correctly and is rea-dy to be cut.

8. Feed the workpiece constantly past the spindle moul-der tool keeping the fingers balled into a fist.

9. Use a push stick at the end of the moulding process if necessary.

10. Switch the machine off once finished moulding.

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8.3.6 Insert moulding

Operation

Note: This step is necessary if the whole length of the workpiece is not machined.Use kickback guards!

Fig. 8-4: Insert moulding


2. The guides of the spindle moulder fence must be ali-gned. Set if required.

3. Leave the workpiece placed against the kickback guards and tip it carefully into the rotating tool.

4. Once the workpiece is located against the spindle moulder fence guide, press the workpiece against the fence and the spindle table, and feed past the spindle moulder tool with fingers and thumbs balled into a fist.


!Spindle fence plates"Clamping jigs#Kickback guard

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Note: This operation (curved moulding or also known as curved shaping) is used to mould curved workpieces.

The stop ring guard and a template are required for cur-ve shaping (Tools and Accessories catalogue)

Use the appropriate guide rings depending on the tooling diameter.1. Take note of general procedures for authorized

working techniques.2. Fasten the EURO curve moulding guard to the

machine table using both screws.3. Set the start batten to the height of the guide ring

with a gap of 1 to 2 mm.4. Adapt the curve moulding guard to the workpiece

using the thumb screws.5. Loosen the thumb screws, place the brushes on the fo-

remost point of the guide ring and tighten the thumb screws again.!Curve Shaping Guard

"Start batten#Moulding guard$Thumb screws%Guide ring&Brush

8.3.7 Curve moulding

6. Clamp the workpiece onto the template (e.g. with clamping levers). Gluing sandpaper to the template reliably prevents the workpiece from slipping.

7. Guide the template with the clamped workpiece slowly along the guide bar to the shaper tool Always press the template against the stop ring or the stop collar.


!Workpiece"Template#Clamping lever

Operation

Fig. 8-5: Curve moulding

Fig. 8-6: Template (with the clamping levers)

46

1 2 3

1 2 3

Montage

Demontage

!


The machine can also be fitted with a high speed spindle as an option.See chapter entitled >Removing and changing moulder spindle<


2. Mount the spindle moulder fence or the EURO Curve moulding guard as a protective device.

3. Press the workpiece against the fence and spindle table and feed past the spindle moulder tool with fingers and thumbs balled into a fist.


8.3.8 Moulding with a high velocity spindle

Note: The high velocity spindle is especially designed for dovetail or duplicate mouldings.

Attention! Risk of material damage!When placing the chucks into the nut of the highspeed spindle take note of the correct order of assembly! See assembly instructions.

Operation

Fig. 8-7: High velocity spindle

Fig. 8-8: Assembling the chucks

47

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Note: The use of a removable power feed unit is only permissible, if the feed unit is automatically switched on and off with the machine, i.e. if the machine is equipped with a switched socket.

Note: A time delayed socket is available as an accessory.

8.3.9 Moulding with a power feeder

Assembling:The power feeder is mounted onto the machine frame.

Assembling and intend eduse:Separate user instructions „feed unit“.


2. If required, set up the power feeder.3. Adjust the power feeder.4. If you are not going to continue working, switch off

the machine and secure it against being turned on again accidentally.

!Power feeder"CEE coupling for additional appliances

Operation

Fig. 8-9: Moulding with a power feeder

48

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9 Service


• Before beginning any maintenance work on the machine, switch it off and secure it against accidentally being switched on again.



• Following the maintenance work, reinstall the guards and check that they are functioning properly.

Service

Attention! Risk of material damage!The following maintenance has to be carried out according to the instructed time intervals!

Warning! Risk of injury!Improper maintenance can cause serious injury or damage. For this reason, this work may only be carried out by authorised, trained personnel who are familiar with how to operate the machine and in strict observance of all safety instructions.


9.2 Maintenance schedule

Interval Component Task to accomplishDaily Machine Remove dust and shavings.

Table surfaces Remove dust and shavings. Remove any resin residue

Dust extractor Check for defectsWeekly Machine Clean thoroughly.Every 40 operating hours, At least once a month

Height spindle LubricationHeight guide Remove dust and shavings.

Monthly Drive belt Check and if required, tighten or change

Dust extractor Check efficiency

49

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Attention! Risk of material damage!Only high quality machine grease order nr. 10.2.001 may be used!Spray oils such as graphite and Mos2 oils may damage the guide tracks!

Attention! Risk of material damage!Never use caustic or abrasive detergents.

The belt tension is factory set to the ideal value.

In time, the belt can stretch, causing the power transmissi-on to deteriorate.The belt tension must be corrected in such a case.

Replace the appropriate belt immediately should tears or side tears appear during the monthly check

9.3 General maintenance instructions

9.3.1 Belt tension

9.3.2 Cleaning and lubrication

Service

Note: Cleaning and care products are available as accessories (Felder catalogue).

Fig. 9-1: Cleaning agent

We recommend that dust and chips are cleaned off the machine on a daily basis, especially from the table sur-faces.

Clean the operating foil with a damp cloth.

Never use caustic or abrasive detergents.

These could damage the foil keyboard and may affect operation.

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#

%


1. Switch the machine off and ensure that it cannot be switched on again.

2. Disconnect the machine from the mains power supply

Remove the cover lid.1. Loosen the screw, press the component inwards,

tighten the screw (4x).2. Remove the cover lid.

Lubricating the height spindle1. Move the milling saw unit into the position shown.2. Clean height guide and height spindle

(Remove chips, dust and grease residues).3. Grease the height spindle and height guide with

normal machine grease throught the chassis opening.4. Move the moulder into the lowest and then into the

highest position.

Screw the cover lid on1. Attach the covering lid.2. Loosen the screw, press the component outwards,

tighten the screw (4x).!Torx screws (15 IP plus)"Component#Cover$Height spindle%Height guide (Spindle moulder socket)

9.4 Maintenance work - Spindle moulder unit

Service

9.4.1 Greasing height spindle and height guide

Fig. 9-2: Lubricating moulder height spindle

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Service

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10 Faults


10.2 What to do if a fault develops

In most cases:

• In the event of a breakdown which creates danger for either personnel or equipment, the machine should be stopped immediately by activating the emergency stop.

• Also disconnect the machine from the mains and ensure it can not be switched on again.

• Inform those responsible for machine faults immediately.

• Type and extent of fault should be determined by an authorised professional, as well as the cause and repair.

10.3 What to do after rectifying the fault

Before switching the machine back on:

• The fault and its cause are professionally repaired.• All safety equipment has been assembled according

to regulations and is working correctly.• Individuals are not located within the danger area of

the machine.

Faults

Warning! Risk of injury!

Warning! Risk of injury!Repairing faults incorrectly can result in personal injury or damage to the machine.For this reason, this work may only be carried out by authorised, trained personnel who are familiar with how to operate the machine and in strict observance of all safety instructions.


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Faults

10.4 Faults, causes and repairs

Fault Cause RepairMachine does not start Safety break switches activated Prepare the machine to operate

Error in the electrical contact. Check the electrical connection (connecting lead, fuses).

The main switch is off („0“ position). Switch on the main switch („I“ position).

The belts squeal when switched on or started.

The belt tension is too slack Retensioning the drive beltThe drive belt is worn out. Replacing the drive belt

Motor´s running, spindle´s not spin-ning

The drive belt is torn. Replace the drive belt.

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Hall in Tirol, 1.5.2013


11 Annex

Annex

11.1 Declaration of Conformity F 3 e-classic

EG-Declaration of ConformityAccording to Machine Guidelines 2006/42/EG

We hereby declare that the machine indicated below, which corresponds to the design and construction of the model we placed on the market, conforms with the health and safety requirements as stated by the EC.

This EC Declaration of Conformity is valid only if the CE label has been affixed to the machine.

Modifying or altering the machine without the express written agreement of the manufacturer shall render the warranty null and void.

The signatory of this statement is the appointed agent for the compilation of the technical information.

Johann Felder, Managing Director FELDER KGKR-FELDER-STR.1 • A-6060 Hall in Tirol

Manufacturer: Felder KG KR-FELDER-STR.1 A-6060 Hall in Tirol

Product designation: spindle moulder

Make: HAMMER

Model designation: F 3 e-classic

The following EC guidelines were applied: 2006/42/EG 2006/95/EG 2004/108/EG

The following harmonised norms were applied: EN 848-1

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Annex

© Felder KGKR-FELDER-STR.1A-6060 Hall in Tirol

Tel.: +43 (0) 5223 / 58 50 0Fax: +43 (0) 5223 / 56 13 0

Email: [email protected]: www.felder.at

User manual spindle moulder F 3 e-classic...when using, maintaining or repairing the machine. Attention! Risk of material damage! The machine must be inspected immediately upon arrival.

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