Danfoss ET4500-001, Operator'S Manual

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Page 2: ...erman Date of revision 2022 10 05 Version 1 0 Copyright by UNIFLEX Hydraulik GmbH Technical modifications reserved The reproduction distribution and utilization of this document as well as the communi...

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Page 4: ...sch Strasse 50 52 D 61184 Karben The following standards codes and specifications have been applied EC Directive 2006 42 EC EMC Directive 2014 30 EC EN ISO 12100 2010 EN 60204 1 2018 UK Supply of Mach...

Page 5: ...4 2 3 5 Risks imposed by substances 14 2 3 6 Risk by hot surfaces 14 2 3 7 Risks in case of fire 15 2 4 Safety 15 2 4 1 Working area 15 2 4 2 Emergency stop button 16 2 4 3 Protection equipment 16 2 4...

Page 6: ...6 Adjusting the depth stop 44 5 7 Setting the forming dimension 46 5 8 Forming travel limitation 47 5 9 Stop 47 5 10 Emergency stop 48 5 11 Cleaning 48 6 Maintenance 50 6 1 What you have to observe 5...

Page 7: ...trol A 71 9 3 Spare parts kit 72 9 4 Service tool 72 9 5 Retaining bolt for standard crimping dies depending on crimping die 73 9 6 Hydraulic diagram 75 9 7 Electric diagram 76 9 8 Maintenance log 79...

Page 8: ...ness of risks and haz ards in compliance with all notes included in this Operation Manual The machine unit may only be operated by staff who has read the Operation Manual has understood it has been in...

Page 9: ...m and fighting means Free access to this equipment must be ensured personal protection equipment is worn safety footwear protec tion gloves and safety glasses Machine unit fitters Machine unit fitters...

Page 10: ...ll times Upon disposal of the machine unit the Operation Manual must also be handed over 1 3 Name plate The name plate is fixed near the power cable 1 4 Voltage codes Voltage variant Voltage rating 23...

Page 11: ...lt in light injuries This warning is supplemented by a triangular hazard symbol The signal word ATTENTION identifies a potentially hazardous situa tion in which the product or property in the environm...

Page 12: ...dered as being not in compliance with the in tended purpose in particular design modification of the machine use in explosive environments forming of non metal workpieces without specific safeguards a...

Page 13: ...is a risk of electrocution near the live parts Work on electric systems may only be performed by qualified electricians or instructed and trained persons under the supervi sion of a qualified electri...

Page 14: ...achine unitry is sim ultaneously used at the workplace The machine unit owner must pro vide for appropriate protection e g instruct staff to wear ear protection provide information instructions on ris...

Page 15: ...t must be ensured Never use water to extinguish a fire For appropriate fire extinguishing action please read the safety data sheet of the hydraulic oil supplier 2 4 Safety 2 4 1 Working area The worki...

Page 16: ...se it by a turn 2 4 3 Protection equipment Due to the variety of customer specific workpieces UNIFLEX is not capable of supplying additional standard protection equipment to gether with the machine fo...

Page 17: ...efore commissioning of the ma chine UNIFLEX will provide you with customized solutions for protection equipment upon request Please do not hesitate to address your per sonal contact for consultation M...

Page 18: ...Oiling greasing prohibited on the die system Illegible or missing warning signs must immediately be replaced by the owner...

Page 19: ...Machine description 3 1 Design and function Basic machine 1 Crimping tool 2 Micrometer 3 Hydraulic tank with electric motor pump 4 Main power switch 5 Control panel with buttons 6 Emergency stop butto...

Page 20: ...die system Crimping tool The die system comprises basic dies intermediate dies depending on the application and crimping dies All basic dies are supported on slide plate The crimping dies and the int...

Page 21: ...m capacity WARNING Risk of injuries In particular non metal workpieces may by overstressed by the forming process so that this may result in a sudden failure Chips or seriously accelerated workpiece p...

Page 22: ...3 Operation and display elements 1 Emergency stop button 2 Illuminated Motor On button 3 Motor Off button 4 Illuminated foot switch button 5 Illuminated Open tool button 6 Illuminated Close tool butto...

Page 23: ...3 4 Depth stop accessory 1 Clamp lever 2 Sleeve 3 Plunger 4 Stop pin 5 Spacer 6 Clamping yoke 7 Guidance 8 Sleeve...

Page 24: ...mode S6 70 Noise level 70 dB A Protection class IP 40 Function Forming force 2800 kN 280 t Max forming range dies 17 mm max outer diameter of the fittings before forming Maximum dies 92 mm Opening si...

Page 25: ...tion power 4 kW Supply voltage See Voltage code in Section 1 Back up fuse 20 A delayed preferably thermal fuses if circuit breakers are used these should be of the class C type Hydraulic system Oil vo...

Page 26: ...bient conditions Ambient temperature 10 o C 35 o C Air humidity 45 65 The data are theoretical computed values or values measured on a prototype Actual values may vary slightly depending on the ma chi...

Page 27: ...l applicable laws and regulations relating to securing loads shall be ob served during transport The machine unit may only be unloaded and transported by means of a forklift a lift truck or a crane Wh...

Page 28: ...k or crane at the desig nated points 2 and transfer it to the location of installation 4 2 Intermediate storage of machine unit If the machine unit cannot be mounted immediately upon delivery it must...

Page 29: ...record training sessions in Decla ration of trained staff Section 9 WARNING Risk of injuries Machine components might loosen during transport Such com ponents might be flung out during to the forming...

Page 30: ...working area and when handling consumables Ensure good ventilation Avoid floor contamination ATTENTION Risk of fire Hydraulic liquid spray or spills imposes a risk of fire Avoid ignition sources weld...

Page 31: ...lations of the Electricity Board Do not operate the machine without a sufficiently rated ground wire Before performing maintenance work switch off the machine and secure it against switching on unint...

Page 32: ...tational di rection or operating the machine without oil will destroy the hyd raulic pump Make sure that the amount of hydraulic oil in the machine is sufficient before starting the machine Ensure tha...

Page 33: ...hydraulic system 1 Switch on the machine 2 Operate the machine in the idle mode for two minutes in order to fill the pump with oil 3 Open and close the tool several times 4 Check oil level add hydraul...

Page 34: ...operation Observe the safety instructions on the machine unit Make sure that no other persons stay in the working area Use appropriate aids to handle heavy workpiece Each movement of the hand must be...

Page 35: ...ectly mounted in the tool The forming dimension is set correctly please also refer to Set ting the forming dimension Section 5 Preferably form the workpiece in the centre of the crimping die length Ec...

Page 36: ...ing pro cess starts and ends when the pre set diameter pressure is reached 4 Press the button upon completion of the forming process to open the tool 5 Remove the workpiece from the tool 6 Check the f...

Page 37: ...the locking bolt 2 Switch off the machine using the main switch and secure it against switching on unintentionally WARNING Risk of squeezing When the die system closes there is a risk of getting squee...

Page 38: ...machine using the main switch and secure it against switching on unintentionally WARNING Risk of squeezing When the die system closes there is a risk of getting squeezed between the dies Only replace...

Page 39: ...nd secure it against switching on unintentionally WARNING Risk of squeezing When the die system closes there is a risk of getting squeezed between the dies Only replace the intermediate dies when the...

Page 40: ...hine using the main switch and secure it against switching on unintentionally WARNING Risk of squeezing When the die system closes there is a risk of getting squeezed between the dies Only replace the...

Page 41: ...ies the locking bolts in the base dies as well as the retaining bolts of the intermediate and criming dies will be destroyed Only mount profile 266 268 237 intermediate dies individually and manually...

Page 42: ...es of the crimping dies 2 4 Rotate anti clockwise and remove the crimping dies 2 from the deposit 5 Check the retaining bolts 3 of the crimping dies for damage 6 Hold the quick die change system with...

Page 43: ...mediate dies and the spring mounted pressure pieces must engage into the retaining bolts 8 Remove the quick die change system 1 and check that the crimping dies fit tightly 9 Proceed in reverse order...

Page 44: ...d see X in the figure In the figure the crimping die 2 is placed incorrectly Place the crimping die 2 in the intermediate die 3 so that it does not protrude In the figure the crimping die 1 is placed...

Page 45: ...ke 2 with the end stop on the spa cers 1 WARNING Risk of squeezing There is risk of getting squeezed between the depth stop and the machine chassis when positioning the depth stop Do not touch the sto...

Page 46: ...ine 8 Form the workpiece 9 Press the button to open the tool 10 Check the workpiece 11 If the workpiece meets the requirements produce other identical workpieces 12 If the dimension is not reached Adj...

Page 47: ...orming range see Technical data in Section 3 the forming distance limitation is activated and the machine stops depending on the equipment With machines without any forming distance limitation tools c...

Page 48: ...d The drive unit is shut down Restart after and emergency WARNING Risk of injuries The emergency stop button was probably activated due to the occurrence of a hazardous situation A restart of the mach...

Page 49: ...ress in the machine and cause serious da mage Do not use a steam jet to clean the machine Do not use compressed air to clean the machine 1 Vacuum the machine from metal abrasion crimping scale in the...

Page 50: ...n in Section 5 Use the lock to prevent the main switch from being switched on and also attach a sign Example text Machine unit out of service for maintenance work Do not switch on Welding flame cuttin...

Page 51: ...Crimping tool Crimping tool Check for damage and wear X Retaining bolt Check for damage X Slide bearing plates Check for wear see Checking and replacing slide bearing plates in Sec tion 6 X Pressure...

Page 52: ...cts Hyd raulic liquid spills impose danger of slipping and falling Observe supplier s protection and safety instructions see data sheet Wear personal protection equipment Do not eat drink or smoke in...

Page 53: ...n 3 7 Close the air ventilation cap 2 8 Mount grating 1 9 Do not operate the machine for a minimum of four hours so that the dirt particles in the system can settle 10 Switch on the machine 11 Operate...

Page 54: ...lates for wear replace defective parts The slide bearing plate 1 is new the slide bearing plate 2 is worn ATTENTION Risk of damage to machinery Worn slide bearing plates may cause damage to the machin...

Page 55: ...ring 2 4 Remove clamping ring 2 5 Pull out old slide bearing plate 3 6 Insert the new slide bearing plate 3 Replace all eight slide bearing plates in this manner 7 Mount clamping ring 2 8 Tighten the...

Page 56: ...the micrometer must be readjusted 1 Release the screws on the cover 2 Remove the cover see Annex in Section 9 3 Loosen the counter nut 1 of the contact screw 2 4 Adjust the contact screw 2 2 5 revolut...

Page 57: ...achine forms unevenly coni cally Bearing plates worn Check bearing plates for wear and replace if necessary Base dies damaged Check base dies for damage and replace if necessary Crimping dies damaged...

Page 58: ...in eyes respiratory and intestinal tracts Hy draulic liquid spills impose danger of slipping and falling Observe supplier s protection and safety instructions see data sheet Wear personal protection e...

Page 59: ...e the machine unit before dismantling it deactivate the hydraulic pump and secure it against restart operate valve manually if any open bolted hydraulic connections slowly and carefully Check the mach...

Page 60: ...Return consumables e g oils greases test media to supplier they are hazardous waste Also observe the information given on the safety data sheet...

Page 61: ...9 Annex Individual machine unit components may deviate in their features Please indicate the serial number of the machine for spare part or ders...

Page 62: ...TU QDS F Basic TU QDS F Shelf TU QDS F 239 l End stop TA S6_S manual TA S6_S A automatic Mirror SHS S6 2 Table machine SHS S6 2 Stand alone machine Camera set OCS 10 3 retro Lamp with magnetic base LU...

Page 63: ...nut 5 2 266 195 3 Bearing segment 6 1 set 266 5 Bearing plates 8 4 266 398 3 Hydraulic cylinder 9 2 266 215 3 Clamping segment 532 8 798 110128 Cylinder bolt DIN EN ISO 4762 M8x100 533 12 798 120066...

Page 64: ...eeve 45 50 length long 1001 8 266 1192 Base dies mounted 266 1195 Complete tool 9 2 2 Basic dies Item Quantity Article code Designation 1 8 266 198 1 Basic dies 2 8 235 008 4 Locking pin 3 8 798 42002...

Page 65: ...2 1 268 284 3 Grid 3 1 268 283 2 Cover plate 4 1 266 281 2 Mounting plate 5 1 266 224 2 Cover 6 1 266 235 2 Designation sign 7 1 Limit switch attachment 8 1 266 256 4 Mounting plate 9 1 211 502 3 Rou...

Page 66: ...268 284 3 Grid 3 1 268 283 2 Cover plate 4 1 266 281 2 Mounting plate 5 1 266 224 2 Cover 12 1 268 349 2 Tank seal 13 1 715 4 Squeezing risk warning sign 14 1 578 4 Oil prohibition sign 15 1 716 4 War...

Page 67: ...9 2 4 Hydraulic system Item Quantity Part code Designation 1 1 268 293 2 Tank cover 2 2 239 517 Suction filter 3 4 3 2 239 518 Double pipe nipple...

Page 68: ...ting valve for hydraulic block 268 325 3_A 268 325 3_D Pressure limiting valve for hydraulic block 268 325 3_B Pressure limiting valve for hydraulic block 268 325 3_C 17 1 777 325 777 338 777 340 Dire...

Page 69: ...Item Quantity Part code Designation 1 2 245 515 Piston pressure switch pressure setting 40 bar...

Page 70: ...in power switch 3 1 800 021 Safety isolating transformer 4 1 8 06 001 8 06 002 Motor protection switch 6 3 10 A Motor protection switch 10 16 A No pic ture 1 8 06 003 Auxiliary switch block 6 1 8 07 0...

Page 71: ...12 1 322 400 Rectifier 9 2 6 Control A Item Quantity Part code Designation 1 1 805 A Control A complete 2 1 888 628 Keyboard PCB 3 1 8 06 013 Emergency stop button 4 1 800 061 Motor Start button 5 1...

Page 72: ...nt 8 per set 239 041 4 sw Plastic retaining pin section 239 239L 8 per set 239 041 4 Retaining bolt steel profile 239 239L 8 per set 239 151 Pressure piece profile 239 239L 8 per set 232 504 4 Retaini...

Page 73: ...standard crimping dies depending on crimping die Retaining bolt Crimping die profile 262 263 239 266 232 237 554 245 246 247 262 104 4 x 262 129 3 x 239 041 4 x 239 041 4 sw x 232 504 4 x x x 232 505...

Page 74: ...Retaining bolt Crimping die profile 262 263 239 266 232 237 554 245 246 247 245 114 4 x x x...

Page 75: ...9 6 Hydraulic diagram...

Page 76: ...9 7 Electric diagram...

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Page 79: ...9 8 Maintenance log Hydraulic oil Hose assembly Retaining bolt Slide bearing plate Pressure springs Guiding plate Relay Remark Date Signature...

Page 80: ...of the UNIFLEX machine and have been informed on all safety related details In addition I declare that I have read and under stood this Operation Manual completely City Date Name Signature City Date N...

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