Danfoss ET5020, 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: ...h 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 Machin...

Page 5: ...osed by noise 14 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 16 2 4 1 Working area 16 2 4 2 Emergency stop button 17 2 4 3 Protection e...

Page 6: ...hanging the crimping dies with the quick die change system only profile 239 45 5 4 Adjusting the depth stop 47 5 5 Setting the forming dimension 49 5 6 Stop 50 5 7 Emergency stop 50 5 8 Cleaning 51 6...

Page 7: ...nual 72 9 4 Depth stop automatic 73 9 5 Spare parts kit 74 9 6 Retaining bolt for standard crimping dies depending on crimping die 75 9 7 Hydraulic diagram 77 9 8 Electric diagram 78 9 9 Maintenance l...

Page 8: ...ss 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 inst...

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: ...unit the Operation Manual must also be handed over 1 3 Name plate The name plate is fixed near the power cable 1 4 Abbreviations CFM Crimp Force Monitoring FD Manual Flow Divider PB Crimping dies PBK...

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: ...with the location as well as with operating the fire alarm and fighting means Free access to this equipment must be ensured Never use water to extinguish a fire For appropriate fire extinguishing acti...

Page 16: ...area The working area is designed as the area 1 metre all around the ma chine shaded Keep the working area free from trip hazards Use ducts for lines and cables Provide good illumination Keep access...

Page 17: ...of supplying additional standard protection equipment to gether with the machine for the prevention of potential residual risks imposed by the machine The necessity of additional workpiece specific pr...

Page 18: ...request Please do not hesitate to address your per sonal contact for consultation Mounted safety equipment must not be removed bypassed or avoided 2 4 4 Warning signs on the machine Hand injury on the...

Page 19: ...Oiling greasing prohibited on the die system Illegible or missing warning signs must immediately be replaced by the owner...

Page 20: ...system 5 Control panel with buttons and control system CONTROL C 2 The crimping tool 1 is closed hydraulically whereby the workpiece is formed The pressure needed for this purpose is built up by the e...

Page 21: ...he die system comprises basic dies and crimping dies All basic dies 4 are supported on sliding plates 3 The crimping dies 1 are plugged onto the basic dies 4 After the forming process the basic dies 4...

Page 22: ...tions PFM option Pressure Force Mo nitoring Forming to a defined pressure This process is used for special applications e g insulators with a fib reglass rod which are pressure sensitive Due to the wo...

Page 23: ...specific safeguards ATTENTION Risk of damage to machinery The machine lifetime is reduced with a high permanent load while wear increases disproportionately When using the machine in series production...

Page 24: ...ted Open tool button 6 Illuminated Close tool button 7 Locking lever angle setting 8 control panel of CONTROL C 2 The illuminated buttons and may be arranged the other way round depending on the contr...

Page 25: ...the relevant optional packages 2 2 x USB sockets for the use of memory media callipers or bar code scanners certified by UNIFLEX only 3 5 Electric sockets 1 Main power switch 2 Socket for single foot...

Page 26: ...chine pedal 2 Open machine pedal WARNING Risk by fatiguing posture A static posture may result in work related musculosceletal disor ders and reduce productivity Make sure that operators have sufficie...

Page 27: ...6 Connection cable with plunger switch 7 Foot clamp 8 Clamp lever 9 Pipe 10 Cross clamp 11 Hollow profile 3 8 Operation modes The control unit provides for the following operation modes for operat in...

Page 28: ...ming process is started manually via the buttons on the control panel or exter nal buttons e g the dual foot switch Activate the button for closing and forming Dual foot switch The right foot switch i...

Page 29: ...The operation of the control system is described in a separate Op eration Manual This description is supplied with the machine...

Page 30: ...ion mode S6 70 Noise level 70 dB A Degree of protection IP 40 Function Forming force 1320 kN 135 t Max forming range dies 12 mm max outer diameter of the fittings before forming Maximum dies 70 mm Ope...

Page 31: ...ses PE 380 V 50 60 Hz 3 phases PE 400 V 50 60 Hz 3 phases PE 420 V 50 Hz 3 phases PE 440 V 60 Hz 3 phases PE 460 V 60 Hz 3 phases PE 480 V 60 Hz 3 phases PE Voltage selection by plug posi tion 230 V 5...

Page 32: ...in 2500 kg m2 Floor quality B25 Evenness Max unevenness 5 mm m Inclination max 5 mm m Ambient conditions Ambient temperature 10 o C 35 o C Air humidity 45 65 The data are theoretical computed values o...

Page 33: ...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 34: ...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 35: ...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 36: ...s protection and safety instructions see data sheet Wear personal protection equipment Do not eat drink or smoke in the working area and when handling consumables Ensure good ventilation Avoid floor...

Page 37: ...tage range described in this Section is only permissible for multi voltage machines MVA Reconnecting the machine with a fixed input voltage will result in the destruction of the ma chine Do not reconn...

Page 38: ...ion switch 1 as specified in Section 3 Technical data The permissible voltage frequency ranges and the relevant motor protection setting are also indicated on the sticker in the control ca binet door...

Page 39: ...or operating the machine without oil will destroy the hyd raulic pump Make sure that the hydraulic oil filling in the machine is suffi cient before starting the machine Ensure that the rotational dir...

Page 40: ...t 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 observed The control cabinet must be closed securely Eating...

Page 41: ...he tool The forming dimension and the dies have been entered in the control system please also refer to Setting the forming dimen sion in Section 5 Preferably form the workpiece in the centre of the c...

Page 42: ...diameter pressure is reached 4 Manual operation mode Press the button upon comple tion of the forming process to open the tool 5 Semiautomatical operation mode Wait until the hold time de fined in th...

Page 43: ...unted workpiece in the tool 3 Hold the workpiece with one hand during the forming process 4 Activate and hold the dual foot switch 5 Manual operation mode When the forming process is comple ted releas...

Page 44: ...k of squeezing When the die system closes there is a risk of getting squeezed between the die and the workpiece Keep the feed opening for the workpiece as small as possi ble Keep a minimum distance of...

Page 45: ...ual dimension and the specified dimension see Setting the forming dimension in Section 5 The Automatic External mode with the depth stop is only functional if the connection of the depth stop is estab...

Page 46: ...yed if the retaining bolts do not fit in the mounting hole of the base dies or intermediate dies Pay attention to the correct position of the quick die change system with crimping dies 7 Press the but...

Page 47: ...base and or intermediate die 3 so that it does not protrude In the figure the crimping die 1 is placed correctly 5 4 Adjusting the depth stop The depth stop must be specifically adjusted according to...

Page 48: ...ne chassis when positioning the depth stop Do not touch the stop in Do not reach into the opening of the crimping tool 2 Loosen clamping lever 1 and clamping lever 4 3 Move the sleeve 2 and or stop di...

Page 49: ...the workpiece Activate automatic opening in the control for series production 5 5 Setting the forming dimension The forming dimension X must be set specifically for the workpiece 1 Read the forming d...

Page 50: ...achine 3 Deactivate the main switch 1 4 Check the machine for contamination leaks and external da mage 5 Check the crimping tool and retaining bolts for contamination damage and secure fitting 6 Check...

Page 51: ...2 Unlock the emergency stop button 3 Reset the error messages on the control 5 8 Cleaning ATTENTION Risk of damage to machinery If the machine is cleaned with a steam jet or compressed air dirt and w...

Page 52: ...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 53: ...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 s...

Page 54: ...signs on the machine in Section 2 X Hydraulic oil changes and wear part replacements must be recor ded in the maintenance log 6 3 Hydraulic oil change CAUTION Risk of injuries Contact with hydraulic...

Page 55: ...e is warm to the touch 3 Dismantle the grating 1 4 Open the air ventilation cap 2 5 Pump out hydraulic oil using an external pump 6 Add new hydraulic oil see Technical Data in Section 3 7 Check oil le...

Page 56: ...ring plates 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...

Page 57: ...w slide bearing plates have two different surfaces The side with the white grey or red coating is the slide bearing plates surface for the dies The shiny metal side of the slide bearing plates is the...

Page 58: ...aced at the same location as before After replacement of the slide bearing plates the machine has to be recalibrated see CONTROL C 2 IPC Operation Manual 6 5 Replacement of relay opto coupler 1 Deacti...

Page 59: ...5 Close flap...

Page 60: ...eplace if necessary Base dies damaged Check base dies for damage and replace if necessary Crimping dies damaged Check crimping dies for da mage and replace if necessary Crimping area not centred Prefe...

Page 61: ...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 62: ...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 63: ...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 64: ...QDS 239 C QDS 239 R TU QDS crimping die deposit system QDS S 2 single row TU QDS F Shelf TU QDS F 239 l End stop TA 220 TA HM 22x 3 C A Mirror SHS 220 290 HM 220 3 SHS 225 HM 225 3 Camera set OCS 10...

Page 65: ...9 2 Spare parts list 9 2 1 Mechanical equipment Item Quantity Article code Designation 1 1 239 018 2 Upper yoke 2 1 239 019 2 Lower yoke 3 1 239 044 3 Beam 4 2 239 024 3 Tension rod...

Page 66: ...49 141 Compression spring 10 2 239 004 4 Lateral dies 11 4 239 008 4 Yoke disc 12 1 239 070 3 Oil collecting ring 13 4 6040 DU DU sleeves 14 8 239 010 4 Protective plate 15 4 239 011 4 Side bearing pl...

Page 67: ...4 Front panel HM 225 22 1 255 054 2 Cover 23 1 255 104 3 Protecting grating 24 2 239 020 3 Side cover HM 220 25 1 239 049 3 Protection cover 26 1 266 353 Oil inspection window 27 1 239 121 4 Position...

Page 68: ...094 3 Blind plate 31 1 255 063 2 Gasket for vacuum plate 315 2 578 4 Oil prohibition sign 316 2 715 4 Squeezing risk warning sign 317 6 716 4 Warning of hand injuries sign 1 000 1 239 1520 Crimping to...

Page 69: ...9 2 2 Hydraulic system Item Quantity Article code Designation 1 1 239 220 2 Tank plate 2 1 264 325 3 Control block 3 1 239 308 Cartridge valve HM 220 3 4 1 227 001 Control valve...

Page 70: ...7 1 239 352 Pump 8 1 777 300 Pump carrier 9 1 777 301 3 Gasket 10 1 GN 552 R3 4 A Bleed screw 11 1 239 517 Suction filter 12 1 N 0 Re suction filter 13 1 239 518 Double pipe nipple 14 1 238 604 Hydrau...

Page 71: ...t Item Quantity Article code Designation 1 1 1 807 700 807 860 CONTROL C 2 CONTROL IPC 2 1 807 415 Position encoder 3 1 8 06 100 Main power switch 4 1 888 621 Voltage selection unit 5 1 888 014 Motor...

Page 72: ...pto coupler 8 1 807 375 CPU 9 1 255 070 1 Electrical sheet complete 10 1 807 453 Outside cable kit 11 1 238 011 Electric motor 9 3 Depth stop manual Item Quantity Part code Designation 1 1 TA 220 Dept...

Page 73: ...h stop automatic Item Quantity Part code Designation 1 1 TA HM 22x 3 C A Depth stop automatic complete 2 1 807 430 Plunger switch complete 3 1 239 008 Cross clamping piece with two clamping levers 4 1...

Page 74: ...39 041 4 Retaining bolt steel profile 239 239L 1 239 151 Pressure spring screw profile 239 1 239 8 Guiding plate set 1 239 7 Lateral die set 1 239 6 Basic die set 1 239 2 Slide bearing plate set 1 239...

Page 75: ...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 76: ...Retaining bolt Crimping die profile 262 263 239 266 232 237 554 245 246 247 245 114 4 x x x...

Page 77: ...9 7 Hydraulic diagram...

Page 78: ...9 8 Electric diagram...

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Page 87: ...9 9 Maintenance log Hydraulic oil Hose assembly Retaining bolt Slide bearing plate Pressure springs Guiding plate Relay Remark Date Signature...

Page 88: ...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...

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