Danfoss ET5025, Operator'S Manual

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Page 2: ...erman Date of revision 2022 09 28 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: ...der system 5 Control panel with buttons and control system IPC The crimping tool 1 is closed hydraulically whereby the workpiece is formed The pressure needed for this purpose is built up by the elect...

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: ...en tool button 4 Illuminated foot switch 5 Motor off button 6 Illuminated Motor on button 7 2 x USB sockets 8 Emergency stop button 9 Control panel of CONTROL IPC The operation of the control system C...

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

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: ...nction Forming force Forming force is adjustable on C 2 control 1600 kN 160 t 750 kN 75 t Max forming range dies 12 mm max outer diameter of the fittings before forming Maximum dies 70 mm Opening size...

Page 31: ...ic connection Connection power 4 kW Supply voltage adjustable 380 V 50 60 Hz 3 phases PE Back up fuse 400 V 16 A delayed preferably thermal fuses if circuit breakers are used these should be of the cl...

Page 32: ...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 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: ...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 37: ...fixed input voltage will result in the destruction of the ma chine Do not reconnect machines with fixed input voltage WARNING Risk by electrical voltage There is a risk of electrocution near the live...

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 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 level 8 Close the air ventilation cap 2 9 Mount grating 1 10...

Page 56: ...ing 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 machine and lead to inaccuracies of the forming dimension R...

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 Part code Designation 1 1 255 018 1 Upper yoke 2 1 255 016 1 Lower yoke 3 1 255 023 3 Beam 4 2 255 035 3 Tension rod...

Page 66: ...l dies 11 4 255 036 3 Yoke disc 12 1 255 050 3 Oil collecting ring 13 4 8060 DU DU sleeves 14 8 255 033 4 Protective plate 15 4 255 011 4 Side bearing plate 16 8 255 027 4 Basic bearing plate 17 4 798...

Page 67: ...ront panel HM 225 25 1 255 054 2 Cover 26 1 255 104 3 Protecting grating 27 2 255 034 4 Side cover HM 225 28 1 255 028 2 Protective cover 29 1 266 353 Oil inspection glass 30 1 239 121 4 Position enco...

Page 68: ...late 34 1 255 063 2 Gasket for vacuum plate 35 1 241 500 Holder IPC 315 2 578 4 Oil prohibition sign 316 2 715 4 Squeezing risk warning sign 317 6 716 4 Warning of hand injuries sign 1000 1 255 1520 C...

Page 69: ...9 2 2 Hydraulic system Item Quantity Article code Designation 1 1 255 055 3 Tank plate 2 1 255 320 3 Control block 3 1 227 001 Control valve No fig 1 220 916 Pressure sensor...

Page 70: ...1 N 0 Re suction filter 12 1 239 518 Double pipe nipple 13 1 238 604 Hydraulic hose 14 1 239 332 Hydraulic hose 15 1 255 062 2 Tank seal 16 2 238 619 Hose line 17 1 239 331 Hose line 18 1 255 602 Hose...

Page 71: ...9 2 3 Electric equipment Item Quantity Article code Designation 1 1 807 880 IPC 2 2 1 807 415 Position encoder 3 1 8 06 100 Main power switch 4 1 888 621 Voltage selection unit...

Page 72: ...411 888 410 Passive interface Relay Opto coupler 8 1 807 375 CPU 9 1 807 601 Electric cabinet 10 1 807 468 Outside cable kit 11 1 232 011 Electric motor 9 3 Depth stop manual Item Quantity Part code...

Page 73: ...lug 9 4 Depth 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 clampin...

Page 74: ...file 239 239L 8 239 041 4 Retaining bolt steel profile 239 239L 1 239 151 Pressure spring screw profile 239 1 255 4 Guiding plate set 1 255 3 Lateral die set 1 255 2 Basic die set 1 255 1 Slide bearin...

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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