Danfoss ET5070, Operator'S Manual

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Page 2: ...erman Date of revision 2022 10 04 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: ...ng the crimping dies intermediate dies with a die key 44 5 4 2 Changing the crimping dies with the quick die change system only profile 239 46 5 5 Adjusting the depth stop 48 5 6 Setting the forming d...

Page 7: ...2 Hydraulic system 74 9 3 3 Electric equipment 76 9 4 Base dies 78 9 5 Intermediate dies 237 239 2L2 79 9 6 Spare parts kit 80 9 7 Retaining bolt for standard crimping dies depending on crimping die...

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: ...ring transport 2 3 2 Risks imposed by electricity There is a risk of electrocution near the live parts Work on electric systems may only be performed by qualified electricians or instructed and traine...

Page 14: ...required Higher noise emissions may occur when other machine unitry is sim ultaneously used at the workplace The machine unit owner must pro vide for appropriate protection e g instruct staff to wear...

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: ...ng area The working area is designed as the area 3 ft all around the machine shaded Keep the working are free from trip hazards Use ducts for lines and cables Provide good illumination Keep access to...

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: ...n equipment upon 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 H...

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

Page 20: ...lectric motor pump control block 4 Control cabinet 5 Control panel with buttons and control system CONTROL C 2 IPC 6 Position encoder system The crimping tool 1 is closed hydraulically whereby the wor...

Page 21: ...es the master dies 1 are lo cated on the positions 3 o clock 6 o clock 9 o clock and 12 o clock The secondary dies 2 are located in between All base dies are mounted on slide plates The crimping dies...

Page 22: ...re set diameter is reached in or der to detect workpiece deviations PFM option Pressure Force Mo nitoring Forming to a defined pressure This process is used for special applications e g insulators wit...

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 6 Electric sockets 1 Main power switch 2 Socket for single foot...

Page 26: ...3 7 Depth stop accessory 1 Connection cable with plunger switch 2 Star handle screw 3 Sleeve 4 Compression spring 5 Stop disc 6 Clamping yoke 7 Locking shaft 8 Gusset plate...

Page 27: ...rovides for the following operation modes for operat ing the forming tool Manual operation C 2 IPC is activated in the control The forming process is controlled manually via the buttons on the control...

Page 28: ...sed automatically when the workpiece acti vates the depth stop by pressure As soon as the forming diameter or forming pressure as defined in the control is reached the tool stops and opens automatical...

Page 29: ...ion mode S6 70 Noise level 70 dB A Protection class IP 40 Function Forming force 3150 kN 315 t Max forming range dies 20 mm max outer diameter of the fittings before forming Maximum dies 145 mm Openin...

Page 30: ...hases 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 50 60 Hz 3 Phases 380 480 V 50 60 Hz 3 Phases Motor protection setting red ma...

Page 31: ...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 or values me...

Page 32: ...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 33: ...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 34: ...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 35: ...ink or smoke in the 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 ig...

Page 36: ...nput 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 parts W...

Page 37: ...e voltage frequency ranges and the relevant motor protection setting are also indicated on the sticker in the control cabinet door 3 Have the power cable of the machine connected to the local mains by...

Page 38: ...oil filling in the machine is suffi cient before starting the machine Ensure that the rotational direction of the motor is correct Observe the red arrow on the motor cover 4 3 3 Bleeding the hydraulic...

Page 39: ...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 40: ...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 41: ...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 42: ...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 43: ...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 44: ...rst forming process Correct the forming dimension in case of deviations between the actual dimension and the specified dimension see Setting the forming dimension in Section 5 The Automatic External m...

Page 45: ...ping dies with the same label and diameter One set comprises eight crimping dies or seven crimping dies and one associated marking die Removing the crimping dies 1 Open the crimping tool fully 2 Deact...

Page 46: ...dies with the quick die change system only profile 239 1 Select the change position for crimping dies in the control by ac tivating the button QDC 2 Press the button to open the crimping tool so that...

Page 47: ...ase dies or intermediate dies Pay attention to the correct position of the quick die change system with crimping dies 7 Press the button to close the tool All retaining bolts 3 must slide into the rel...

Page 48: ...ng die 2 in the base and or intermediate die 3 so that it does not protrude In the figure the crimping die 1 is placed correctly 5 5 Adjusting the depth stop The depth stop must be adjusted specifical...

Page 49: ...Risk of squeezing There is risk of getting squeezed between the depth stop and the machine chassis when positioning the depth stop Mount the linchpin Tighten the star handle screw 5 Tighten the star...

Page 50: ...he dimension is not reached Adjust difference on the control unit form again and check the workpiece Activate automatic opening in the control for series production 5 6 Setting the forming dimension T...

Page 51: ...meter repeat the forming process and check the workpiece 5 7 Stop 1 Complete the forming process 2 Deposit the work piece outside the machine 3 Deactivate the main switch 1 4 Check the machine for con...

Page 52: ...nd emergency WARNING Risk of injuries The emergency stop button was probably activated due to the occurrence of a hazardous situation A restart of the machine may cause injuries if the hazardous situa...

Page 53: ...ay ingress 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 i...

Page 54: ...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 cutting...

Page 55: ...ure that replacement hoses are of equivalent quality high pressure hoses 6 Crimping tool Crimping tool Check for damage and wear X Retaining bolt Check for damage X Slide bearing plates Check for wear...

Page 56: ...ety equipment Emergency stop button Check function X Check permanently installed partitioning protection equipment and covers for completeness and correct installation X Check case foot switch for com...

Page 57: ...r 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 58: ...heck oil level The oil level should be at the centre of the fill level indicator 2 refill hydraulic oil if required Hydraulic oil filter The hydraulic oil filter is located in the machine enclosure an...

Page 59: ...level refill hydraulic oil if required 11 Operate the machine in the idle mode for two minutes Dispose of the oil and filter in compliance with the applicable local environmental protection regulatio...

Page 60: ...es of the forming dimension Replace worn slide bearing plates in good time Replacing slide bearing plates 1 Open the crimping tool fully 2 Deactivate the machine on the main switch and secure it again...

Page 61: ...ed screws with slot 6 four each in the front and back 9 Slightly lift off the master dies 10 by using a screw driver and replace the four main bearing plates 5 by new ones In doing so use the new main...

Page 62: ...onal spring mounted pressure piece 4 has to be mounted in the intermediate dies 1 Remove the intermediate die from the machine 2 Insert a pressure piece 4 in the hole 3 and screw it in by twelve revol...

Page 63: ...e power switch and secure it against unintentional restart 2 Open the control cabinet 3 Open the flap 90 and press down on the hinge with the opened flap 1 The relay opto coupler 2 will spring up 4 Re...

Page 64: ...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 Check crimping dies for da mage and replace if n...

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Page 66: ...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 67: ...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 68: ...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 69: ...39 C QDS 239 R TU QDS system QDS S 2 double row TU QDS F Shelf TU QDS F 239 l Depth stop TA HM 3xx C A Mirror SHS 375 380 Camera set OCS 10 3 retro Lamp with magnetic base LUS Die key 239 017 4 Oil co...

Page 70: ...9 2 Options only available ex works Options Item number Manual current regulator 257 920 not for PFC machines 9 3 Spare parts list 9 3 1 Mechanics...

Page 71: ...head screw DIN 921 M8x12 25 32 798 220016 Shim ring DIN 988 6 0x12 0x0 1 30 2 238 300 3 Hydraulic cylinder 31 1 238 311 3 Hydraulic cylinder 505 2 798 120012 Hexagon socket head screw DIN EN ISO 4762...

Page 72: ...pad 203 2 232 168 3 Protection plate lateral Guidance 206 1 241 018 3 RAL 9007 Protection hood position sensor 208 1 241 021 3 RAL 5012 protection plate 209 1 235 015 3 Holder operator panel 312 1 266...

Page 73: ...er Description 315 2 578 4 Oil prohibition sign 316 2 715 4 Warning sign crushing risk 317 6 716 4 Warning sign Warning of hand injuries 1000 1 238 1100 Pressing tool complete HM 325 HM 375 1001 1 Set...

Page 74: ...9 3 2 Hydraulic system Item Quantity Part code Designation 300 1 232 059_XYZ Hydraulic manifold complete XYZ supplier ID letter...

Page 75: ...ell housing HM 325 HM 375 HM 380 HM 3xxPFC No pic ture 1 1 M28 238 251 Coupling HM 325 Coupling HM 375 HM 380 HM 3xx PFC 350 2 232 031 Hose assembly 351 1 238 603 Hose assembly 352 2 238 604 Hose asse...

Page 76: ...osition encoder 402 1 8 06 100 Main power switch 403 1 888 621 Voltage selection unit 404 1 880 014 Motor protection combination 405 1 807 318 Switching power supply 406 1 888 406 888 411 888 410 Pass...

Page 77: ...011 Electrical motor 4 kW Electrical motor 5 5 kW 412 1 888 701 Selec amplifier for PFC machines only Position Number Article number Designation 420 1 TA HM 3xx C A Depth stop complete 421 1 807 430...

Page 78: ...rt code Designation 1 4 4 237 101 2 237 102 2 Master dies Secondary dies 2 8 232 153 4 Locking bolt 3 8 D 195A 21 Pressure spring 4 8 798 420027 Threaded pin DIN EN ISO 4028 M5x10 5 8 798 420026 Threa...

Page 79: ...9 5 Intermediate dies 237 239 2L2 Item Quantity Article code Designation 1 8 239 151 Spring mounted pressure piece 2 8 232 504 4 Holding pin...

Page 80: ...8 232 504 4 Retaining bolt profile 232 237 237L 554 8 239 041 4 sw Retaining bolt plastic profile 239 239L 8 239 041 Retaining bolt steel profile 239 239L 1 239 151 Pressure spring screw profile 239 1...

Page 81: ...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 82: ...Retaining bolt Crimping die profile 262 263 239 266 232 237 554 245 246 247 245 114 4 x x x...

Page 83: ...9 8 Hydraulic diagram...

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Page 85: ...9 9 Electric diagram...

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Page 91: ...9 10 Maintenance log Hydraulic oil Hose assembly Retaining bolt Slide bearing plate Pressure springs Guiding plate Relay Remark Date Signature...

Page 92: ...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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