Danfoss ET4200 Operator'S Manual Download

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Summary of Contents for ET4200

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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: ...nt 13 2 3 4 Risks imposed 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 14 2 4 Safety 15 2 4 1 Working area 15 2 4 2 Emergency Stop 16 2 4...

Page 6: ...orming dimension 41 5 6 Forming travel limitation 41 5 7 Stop 42 5 8 Emergency stop 43 5 9 Cleaning 43 6 Maintenance 45 6 1 What you have to observe 45 6 2 Maintenance schedule 45 6 3 Hydraulic oil ch...

Page 7: ...s kit 64 9 5 Service tool 64 9 6 Retaining bolt for standard crimping dies depending on crimping die 65 9 7 Hydraulic diagram 67 9 8 Electric diagram 68 9 9 Maintenance log 72 9 10 Declaration of qual...

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: ...ate is fixed near the power cable 1 4 Abbreviations CFM Crimp Force Monitoring FD Manual Flow Divider PB Crimping dies PBK Calibration crimping dies PFC Pressure Force Control PFM Pressure Force Monit...

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: ...e machine unit owner must pro vide for appropriate protection e g instruct staff to wear ear protection provide information instructions on risks identify hazardous areas provide health monitoring 2 3...

Page 15: ...safety data sheet of the hydraulic oil supplier 2 4 Safety 2 4 1 Working area The working area is defined as the area 1 metre all around the ma chine shaded Keep the working area free from trip hazard...

Page 16: ...omer specific workpieces UNIFLEX is not capable of supplying additional standard protection equipment to gether with the machine for the prevention of potential residual risks imposed by the machine T...

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 operator...

Page 19: ...gency stop button 4 Control panel 5 Micrometer 6 Crimping tool The crimping tool 6 is closed hydraulically whereby the work piece is formed The pressure needed for this purpose is generated in the cyl...

Page 20: ...es are to be formed on a large machine After the forming process the base dies are pressed apart by the pressure springs 3 when the tool opens The bearing segments 1 on the front guide the base dies a...

Page 21: ...es may by overstressed by the forming process so that this may result in a sudden failure Chips or seriously accelerated workpiece parts impose a high risk po tential for operators individuals and obj...

Page 22: ...3 4 Operation and display elements 1 Close tool button 2 Main switch emergency stop button 3 Open tool button 3 5 Depth stop accessory 1 Connection cable with plunger switch...

Page 23: ...2 Clamp lever 3 Compression spring 4 Compression spring 5 Stop cone 6 Clamp 7 Bushing 8 Plunger sleeve...

Page 24: ...level 70 dB A Protection class IP 40 Function Forming force 1200 kN 120 t Max forming range crimping dies 12 mm max outside diameter of the fittings before the forming process Maximum crimping dies 6...

Page 25: ...ll load current of circuit 13 7 A Full load current of control circuit primary 0 48 A Hydraulic system Oil volume approx 35 l Oil type HM 46 or HLP 46 ISO 11158 ISO 6743 4 10 filtered The oil type can...

Page 26: ...tions 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 chine Work pie...

Page 27: ...aws and regulations relating to securing loads shall be ob served during transport The machine must only be unloaded and transported with a crane Lifting gear with a sufficient length width and liftin...

Page 28: ...that it supports with its full width 4 Use the crane to lift the machine with the lifting gear and trans port it to the installation site 4 2 Intermediate storage of machine unit If the machine unit c...

Page 29: ...taff Section 9 WARNING Risk of injuries Machine components might loosen during transport Such com ponents might be flung out during to the forming process There is a risk of being injured Open and clo...

Page 30: ...e supplier 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 Av...

Page 31: ...power cable of the machine connected to the local mains by a electrically qualified person according to the regu lations of the Electricity Board Do not operate the machine without a sufficiently rate...

Page 32: ...y the hyd raulic pump Make sure that the amount of hydraulic oil in the machine is sufficient before starting the machine 4 3 3 Bleeding the hydraulic system 1 Switch on the machine 2 Operate the mach...

Page 33: ...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 34: ...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 35: ...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 36: ...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 37: ...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 38: ...ce the crimping die 2 in the 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 adjusted specifica...

Page 39: ...the cable 3 into the socket for the depth stop 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 t...

Page 40: ...4 5 Push the sleeve 2 towards the fitting 6 Tighten the clamping lever 4 securely 7 Switch on the machine 8 Activate the illuminated foot pedal The machine is closed automatically when the workpiece i...

Page 41: ...g dimension less crimping die di ameter 5 Form the workpiece 6 Check the workpiece 7 If the dimension is reached manufacture other identical workpie ces 8 If the dimension is not reached Adjust differ...

Page 42: ...ain 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 the oil level 7 Remove c...

Page 43: ...hazardous situation A restart of the machine may cause injuries if the hazardous situation has not yet been remedied Remedy the hazardous situation before a restart 1 Remedy the cause of the emergency...

Page 44: ...1 Vacuum the machine from metal abrasion crimping scale in the opened crimping tool or use a soft cloth to clean it For this pur pose remove the crimping dies and the intermediate dies...

Page 45: ...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 46: ...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 47: ...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 48: ...ion cap 1 7 Do not operate the machine for a minimum of four hours so that the dirt particles in the system can settle 8 Switch on the machine 9 Operate the machine in the idle mode for two minutes 10...

Page 49: ...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 50: ...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 51: ...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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...9 1 Machine overview...

Page 58: ...9 C QDS 239 R TU QDS crimping die deposit system TU QDS F Basic TU QDS F Shelf TU QDS F 239 l End stop TA S3 1 4 1 Mirror SHS S3 1 Camera set OCS 10 3 retro Lamp with magnetic base LUS Die wrench 239...

Page 59: ...64 191 0 Pressure plate back 2 1 264 171 0 Pressure plate front 3 4 263 390 3 Hydraulic cylinder 4 1 264 2 Base dies set 5 4 264 194 3 Ball nut 6 4 264 186 4 Sleeve 7 2 264 185 3 Bearing segment 8 8 2...

Page 60: ...ocket ISO 4762 M5x35 galvanised 504 4 798 210035 Washer DIN EN ISO 7089 36 galvanised 505 8 798 110127 Cylinder screw with hexagon socket ISO 4762 M8x80 galvanised 506 8 798 750004 Spring washer DIN12...

Page 61: ...side 6 1 777 943 Designation sign 7 1 219 400 3 Crimping micrometer 8 1 211 502 3 Round closing blank Uniflex 9 1 578 4 Oil prohibition sign 10 1 715 4 Squeezing risk warning sign 11 1 716 4 Hand inj...

Page 62: ...ydraulic block complete 6 1 235 326 Hydraulic block pressure limitation valve 7 2 239 516 Suction filter 8 1 227 001 NG 6 directional valve 24 V DC 9 1 264 321 3 Air ventilation cap with oil dipstick...

Page 63: ...mer 2 2 2 8 06 077 8 06 078 Pushbutton frame Contact block 1 make 1 break with retainer 3 1 800 053 Main switch 4 1 8 06 001 8 06 002 8 06 145 8 06 147 Motor protection switch 6 3 10 A Motor protectio...

Page 64: ...ts set S3 1 4 1 front bearing segments 8 per set 239 041 4 sw Retaining bolt plastic profile 239 239L 8 per set 239 041 4 Retaining bolt steel profile 239 239L 8 per set 239 151 Pressure piece 1 263 1...

Page 65: ...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 66: ...Retaining bolt Crimping die profile 262 263 239 266 232 237 554 245 246 247 245 114 4 x x x...

Page 67: ...9 7 Hydraulic diagram...

Page 68: ...9 8 Electric diagram...

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Page 72: ...9 9 Maintenance log Hydraulic oil Hose assembly Retaining bolt Slide bearing plate Pressure springs Guiding plate Relay Remark Date Signature...

Page 73: ...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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Danfoss ET4200, Operator'S Manual

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