Danfoss ET4350 User Manual Download

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Summary of Contents for ET4350

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Page 2: ...German 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 communication of its contents to others without explicit authori zation are prohibited Offenders will be held liable for the payment of damages All rights reserved in the event of the grant of a patent util...

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Page 4: ...ch 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 Machinery Safety Regulations 2008 UK Electromagnetic Compatibility Regulations 2016 This declaration are invalid when the machine is modified or if unau thorized and unapproved third party components are u...

Page 5: ...e 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 15 2 4 1 Working area 15 2 4 2 Protection equipment 16 2 4 3 Warning signs on the machine 16 3 Machine description 18 3 1 Design and function 18 3 2 Operating elements 20 3 3 Forming process 20 3 4 Depth stop accessory 21 3 5 Technical data 22 4 Transport and commissioning 25 4 1 Trans...

Page 6: ...etting the forming dimension 42 5 7 Forming travel limitation 42 5 8 Stop 43 5 9 Emergency stop 43 5 10 Cleaning 44 6 Maintenance 45 6 1 What you have to observe 45 6 2 Maintenance schedule 45 6 3 Hydraulic oil change 47 6 4 Checking and replacing slide bearing plates 49 6 5 Micrometer adjustment 51 7 Troubleshooting 52 8 Decommissioning disposal 53 8 1 Dismantling 54 8 2 Recycling 54 8 3 Consumab...

Page 7: ...9 5 Retaining bolt for standard crimping dies depending on crimping die 63 9 6 Hydraulic diagram 65 9 7 Electric diagram 66 9 8 Maintenance log 67 9 9 Declaration of qualified staff 68 ...

Page 8: ...ess 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 instructed in the operation of the machine unit and has signed in the Annex Figures may include accessories options Customer specific equipment may vary The product images shown are for reference only an...

Page 9: ...rm 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 must be at least 18 years old and have completed training for the task i e they must have attended a specialist voca tional training A fitter must observe the instructions in the Operation Manual mu...

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 Calibration crimping dies PFC Pressure Force Control PFM Pressure Force Monitoring QDC Quick crimping die change system ZWB Intermediate dies ...

Page 11: ...ult 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 environment may be dam ages This warning is supplemented by a hazard symbol or a excla mation mark 2 2 Intended use This machine is a forming machine for industrial use only suitable for the manufacture of h...

Page 12: ...idered 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 ap proved by UNIFLEX misuse of consumables and waste materials In particular non metal workpieces may by overstressed by the for ming process so that this may result in a sudden failure Chips or se ri...

Page 13: ...e 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 electrician Deactivate the machine unit and secure it against unintentional restart before maintenance 2 3 3 Risks imposed by hydraulic equipment Risks are imposed by all hydraulic lines and connections Hyd...

Page 14: ...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 ear protection provide information instructions on risks identify hazardous areas provide health monitoring 2 3 5 Risks imposed by substances Oils greases and emulsions may penetrate the skin When handling hazardous substances oils and greases the manuf...

Page 15: ... 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 working area is defined 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 to hydraulic supply free ...

Page 16: ...eing inserted into the forming machine The pres sure joining of insulators structural steel and steel ropes too may re quire special safeguards The owner has to consider the need for adapted protection equip ment before commissioning If such need exists the relevant protec tion equipment has to be mounted before commissioning of the ma chine UNIFLEX will provide you with customized solutions for p...

Page 17: ...Hand injury on the die system Risk of squeezing on the die system Oiling greasing prohibited on the die system Illegible or missing warning signs must immediately be replaced by the operator ...

Page 18: ...eter measuring range 0 400 bar The crimping tool 1 is closed hydraulically whereby the work piece is formed The pressure needed for this purpose is generated in the cylinders by the pump 4 driven by the power unit The actual forming process is controlled via the buttons on the control console 3 The micrometer 2 is used to change the final diameter of the die system ...

Page 19: ...o the base dies 2 The intermediate dies are required if small work pieces 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 axially in the tool Accessories The machine can be fitted with accessories A list of the available ac cessories is included in the...

Page 20: ...e set diameter regar dless of the required forming force The required forming force may be up to the machine s maximum 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 parts impose a high risk po tential for operators individuals and objects even outsi...

Page 21: ...y Forming machines for servicing are not intended for permanent operation and are not suitable for series production Do not perform more than 200 crimping actions per day 3 4 Depth stop accessory 1 Connection cable with plunger switch 2 Clamp lever 3 Compression spring 4 Compression spring 5 Stop cone 6 Clamp 7 Bushing 8 Plunger sleeve ...

Page 22: ...rox 17 kg Control CONTROL A Noise level 70 dB A Operation mode S3 10 Protection class IP 40 Function Forming force 1800 kN 180 t Max forming range Ø crimping dies 12 mm max outside diameter of the fittings before the forming process Maximum Ø crimping dies 62 mm Opening size without dies 105 mm Opening distance 35 mm Closing speed 1 44 mm s Forming speed 0 44 mm s Opening speed 1 58 mm s ...

Page 23: ...connection Power rating 2 kW Voltage rating 12 V Hydraulic system Oil volume approx 4 l Oil type HLP 46 DIN 51524 10 filtered System pressure max 330 bar Workbench Stable level workbench with a carrying capacity of approx 500 kg We recommend industrial flooring which meets the following structural requirements Permanent floor loading Approx 0 07 kg mm2 Floor carrying capacity Min 2500 kg m2 Floor ...

Page 24: ...mbient 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 chine ...

Page 25: ...secured safely within the packaging All applicable laws 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 lifting capacity must be used For machine weight please refer to Technical data in Section 3 ...

Page 26: ...pursu ant to DIN EN 1492 1 with a width of 120 mm through the crimp ing tool The lifting belt must be placed around the crimping tool in such a manner 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 cannot be mounted immediately upon delivery it mus...

Page 27: ...ay so that it is easily accessible for main tenance work from all sides 3 Check the machine for damage 4 Check the electric cables for damage 5 Train the operating staff and 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 process There is a risk of...

Page 28: ...ce the hydraulic unit on a solid and level workbench 3 Bolt the hydraulic unit to the workbench on the rubber metal buf fers 4 3 1 Connecting the hydraulic unit 4 Remove the protective caps on the hydraulic unit 1 5 Remove the protective caps on the machine 2 6 Connect the connections A B and T with hose assemblies ...

Page 29: ...ies for the skin eyes respiratory and intestinal tracts Hyd raulic liquid spills impose a 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 the working area and when handling consumables Ensure good ventilation Avoid floor contamination ATTENTION Risk of fire Hydraulic liquid spray or ...

Page 30: ...rticles in the system can settle 4 3 3 Electrical connection WARNING Risk by electrical voltage There 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 su pervision of a qualified electrician Deactivate the machine and secure it against unintentional restart before maintenance The cabl...

Page 31: ...rrectly and properly Improper installation may result in excessive heating of the connection terminals and the power cable A minimum of 88 Ah battery power of the vehicle is required Do not use any gel batteries In order to prevent the battery from being discharged the hydraulic unit should only be started when the vehicle engine is running ATTENTION Risk of damage to machinery The hydraulic power...

Page 32: ...3 Open and close the tool several times 4 Check oil level add hydraulic oil if required ...

Page 33: ...dle heavy workpiece Each movement of the hand must be observed The control cabinet must be closed securely Eating drinking and smoking at the workplace is prohibited Wear close fitting clothes Do not wear watches or jewellery 5 2 Start 1 Connect the power cable to the power grid see Electrical connection in Section 4 5 3 Forming the workpiece 5 3 1 Prerequisites Prerequisites for a correct forming...

Page 34: ...g squeezed between the die and the workpiece Keep the feed opening for the workpiece as small as possi ble Keep a minimum distance of 120 mm A to the die system 1 Manually position the pre mounted workpiece in the tool 2 Hold the workpiece with one hand during the forming process 3 Press and hold the button to close the tool the forming pro cess starts and ends when the pre set diameter pressure i...

Page 35: ...ueezing When the die system closes there is a risk of getting squeezed between the die and the workpiece Open the crimping tool only so much that the hose may be placed and or removed easily 5 4 Changing the crimping dies 5 4 1 Changing the crimping dies using a die wrench Positioning the crimping dies 1 Completely open the crimping tool 2 Switch off the machine using the main switch and secure it...

Page 36: ...g dies with the same identification and diameter One set comprises eight crimping dies or seven crimping dies and one matching marking die Removing the crimping dies 1 Completely open the crimping tool 2 Switch off the machine at the main switch WARNING Risk of squeezing When the die system closes there is a risk of getting squeezed between the dies Only replace the crimping dies when the machine ...

Page 37: ... stop The depth stop must be adjusted specifically for the work piece When inserting the hose the crimping process is triggered by contact with the stop cone When the pre defined forming diameter or forming pressure is reached the tool will stop automatically Remove depth stop for special applications e g pipe bends 1 Replace the screws 1 by the cylinder bolt the washer and the circlip ...

Page 38: ...are tight to the crimped sleeve 3 Disconnect the machine from power supply and secure it against unintentional restart 4 Loosen the clamping lever 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 is pressed against the depth stop 9 Form the work piec...

Page 39: ...les 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 crimping dies in the centre of the crimping tool WARNING Risk of squeezing When the die system closes there is a risk of getting squeezed between the dies Take care that no parts of your body are ins...

Page 40: ...rmediate 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 to remove the crimping dies For machines with a basic die system different from PB 239 the intermediate dies must be inserted as instructed The QDC 239 5 may only be used to insert or remove the crim...

Page 41: ...e dies during forming the crimping dies the intermediate dies and the machine will be damaged 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 correctly ...

Page 42: ...ming 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 difference on control and or in the micrometer repeat the forming process and check the workpiece 5 7 Forming travel limitation If the forming process is started outside the maximum forming range see Tec...

Page 43: ...r other irregularities 5 9 Emergency stop In case of an emergency Actuate the battery disconnection switch immediately in the event of an emergency The crimping tool movement will be stopped The drive unit is shut down Restart after and emergency WARNING Risk of injuries The battery disconnection switch was probably activated due to the occurrence of a hazardous situation A restart of the machine ...

Page 44: ... may 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 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: ...on 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 and grinding work on and in the ma chine unit and its environment must be approved in advance There is a risk of fire The machine unit must be cleaned from dust and inflammable substances Adequate ...

Page 46: ...6 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 springs between base dies Check for da mage X Check all bolted connections for secure fitting and retighten if necessary 1 Safety equipment Emergency stop button Emergency stop device Check function ...

Page 47: ...acts 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 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 ignition sources ...

Page 48: ...tion 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 Run the tool several times to bleed the hydraulic oil system 11 Check oil level The oil level can be read on the dipstick of the air ventilation cap The oil level should be in the middle of the mark...

Page 49: ...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 machine and lead to inaccuracies of the forming dimension Replace worn slide bearing plates in good time ...

Page 50: ...g 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 hexagon socket head screws 1 Shims if present have to be inserted at the same position as be fore Check the machine zero point after each bearing plate replace ment and readjust the micrometre if ne...

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 revolutions of the contact screw correspond to 1 mm change in the forming dimension V 5 Remount the enclosure front panel 6 Test the crimping process and readjust if necessary ...

Page 52: ...ce 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 Preferably form the workpiece in the centre of the crimping die length Crimping dimension not achie ved Bearing plates worn Check bearing plates for wear and replace if necessary Oil pressure too low Check oil...

Page 53: ...kin 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 equipment Do not eat drink 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 ...

Page 54: ...se 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 machine unit for mechanical tension and consider it during dismantling Empty the machine unit of all consumables see Maintenance Section 6 8 2 Recycling The machine unit contains metal hydraulic hoses el...

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: ...239 C QDS 239 R TU QDS crimping die deposit system TU QDS F Basic TU QDS F Shelf TU QDS F 239 l Depth stop TA S3 1 4 1 TA S3 1 4 1 A Mirror SHS S3 1 Camera set OCS 10 3 retro Lamp with magnetic base LUS LUF Universal table TU Crimping dies system PB 239 Please contact our Sales department for ordering accessories ...

Page 58: ...64 191 0 Pressure plate back 2 1 264 171 0 Pressure plate front 3 4 264 390 3 Hydraulic cylinder 4 4 264 2 Set of base dies 5 4 264 184 3 Ball nut 6 4 264 186 4 Sleeve 7 2 264 185 3 Bearing segment 8 8 264 196 4 Bearing plate rear pressure plate 500 8 798 320003 T groove nut ...

Page 59: ...ew with hexagon socket 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 DIN127 A 8 galvanised 700 8 239 151 Pressure spring screw 701 16 268 150 Pressure spring 702 4 3550 DU Bearing bush 9 2 2 Mechanical equipment Item Quantity Part code Designation 1 1 263 2...

Page 60: ...e 5 1 263 253 3 Protective plate left side 6 1 263 241 3 Switch attachment angle 7 1 263 242 3 Angle for bolted connection 9 1 219 400 3 Crimping micrometer 10 1 211 502 3 Round closing blank Uniflex 11 1 578 4 Oil prohibition sign 12 1 715 4 Squeezing risk warning sign 13 1 716 4 Hand injuries warning sign 9 2 3 Hydraulic unit DC ...

Page 61: ...DC complete 1 276 3501 Hydraulic unit 24V DC complete 9 3 Spare parts kit Quantity Part code Designation 1 set 263 1 Spare parts set S3 1 4 1 bearing plates for base dies 1 set 263 2 Spare parts 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 11 Repair...

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Page 63: ... 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 4 Ø96 Ø103 220 502 4 x ...

Page 64: ...Retaining bolt Crimping die profile 262 263 239 266 232 237 554 245 246 247 245 114 4 x x x ...

Page 65: ...9 6 Hydraulic diagram ...

Page 66: ...9 7 Electric diagram ...

Page 67: ...9 8 Maintenance log Hydraulic oil Hose assembly Retaining bolt Slide bearing plate Pressure springs Guiding plate Relay Remark Date Signature ...

Page 68: ... 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 Name Signature City Date Name Signature City Date Name Signature City Date Name Signature City Date Name Signature ...

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