Danfoss ET4500-002 User Manual Download

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Summary of Contents for ET4500-002

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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: ...sch 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 Mach...

Page 5: ...ed 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 Emergency stop button 16 2 4 3 Protection equipment 16 2 4 4 Warning signs on...

Page 6: ...wrench 46 5 5 Replacing the intermediate dies 48 5 5 1 Changing the crimping dies with the quick die change system only profile 239 51 5 6 Depth stop accessory 53 5 7 Setting the forming dimension 54...

Page 7: ...system 75 9 2 5 Electric equipment 77 9 3 Spare parts kit 79 9 4 Service tool 80 9 5 Retaining bolt for standard crimping dies depending on crimping die 81 9 6 Hydraulic diagram 83 9 7 Electric diagra...

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 ins...

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: ...Manual is part of the machine unit and must be kept near the machine unit at all times Upon disposal of the machine unit the Operation Manual must also be handed over 1 3 Name plate The name plate is...

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: ...t must be ensured 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 worki...

Page 16: ...LEX 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 The necessity of additional wo...

Page 17: ...t 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 die s...

Page 18: ...Illegible or missing warning signs must immediately be replaced by the owner...

Page 19: ...ctric motor pump 3 Main power switch 4 Control panel with buttons and control system CONTROL C 2 IPC 5 Emergency stop button The crimping tool 1 is closed hydraulically whereby the workpiece is formed...

Page 20: ...h stop or the dual foot switch Crimping tool The die system comprises basic dies intermediate dies depending on the application and crimping dies All basic dies are supported on slide plate The crimpi...

Page 21: ...the pre 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 insulato...

Page 22: ...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 23: ...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 24: ...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 4 Electric sockets 1 Main power switch 2 Socket for single foot...

Page 25: ...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 26: ...ith plunger switch 9 Sleeve 3 7 Operation modes The control unit provides for the following operation modes for operat ing the forming tool Manual operation C 2 IPC is activated in the control The for...

Page 27: ...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 is used for closing Depth stop The tool is closed automat...

Page 28: ...The operation of the control system is described in a separate Op eration Manual This description is supplied with the machine...

Page 29: ...17 mm max outside diameter of the fit tings before the forming process Maximum crimping dies 92 mm Opening size without dies 147 mm Opening distance 45 mm Closing speed 6 2 mm s Forming speed 1 7 mm...

Page 30: ...approx 70 l Oil type HM 46 or HLP 46 ISO 11158 ISO 6743 4 10 filtered The oil type can be adapted for specific applications Viscosity class 68 mm s for high temperature operating conditions Viscosity...

Page 31: ...easured on a prototype Actual values may vary slightly depending on the ma chine The use of special hydraulic oil with improved properties and addi tives can prolong the service life of the machine an...

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: ...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 36: ...a 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 liv...

Page 37: ...permissible voltage frequency ranges and the relevant motor protection setting are also indicated on the sticker in the control ca binet 3 Have the power cable of the machine connected to the local ma...

Page 38: ...tational di rection 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...

Page 39: ...hydraulic system 1 Switch on the machine 2 Operate the machine in the idle mode for two minutes in order to fill the pump with oil 3 Open and close the tool several times 4 Check oil level add hydraul...

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: ...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 crim...

Page 42: ...ion mode When the forming process is comple ted release the foot switch Close and activate the foot switch Open to open the tool 6 Semi automatic operation mode Wait until the hold time defi ned in th...

Page 43: ...ith 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 is reached 4 Manual operation mode Press t...

Page 44: ...s 5 3 4 Remote automatic mode via depth stop WARNING Risk 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 wo...

Page 45: ...me defi ned in the control has expired the tool will then open automati cally 6 Remove the workpiece from the tool 7 Check the forming dimension after the first forming process Correct the forming dim...

Page 46: ...the locking bolt 2 Switch off the machine using the main switch and secure it against switching on unintentionally WARNING Risk of squeezing When the die system closes there is a risk of getting squee...

Page 47: ...machine using the main switch and secure it against switching on unintentionally WARNING Risk of squeezing When the die system closes there is a risk of getting squeezed between the dies Only replace...

Page 48: ...nd secure it against switching on unintentionally WARNING Risk of squeezing When the die system closes there is a risk of getting squeezed between the dies Only replace the intermediate dies when the...

Page 49: ...hine using the main switch and secure it against switching on unintentionally WARNING Risk of squeezing When the die system closes there is a risk of getting squeezed between the dies Only replace the...

Page 50: ...ies the locking bolts in the base dies as well as the retaining bolts of the intermediate and criming dies will be destroyed Only mount profile 266 268 237 intermediate dies individually and manually...

Page 51: ...e quick die change system 1 into the front holes 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 d...

Page 52: ...the tool All retaining bolts 3 must slide into the relevant mounting hole 4 of the basic or intermediate dies and the spring mounted pressure pieces must engage into the retaining bolts 8 Remove the...

Page 53: ...he 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 base and or intermediate die 3 so that it does not protrude In the...

Page 54: ...ed dimension Control system Forming dimension diameter Micrometer Workpiece forming dimension less crimping die di ameter 5 Form the workpiece 6 Check the workpiece 7 If the dimension is reached manuf...

Page 55: ...sit the work piece outside the machine 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 d...

Page 56: ...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 stop 2 Unlock the em...

Page 57: ...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 58: ...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 59: ...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 60: ...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 61: ...n 3 7 Close the air ventilation cap 2 8 Mount grating 1 9 Do not operate the machine for a minimum of four hours so that the dirt particles in the system can settle 10 Switch on the machine 11 Operate...

Page 62: ...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 63: ...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 Remount clamping ring 2 8 Tighten screws 1...

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Page 65: ...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 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: ...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 70: ...stop TA S6 2 manual TA S6 3 C A automatic C 2 Mirror SHS S6 2 Table machine SHS S6 2 B free standing machines only Camera set OCS 10 3 retro Lamp with magnetic base LUS Die wrench 239 017 4 Universal...

Page 71: ...nut 5 2 266 195 3 Bearing segment 6 1 set 266 5 Bearing plates 8 4 266 398 3 Hydraulic cylinder 9 2 266 215 3 Clamping segment 532 8 798 110128 Cylinder bolt DIN EN ISO 4762 M8x100 533 12 798 120066...

Page 72: ...eeve 45 50 length long 1001 8 266 1192 Base dies mounted 266 1195 Complete tool 9 2 2 Basic dies Item Quantity Article code Designation 1 8 266 198 1 Basic dies 2 8 235 008 4 Locking pin 3 8 798 42002...

Page 73: ...ate 5 1 266 224 2 colour code Cover 6 1 777 924 2 Designation sign 7 1 266 256 3 Position encoder mounting angle 8 1 264 243 4 Position encoder stop bracket 9 1 266 255 3 Position encoder cover 10 1 2...

Page 74: ...Item Quantity Part code Designation No pic ture 1 716 4 Warning of hand injuries sign...

Page 75: ...9 2 4 Hydraulic system Item Quantity Part code Designation 1 1 268 293 2 Tank cover 2 2 239 517 Suction filter 3 4 3 2 239 518 Double pipe nipple...

Page 76: ...ting valve for hydraulic block 268 325 3_A 268 325 3_D Pressure limiting valve for hydraulic block 268 325 3_B Pressure limiting valve for hydraulic block 268 325 3_C 17 1 777 325 777 338 777 340 Dire...

Page 77: ...Pressure sensor 0 400 bar 9 2 5 Electric equipment Item Quantity Part code Designation 1 1 807 601 E plate complete 2 1 888 652 Clamping block 3 1 888 653 Voltage selection plug 4 1 888 014 Motor prot...

Page 78: ...Fine wire fuse Item Quantity Part code Designation 1 1 807 710 Control panel 800 mm C 2 with memory card 2 1 807 374 Uniflex Touch Panel 3 1 777 022 Clamp lever 4 1 807 067 Emergency stop button compl...

Page 79: ...223 Mounted housing 4 1 888 224 Socket insert 5 2 888 227 Mounted housing 6 1 888 228 Socket insert 3 pin 7 1 888 229 Socket insert 4 pin 8 1 888 498 Cover plug 9 3 Spare parts kit Quantity Part code...

Page 80: ...per set 239 151 Pressure piece profile 239 239L 8 per set 232 504 4 Retaining bolt profile 266 1 set 266 11 Repair tool set 9 4 Service tool Quantity Article code Designation 1 266 550 Mounting aid ba...

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 6 Hydraulic diagram...

Page 84: ...9 7 Electric diagram...

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Page 92: ...9 8 Maintenance log Hydraulic oil Hose assembly Retaining bolt Slide bearing plate Pressure springs Guiding plate Relay Remark Date Signature...

Page 93: ...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 N...

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