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T-Drill F-400, Instruction Manual

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T-Drill F-400 Instruction Manual Download Page 58

INSTRUCTION MANUAL

58

8.1 LUBRICATION

DAILY LUBRICATION MAINTENANCE:

1. Bearings of the flanging pin and or expanding pin. 

- Grease nipple behind swinging frame 
- Lubricant: DIN 51825 KP 2K or NLGI 2, EP-grease, lithium complex, 40°C 190cSt, 

20…+120°C. E.g. Shell Gadus S2 V220 2 or equivalent.

2. Carriage guideways

- Clean with clean cotton cloth and apply grease through the grease nipples in bearing 

housings.
- Lubricant: NLGI 1,5 , EP-grease, lithium complex, viscosity 40°C 550cSt, -20°…+150°C. 

E.g. Shell Gadus S3 V550L 1 or equivalent.

Summary of Contents for F-400

Page 1: ...F 400 FLANGING MACHINE COLD INSTRUCTION MANUAL...

Page 2: ...rate this instruction book with the greatest possible care and attention The accuracy of the information has been carefully checked during the preparation of the manual Should any subsequent modificat...

Page 3: ...5 1 Installation and levelling of the machine 15 5 1 1 Layout 15 5 1 2 Space requirement 16 5 1 3 Leveling 17 5 2 Ambient conditions 18 5 3 Connection of the machine to the sources of energy 18 5 3 1...

Page 4: ...the pipe 50 6 7 Working instructions for bevelling 51 6 7 1 The installation of the bevelling tool 51 6 7 2 The adjustment of the forming tool 52 6 7 3 The work cycle of the bevelling operation 53 6...

Page 5: ...of Flanging 68 10 3 1 Fixing of the Pipe into the Clamp 68 10 3 2 Flanging machine time 68 10 4 Installation Times 69 10 5 Loose Flange Joint 70 10 5 1 Lapped Joint 70 10 5 2 Loose Flange 70 10 5 3 G...

Page 6: ...ration sequence before proceeding with installation operation or maintenance of the machine 1 2 SYMBOLS FOR WARNING AND DANGER USED IN THIS MANUAL L L DANGER May cause a serious accident or even death...

Page 7: ...ing spindle Don t look into the pipe during the process relating to the collar Don t stay on the pipe line or beside the holes Warning Moving parts Be extremely cautious when handling this area of the...

Page 8: ...in the way as specified in this manual Do not allow visitors or unqualified persons to enter the working area or to come near the machine When operating the machine all protection devices should be fi...

Page 9: ...careful at all times Ensure that there are no unauthorized persons in the vicinity of the machine Flanging shall take place under the supervision of the management in such a manner as no excess of th...

Page 10: ...cept for the spindle rotation and the movement of the arm of the heating burner The flanging operation 1 Spindle 2 Flange forming tool 3 Forming pin 4 Pipe clamp 5 Pipe The pipe remains immobile durin...

Page 11: ...In hot forming the sealing surface can be changed in quality from smooth to rough by selecting the appropriate profile for the forming cone Flange O D d4 42 4 O D 50 d4 EN1092 1 50 O D 406 4 d4 EN1092...

Page 12: ...ming pins are available for forming a grooved flange and for flanging stainless steel pipes The standard forming pin delivered with the machine is for use on normal steel pipes For flaring not necessa...

Page 13: ...5 See Machine plate Max size of fuses A 3 x 100 Working voltage 3 x 200V 240 V 50 60 Hz 3 x 380V 480V 50Hz 60Hz See Machine plate Spindle motor kW 11 Rotational speed of spindle rpm approx 41 Measure...

Page 14: ...ine feet requires special tools To lift the machine use adequately strong lifting chains The machine must be lifted from the lifting eyes do not use fork lift to lift the machine The lifting eyes can...

Page 15: ...INSTALLATION 5 1 INSTALLATION AND LEVELLING OF THE MACHINE 5 1 1 LAYOUT 1 Gas valve 2 Oxygen valve 3 Electric connection 4 Compressed air connection and regulator 5 Machine outline measures Heating s...

Page 16: ...INSTRUCTION MANUAL 16 5 1 2 SPACE REQUIREMENT Leave enough space around the machine for operation and maintenance Also take into account the space required for the pipe to be formed...

Page 17: ...e must be leveled on its foundation before use The leveling tolerance is 0 05mm on 1000mm Use a spirit level After leveling fastening the machine to the foundation by means of anchor bolts is recommen...

Page 18: ...n is allowed to carry out the connection of the F 400 machine to the mains The terminals for connection of the external supply cable of the F 400 machine are located in the electric box Pay special at...

Page 19: ...ry adjust the values to coincide with the data indicated in the technical specifications 4 Check the amount of the hydraulic oil and of the lubrication oil of the machine 5 Check the rotation directio...

Page 20: ...hine The power is connected by turning the main switch to the position I ON The power is disconnected by turning the switch to the position 0 OFF The main switch can be locked in the 0 position by mai...

Page 21: ...orming pin Guide value 14 16 sec One scale number increment equals to 2 sec For example Scale value 7 is 14 sec and scale value 8 is 16 sec 1 st and 2 nd return times for forming pin are the times det...

Page 22: ...Control switch of the tool Turns the tool 16 Rotation of the drum Pipe clamps cannot be opened if the drum is not in correct position When the automatic cycle stops the drum is normally positioned au...

Page 23: ...s is used when expansion tool is used Welding bevel of the pipe end OPTIONAL 2 FORMING TYPE SELECT SWITCH Cold forming Hot forming Flame adjustment Heating system is optional accessory 3 FLANGING MODE...

Page 24: ...ge mobile phones or any other devices The USB connection is only for program upload download 6 1 4 SIGNAL LIGHTS OPTIONAL Machine is equipped with signal lights which indicate the state of the machine...

Page 25: ...FLANGING MACHINE 25 F 400 6 1 6 CONTROL ELEMENTS...

Page 26: ...anging Limit switch S36 burner arm heating start position expanding mode Reed switch B 3 burner arm side position Reed switch B 4 burner arm up position heating position 7 Limit switch S37 Indicates t...

Page 27: ...regulates the working pressure of the forming pin Pressure switch is set just below the main pressure 155 bar Clamp pressure regulator Clamp closed pressure switch SP1 If you change the clamp pressure...

Page 28: ...80 bars 17 Limit switch Clamp open limit switch S38 18 Limit switch of safety cover Indicates that the safety cover is closed Machine won t start if the safety cover is open 6 1 7 THE VALVE ARRANGEME...

Page 29: ...the pressure regulation of the clamping jaws 1 Set the machine so that the work cycle can be started drive the carriage to the stop of the regulating rod and the spindle into the correct position 2 Fa...

Page 30: ...In case of danger stop the machine by pressing the emergency stop button the red STOP push button completely down This interrupts immediately all functions of the F 400 6 3 THE MACHINE SETTING 6 3 1...

Page 31: ...position by means of the switch and at the same time turn the control switch of the tool to the position 5 Press the EMERGENCY STOP button completely down 1 Key switch 1 auto 2 manual 2 Brake release...

Page 32: ...e hexagon socket screw has not been removed completely but is screwed sufficiently inside 13 Check that the forming pin and chuck are clean and the forming pin is fitted in its place and that it turns...

Page 33: ...ge Check the table below Stoppers Order number Stopper thickness mm 6402347 3 5 6402348 4 0 6402349 4 5 6402350 5 0 6402351 5 5 6402352 6 0 6402353 6 5 6402354 7 0 6402355 7 5 6402426 8 0 6402427 8 5...

Page 34: ...orrected by decreasing the thickness of the end position stoppers Angle of the flange is correct but there is fold behind the flange If there occurs folding of the tube behind the flange it might be r...

Page 35: ...ming pin will crash into the clamp F 400 theoretical bending radius Adjusting reading Eccentric sleeve Internal bending radius F 200 Forming pin Internal bending radius F 400 Forming pin 1 1 2 DO NOT...

Page 36: ...rews 4 pcs socket head screw M6 to release fastening pieces 1 Do not remove the screws and pieces 2 Turn forming pin to required radius with forming pin tool 4 3 Tighten locking screws with care See f...

Page 37: ...L1 L2 mm N S Inch mm inch mm inch 42 4 1 1 4 125 4 92 260 10 24 48 3 1 1 2 125 4 92 260 10 24 60 3 2 125 4 92 260 10 24 73 0 2 1 2 125 4 92 260 10 24 88 9 3 125 4 92 260 10 24 114 3 4 125 4 92 260 10...

Page 38: ...4 To pressurize the hydraulic system close the clamp with switch 13 Make sure that the clamp jaw can move freely i e no foreign obstacles are between jaws L LDANGER Before closing the clamping jaws m...

Page 39: ...plates according to the wall thickness The plates are located on the guide bars Open lock screw and pull the pin out together with back up plates Insert correct thickness of back up plates and lock wi...

Page 40: ...Fixing pins removed 1 Adapters 2 Fixing pin holes 3 Fixing extension of the clamp 4 Clamps Note that in picture the clamp adapter is in use 14 Insert and tighten the fixing pins of the pipe clamp upp...

Page 41: ...ging machine is equipped with potentiometer and display picture below Display unit is located on the top of the control panel With the display you can adjust length of the part of the pipe which is to...

Page 42: ...tion screen Select language Now the menu screen is shown 6 4 1 MENU SCREEN Menu screen Description of the buttons Move to Language selection screen Move to User level selection screen 6 4 1 1 Move to...

Page 43: ...ching the password field There are three different user levels Basic level On basic level you can execute programs User level 1 Default password 1 On level 1 you can compile programs change the units...

Page 44: ...On Back pos field is shown the position where the work cycle starts After that the frame slides to start position of the forming You can change the value by pushing the field NOTE The value of the Ba...

Page 45: ...pos For example if the Start pos 25mm the Back pos has to be at least 25mm 60mm 85mm You can also open the Library screen by pushing button With arrow button you can return to Menu screen 6 4 1 3 1 LI...

Page 46: ...specific input the name of the input is shown Enter the Outputs screen with Output button to check the status of the outputs the same way 6 4 1 5 ALARMS SCREEN In the Alarm screen is shown the cause...

Page 47: ...from left to right 1 Model of the machine 2 Type of the forming Cold or Hot Hot forming is option 3 Forming mode 1 One phase flanging flaring expanding and bevelling 2 Two phase flanging 3 Three phase...

Page 48: ...oth switches have to be pressed simultaneously 4 Press power off open the protective hood and ensure that the forming pin can go into the pipe without collision If not adjust the forming pin position...

Page 49: ...length of the part of the pipe which is to be flanged Start pos to the program See chapter 6 2 5 A recommended value for this setting is that the display readings indicates 23mm the thickness of the b...

Page 50: ...interrupt the work cycle immediately by pressing EMERGENCY STOP Measure the flange make necessary corrections and then enter to the setting value table 6 6 COLD FLANGING AND FLARING OF THE PIPE The w...

Page 51: ...at the left side of the arch for a M8x25 fixing screw and tighten it properly 4 Tighten the locking pin on the fixing screw by means of a 17mm wrench 5 Tighten the bevelling tool in the locking nut by...

Page 52: ...the switch 13 at the same time turning the control switch of the carriage 14 into the position until the bevelling blade almost reaches the tube 6 Stop the machine and push the protective hood backwa...

Page 53: ...roperly 5 Press the push button The machine performs the automatic work cycle L LDANGER If the spindle does not rotate evenly or it stops interrupt the work cycle immediately by pressing the EMERGENCY...

Page 54: ...sition distance between the front surface of the clamp and the forming tool in its final position replacing the buffer plate according to the table 4 Set back and start position values buffer plate th...

Page 55: ...ss the emergency stop and open the hood 4 Install the lifting eyelet to slide Picture 5 Remove hydraulic lines from spindle at large hex nut Make sure the connectors opened in the right place Keep the...

Page 56: ...ith crane until adjustment screw gets loose When the screw is loose lift slide carefully upwards until you can move it aside Picture 11 Installing of flanging slide in reverse order NOTE When the slid...

Page 57: ...FLANGING MACHINE 57 F 400 8 MAINTENANCE Maintenance points F 400 cold flanging machine See following pages for details...

Page 58: ...Lubricant DIN 51825 KP 2K or NLGI 2 EP grease lithium complex 40 C 190cSt 20 120 C E g Shell Gadus S2 V220 2 or equivalent 2 Carriage guideways Clean with clean cotton cloth and apply grease through...

Page 59: ...ce thermometer max temperature 65oC See separate instructions of the hydraulic unit delivered on a memory stick with machine 4 Clamp guideways Clean with clean cotton cloth and apply grease through th...

Page 60: ...AL 60 6 The slide Lubricate with a brush Lubricant NLGI 1 5 EP grease lithium complex viscosity 40 C 550cSt 20 150 C E g Gadus S3 V550L 1 or equivalent 7 Chain transmission Lubricate with oil can lubr...

Page 61: ...ns the closing speed of the clamps is restricted to less than 10mm s Check the speed and adjust to 9 10mm s if necessary Valve is located on the rear end of the machine See separate instructions for m...

Page 62: ...tighten the retaining screws 1 of the base carefully Before inspection the chain should be oiled lubricant chain oil At this stage the chain wheel retaining screws 3 should also be checked 1 2 3 8 2 2...

Page 63: ...e battery cover A Grasp the cover A between your fingers and remove it 3 Remove the old battery Extract the old battery from the battery holder C and disconnect the battery connector D 4 Install the n...

Page 64: ...2 Protection against short circuiting is provided by means of the fuses and the protecting elements in the connection box 3 Electric motors have a contactor and an overloading relay thermal relay 4 T...

Page 65: ...ch mm inch mm inch 42 4 1 1 4 125 4 92 260 10 24 48 3 1 1 2 125 4 92 260 10 24 60 3 2 125 4 92 260 10 24 73 0 2 1 2 125 4 92 260 10 24 88 9 3 125 4 92 260 10 24 114 3 4 125 4 92 260 10 24 139 7 5 260...

Page 66: ...N MANUAL 66 10 2 F 400 CAPABILITIES 10 2 1 CARBON STEELS Flanging by cold forming Pipe dimensions to be flanged 10 2 2 AUSTENITIC STAINLESS STEELS Flanging by corld or warm forming Pipe dimensions to...

Page 67: ...FLANGING MACHINE 67 F 400 10 2 3 COPPER ALLOYS COPPER COPPER NICKEL ALUMINIUM BRASS Flanging by cold forming Pipe dimensions to be flanged...

Page 68: ...alled equipment 10 3 1 FIXING OF THE PIPE INTO THE CLAMP 10 3 2 FLANGING MACHINE TIME A One turn flanging generally if S 3 4 mm F I carbon steel 114 3 4 Cold forming B Multiturn flanging generally by...

Page 69: ...FLANGING MACHINE 69 F 400 10 4 INSTALLATION TIMES Operation time 0 7 5 6 min flange Installation time 3 1 min dimension...

Page 70: ...kness D4 max EN1092 1or BS 4504 or corresponding D4 min OD 30 x 0 02 x OD R EN1092 1 or BS 4504 or corresponding 10 5 2 LOOSE FLANGE D EN1092 1 or BS 4504 DIN 2576 K EN1092 1 or BS 4504 DIN 2576 e EN1...

Page 71: ...e end The wall thickness of the flanged pipe end O D Outside diameter of the pipe S0 the original wall thickness of the pipe r the inner radius of the bent area D2 the running measure of the diameter...

Page 72: ...pressure switch just below the clamp pressure The moving carriage does not come forward in automatic cycle The forming pin on the starting position pressure switch SP2 does not act Adjust the pressur...

Page 73: ...r from the pipe I D Check the flanging pin setting If the problem is not solved with the help of trouble shooting instructions contact your local T DRILL dealer Give your contact information The name...

Page 74: ...formation can be found from parts list For example 1 Part number 2 Description 3 Quantity When ordering spare parts send an e mail or a fax with all required information By proceeding this way you wil...

Page 75: ...with 2 axis positioning up to 114 3 mm collars SEC 100 TBC Powerful and competitive collaring system for large pipe vessel collaring by one operator for most malleable materials Run pipe diameter rang...

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