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F-200

FLANGING MACHINE

INSTRUCTION MANUAL

Содержание F-200

Страница 1: ...F 200 FLANGING MACHINE INSTRUCTION MANUAL...

Страница 2: ...rmission of T DRILL Oy Is has been our aim to elaborate this instruction book with the greatest possible care and attention The accuracy of the in formation has been carefully checked during the prepa...

Страница 3: ...16 5 1 Installation of the F 200 16 5 2 Ambient conditions 17 5 3 Connection of the machine to the sources of energy 18 5 3 1 Connection to the electric network 18 5 3 2 Connection to the compressed...

Страница 4: ...cycle of the hot flanging and flaring 60 8 2 Adjustment of the heating starting position 61 8 3 Changing the heating burner 62 8 4 The adjustment of the burner flame and heating time 63 8 5 Setting of...

Страница 5: ...FLANGING MACHINE 5 F 200 15 1 Capacity of the machine 90 15 2 Processing times 92 15 3 The measures of the loose flange joints 93 16 T drill standard warranty 95 17 Ordering spare parts 96...

Страница 6: ...use NOTE Read all the instructions for the entire operation sequence before proceeding with the installation operation or maintenance of the machine 1 2 SYMBOLS FOR WARNING AND DANGER USED IN THIS MA...

Страница 7: ...pe during the process relating to the collar Don t stay on the pipe line or beside the holes Don t put your hands on the tube line under the machine or in the end of the machine during process Warning...

Страница 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...

Страница 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...

Страница 10: ...ns directed by the guide of the slide and while turning forms the flange in the pipe end All machine movements are hydraulic except for the spindle rotation and the movement of the arm of the heating...

Страница 11: ...UIPMENT Following equipment is available for th F 200 machine Heating unit is an equipment used for heating the pipe to be flanged or otherwise formed The heating unit enables the flanging of thick wa...

Страница 12: ...ller track auxiliary support table with lift trolley option 5391547 Designed to help handling of larger and longer pipes and to ease removal from the clamps after the flanging Read the instructions wh...

Страница 13: ...reatment after flanging is then necessary The heat treatment instructions regarding the material to be treated must be observed The wall thicknesses of the pipe to be used are s 3 8mm depending on the...

Страница 14: ...ameter of the pipe to be beveled can be between 42 4 and 219 1mm and the wall thickness of the pipe to be beveled must be more than 3mm 3 5 TECHNICAL SPECIFICATIONS See 15 Addenda 15 1 Capacity of the...

Страница 15: ...he pallet To remove the machine from the pallet remove all fixing screws first The corner plates have to be removed to reach the screws and adjustable machine feet adjustment of the machine feet requi...

Страница 16: ...vel After leveling fastening the machine to the foundation by means of anchor bolts is recommended Use anchor bolts M12 x 150 200 mm Remove the protective grease from the machine using a detergent whi...

Страница 17: ...2 AMBIENT CONDITIONS The F 200 flanging machine must be placed in a working area the environmental conditions of which do not exceed the following limit values Temperature 12 5 40 C 32 104 F Relative...

Страница 18: ...current value of the overload circuit breakers corresponds to the current value of the motors The machine can be supplied for a voltage range of 200 240V 50Hz 60Hz and of 380V 480 50Hz 60Hz Check the...

Страница 19: ...et loose from the inside of the heating gas or oxygen pipes the operation of the valves must be assured by installing a filter in the heating gas and oxygen feed line filtering at least 50 m E g Krom...

Страница 20: ...ust the values to coincide with the data indicated in the technical specifications chapter 3 6 of the instruction book 3 Check the amount of the hydraulic oil and of the lubrication oil of the machine...

Страница 21: ...he power is disconnected by turning the switch to the position 0 OFF The main switch can be locked in the 0 position by mains of a separate padlock in order to prevent unauthorized use of the machine...

Страница 22: ...s the power to the control logic 9 Heating stop push button Stops the heating during the automatic work cycle but the operations of the work cycle will continue until finished Drives the heating burne...

Страница 23: ...mp of the area scanner OPTION Lamp will light when lens of the scanner is dirty Clean the lens 1 FORMING MODE SELECT SWITCH Flanging Small pipe flanging Expansion This is used when expansion tool is u...

Страница 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...

Страница 25: ...FLANGING MACHINE 25 F 200 6 1 6 CONTROL ELEMENTS AND ADJUSTMENT POINTS 5 3 8 6 6 1 4 9 13 11 15 14 2 10 7 12...

Страница 26: ...ve the moving frame by manual control into the foremost position the cam has to be moved back In automatic flanging cycle the moving frame stops to this limit in the end of cycle 4 Limit switch S37 Li...

Страница 27: ...he main pressure 155 bar Clamp pressure regulator Clamp closed pressure switch SP1 If you change the clamp pressure set the pressure switch SP1 about 10 bars below the clamp pressure See attached hydr...

Страница 28: ...oard is located in the rear part of the machine on the hydraulic system It can be pulled out for adjustment purposes A C D SP1 SP2 SP3 1 21 2 3 4 5 6 7 8 9 10 22 15 B 12 14 16 17 18 19 11 20 15 13 The...

Страница 29: ...mp pressure regulator 13 Pressure switch SP2 tool in flanging start position 14 Tool valve 15 Pressure selection valve work pressure auxiliary pressure 16 Clamp valve Y10 17 Tool pressure measuring po...

Страница 30: ...INSTRUCTION MANUAL 30 6 1 8 HEATING UNIT OPTIONAL 24 28 23 29 22 27 26 25 21 16 10 13 20 19 11 8 7 5 6 15 9 2 3 12 18 17 14 4 Heating unit...

Страница 31: ...re reducing regulator for fuel gas pilot burner 14 Magnetic valve for compressed air pilot burner 15 Flashback arrestor for fuel gas 16 Flashback arrestor for oxygen 17 Mixer 18 Pressure regulator for...

Страница 32: ...push button red STOP button completely down 4 Disconnect the current to the machine by turning the main switch on the electric box on the back side of the machine to the position 0 5 Close the main va...

Страница 33: ...fore closing the clamping jaws make sure they can move freely the jaws may crush your hands 1 Start the machine by pushing the power on push button 2 Close the clamping jaws by turning the clamp contr...

Страница 34: ...ition the adjustment unit will then point to the side Lock the forming device by releasing the brake push button 10 Turn the key switch to the position 0 11 Block the rotary movement of the forming pi...

Страница 35: ...e forming pin is in a position where it easily can be handled If necessary turn the spindle into the correct position by pressing the push button 2 Press the emergency stop button completely down and...

Страница 36: ...g device 6 When using forming device adjust the stopper screws so that the pin line is parallel with the pipe When using expansing tool the adjusting can be the same what forming tool has Beveling dev...

Страница 37: ...rol panel down and turn the forming head until the tool is upside down 3 Open the locking screw and adjust the tool housing 4 Adjust the turning radius wanted of the forming pin by turning the eccentr...

Страница 38: ...ing the following pipe dimensions are required O D L1 L2 219 200 200 168 200 200 139 200 200 114 125 200 89 125 200 76 125 200 60 125 200 48 125 200 42 125 200 33 120 200 27 120 200 21 120 200 Fasteni...

Страница 39: ...he control device in this position until the clamps are closed 4 Drive the frame to back position by turning the switch clamps close and turning at the same time the control switch of the frame to the...

Страница 40: ...er plate is stamped on the plate itself 9 Loosen the fixing screw and draw out the pin with the buffer plate Install buffer plates of the correct thickness on both sides and lock them in this position...

Страница 41: ...the clamp using the setting gauge of the pipe Install the pipe to be beveled into the clamp using the setting gauge of the pipe Install the pipe to be flared into the clamp using the setting gauge of...

Страница 42: ...the clamp control switch and close them by turning the clamp control switch 5 Adjust the pressure of the jaws to the desired value look at the manometer by operating the pressure regulator of the jaws...

Страница 43: ...n Protrusion B of the pipe Expansion 35mm Beveling 12 15mm Flaring max 50mm B 1 2 A 3 4 The setting gauge of the pipe 1 Pipe clamp 2 Wing screw 3 Slide piece 4 Setting gauge of the pipe 1 Open the cla...

Страница 44: ...en Select language Now the menu screen is shown in selected language Return to previous screen by pushing button 6 4 2 MENU SCREEN Description of the buttons Move to Language selec tion screen Move to...

Страница 45: ...the password by touching the password field There are three different levels Basic level On basic level you can execute programs User level 1 Default password 1 On level 1 you can compile programs ch...

Страница 46: ...ers can be checked and the piece counter can be reset if necessary total piece counter cannot be reset also buffer plate and password changing screens are entered from this screen USB usage and clock...

Страница 47: ...adjustment 2 Tap to enter Buffer plate thickness setting screen Give buffer plate thickness to the field 3 Tap to enter Password setting screen For level 2 users 6 4 2 1 5 MULTIPHASE FLANGING OPTIONAL...

Страница 48: ...lue by pushing the field NOTE The value of the Back pos has to be 60mm larger than the value of the Start pos For example if the Start pos 25mm the Back pos has to be at least 25mm 60mm 85mm On Start...

Страница 49: ...in setting see 7 1 1 Setting of the pipe end forming device 2 Angle block blocks in F 400 only F 200 see 6 3 2 The adjustment of the turning angle of the forming pin 3 Pin position scale in F 400 only...

Страница 50: ...he program on library screen Tap Library button to enter library Return to previous screen from the black arrow button Browse library programs from the arrow buttons or give a memory location number t...

Страница 51: ...the original program which was chosen or as a new program to another memory location Browse library programs locations from the arrow buttons or give a number to the right top corner field NOTE The ne...

Страница 52: ...e input is shown Switch to check the status of the outputs the same way by pushing Output button I O screen helps with troubleshoot 6 4 2 5 ALARM SCREEN The cause of the alarm is shown in the Alarms s...

Страница 53: ...he Main screen from left to right 1 Model of the machine 2 Type of the forming Cold or Hot Hot forming is optional 3 Forming mode 1 One stage flanging flaring expanding and beveling 2 Two stage flangi...

Страница 54: ...pin works as a backstop when working Push the pipe firmly against forming pin Edit programs screen Start pos setting defines the lip of the flange The flange width setting has to be decided through t...

Страница 55: ...t be in such position where the top of the unit is up If this is not the case turn the spindle in the correct position by pressing shortly the push button until the pilot lamp lights 4 Set the Start P...

Страница 56: ...he locking screws of the slide carefully and adjust the position of the slide by means of the adjusting bolt so that the digital measure device indicates inside radius of the pipe See instruction poin...

Страница 57: ...lue of the digital reader is to be decreased correspondingly If the eccentric sleeve is turned in the direction of the bigger radius this value is to be increased correspondingly Adjust the slide in s...

Страница 58: ...scale should be 23mm 4mm 27mm NOTE The value of the Back pos has to be 60mm larger than the value of the Start pos For example if the Start pos 25mm the Back pos has to be at least 25mm 60mm 85mm 16 T...

Страница 59: ...Before starting the automatic work cycle make sure that the pipe has been clamped properly L DANGER If the spindle does not rotate evenly or it stops interrupt the work cycle immediately by pressing t...

Страница 60: ...burner will start and the light in the push button will start blinking L DANGER If the pilot burner does not go on interrupt the work cycle immediately by pressing the EMERGENCY STOP push button comp...

Страница 61: ...also the ball joint of the cylinder If you want to change the ascending stroke of the burner adjust the stop screw on the burner arm and if necessary the ball joint of the cylinder If the burner does...

Страница 62: ...e burner arm will turn into heating position 6 Press the stop button and open the protective hood 7 Remove the burner which is fastened to its arm by a screw coupling Keep the burner arm in its place...

Страница 63: ...mping jaws and insert the pipe into the clamp so that the end of the pipe is against the forming pin Close the clamping jaws 6 Open the valve of the gas supplies and adjust the gas pressures The oxyge...

Страница 64: ...until the flame is alright NOTE The F 200 machine is provided with a timer which gives the operator 30 seconds time to adjust the flame If this time is exceeded the valves will close and the adjustme...

Страница 65: ...00 8 5 SETTING OF THE INFRARED TEMPERATURE MEASURING UNIT Infrared temperature measuring unit has to be pointed to the end of the tube i e about 10 15 mm from the end of the clamp as shown in picture...

Страница 66: ...2 3 4 1 Screws of the card 2 Pulling direction 3 PAR button 4 ESC button 5 Laser targeting light push button 2 Check the correct value for the used material from the table below Press the PAR button o...

Страница 67: ...celaine glazed 60 Focusing the lens 1 Release the lock of the lens by turning the lens counter clockwise 2 Push the laser targeting light push button on the back of the camera to activate the laser Wh...

Страница 68: ...DANGER Before closing the clamping jaws make sure that they can move freely the jaws might crush your hands 1 Fasten the pipe into the clamp see chapter The fastening of the pipe 2 Turn the expansion...

Страница 69: ...1 Adjust the slide in such way that the expansion pin just touches the inner surface of the pipe Tighten the locking screws 4 pcs 12 Start the machine 13 Drive the frame to its rear position by turnin...

Страница 70: ...stall the expansion pin see chapter Changing of the forming pin 2 Fasten the pipe into the clamp see chapter The fastening of the pipe 3 Carry out the adjustment of the forming tool 4 Install a heatin...

Страница 71: ...ating operation is finished the machine carries out the expansion work cycle until the end When the work cycle is finished the spindle stops in the correct position ready for the next cycle NOTE The p...

Страница 72: ...een ordered with this optional accessory 10 1 1 THE INSTALLATION OF THE BEVELING TOOL 1 Remove the forming pin see chapter 6 3 1 Changing of the forming pin points 1 12 2 Install the beveling tool int...

Страница 73: ...TOOL FOR BEVELING L DANGER Before closing the clamping jaws make sure that they can move freely the jaws might crush your hands 1 Install s 10 mm buffer plates 2 pcs See picture measurement B Tube end...

Страница 74: ...to inform that the spindle is in correct position 6 Set the Start Pos to zero 0 0mm on the display See chapter 6 2 6 7 Drive the frame forward towards the pipe by turning clamp control switch to at th...

Страница 75: ...rk cycle immediately by pressing the EMERGENCY STOP button completely down 13 Check the swarf thickness If the frame speed is not correct stop the machine and adjust the speed of the frame movement At...

Страница 76: ...hickness 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 result of following matters 1...

Страница 77: ...ment of the roller track A hand control is also available 12 1 INSTALLATION OF THE ROLLER TRACK OPTION Align the roller track to meet the machine tube line center line see layout Leave enough room for...

Страница 78: ...electric plug Lifting moving the roller track Use a fork lift truck to move the roller track Place wooden planks between the forks and track frame NOTE DO NOT LET THE TRACK TO TIP OVER OR FALL FROM FO...

Страница 79: ...5 25 mm If the pipe is not within nominal size it will not fit into the clamps NOTE The pipe must be lowered to the roller track in a controlled manner to avoid damaging the track A falling track wil...

Страница 80: ...he pipe Lower the roller track so that the F 200 clamps hold the pipe and there is a gap between the roller track and the pipe Start work cycle When the work cycle is done stop the machine Lift the ro...

Страница 81: ...st roll of the roller track Move the lifting strap behind the mass centre to tilt the pipe Lift the pipe with the crane a bit NOTE The pipe must be lowered to the roller track in a controlled manner t...

Страница 82: ...ly off the crane lifting strap support strap can remain around the pipe Lower the roller track so that the F 200 clamps hold the pipe and there is a gap between the roller track and the pipe Run the w...

Страница 83: ...FLANGING MACHINE 83 F 200 13 THE MAINTENANCE OF THE MACHINE 13 1 LUBRICATION AND INSPECTION POINTS 7 8 9 2 2 2 2 4 3 1 5 3 6 Lubrication points of the machine...

Страница 84: ...bearing shells with a grease gun Lubricant NLGI 1 5 EP grease lithium complex viscosity 40 C 550cSt 20 150 C E g Shell Gadus S3 V550L 1 or equivalent 3 The slide bearings of the clamping jaws Lubrica...

Страница 85: ...fillerplug 1 until the oil comes out from the drainplug 2 Install and tighten the plugs The maximum amount of oil is 3 5 litre Lubricant ISO VG 220 DIN 51517 part 3 CLP or ISO 12925 1 type CKC or AGM...

Страница 86: ...urn easily when moved by hand The radial play may not be more than 0 2mm and the axial play may not exceed 0 4mm If necessary change the bearings Limit switches Check that the switches S33 and S34 tri...

Страница 87: ...sten screws Preset the display according the Digimatic Scale Unit 572 manual Chapter 10 Preset value is the same as minimum radius of machine Presetting value is 6 5mm at 2 5mm of forming pin housing...

Страница 88: ...e pipe clamp and the pipe correspond to each other and close the clamp The clamping jaw pressure switch SP 1 does not function Adjust the pressure switch SP1 The arm of the burner does not go up The s...

Страница 89: ...e centering of the forming pin The radius of the flange is not even The heating uneven Check the burner The digital readout of the forming head is off or not working properly Battery is dead Charge th...

Страница 90: ...he elongation of the material is a decisive factor which determines the greatest possible diameter of the flange By means of the multidimensional way of elongation however much greater elongation valu...

Страница 91: ...FLANGING MACHINE 91 F 200 Hot flanging of carbon steels Flanging of copper alloys Expansion of pipe ends Expansion of pipes...

Страница 92: ...The processing times for the different stages of flanging The fastening into and removing from the machine of the pipe The flanging time of the machine A Flanging in one stage B Multi stage flanging C...

Страница 93: ...e S Wall thickness of pipe D4 According to EN 1092 1 or equivalent standards Loose flange D According to EN 1092 1 PN10 K According to EN 1092 1 PN10 e According to EN 1092 1 PN10 b According to EN 10...

Страница 94: ...d mm 50 1 2 D O D d 4 1 O D 50mm d 20 0 047 O D 2 O D 50mm d 30 0 02 O D 4 The outer diameter of the flange The wall thicknesses of the flanged pipe end The wall thicknesses of the flanged pipe end S0...

Страница 95: ...air misuse neglect accident or abuse or damaged by any other external causes c repaired or altered by any third party or maintenance is carried out by other than T Drill authorized service provider d...

Страница 96: ...e 2 2 3500904 Fastening plate 2 3 9214010 Screw M8 x 25 8 8 DIN7984 8 4 9016007 Set screw M8 x 8 12 9 DIN913 4 5 4280104 Clamp holder pin 4 6 9018037 Parallel pin 6m6 x 32 DIN6325 4 7 9018219 Spring p...

Страница 97: ......

Страница 98: ...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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