Danfoss ET6200 Operator's Manual
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Danfoss ET6200 Operator's Manual

Danfoss ET6200 Operator's Manual

Nipple inserter machine
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  • Page 2 Imprint Manufacturer: UNIFLEX-Hydraulik GmbH Robert-Bosch-Strasse 50-52 D-61184 Karben Germany Phone: +49 (0) 60 39 / 91 71 - 0 Fax: +49 (0) 60 39 / 91 71 - 181 This Operating Manual of the machine is a translation; the origi- nal is in German.
  • Page 4 EC Declaration of Conformity In accordance with EC Machinery Directive 2006/42/EC. The following machine Danfoss ET6200 was developed, designed and manufactured in compliance with EC Directive 2006/42/EC, in the sole responsibility of UNIFLEX-Hydraulik GmbH Robert-Bosch-Strasse 50 - 52 D-61184 Karben The following standards, codes and specifications have been applied: •...

  • Page 5: Table Of Contents

    Contents About this document ..................7 1.1 Target groups ....................7 1.2 Storage ......................8 1.3 Name plate ....................9 Safety instructions .................... 10 2.1 Presentation of warnings ................10 2.2 Intended use ....................10 2.3 Product-specific risks .................. 11 2.3.1 Risks posed by mechanical equipment..........
  • Page 6 Troubleshooting ....................31 Decommissioning, disposal ................32 8.1 Dismantling ....................32 8.2 Recycling ..................... 32 8.3 Consumables and waste ................32 Annex ........................33 9.1 Accessories (retrofittable) ................33 9.2 Spare parts list ..................... 34 9.2.1 Wear parts ..................35 9.3 Pneumatic diagram ..................

  • Page 7: About This Document

    About this document In this Operation Manual, the “nipple inserterDanfoss ET6200” is con- sistently referred to as machine. This Operation Manual includes important notes on how you operate your machine/unit safely, properly and economically. Use not in compliance with the intended purpose may result in hazard to the operator's health and life and/or in the risk of damage to/the machine/unit.

  • Page 8: Storage

    • persons working on the machine/unit are adequately qualified; • persons working on the machine/unit are suitable for operating the machine/unit; • the Operation Manual has been read and understood. One hard- copy of the Operation Manual must always be kept at a desig- nated place where the machine/unit is used.

  • Page 9: Name Plate

    Name plate The name plate is fixed on the machine back.

  • Page 10: Safety Instructions

    Safety instructions Presentation of warnings Warning notes in the Operation Manual warn against risks involved with the handling of the machine/unit. Risk levels are identified as fol- lows: The signal word HAZARD identifies an imminent hazard resulting in HAZARD! serious injuries or death. This warning is supplemented by a triangu- lar hazard symbol.

  • Page 11: Product-Specific Risks

    ➢ children and persons under age; ➢ persons with a restricted capability for the operation of ma- chines (e.g. under the influence of drugs, alcohol or narcot- ics) Use of the control in compliance with the intended purpose also inclu- des compliance with the instructions in this Operation Manual.

  • Page 12: Risk Imposed By Pneumatic System

    • When closing the protective cover, make sure that your extremi- ties are not between the hose feed and the knife protection. Risk of squeezing There is risk of getting squeezed between the protection cover and the chassis when closing the protection cover. •...

  • Page 13: Safety

    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.

  • Page 14: Warning Signs On The Machine

    2.4.2 Warning signs on the machine Squeezing risk on the protective cover and the clamping de- vice. Hand injury on the cover Illegible or missing warning signs must immediately be replaced by the operator.

  • Page 15: Machine Description

    Machine description Design and function (1) Inserter cylinder (2) Hand lever (3) Hand wheel...
  • Page 16 (4) Clamping dies (5) Holding rings (6) Seat (7) Catch bolt (8) Clamping cylinder (9) Protection cover The machine is ready for operation as soon as it is connected to the compressed air system. In order to insert nipples into hoses or extract nipples from hoses, the work piece is mounted in the seat (6) using a holding ring (5).

  • Page 17: Technical Data

    Technical data Machine Dimensions L x W x H 625 x 795 x 325 mm Weight approx. 35 kg Noise level < 70 dB(A)* Function Insertion force 5.1 kN( 6 bar) Hose feed Manual Work piece capacity Working area 2" Max.
  • Page 18 Ambient conditions C – 40 Ambient temperature 45 % – 65 % Air humidity The * data are theoretical/computed values, or values measured on a prototype. Actual values may vary slightly, depending on the ma- chine.

  • Page 19: Transport And Commissioning

    Transport and commissioning Transport The goods should be transported in the original packaging. During transport, the goods must be secured safely within the packaging. All applicable laws and regulations relating to securing loads shall be ob- served during transport. The machine can only be transported manually. For machine weight, please refer to "Technical data"...

  • Page 20: Intermediate Storage Of Machine/Unit

    Intermediate storage of machine/unit If the machine/unit cannot be mounted immediately upon delivery, it must be protected against: • Contamination, • Weather influences, • Mechanical damage. The machine/unit components may only be stored in closed rooms and under the following conditions: •...

  • Page 21: Connection Of Compressed Air

    4.3.1 Connection of compressed air The compressed air connection must supply 6 bar. Establish the compressed air connection (1) between the grid and the compressed-air maintenance unit. Check the pressure at the compressed-air maintenance unit (2) and adjust to 6 bar. Check that the scale (3) of the compressed-air maintenance unit is at the value 1.

  • Page 22: Operation

    Operation What you have to observe The operator has received the Operation Manual from the owner, has read and understood it and will observe it. Prior to starting work • Ensure sufficient illumination of the working area of the machine. During operation •...

  • Page 23: Inserting/Extracting Nipples

    Inserting/extracting nipples 5.2.1 Prerequisites Prerequisites for correct insertion/extraction: • The machine must be connected to the compressed-air system. • Only work pieces of permissible diameters may be used (see Technical Data). • Skiving of the hose may be necessary before the nipple can be inserted.

  • Page 24: Inserting Nipples

    ATTENTION! Risk of damage to machinery If the catch bolt is not engaged, this may result in damage to the machine and/or work piece when the machine is operated. • Before inserting/extracting, make sure that the catch bolt is engaged properly. Release the catch bolt (3) and allow it to engage.
  • Page 25 CAUTION! Risk of squeezing There is a risk of injury from the clamping device when closing the protective cover. • Make sure that no extremities are in the working area behind the protective cover. Close protective cover (1). Move the hand lever (3) to the PUSH position. Open protective cover (1).

  • Page 26: Extracting Nipples

    5.2.4 Extracting nipples Move the hand lever (3) to the PUSH position. Open protective cover (1). Select the suitable holding ring (2) and insert it into the seat (6). Place the work piece in the seat (6). Use the hand wheel (4) to adjust the clamping die (5) in order to centre the hose.
  • Page 27 10. Close protective cover (1). 11. Move the hand lever (3) to the STOP position. The movement of the inserter cylinder can be stopped at any time. To do this, move the hand lever to the STOP position.

  • Page 28: Cleaning

    Cleaning ATTENTION! Risk of damage to machinery! If the machine is cleaned with a steam jet or compressed air, dirt and water may ingress in the machine and cause serious da- mage. • Do not use a steam jet to clean the machine. •...

  • Page 29: Maintenance

    Maintenance Regular maintenance will ensure the continuous operation reliability of the machine. What you have to observe This Section describes action to be taken by you as the fitter regularly to ensure the troublefree use of the machine. • Maintenance work may only be performed by qualified mainte- nance staff (fitter).
  • Page 30 Maintenance item Machine Clean the machine. Check machine for damage and wear. Check the clamping dies for secure fitting. Check the clamping dies for damage. Grease the threaded spindle of the clamping dies. Inserter unit Check seat for damage and wear. Check the seat for secure fitting.

  • Page 31: Troubleshooting

    Troubleshooting Error Cause Remedy Machine is not working Compressed air supply dis- Connect compressed air connected Air pressure too low Check air pressure...

  • Page 32: Decommissioning, Disposal

    Decommissioning, disposal CAUTION! Risk of injuries! Parts of the machine/unit may be under pressure and/or tension. Loosening components may impose a risk of injuries! • De-pressurize the machine/unit before performing any work and check for potential sources of hazard. Dismantling This section describes activities to be performed by you as the opera- tor to ensure the safe dismantling of the machine/unit.

  • Page 33: Annex

    Annex Individual machine/unit components may deviate in their features. Please indicate the serial number of the machine for spare part or- ders. Accessories (retrofittable) Accessories Part code Workbench Hard rubber wheels (set = 4 wheels, 2 with fixing 778.2 brake) Please contact our Sales department for ordering optional acces- sories.

  • Page 34: Spare Parts List

    Spare parts list Item Quantity Part code Designation 102.010 5/3-way pneumatic manual valve PJ_PLS350 Stem-actuated valve No pic- Inserter cylinder PJ_PLS100 ture...

  • Page 35: Wear Parts

    Item Quantity Part code Designation No pic- Compressed-air maintenance unit PJ_PFRL2000 ture No pic- Clamping cylinder PJ_PSL75 ture PJ_AMHD Handle PJ_MHW350 Hand wheel PJ_AHC250 Hinge 715.4 Squeezing risk warning sign 716.4 Warning of hand injuries sign 102.011 Sticker UNE 10 102.012 Sticker Back/Stop/Push 9.2.1 Wear parts...

  • Page 36: Pneumatic Diagram

    Pneumatic diagram...

  • Page 37: Maintenance Log

    Maintenance log Remark Date Signature                                    ...

  • Page 38: Declaration Of Qualified Staff

    Declaration of qualified staff I herewith declare that I have attended an internal training for the operation 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...

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