Danfoss ET5070 Operator's Manual
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Danfoss ET5070 Operator's Manual

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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 In accordance with EC Machinery Directive 2006/42/EC and UK-Sup- ply of Machinery (Safety) Regulations 2008. The following machine Danfoss ET5070 was developed, designed and manufactured in compliance with EC Directive 2006/42/EC and UK-Supply of Machinery (Safety) Regulations 2008, in the sole responsibility of...

  • Page 5: Table Of Contents

    Contents About this document ..................8 1.1 Target groups ....................8 1.2 Storage ....................... 10 1.3 Name plate ....................10 1.4 Abbreviations ....................10 Safety instructions .................... 11 2.1 Presentation of warnings ................11 2.2 Intended use ....................11 2.3 Product-specific risks .................. 13 2.3.1 Risks imposed by mechanical equipment ........
  • Page 6 4.1 Transport ..................... 32 4.2 Intermediate storage of machine/unit ............33 4.3 Commissioning .................... 33 4.3.1 Filling hydraulic oil ................34 4.3.2 Electrical connection ................ 36 4.3.3 Bleeding the hydraulic system ............38 Operation ......................39 5.1 What you have to observe ................39 5.2 Activation .....................
  • Page 7 9.1 Accessories (upgradable) ................69 9.2 Options (only available ex works) ............... 70 9.3 Spare parts list .................... 70 9.3.1 Mechanics ..................70 9.3.2 Hydraulic system ................74 9.3.3 Electric equipment ................76 9.4 Base dies ....................78 9.5 Intermediate dies 237.239.2L2 ..............79 9.6 Spare parts kit .....................

  • Page 8: About This Document

    About this document In this Operation Manual, the “forming machine Danfoss ET5070” is consistently 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 9 • national provisions, occupational safety regulations and applica- ble environmental protection regulations are fully complied with; • 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 10: Storage

    Storage The Operation 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. Name plate The name plate is fixed near the power cable. Abbreviations Crimp Force Monitoring Manual Flow Divider...

  • Page 11: 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 12 • use of eight identical original UNIFLEX dies with the same label or seven dies and one associated marking crimping die. • The machine must not be operated by persons not capable of operating the machine without any risk. These may include: ➢...

  • Page 13: Product-Specific Risks

    Product-specific risks The machine/unit is designed in accordance with the latest state of technology. Nevertheless, the machine/unit may impose risks: 2.3.1 Risks imposed by mechanical equipment Risk of squeezing When the die system closes, there is a risk of getting squeezed between the die and the workpiece.

  • Page 14: Risks Imposed By Noise

    • Relieve the residual pressure in the system before performing repair or maintenance work on hydraulic systems. • Regularly check lines and bolted connections for leaks and visi- ble damage. Immediately remedy any damage detected. Repair work on the hydraulic system of the machine/unit or on its components may only be performed by UNIFLEX specialist staff.

  • Page 15: Risks In Case Of Fire

    2.3.7 Risks in case of fire The operating staff has to be familiar with the location as well as with operating the fire alarm and fighting means. Free access to this equipment 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.

  • Page 16: Safety

    Safety 2.4.1 Working area The working area is designed as the area 3 ft all around the machine (shaded). • Keep the working are free from trip hazards. • Use ducts for lines and cables. • Provide good illumination. • Keep access to hydraulic supply free.

  • Page 17: Emergency-Stop Button

    2.4.2 Emergency-stop button The machine is fitted with an emergency-stop button on the control panel. Immediately activate the emergency-stop button (1) in cases of emer- gency. Remedy the cause of the emergency stop first before unlocking the emergency-stop button. Do not pull the emergency-stop button for unlocking it, but release it by rotating it.

  • Page 18: Warning Signs On The Machine

    UNIFLEX will provide you with customized solutions for protection equipment upon request. 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 system Risk of squeezing...
  • Page 19 Hot surface on the electric motor Oiling / greasing prohibited on the die system Illegible or missing warning signs must immediately be replaced by the owner.

  • Page 20: Machine Description

    Machine description Design and function Base machine (1) Crimping tool (2) Oil sight glass (3) Power unit (comprising electric motor, pump, control block) (4) Control cabinet (5) Control panel with buttons and control system CONTROL C.2 / (6) Position encoder system The crimping tool (1) is closed hydraulically, whereby the work piece is formed.

  • Page 21: Accessories

    The position encoder system (6) records the current position of the die system and transfers the value to the control system. Data records may be saved in the item memory and recalled at any time in the control system. Depending on the operation mode, the ac- tual forming process is controlled via the buttons on the control panel (5).

  • Page 22: Options

    Options The machine can be fitted with Options. A list of the available options is included in the Annex, Section "Options". Forming process There are two types of forming process with different target parame- ters: • Forming to a defined diameter •...
  • Page 23 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 outside the working area! •...

  • Page 24: Operation And Display Elements C.2

    Operation and display elements C.2 (1) Emergency-stop button (2) Illuminated Motor on button (3) Motor off button (4) Illuminated foot switch (5) Illuminated Open tool button (6) Illuminated Close tool button (7) Locking lever / angle setting (8) control panel of CONTROL C.2 The illuminated buttons may be arranged the other way round, depending on the control version.

  • Page 25: Electric Sockets

    (1) LAN socket for connection with a network. Network connection options are set out in the description of the relevant optional packages. (2) 2 x USB sockets (for the use of memory media, callipers or bar- code scanners certified by UNIFLEX, only) Electric sockets (1) Main power switch (2) Socket for single foot switch...

  • Page 26: Depth Stop (Accessory)

    Depth stop (accessory) (1) Connection cable with plunger switch (2) Star handle screw (3) Sleeve (4) Compression spring (5) Stop disc (6) Clamping yoke (7) Locking shaft (8) Gusset plate...

  • Page 27: Foot Pedal (Accessory)

    Foot pedal (accessory) (1) Close machine 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 sufficient periods of relief and recreation.
  • Page 28 activates the depth stop by pressure. Press the button to open the tool. As soon as the pre-set forming diameter or forming pressure is reached in the control, the tool stops and opens automatically. • Semi-automatic operation / IPC is activated in the control. The forming process is started manually via the buttons on the control panel or exter- nal buttons, e.g.

  • Page 29: Technical Data

    3.10 Technical data Machine Dimensions L x W x H 1200 x 600 x 1700 mm Weight approx. 750 kg Control CONTROL C.2 Operation mode S6-70 % Noise level < 70 dB(A)* Protection class IP 40 Function Forming force 3150 kN / 315 t Max.
  • Page 30 Workpiece capacity max. 2″, depending on fitting SAE R13 2½”, depending on fitting SAE R 15 Industry max. 4" (6"), without flange, de- pending on fitting Die type 237 L / 239 Electric connection Connection power 4 kW Supply voltage adjustable 230 V 50/60 Hz, 3 phases+PE 380 V 50/60 Hz, 3 phases+PE 400 V 50/60 Hz, 3 phases+PE...
  • Page 31 Permanent floor loading Approx. 0.07 kg/mm Floor carrying capacity Min. 2500 kg/m Floor quality Evenness Max. unevenness 5 mm/m Inclination max. 5 mm/m Ambient conditions C – 35 Ambient temperature 45 % – 65 % Air humidity The *data are theoretical/computed values, or values measured on a prototype.

  • Page 32: 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/unit may only be unloaded and transported by means of a forklift, a lift truck or a crane.

  • Page 33: Intermediate Storage Of Machine/Unit

    WARNING! Danger from falling loads! Risk of injury from falling loads. • Do not stand under suspended loads. WARNING! Danger from tilting machine/unit! The machine/unit may tilt if it is transported improperly. There is a risk of being injured. • Consider the machine/unit's centre of gravity (1).

  • Page 34: Filling Hydraulic Oil

    WARNING! Risk by tilting machine! If not bolted to the floor, the machine may tilt. There is a risk of being injured. • Fix the machine on the floor. Use suitable bolts to fix the machine legs on the floor. Place the machine in a way so that it is easily accessible for main- tenance work from all sides.
  • Page 35 CAUTION! Risk of injuries! Contact with hydraulic oil and other consumables imposes a risk of injuries for the skin, 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).

  • Page 36: Electrical Connection

    Do not operate the machine for a minimum of four hours so that the dirt particles in the system may settle. 4.3.2 Electrical connection ATTENTION! Risk of damage to machinery The voltage range described in this Section is only permissible for multi-voltage machines (MVA).
  • Page 37 Connect the voltage selection plug to the correct slot in the con- trol cabinet - Δ 230 V on connection (3), Υ 400 V on connection (1). Set the motor protection switch (2) as specified in the Technical data. The permissible voltage frequency ranges and the relevant motor protection setting are also indicated on the sticker in the control cabinet door.

  • Page 38: Bleeding The Hydraulic System

    ATTENTION! Risk of damage to machinery! Extended operation of the motor with an incorrect rotational di- rection or operating the machine without oil will destroy the hy- draulic pump. • Make sure that the hydraulic oil filling in the machine is suffi- cient before starting the machine.

  • Page 39: 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. Before starting and/or re-starting • Ensure sufficient illumination of the working area of the ma- chine/unit.

  • Page 40: Forming The Workpiece

    Forming the workpiece 5.3.1 Prerequisites Prerequisites for a correct forming process: • The die system and the workpiece match each other. • The proper jaw system is correctly mounted in the tool. • The forming dimension and the dies have been entered in the control system, please also refer to "Setting the forming dimen- sion"...
  • Page 41 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 workpiece as small as possi- ble. • Keep a minimum distance of 120 mm (A) to the die system. Manually position the pre-mounted workpiece in the tool.

  • Page 42: Remote Automatic Mode, Via Dual Foot Switch

    5.3.3 Remote automatic mode, via dual foot switch 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 workpiece as small as possi- ble.

  • Page 43: Remote Automatic Mode, Via Depth Stop

    actual dimension and the specified dimension (see "Setting the forming dimension" in Section 5). The operation mode Remote automatic via the dual foot switch is only functional if the plug of the dual foot switch is connected to the control cabinet. 5.3.4 Remote automatic mode, via depth stop WARNING! Risk of squeezing!

  • Page 44: Changing The Crimping Dies

    Manual operation mode: Press the button to open the ma- chine when the forming process is completed. Semi-automatic operation mode: Wait until the hold time defi- ned in the control has expired; the tool will then open automati- cally. Remove the workpiece from the tool. Check the forming dimension after the first forming process.
  • Page 45 WARNING! Risk of squeezing! When the die system closes, there is a risk of getting squeezed between the dies. • Only replace the dies when the motor is deactivated. Use the die key to press and hold the locking pin (2) in the basic die (3) backward.

  • Page 46: Changing The Crimping Dies With The Quick Die Change System (Only Profile 239)

    Intermediate dies are positioned and removed in the same manner when needed. After forming heavy fittings, the locking pin (2) may be a little slug- gish. In this case, use a rubber mallet to loosen the locking pin (2) by carefully knocking on the die key. 5.4.2 Changing the crimping dies with the quick die change system (only profile 239) Select the change position for crimping dies in the control by ac-...
  • Page 47 Hold the quick die change system with crimping dies in the cen- tre 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 inside the forming area when the crimping dies close.

  • Page 48: Adjusting The Depth Stop

    ATTENTION! Risk of damage to machinery! If the crimping dies protrude beyond the basic and intermediate dies, 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. •...
  • Page 49 Dismantle the linchpin (6). Loosen the star handle screw (7). Move the clamping yoke (5) into the desired position. Mount the linchpin (6). WARNING! Risk of squeezing! There is risk of getting squeezed between the depth stop and the machine chassis when positioning the depth stop. •...

  • Page 50: Setting The Forming Dimension

    Connect the cable (1) into the socket for the depth stop. Adjusting the control unit: Activate the illuminated foot pedal. The machine is closed automatically when the workpiece is pressed against the depth stop. Form the workpiece. Press the button to open the tool. Check the workpiece.

  • Page 51: Stop

    Micrometer: Workpiece forming dimension less crimping die di- ameter Form the workpiece. Check the workpiece. If the dimension is reached: manufacture other identical workpie- ces. If the dimension is not reached: Adjust difference on control and/or in the micrometer, repeat the forming process and check the workpiece.

  • Page 52: Emergency Stop

    Emergency stop In case of an emergency Immediately press the emergency-stop button (1) in cases of emergency. The crimping tool movement will be stopped. The drive unit is shut down. Restart after and emergency WARNING! Risk of injuries! The emergency-stop button was probably activated due to the occurrence of a hazardous situation.

  • Page 53: 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 54: Maintenance

    Maintenance Regular maintenance will ensure the continuous operation reliability of the device. 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/unit. • Maintenance work may only be performed by qualified mainte- nance staff (machine/unit fitters).
  • Page 55 Maintenance item Hydraulic system Hydraulic energy lines – hoses: Check for porosity and leaks. Hydraulic energy lines - bolted connections of hoses and pipes: Check for leaks. Hydraulic oil: Check oil level, add oil if required (see “Replacing hydraulic oil” in Section 6). Hydraulic oil filter: Change according to control dis- play.
  • Page 56 Maintenance item Complete crimping tool: overhaul after 150,000 crim- ping cycles. Only in case of extreme loads when insulators, struc- tural steel as well as steel ropes (PFC applications) are pressure–joined. Safety equipment Emergency-stop button: Check function Check permanently installed partitioning protection equipment and covers for completeness and correct installation Check case foot switch for completeness.

  • Page 57: Hydraulic Oil And Hydraulic Oil Filter Replacement

    Hydraulic oil and hydraulic oil filter replacement CAUTION! Risk of injuries! Contact with hydraulic oil and other consumables imposes a risk of injuries for the skin, eyes, respiratory and intestinal tracts! Hy- draulic liquid spills impose danger of slipping and falling! •...
  • Page 58 Let the hydraulic oil cool down until the tank enclosure is warm to the touch. Open the cover (1) and unscrew the screen. Pump out hydraulic oil by using an external pump. Fill in new hydraulic oil (see “Technical Data” in chapter 3). Close the cover (1).

  • Page 59: Checking And Replacing Slide Bearing Plates

    Place an oil sump (3) beneath the machine. Loosen the screws on the filter (2) and remove it. Remove the filter housing (1). Replace the filter element. Reassemble everything in the reverse order. 10. Check oil level, refill hydraulic oil, if required. 11.
  • Page 60 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. Replacing slide bearing plates Open the crimping tool fully. Deactivate the machine on the main switch and secure it against unintentional restart.
  • Page 61 Loosen the hexagon socket screws (4) (eight at the front and the back, each) with adjusting washers and remove the guiding plates (3). Use die wrench to press secondary dies (9) towards the centre of the tool. Replace the four secondary bearing plates (8) by new ones. In doing so, use the new secondary bearing plates to push out the old secondary bearing sheets, each.

  • Page 62: Installation Of Spring-Mounted Pressure Piece In Intermediate Dies

    After replacement of the slide bearing plates, the machine has to be recalibrated (see CONTROL C.2 / IPC Operation Manual). Installation of spring-mounted pressure piece in intermediate dies The intermediate die 237.239.2L2 (1) has to pin holes. For using the second pin hole, an additional spring-mounted pressure piece (4) has to be mounted in the intermediate dies: Remove the intermediate die from the machine.

  • Page 63: Replacement Of Relay/Opto-Coupler

    Replacement of relay/opto-coupler Deactivate the machine on the power switch and secure it against unintentional restart. Open the control cabinet. Open the flap 90° and press down on the hinge with the opened flap (1). The relay/opto-coupler (2) will spring up. Remove the relay/opto-coupler and replace it by a new one.

  • Page 64: Troubleshooting

    Troubleshooting Error Cause Remedy Machine does not close/open Main switch is OFF Activate the main switch Voltage incorrect Check voltage supply Power plug defective Check power plug and replace if necessary Rotational direction of electric Check rotation direction, cor- motor incorrect rect electrical connection Insufficient amount of hydrau- Refill oil...

  • Page 66: Decommissioning, Disposal

    Decommissioning, disposal WARNING! Risk by electrical voltage! There is a risk of electrocution near the live parts! • Shut down the machine/unit. • Disconnect the machine/unit from the power supply. CAUTION! Risk of injuries! Contact with hydraulic oil and other consumables imposes a risk of injuries for the skin, eyes, respiratory and intestinal tracts! Hy- draulic liquid spills impose danger of slipping and falling! •...

  • Page 67: Dismantling

    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 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: 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 (upgradable) Accessories Article code Quick die change system QDC 239.5 Die deposit QDS 239 B QDS 239 C QDS 239 R TU-QDS system QDS-S.2 double row...

  • Page 70: Options (Only Available Ex Works)

    Options (only available ex works) Options Item number Manual current regulator 257.920 (not for PFC machines) Spare parts list 9.3.1 Mechanics...
  • Page 71 Item Quantity Article code Description 232.104.3 U-profile 1 set SK 1130.3 Lateral guidance 232.113.4 Main counter-plate 232.114.3 Side counter-plate 237.103.4 Counter-plate 2 sets 232.128.3 protection plate 798.110142 Flathead screw DIN 921 M8x12 798.220016 Shim ring DIN 988 6.0x12.0x0.1 238.300.3 Hydraulic cylinder 238.311.3 Hydraulic cylinder 798.120012...
  • Page 72 Position Quantity Article number Description 232.132.2 / 232.133.2 Protection pad 232.168.3 Protection plate, lateral Guidance 241.018.3 RAL 9007 Protection hood position sensor 241.021.3 RAL 5012 protection plate 235.015.3 Holder operator panel 266.353 Oil sight glass UC-AB-1163-40 Oil filler plug 777.022 Clamp lever...
  • Page 73 Position Quantity Article number Description 578.4 Oil prohibition sign 715.4 Warning sign crushing risk 716.4 Warning sign Warning of hand injuries 1000 238.1100 Pressing tool complete HM 325 / HM 375 1001 1 Set 237.1003 Base jaws set PB 237...

  • Page 74: Hydraulic System

    9.3.2 Hydraulic system Item Quantity Part code Designation 232.059_XYZ Hydraulic manifold complete XYZ = supplier ID letter...
  • Page 75 Item Quantity Part code Designation 232.057 Suction valve, complete 220.916 Pressure sensor Hydraulic pump 239.350 HM 325 239.351 HM 325 H 232.013 HM 375 / HM 380 / HM 3xxPFC 232.010 HM375 H / HM380 H Bell housing 777.303 HM 325 PR250-122-433-1 HM 375 / HM 380 / HM 3xxPFC No pic-...

  • Page 76: Electric Equipment

    9.3.3 Electric equipment Item Quantity Article code Designation 807.710 CONTROL C.2 800 mm 807.711 CONTROL C.2 1800 mm 807.860 CONTROL IPC 800 mm 807.415 Position encoder 8.06.100 Main power switch 888.621 Voltage selection unit 880.014 Motor protection combination 807.318 Switching power supply 888.406 Passive interface 888.411...
  • Page 77 Item Quantity Article code Designation 232.011 Electrical motor 4 kW 238.011 Electrical motor 5.5 kW 888.701 Selec amplifier (for PFC machines only) Position Number Article number Designation TA HM 3xx C A Depth stop, complete 807.430 Plunger switch, complete 232.036 Star knob screw M8...

  • Page 78: Base Dies

    Base dies Item Quantity Part code Designation 237.101.2 Master dies 237.102.2 Secondary dies 232.153.4 Locking bolt D-195A-21 Pressure spring 798.420027 Threaded pin DIN EN ISO 4028 M5x10 798.420026 Threaded pin DIN EN ISO 4026 M12x20...

  • Page 79: Intermediate Dies 237.239.2L2

    Intermediate dies 237.239.2L2 Item Quantity Article code Designation 239,151 Spring-mounted pressure piece 232.504.4 Holding pin...

  • Page 80: Spare Parts Kit

    Spare parts kit Number per Part code Designation machine 238.1100 Replacement tool HM 325 / HM 375 238.1102 Replacement tool HM 380 / HM 3xx PFC D-106340 Pressure spring 232.504.4 Retaining bolt (profile: 232 / 237 / 237L / 554) 239.041.4 sw Retaining bolt, plastic (profile: 239 / 239L) 239.041...

  • Page 81: Retaining Bolt For Standard Crimping Dies (Depending On Crimping Die)

    Retaining bolt for standard crimping dies (depending on crimping die) Crimping die profile Retaining bolt 262.104.4 262.129.3 239.041.4 239.041.4 (sw) 232.504.4 Ø96 / Ø103 232.505.4 220.502.4...
  • Page 82 Crimping die profile Retaining bolt 245.114.4...

  • Page 83: Hydraulic Diagram

    Hydraulic diagram...

  • Page 85: Electric Diagram

    Electric diagram...

  • Page 91: Maintenance Log

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

  • Page 92: Declaration Of Qualified Staff

    9.11 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.

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