Danfoss ET4400 Operator's Manual
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Danfoss ET4400 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 ET4400 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 Voltage codes ..................... 10 Safety instructions .................... 11 2.1 Presentation of warnings ................11 2.2 Intended use ....................11 2.3 Product-specific risks ..................
  • Page 6 4.3.1 Filling hydraulic oil ................31 4.3.2 Electrical connection ................ 33 4.3.3 Bleeding the hydraulic system ............35 Operation ......................36 5.1 What you have to observe ................36 5.2 Start ......................36 5.3 Forming the workpiece ................37 5.3.1 Prerequisites ..................37 5.3.2 Operation mode buttons control panel ..........
  • Page 7 9.2.3 Mechanical equipment ..............67 9.2.4 Hydraulic system ................68 9.2.5 Electric equipment ................70 9.2.6 Electric equipment ................71 9.3 Spare parts kit ..................... 73 9.4 Service tool ....................73 9.5 Retaining bolt for standard crimping dies (depending on crimping die)..74 9.6 Hydraulic diagram ..................

  • Page 8: About This Document

    About this document In this Operation Manual, the “forming machine Danfoss ET4400” is consistently referred to as machine. This Operation Manual includes important notes on how you oper- ate your machine/unit safely, properly and economically. Use not in compliance with the intended purpose may result in haz- ard 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 appli- cable 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 hardcopy of the Operation Manual must always be kept at a designated 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 ma- chine/unit, the Operation Manual must also be handed over. Name plate The name plate is fixed near the power cable. Voltage codes Voltage variant Voltage rating...

  • 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 follows: The signal word HAZARD identifies an imminent hazard resulting in HAZARD! serious injuries or death. This warning is supplemented by a trian- gular hazard symbol.
  • Page 12 • use of eight identical original UNIFLEX dies with the same la- bel 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

    • Regularly check lines and bolted connections for leaks and visible 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. 2.3.4 Risks imposed by noise The noise level meter acc.

  • Page 15: Safety

    Never use water to extinguish a fire. For appropriate fire extin- guishing action, please read the safety data sheet of the hydraulic oil supplier. Safety 2.4.1 Working area The working area is defined as the area 1 metre all around the ma- chine (shaded).

  • Page 16: Emergency-Stop

    2.4.2 Emergency-Stop The machine is fitted with an emergency-stop switch on the control panel. Immediately activate the emergency-stop switch (1) in cases of emergency. Remedy the cause of the emergency stop first before re-starting the machine. 2.4.3 Protection equipment Due to the variety of customer-specific workpieces, UNIFLEX 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.

  • Page 17: Warning Signs On The Machine

    The owner has to consider the need for adapted protection equip- ment before commissioning. If such need exists, the relevant pro- tection equipment has to be mounted before commissioning of the machine. UNIFLEX will provide you with customized solutions for protection equipment upon request.
  • Page 18 Oiling / greasing prohibited on the die system Illegible or missing warning signs must immediately be replaced by the owner.

  • Page 19: Machine Description

    Machine description Design and function Base machine (1) Manometer connection for pressure test (manometer measur- ing range: 0 – 400 bar) (2) Hydraulic tank (with electric motor, pump) (3) Control console (4) Main switch/ emergency-stop button (5) Operation selector switch (foot switch/button) (6) Socket for double foot switch only (PS.2-Double) (7) Micrometer (8) Crimping tool...

  • Page 20: Accessories

    The micrometer (7) is used to change the final diameter of the die system. Crimping tool The die system comprises base dies, intermediate dies (depending on the application) and crimping dies. All base dies are mounted on slide plates. The crimping dies and the intermediate dies, if present, are attached to the base dies (1).

  • Page 21: Forming Process

    Forming process There is one type of forming: • Forming to a defined diameter Forming to a defined diameter This is the standard process for forming to produce hydraulic ho- ses. The crimping tool closes until it reaches a pre-set diameter, re- gardless of the required forming force.

  • Page 22: Operation And Display Elements

    Operation and display elements (1) Close tool button (2) Main switch / emergency-stop button (3) Open tool button (1) Operation via button (2) Operation via double foot switch...

  • Page 23: Foot Pedal (Accessory)

    (1) Socket for double foot switch (PS.2-Double) When an automatic end stop is connected, the crimping tool is opened by means of the Open tool button. Foot pedal (accessory) (1) Close machine pedal (2) Open machine pedal...

  • Page 24: End Stop (Accessory)

    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. End stop (accessory) (1) Clamp lever (2) Sleeve (3) Plunger (4) Stop pin (5) Clamp (6) Guidance...

  • Page 25: Technical Data

    Technical data Machine Dimensions L x W x H 700 x 600 x 735 mm Machine weight approx. 248 kg Control CONTROL A Operation mode S3-30% Noise level < 70 dB(A)* Protection class IP 40 Function Forming force 2000 kN / 200 t Max.
  • Page 26 Work piece capacity SAE R15 / 4SH 1 Part fittings 2", depending on the fitting SAE R15 2 Part fittings 1 1/2", depending on the fitting 4SH 2 Part fittings 2", depending on the fitting Industry 3" 90° bend 2", depending on the fitting Die type Electrical connection Power rating...
  • Page 27 Hydraulic system Oil volume approx. 50 l Oil type HM 46 or HLP 46, ISO 11158 / ISO 6743-4, 10 filtered The oil type can be adapted for Viscosity class 68 mm²/s for high- specific applications. temperature operating conditions. Viscosity class 32 mm²/s for low- temperature operating conditions.
  • Page 28 The use of special hydraulic oil with improved properties and addi- tives can prolong the service life of the machine and extends the oil change interval. Information and assistance for the oil analysis can be provided by you local oil supplier.

  • Page 29: 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 must only be unloaded and transported with a crane. Lifting gear with a sufficient length, width and lifting capacity must be used.

  • Page 30: 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! The machine may tilt if it is transported improperly. There is a risk of being injured. • Consider the machine's centre of gravity (1).

  • Page 31: Commissioning

    • temperature between 10°C and 35°C, • maximum air humidity 80% (non-condensating). Commissioning The machine is commissioned by the customer's fitter. Place the machine on a stable and level workbench. Bolt the machine onto the workbench. The workbench must be sufficiently solid and stable. Place the machine in a way so that it is easily accessible for main- tenance work from all sides.
  • Page 32 filled before commissioning (for oil type, please refer to "Technical data" in Section 3). 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 a danger of slipping and falling! •...

  • Page 33: Electrical Connection

    1. Open the air ventilation cap (1). 2. Add hydraulic oil; for quantity and type, please refer to "Technical data" in Section 3. The oil level can be read on the dipstick of the air ventilation cap. The oil level should be at the centre of the marking.
  • Page 34 ATTENTION! Risk of damage to machinery! Prolonged operation of the motor with an incorrect rotational di- rection or operating the machine without oil will destroy the hyd- raulic pump. • Make sure that the amount of hydraulic oil in the machine is sufficient before starting the machine.

  • Page 35: Bleeding The Hydraulic System

    4.3.3 Bleeding the hydraulic system Switch on the machine. Operate the machine in the idle mode for two minutes in order to fill the pump with oil. Open and close the tool several times. Check oil level, add hydraulic oil if required.

  • Page 36: 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 37: Forming The Workpiece

    Forming the workpiece 5.3.1 Prerequisites Prerequisites for a correct forming process: • The die system and the workpiece are compatible. • The proper jaw system is correctly mounted in the tool. • The forming dimension is set correctly, please also refer to “Set- ting the forming dimension”, Section 5.
  • Page 38 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 39: 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 40: Changing The Crimping Dies

    Operation via the double foot switch is only possible if the plug of the double foot switch is connected to the electrical plate. Changing the crimping dies 5.4.1 Changing the crimping dies using a die wrench Positioning the crimping dies Close the crimping tool until the holes (5) are visible for using the locking bolt.
  • Page 41 WARNING! Risk of squeezing! When the die system closes, there is a risk of getting squeezed between the dies. • Only replace the crimping dies when the machine is switched off. Use the supplied die wrench (3) to push and hold the locking bolt backward in the basic die (1).

  • Page 42: Replacing The Intermediate Dies

    After forming heavy fittings, the locking bolt may be slightly slug- gish. In this case, use a mallet to release the locking bolt by slightly hitting on the die wrench. Replacing the intermediate dies Position the intermediate dies Close the crimping tool until the holes (5) are visible for using the locking bolt.
  • Page 43 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 machine is deactivated. Use the supplied die wrench (3) to push and hold the locking bolt backward in the basic die (1).
  • Page 44 Remove the die wrench(3) and release the pressure on the lo- cking bolt. ATTENTION! Risk of damage to machinery! If the profile 266/268/237 intermediate dies (1) are placed in the tool by means of crimping dies PB 239 and QDC 239, the base dies, the locking bolts in the base dies as well as the retaining bolts of the intermediate and criming dies will be destroyed.

  • Page 45: Changing The Crimping Dies With The Quick Die Change System (Only Profile 239)

    5.5.1 Changing the crimping dies with the quick die change system (only profile 239) Set micrometer to 0.0 mm position. Open the crimping tool fully by activating the button. Push the eight pins of the quick die change system (1) into the front holes of the crimping dies (2).
  • Page 46 ATTENTION! Risk of damage to machinery! The retaining bolts and the crimping dies will be destroyed if the retaining bolts do not fit in the mounting hole of the base dies or intermediate dies. • Pay attention to the correct position of the quick die change system with crimping dies.
  • Page 47 ATTENTION! Risk of damage to machinery! If the crimping dies protrude beyond the base and intermediate dies during forming, 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 48: Setting The Forming Dimension

    Setting the forming dimension The forming dimension (X) must be set specifically for the workpiece. Read the forming dimension in the forming dimension table of the system supplier, e.g. Ø 17.4 mm. Select crimping dies with a smaller or the same diameter, e.g. Ø...

  • Page 49: Stop

    Stop Complete the forming process. Deposit the work piece outside the machine. Deactivate the main switch (1). Check the machine for contamination, leaks and external da- mage. Check the crimping tool and retaining bolts for contamination, damage and secure fitting. Check the oil level.

  • Page 50: Cleaning

    Restart after and emergency WARNING! Risk of injuries! The emergency-stop button was probably activated due to the occurrence of a hazardous situation. A restart of the machine may cause injuries if the hazardous situation has not yet been remedied! • Remedy the hazardous situation before a restart.

  • Page 51: 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 52 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: Replace Hydraulic hoses: Have replaced (DIN 20066) no later than six years after manufacture (see label).
  • Page 53 Hydraulic oil changes and wear part replacements must be recor- ded in the maintenance log!

  • Page 54: Hydraulic Oil Change

    Hydraulic oil change CAUTION! Risk of injuries! Contact with hydraulic oil and other consumables imposes a risk of injuries for the skin, eyes, respiratory and intestinal tracts! Hyd- raulic liquid spills impose danger of slipping and falling! • Observe supplier's protection and safety instructions (see data sheet).
  • Page 55 Deactivate the machine on the main switch and secure it against unintentional restart. Let the hydraulic oil cool down until the tank enclosure is warm to the touch. Open the air ventilation cap (1). Pump out hydraulic oil using an external pump. Add new hydraulic oil (see “Technical Data”...

  • Page 56: Checking And Replacing Slide Bearing Plates

    Checking and replacing slide bearing plates Checking slide bearing plates Check slide bearing plates 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 machine and lead to inaccuracies of the forming dimension.
  • Page 57 Replacing slide bearing plates Open the crimping tool fully. Deactivate the machine on the main switch and secure it against unintentional restart. Loosen the hexagon socket head screws (1) on the clamping ring (2). Remove clamping ring (2). Pull out old slide bearing plate (3). Insert the new slide bearing plate (3).

  • Page 58: Micrometer Adjustment

    Micrometer adjustment If the measured forming dimensions of the workpiece deviate from the forming dimensions of the crimping die when the micrometer is set to zero, the micrometer must be readjusted. Release the screws on the cover. Remove the cover (see “Annex” in Section 9). Loosen the counter-nut (1) of the contact screw (2).

  • Page 59: Troubleshooting

    Troubleshooting Error Cause Remedy Machine does not close/open Main switch is OFF Switch on 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 Phase applied to neutral...

  • Page 60: 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 61: 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 62 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 63: Annex

    Annex Individual machine/unit components may deviate in their features. Please indicate the serial number of the machine for spare part or- ders.

  • Page 64: Accessories (Retrofittable)

    Accessories (retrofittable) Accessories Part code Quick die change system QDC 239.5 Die deposit QDS 239 B QDS 239 C QDS 239 R TU-QDS crimping die deposit system TU-QDS F Basic TU-QDS F Shelf TU-QDS F 239 l End stop TA S6.2 manual Double foot switch PS.2 Double Mirror...

  • Page 65: Spare Parts List

    Spare parts list 9.2.1 Tool Item Quantity Part code Designation 266.190.0 Pressure plate, front 266.192.4 Sleeve 266.191.0 Pressure plate, back 266.194.3 Ball nut 1 set 266.8 Bearing segments 1 set 266.5 Bearing plates 266.390.3 Hydraulic cylinder 266.213.3 Clamping ring 798.110128 Cylinder bolt DIN EN ISO 4762 –...

  • Page 66: Basic Dies

    Item Quantity Part code Designation 798.750004 Snap ring DIN 127 Ø8 268,150 Pressure spring 266,193 Sleeve, Ø 45/Ø 50/ length long 1001 266.1192 Base dies mounted 266.1190 Complete tool 9.2.2 Basic dies Item Quantity Article code Designation 266.198.1 Basic dies 235.008.4 Locking pin 798.420027...

  • Page 67: Mechanical Equipment

    9.2.3 Mechanical equipment Item Quantity Article code Designation 266.240.1 Chassis Ecoline 266.243.2 Tank cover 264.213.3 + colour Cover code 266.224.2 + colour Cover code 777.924.2 Designation sign 226.051.4 Limit switch attachment...

  • Page 68: Hydraulic System

    Item Quantity Article code Designation 211.502.3 Round closing blank UNIFLEX 264.248.4 Mounting plate, roller switch 266.331.2 Tank gasket S6.2 Ecoline 264.321.3 Bleed screw with oil dipstick Z 15 GQ 3 Limit switch 219.400.3 Crimping micrometer 715.4 Squeezing risk warning sign 578.4 Oil prohibition sign 716.4...
  • Page 69 Item Quantity Part code Designation 266.415 Electric motor 4 kW, EcoLine, 3 phases MVA 266.411 Electric motor 4 kW, EcoLine, 230 V - 60 Hz, 1 phase 266.414 Electric motor 4 kW, EcoLine, 230 V - 50 Hz, 1 266.416 phase Electric motor 4 kW, EcoLine, 200 V - 60 Hz, 3 phases...

  • Page 70: Electric Equipment

    9.2.5 Electric equipment Item Quantity Part code Designation 888.698 Closing contact maker 888.699 Opening contact maker 800.053 Main power switch QXWA Selector / selector switch Contact maker 8.12.031 Mounted housing 888.229 Sleeve insert, 4-pole type 800.021 Transformer 8.06.002 Motor protection switch 10 – 16 A 15 GQ3 Limit switch 888.132...

  • Page 71: Electric Equipment

    Item Quantity Part code Designation 888.131 Actuating magnet 230 V – 50/60 Hz – 1phase 9.2.6 Electric equipment Item Quantity Part code Designation 888.698 Closing contact maker 888.699 Opening contact maker 800.053 Main power switch QXWA Selector / selector switch Contact maker 8.12.031 Mounted housing...
  • Page 72 Item Quantity Part code Designation 800.021 Transformer 8.06.147 Motor protection switch 25 – 10 A 15 GQ3 Limit switch 888.132 Magnetic switch 888.131 Actuating magnet...

  • Page 73: Spare Parts Kit

    Spare parts kit Quantity Part code Designation 1 set 266.5 Pressure plate slide bearing plate, back 1 set 266.8 Bearing plate segments, front 8 per set 239.041.4 sw Plastic retaining pin (section: 239 / 239L) 8 per set 239.041.4 Retaining bolt, steel (profile: 239 / 239L) 8 per set 239.151 Pressure piece (profile: 239 / 239L)

  • Page 74: 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 75 Crimping die profile Retaining bolt 245.114.4...

  • Page 76: Hydraulic Diagram

    Hydraulic diagram...

  • Page 77: Electric Diagram

    Electric diagram 380 V – 50/60 Hz – 3 phases...
  • Page 78 230 V – 50/60 Hz – 1phase...

  • Page 79: Maintenance Log

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

  • Page 81: 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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