Danfoss ET6200 User manual

Imprint
Manufacturer:
UNIFLEX-Hydraulik GmbH
Robert-Bosch-Strasse 50-52
D-61184 Karben
Germany
Phone: [phone] / 91 71 - 0
Fax: [phone] / 91 71 - 181
This Operating Manual of the machine is a translation; the origi-
nal is in German.
Date of revision:2022-10-17
Version: 1.0
© Copyright by UNIFLEX-Hydraulik GmbH
Technical modifications reserved.
The reproduction, distribution and utilization of this document as well
as the communication of its contents to others without explicit authori-
zation are prohibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant of a patent, util-
ity model or design.

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:
•EC Directive 2006/42/EC
•EN ISO 12100: 2010
This declaration are invalid when the machine is modified or if un-
authorized and unapproved third-party components are used without
our prior approval.
Entity authorised for documentation: Uniflex-Hydraulik GmbH, Tech-
nical Documentation Dept.
Karben, 13.10.2022
Managing Director Harald von Waitz

Contents
1About this document .......................................................................................... 7
1.1 Target groups ............................................................................................... 7
1.2 Storage.........................................................................................................8
1.3 Name plate ...................................................................................................9
2Safety 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............................................ 11
2.3.2 Risk imposed by pneumatic system ................................................ 12
2.4 Safety.......................................................................................................... 13
2.4.1 Working area................................................................................... 13
2.4.2 Warning signs on the machine ........................................................ 14
3Machine description.......................................................................................... 15
3.1 Design and function.................................................................................... 15
3.2 Technical data ............................................................................................ 17
4Transport and commissioning......................................................................... 19
4.1 Transport .................................................................................................... 19
4.2 Intermediate storage of machine/unit.......................................................... 20
4.3 Commissioning ........................................................................................... 20
4.3.1 Connection of compressed air......................................................... 21
5Operation ........................................................................................................... 22
5.1 What you have to observe.......................................................................... 22
5.2 Inserting/extracting nipples ......................................................................... 23
5.2.1 Prerequisites.................................................................................... 23
5.2.2 Positioning the inserter cylinder....................................................... 23
5.2.3 Inserting nipples .............................................................................. 24
5.2.4 Extracting nipples ............................................................................ 26
5.3 Cleaning...................................................................................................... 28
6Maintenance....................................................................................................... 29
6.1 What you have to observe.......................................................................... 29
6.2 Maintenance schedule................................................................................ 29

7Troubleshooting.................................................................................................31
8Decommissioning, disposal..............................................................................32
8.1 Dismantling..................................................................................................32
8.2 Recycling.....................................................................................................32
8.3 Consumables and waste .............................................................................32
9Annex..................................................................................................................33
9.1 Accessories (retrofittable)............................................................................33
9.2 Spare parts list.............................................................................................34
9.2.1 Wear parts........................................................................................35
9.3 Pneumatic diagram......................................................................................36
9.4 Maintenance log..........................................................................................37
9.5 Declaration of qualified staff ........................................................................38

1 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. Consequently, please only use the machine/unit
•in good order and condition,
•in accordance with its intended purpose,
•in a safety-conscious manner, with awareness of risks and haz-
ards,
•in compliance with all notes included in this Operation Manual.
The machine/unit may only be operated by staff who
•has read the Operation Manual,
•has understood it,
•has been instructed in the operation of the machine/unit, and
•has signed in the Annex.
Figures may include accessories/options. Customer-specific
equipment may vary.
The product images shown are for reference only and may differ
from the product delivered.
1.1 Target groups
The target groups of this Operation Manual are:
Owner
An owner is a natural person or entity using the device himself/her-
self/itself, or on whose behalf the device is used. An owner may ap-
point a representative to exercise the owner's rights and obligations.
The owner has to make sure that
•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.
•persons working on the machine/unit are aware of potential
risks;
•the operating staff is familiar with the location as well as with op-
erating the fire alarm and fighting means. Free access to this
equipment must be ensured.
•personal protection equipment is worn (safety footwear, protec-
tion gloves and safety glasses).
Machine/unit fitters
Machine/unit fitters must be at least 18 years old and have completed
training for the task, i.e. they must have attended a specialist voca-
tional training.
A fitter
•must observe the instructions in the Operation Manual;
•must inform the owner on failures and damage.
Operator
An operator is a person charged with and instructed in the proper op-
eration of the machine/unit by the owner or the otherwise contractu-
ally obliged person.
The operator
•must observe the instructions in the Operation Manual;
•must inform the owner on failures and damage.
•must not perform and maintenance or repair work on the ma-
chine/unit.
1.2 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.

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

2 Safety instructions
2.1 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
serious injuries or death. This warning is supplemented by a triangu-
lar hazard symbol.
The signal word WARNING identifies a potentially hazardous situa-
tion, which might result in serious injuries or death. This warning is
supplemented by a triangular hazard symbol.
The signal word CAUTION identifies a potentially hazardous situa-
tion, which might result in light injuries. This warning is supplemented
by a triangular hazard symbol.
The signal word ATTENTION identifies a potentially hazardous situa-
tion, in which the product or property in the environment may be dam-
ages. This warning is supplemented by a hazard symbol or a excla-
mation mark.
2.2 Intended use
This machine is intended for industrial use; it is only suitable for inser-
ting nipples in hoses up to a specific permissible diameter (see
"Technical Data”, Section 3). Nipples which have not been crimped
can also be extracted from the hose by the machine.
Intended purposes include:
•Single user workplace for one person only
•Manual input and retrieval
•Operating temperatures between 10 °C and 35 °C
•Operation in a closed operation room
•The machine must not be operated by persons not capable of
operating the machine without any risk. These may include:
➢persons with physical or mental disabilities;
HAZARD!
WARNING!
CAUTION!
ATTENTION!

➢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.
Use for other than the intended purpose
Any other use is considered as being not in compliance with the in-
tended purpose, in particular:
•Design modifications of the machine
• Nipples and hoses must match each other
•Use in explosive environments
•misuse of consumables and waste materials.
WARNING!
Risk for life and health!
Use not in compliance with the intended purpose imposes risks
for life and health. Consequences resulting from use for other
than the intended purpose shall be under the sole responsibility
of the owner.
•Always use the machine in compliance with its intended pur-
pose.
2.3 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 posed by mechanical equipment
Risk of shearing
There is risk of shearing between the protective cover and the chas-
sis when closing the protective cover.
•Close the protective cover by the handle.

•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.
•Close the protective cover by the handle.
•When closing the protective cover, make sure that your extremi-
ties are not between the hose feed and the knife protection.
There is risk of getting squeezed between the work piece and the
clamping dies when closing the clamping device.
•Keep sufficient distance to the clamping device.
Tilting hazard
The risk of tilting mainly exists while the machine is being trans-
ported.
•Observe the machine's centre of gravity during transport.
2.3.2 Risk imposed by pneumatic system
Risks are imposed by all pneumatic lines and connections. Pneu-
matic systems are subject to special safety provisions.
•After the machine is deactivated, the given and potentially haz-
ardous residual energy has to be considered.
•Use correct hoses and hose clamps.
•Only work in the permissible pressure range.

2.4 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.

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.

3 Machine description
3.1 Design and function
(1) Inserter cylinder
(2) Hand lever
(3) Hand wheel

(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). In addi-
tion, the work piece is centred by the clamping dies (4). The clamping
dies (4) are adjusted using the hand wheel (3). The position of the in-
serter cylinder (1) can be adapted to the work piece. Once the posi-
tion of the inserter cylinder (1) has been set, the position is secured
by means of the catch bolt (7).
The protective cover (9) is closed manually before beginning with the
insertion or extraction process. When the protective cover (9) is
closed, the clamping cylinder (8) extends automatically and clamps
the work piece. The insertion/extraction is controlled by means of the
hand level (2). For this purpose, the hand lever (2) has the positions
BACK, STOP and PUSH. The protective cover (9) is opened manu-
ally after the insertion or extraction process. When the protective
cover (9) is opened, the clamping cylinder (8) retracts automatically
and releases the work piece so that it can be removed.
Accessories
The machine can be fitted with accessories. A list of the available ac-
cessories is included in the Annex, Section "Accessories".

3.2 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. outside
Ø up to 54 mm
Pneumatic connection
Power rating
7 bar
Workbench
Solid, plane workbench with a
carrying capacity of
approx. 500 kg
We recommend industrial flooring which meets the following
structural requirements
Permanent floor loading
Approx. 0.07 kg/mm2
Floor carrying capacity
Min. 2,500 kg/m2
Floor quality
B25
Evenness
Max. unevenness 5 mm/m
Inclination
max. 5 mm/m

Ambient conditions
Ambient temperature
10 oC –40 oC
Air humidity
45 % –65 %
The * data are theoretical/computed values, or values measured on a
prototype. Actual values may vary slightly, depending on the ma-
chine.

4 Transport and commissioning
4.1 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" in Section 3.
WARNING!
Danger from falling loads!
Risk of injury from falling loads.
•Do not stand under suspended loads.
WARNING!
Danger from moving parts
Risk of injury from moving protective cover.
•Do not lift the machine by the protective cover.
WARNING!
Danger from increased load weights!
The weight of the machine is approx. 30 kg.
•Transport the machine with two persons.
•Use transport aids.
1. Lift the machine manually and transfer it to the installation site.

4.2 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:
•temperature between 10°C and 35°C,
•maximum air humidity 80% (non-condensating).
4.3 Commissioning
The machine is commissioned by the customer's fitter.
1. Place the machine onto the optionally supplied table.
2. Bolt the machine on the bench.
Place the machine in a way so that it is easily accessible for main-
tenance work from all sides.
3. Check the machine for damage.
4. Check the compressed-air hoses for damage.
5. Train the operating staff and record training sessions in “Decla-
ration of trained staff”, Section 9.
WARNING!
Risk of injuries!
Machine components might loosen during transport. Such com-
ponents might be flung out during the nipple insertion process.
There is a risk of being injured.
•Simulate the nipple insertion process several times without a
work piece.
•Check the machine for atypical noise.