Interpump Hydralok HydraTouch H32 User manual
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
2
TABLE OF CONTENTS
WARRANTY CONDITIONS ..........................................................................................................3
EC DECLARATION OF CONFORMITY.......................................................................................4
SAFETY REGULATIONS...............................................................................................................5
TECHNICAL / DIMENSIONAL DATA .........................................................................................6
HANDLING/TRANSPORT .............................................................................................................6
PRELIMINARY CHECKS...............................................................................................................6
LIGHTING........................................................................................................................................6
ROUTINE MAINTENANCE...........................................................................................................6
INSTALLATION..............................................................................................................................7
Three Phase Machines:..............................................................................................................7
Single Phase Machines:.............................................................................................................7
Starting The Machine For The First Time: ...................................................................................7
SAFETY PRECAUTIONS ...............................................................................................................7
BASIC SWAGING PROCEDURE................................................................................................... 9
Basic Swage Screen: .................................................................................................................9
Important Note On Swage Dimensions:......................................................................................10
QUICK CHANGE TOOL OPERATING INSTRUCTIONS†........................................................11
Inserting Dies Into The Machine:............................................................................................11
ADVANCED SWAGE PROCEDURE...........................................................................................12
Swage Diameter ......................................................................................................................12
Swage Offset:..........................................................................................................................12
Opening Time:.........................................................................................................................12
Dwell:......................................................................................................................................13
PRESET MENU..............................................................................................................................14
CSV Table:..............................................................................................................................14
USB UPDATES..............................................................................................................................15
SETTINGS MENU .........................................................................................................................16
Settings Page 1 ........................................................................................................................16
Lubrication ..............................................................................................................................17
Settings Page 2 ........................................................................................................................19
Calibration.......................................................................................................................................19
HELP SCREEN...............................................................................................................................21
TECHNICAL INFORMATION .....................................................................................................22
Maintenance And Service: ..........................................................................................................22
Spare Parts:..................................................................................................................................22
Die Fitting Instructions................................................................................................................24
Electrical Diagram: 3 Phase........................................................................................................25
Electrical Diagram: 1 Phase........................................................................................................26
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
3
WARRANTY CONDITIONS
1. Please note that all machines undergo strict testing before shipment.
2. All machines are warranted against any defects for a period of twelve (12) months starting
from the date of delivery to the customer.
3. Defective items/machines must be returned to our address with shipping charges pre-paid. We
will return items/machines with “carriage forward”. We are unable to accept items/machines
returned to us unless carriage charges have been paid.
4. This warranty covers the replacement and or repair of any component found to be defective
during the warranty period.
5. Replacements and repairs completed under this warranty do not extend the original twelve (12)
month warranty period.
6. This warranty does not cover normal wear under normal operating conditions
7. This warranty is not valid for damage resulting from incorrect operation, or use not in
compliance with the machine instructions.
8. This warranty is not valid in case of unauthorized machine modification.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
5
SAFETY REGULATIONS
Always work in safe conditions and with the necessary space around the machine.
Ensure that the machine is placed on a stable and appropriate working surface.
1. DO NOT USE the equipment before reading the user manual.
2. CAUTION! If improperly used, the equipment may be dangerous and may cause
injury. Do not touch any moving parts.
3. CAUTION! It is absolutely essential that all working operations are carried out by
one operator only
4. This manual must be provided for the machine operator. Ensure that the operator
is aware of his/her responsibilities.
5. Guards must never be removed or tampered with.
6. (Where applicable) A fully trained and competent electrician must connect the
machine to the appropriate electricity supply.
7. Always wear protective gloves, safety glasses and appropriate clothing.
8. (Where applicable) Disconnect the power supply before removing any covers, or
attempting any maintenance of the machine
9. Only original spare parts can be used in the maintenance of the machine.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
6
TECHNICAL / DIMENSIONAL DATA
TECHNICAL
DATA
H32HydraTouch
H50HydraTouch
H50-46HydraTouch
H50-6HydraTouch
Capacity
3/16”- 1¼” (4 wire)
3/16”- 2” (4 wire)
3/16”- 2” (4 wire)
And 1½” (6 wire)
3/16”- 2” (6 wire)
Motor
2.2KW
2.2KW
2.2KW
2.2KW
Gross weight
(Kg)
143
178
213
264
Voltage, Phase
and Frequency
Options
220/240-1- 50HZ or
220/240 - 380/440-3-50
Hz 225/280 –440/480
60 Hz
220/240-1-50HZ or
220/240 - 380/440-3-50
Hz 225/280 –440/480
60 Hz
220/240-1-50HZ or
220/240 - 380/440-3-50
Hz 225/280 –440/480
60 Hz
220/240-1-50HZ or
220/240 - 380/440-3-50
Hz 225/280 –440/480
60 Hz
Swaging Force
1750 KN
2509 KN
3195KN
4500 KN
Swaging Range
6 mm –45.9 mm
6 mm –76 mm
6 mm –76 mm
6 mm –82 mm
Standard Dies
16 19 22 26 30 34
40 46
16 19 22 26 30 34
40 46 52 58 64 70
16 19 22 26 30 34 40
46 52 58 64 70
16 19 22 26 30 34 40
46 52 58 64 70 76
Max Operating
Pressure
320 Bar
320 Bar
320 Bar
320 Bar
HANDLING/TRANSPORT
The machine will normally be shipped bolted to a wooden pallet. The bolts should be removed
and the machine lifted onto the work place using suitable lifting equipment.
PRELIMINARY CHECKS
Place the machine on a flat and stable base.
Where applicable, ensure that the power supply line is fitted with a differential safety breaker and
overload cut-out.
LIGHTING
The equipment does not have its own lighting and so it must be used in a suitably illuminated area.
ROUTINE MAINTENANCE
Ensure that moving parts are always lightly greased. Where applicable, check periodically that the
limit switches and emergency controls are in good working order.
At the top of the machine base, remove the oil filler cap and check that the oil level is correct.
Where necessary add oil (ISO 32 Hydraulic oil).
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
7
INSTALLATION
The machine must be bolted to a firm workbench in a horizontal position. If a quick change rack is
supplied, the machine must be bolted to it with the bolts supplied. The machine is top heavy so
please ensure that it is stable and does not pose a danger to the user or to other people.
All electrical installation must be carried out by a qualified electrician. Check that the electrical
installation is compatible with the motor requirements and specification supplied with the swaging
machine such as: 380V / 3 ph or 220V / 3ph supply
230V 1 ph or 110V 1 ph supply
Three Phase Machines:
When operating the machine for the first time check that the motor rotation direction is correct.
(Three phase machines only) If the motor starts but jaws of the swaging head do not begin to close
when the green button is pressed to swage, the phase rotation of the motor will have to be
reversed. To reverse the rotation of the motor change over any two of the phase cables in the
machine’s plug. A competent electrician should carry out the rewiring of the electric plug.
Single Phase Machines:
IMPORTANT: 220/240V Single phase machines require a minimum 16 Amp C type motor rated
MCB / Fuse. It is not recommended to connect the machine to a domestic supply. Install the
machine as close to the socket as possible, without using long extension leads as this increases the
current demand from the machine.
Starting The Machine For The First Time:
After the machine is connected to the power supply, if the Emergency Stop is pressed, rotate it to
disengage. The touchscreen will cycle through the boot process (this may take several minutes)
and wait for the screen to display the user login screen.
Login as User
Login as Administrator
All passcodes for logins are default to “0” To change
the login passcodes for both User and Administrator
see page 17.
SAFETY PRECAUTIONS
Switch off machine when not in use by using the latching emergency stop (E-Stop) button. To
unlatch the stop button, twist the E-Stop button clockwise, then release.
To stop the machine in an emergency, press the RED EMERGENCY STOP BUTTON.
DO NOT START THE MACHINE UNDER LOAD.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
9
BASIC SWAGING PROCEDURE
Basic Swage Screen:
Press to begin a basic swage.
Touch to input target swage size.
The forward (right) arrow will always
progress to the next sequential screen.
This field will display the die
set required to swage the specified swage size.
These dies may be fitted manually, or the
button can be pressed to use the quick change tool,
if quick change system is present and activated.
Press after correct dies have been fitted.
Follow onscreen instructions to complete swage.
Displays the current diameter in
real time to indicate when the final swage size
reached.
Press to activate the rear view camera to view
the reverse of the head while swaging.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
10
Remove the hose and measure the ferrule. Adjust swage size if necessary to
compensate for any discrepancies until correct swage size is achieved. Please see
note on the following page.
Important Note On Swage Dimensions:
!
The dimensions shown on the display are only an indication of the position of the
machine components and must not be taken at face value. Due to several factors
including fitting design and material, hose characteristics, elastic memory in the
fitting and machine tolerances, the display diameter readout may differ from the
actual ferrule dimension. To overcome discrepancies, adjust the swage size
accordingly (larger or smaller) or use the offset to compensate until the correct
swage size is achieved.
NOTE! Always measure the ferrule after swaging to ensure that it is within the
tolerances given by the hose and fitting manufacturer.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
11
QUICK CHANGE TOOL OPERATING INSTRUCTIONS†
†For Machines fitted with a Quick Change Tool
The electromagnetic quick change (QC) tool is used to fit and remove all the dies in one operation
without having to install them by hand one by one. It is connected to the machine base and
operated using a switch located on the tool handle. To correctly use the tool, follow these
instructions.
Inserting Dies Into The Machine:
1. When the button is pressed to use a QC tool to change the dies the head automatically
closes to the correct diameter to insert the correct dies.
2. Remove the QC tool from the holder and select required die set from the die rack.
3. Holding the QC tool firmly with both hands, align the tool with the required die set. The
tool should be orientated such that the pins on the tool are fully inserted into the
positioning holes in the
dies.
4. Switch on quick change
tool, the red light will
come on the switch, and
the dies will now be
magnetically held by the
tool.
5. Pull the dies out of the
insert on the rack in a
smooth, linear movement.
6. Insert the dies into machine in a similar movement parallel to the machine axis, (not at an
angle), with a firm push so that they click into place past the location ball bearings, and
then switch the QC tool off.
7. Remove the QC tool from the dies and replace back into the holder. NOTE! Never open
the dies with the tool still inserted into the dies.
8. Press the red button on the machine base to open the machine jaws to begin the swaging
operation.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
12
ADVANCED SWAGE PROCEDURE
The advanced swage feature of the HydraTouch expands on the basic swage operation allowing
the user to determine additional parameters of the swage to provide a more comprehensive
swaging profile.
Select advanced swage from the home screen.
Swage Diameter
Touch to input target swage size.
Swage Offset:
This function allows you to adjust the swage size to
compensate for ferrule elastic memory or any other
factors such as ferrule temperature that may affect the
final swage dimensions.
Touch to input swage offset.
Opening Time:
In certain circumstances, it may not be necessary to
fully open the machine after each swaging operation.
It may save time to open the machine just enough to
remove the fitting.
Touch to input opening time.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
13
Dwell:
In order to allow a more controlled and precise swage
finish, it is sometimes beneficial to maintain pressure
on the ferrule for a period of time at the swage
diameter. This helps to minimise the elastic memory
that a ferrule experiences after swaging, especially on
larger hoses.
Touch to input dwell time.
Press to save the advanced swage data into
a preset table record.
This screen will allow the user to save the defined
advanced swage parameters into the preset table for
recovery at a later time.
Press to choose the preset number to locate
the record under.
Press to save the swage parameters into the
specified preset table record.
For preset table record recovery and all other information regarding the presets see page 13 :
Preset Menu
This field will display the die set
required to swage the specified swage size. These
dies may be fitted manually, or the button can be
pressed to use the quick change tool, if quick change
system is present and activated.
Press after correct dies have been fitted.
Follow onscreen instructions to complete swage.
Displays the current diameter in real
time to indicate when the final swage size reached.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
14
PRESET MENU
The preset menu allows the user to save machine settings using a unique location number which
can be stored, reloaded and edited by the user.
The preset menu shows two options:
The comma separated value (CSV) table is
uploaded via a USB stick and is only
editable from a computer. The records in this table
can be exported into the local preset menu for editing
but entries in the local preset table cannot be
imported into the CSV table.
The local preset table contains records
saved from advanced swage, inputted
locally, or exported from the CSV table.
CSV Table:
The CSV table shows the records as a spreadsheet
listing each of the variables. It also includes the A
column titled Name to more easily clarify for the
user the reference of the preset record.
Once a preset has been chosen press to
highlight and press the forward arrow to
proceed.
Pressing this option will load the
parameters of the record into the advanced
swage feature for immediate use.
Pressing this option will load the record
into the local preset table for future
editing.
Note! The record number to be copied will be
displayed here.
This screen verifies the record to be copied from the
CSV table and requires the destination record
number to be defined.
Press to input the destination record number.
NOTE! If the destination number is already in use
the record will be overwritten with the new
information. Ensure an empty record is specified to
prevent unwanted loss of data.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
15
Pressing the local preset table option on
the preset menu will open the first record
in the table.
Press to cycle through all local table records.
This icon indicates that this preset is editable.
Press to cycle between editable and read only ( )
Press to save changes after editing a preset.
Press to load selected record to advanced swage.
USB UPDATES
There are two updates which can be uploaded to the
machine via USB stick:
Press to update Die Table
Press to update CSV Preset Table
Selecting an option will load the table to be updated
pressing the icon beside the table with overwrite the
table with the information stored on the USB stick.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
16
SETTINGS MENU
Press settings from the home screen.
Settings Page 1
Press to navigate to settings page two.
Brightness Die Table
Counters Quick Change
Set Passcodes Language
Brightness
Adjust the brightness to suit the environment that the
machine is located in.
Press to adjust the backlight intensity (5-100)
Counters
Lubrication and hose counters can be set here. The
recommended lubrication cycle is 350 machine cycles.
The hose counter can be set for a batch run of hoses.
Amendments can also be done to account for
unacceptable swages.
When the count is met a notification will be displayed
at the top of the screen.
On the counters screen all numerical fields are editable by pressing the required number.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
17
Lubrication
The swaging head must be lubricated at least every 350 swage cycles. To apply the grease, ensure
that the machine is fully opened and disconnected from the power supply. Lubrication is easily
done with a small clean brush ensuring that the inside of the swaging ring (chromed moving
piston) and flat face of the die holders are evenly coated with grease.
The lubrication counter has been designed as a reminder for the user to lubricate the head.
!
VERY IMPORTANT
Lubrication is the single most important factor that affects the
performance of your Hydralok swaging machine. It is vital that the
machine is regularly lubricated using a high performance Molybdenum
Disulphide based grease. Lack of lubrication or the use of any other type
of lubricant may cause irreparable damage to the swaging head and it
will void the manufacturer’s warranty.
Lubricate Here
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
18
Set Passcodes
All passcodes are default to “0”. It is advised that the
administrator immediately set the passcode for Admin
user to a unique code (no longer than 10 digits).
Press to edit passcode for each user.
Die Table
This is for reference purposes only as the die table
cannot be edited from within the machine. The die
table can be updated via a USB stick to reflect the
addition or removal of die sets from the range
available.
Press the top or bottom of the table to scroll through
available records.
Quick Change
Press to adjust the position the head closes to in
order to use the quick change tool to remove or insert
the dies. Press OK to accept the entered value.
Language
Press the flag which represents the required language.
The text box will indicate the selected language.
!
IMPORTANT: ALWAYS REMOVE THE QC TOOL BEFORE
PRESSING THE GREEN BUTTON, OTHERWISE THE QC TOOL
MAY BE SERIOUSLY DAMAGED.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
19
Settings Page 2
Press to return to settings page one.
Calibration
Master Offset
Machine Upgrade
Machine Clock
Calibration
Press for machine calibration.
Press to edit calibration mandrel sizing.
Machine Calibration
Follow the onscreen instructions to calibrate the
machine.
Fit 46 dies for calibration using a standard mandrel.
Press each text box to determine the mandrel end
sizes. The largest size must be input on the left.
Machines manufactured by Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
20
Master Offset
Due to the range of different applications in which the
swaging machine can be used, occasionally the
general calibration of the machine may need to be
adjusted. The master offset allows a global adjustment
of the machine for all swaging operations. The master
offset remains permanently stored in the machine, in
contrast to each individual offset which is removed
when a new swage diameter is selected.
Note! Changing the master Offset value will not affect the Presets stored in memory.
The default value of the Master Offset is 0.00.
Machine Upgrade
Press each section of the long field to enter an
upgrade code. Codes are provided by Endeavour
International Ltd to unlock and upgrade various
elements of the machine such as Foot Pedal operation
or Quick Change functionality. Press Enter to accept
the entered code.
If the code entered is correct a list of the applied
upgrades will be listed in the box shown.
This manual suits for next models
3
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