Lillbacka Powerco FINN-POWER P20 MS User manual

OPERATING
INSTRUCTIONS
FINN-POWER
P20 MS ¨
P20 IS/AS ¨
P20 VS ¨
P21 MS ¨
P21 IS/AS ¨
P21 VS ¨
P32 MS ¨
P32 IS/AS ¨
P32 VS ¨
P51 IS/AS ¨
P51 VS ¨
CC22 IS/AS ¨
CC22 VS ¨
MANUFACTURING YEAR ____________
RELEASED 06/00
KEEP THIS MANUAL FOR FUTURE NEEDS
THE MACHINE HAS BEEN DESIGNED FOR CRIMPING HOSE FITTINGS.
LILLBACKA POWERCO SHALL NOT BE HELD LIABLE FOR ANY
PRODUCT WHICH HAS BEEN CRIMPED ON THE MACHINE. THE
MACHINE HAS BEEN DESIGNED TO OPERATE IN ROOM
TEMPERATURE, IN DRY INDOOR CONDITIONS AND IN SUFFICIENT
ILLUMINATION. USING THE MACHINE FOR ANY OTHER PURPOSE IS
NOT ALLOWED WITHOUT WRITTEN CONSENT FROM THE FACTORY.
Lillbacka Powerco Oy
P.O.B. 1
FIN-62301 Härmä, Finland
tel. + 358 6 485 4444
fax + 358 6 485 4400

CONTENTS
CONTENTS ...........................................................................................................................2
GENERAL .............................................................................................................................3
TRANSPORT ......................................................................................................................................................3
STORAGE ...........................................................................................................................................................3
MOUNTING .........................................................................................................................................................3
WARNINGS ...........................................................................................................................4
GENERAL ...........................................................................................................................................................4
DANGER ZONES................................................................................................................................................4
COMMISSIONING .................................................................................................................5
OIL FILL ..............................................................................................................................................................5
ELECTRICAL CONNECTION .............................................................................................................................5
QUICK FIX-PACKAGE ........................................................................................................................................5
OPERATION..........................................................................................................................6
CONTROL IDENTIFICATION MS -CONTROL..................................................................................................6
CONTROL IDENTIFICATION IS/AS/VS -CONTROLS......................................................................................6
CONTROL PANEL IS/AS ..................................................................................................................................7
CONTROL PANEL VS.......................................................................................................................................9
COVERS P32 ...................................................................................................................................................11
TEST RUN MS/IS/AS CONTROLS ................................................................................................................11
TEST RUN VS CONTROL .............................................................................................................................11
SELECTING THE DIE SET P20, P21 ...........................................................................................................12
SELECTING THE DIE SET CC22 ..................................................................................................................12
SELECTING THE DIE SET P32....................................................................................................................13
SELECTING THE DIE SET P51....................................................................................................................13
FP140 DIE SETS FOR P51 -MODEL .......................................................................................................14
INSTALLING THE DIE SET............................................................................................................................14
QUICK CHANGE MS/IS/AS........................................................................................................................14
QUICK CHANGE VS ..................................................................................................................................15
CHANGE OF A SINGLE DIE P20, P21, P32, CC22................................................................................15
CHANGE OF A SINGLE DIE P51............................................................................................................15
SETTING THE CRIMPING DIAMETER MS...................................................................................................16
SETTING THE CRIMPING DIAMETER IS/AS...............................................................................................17
SETTING THE CRIMPING DIAMETER VS ...................................................................................................18
OPERATION LIMITATIONS P51, CC22..........................................................................................................18
CRIMPING MS -CONTROL..............................................................................................................................18
CRIMPING IS/AS/VS -CONTROLS.................................................................................................................19
ADJUSTMENT OF RETRACTION DIAMETER IS/AS ................................................................................... 20
IF THE MACHINE DOES NOT WORK.........................................................................................................21
PREVENTIVE MAINTENANCE........................................................................................... 21
GREASING P20, P21, P32 ..............................................................................................................................21
GREASING P51 ...............................................................................................................................................21
GREASING CC22 ............................................................................................................................................22
OIL CHANGE ...................................................................................................................................................22
FILTER CHANGE P20, P21, P32, CC22...........................................................................................................22
FILTER CHANGE P51 ....................................................................................................................................23
PRESSURE PIPES ...........................................................................................................................................23
FINAL DECELERATION P51 ..........................................................................................................................23
RE-CALIBRATION OF CRIMPING DIAMETER DIAL MS -CONTROL......................................................... 23
TROUBLESHOOTING......................................................................................................... 24
GUARANTEE.......................................................................................................................24
TECHNICAL DATA............................................................................................................. 25
TECHNICAL DATA P20 ..................................................................................................................................25
TECHNICAL DATA P21 ..................................................................................................................................27
TECHNICAL DATA P32 ..................................................................................................................................29
TECHNICAL DATA P51 ..................................................................................................................................30
TECHNICAL DATA CC22.....................................................................................................................32

GENERAL
FINN-POWER crimping machines are electrically operated hydraulic crimping machines for hydraulic hose
assemblies.
The crimping machine comprises a crimping head and a hydraulic unit mounted on the oil tank which serves
as machine frame.
FINN-POWER crimping machine is normally delivered with a 3-phase electric motor. On request it can be
equipped with a single phase motor.
Transport
The packed machine is transported on a pallet,
which is easy to move and lift by a fork-lift
truck. After unpacking, the machine can be
lifted using a hoisting belt.
Size of package for P51-models:
x = 102, y = 82, z = 113 cm.
Size of package for other models:
x = 77, y = 62, z = 81 cm.
Storage
The manufacturer has protected the machine
against corrosion by using the Zerust method.
The machined parts have been treated with
Axxatec 77C protective agent. A Zerust vapor
capsule has been put into the electric box,
and the machine has been packed into a bag
made of Zerust film.
The protection is effective for months if the
package is not opened. After opening it, the
protection of the wrapping film ceases. If the
machine is not yet brought into use, it must be
reprotected against corrosion. The machine is
to be stored in dry indoor conditions.
Remove the protective agent according to the
instructions enclosed in the package.
Mounting
The adjacent picture shows an appropriate
way to lift the machine after it has been
unpacked.
It is recommended to mount the machine on a
Finn-Power table. Before mounting, the table
must be screwed on the floor with four M12
wedge anchors. Boreholes in the floor: Ø 12
mm, depth 55 mm.
When the machine is mounted on a Finn-
Power table, the four shoes under the
machine are removed.
The table with assembly instructions is
packed separately.
The crimper may be installed on some other
table as well, provided it is sturdy and broad
enough or it has been fastened on the floor so
that it cannot fall over. Furthermore, there
must be a hole in the table to enable emptying
the oil tank through the drain plug.
P20, P21 and CC22 -models: x = 558, y = 560
P32 and P51 -models: x = 625, y = 560.
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WARNINGS
General
The machine is intended for professional use. It is to be operated only by a trained operator who has
understood the dangers involved in the operation.
Openings between the dies exceed 6 mm, thus being large enough to let fingers go between the dies and
get crimped. It is, therefore, ABSOLUTELY necessary to follow operating instructions and warnings
indicated by the stickers on the machine when changing dies and crimping fittings.
Danger zones
WARNING 1
Do not put your hands inside the dies
while the motor is running!
WARNING 2
When crimping a fitting, hold the hose
far enough to avoid crimping your
hand!
WARNING 3
Dies open and close by depressing
the hand emergency push-buttons at
both ends of the valve. Do not touch
these push-buttons during normal
operation!
WARNING 4
High voltage.
The electric box is to be opened
only by a professional electrician!
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WARNING 5 (P32 model)
The rear of the crimping head is covered by a
housing protecting the operator from the
crimping hazard under the housing between
rear flange and cylinder.
Do not remove this housing!
WARNING 6
When changing dies with the quick change
tool, hold the handle as shown in the above
figures. Make sure your hand will not get
between the dies!
COMMISSIONING
Oil fill
Fill the oil tank to centre line of the indicators in the dipstick with hydraulic oil like Shell Tellus T46 or
equivalent. Volume of the tank is 32 litres (P51 –model: 50 litres).
It is recommended to pump the oil into the tank through a 20 µfilter, because new oil in drums is not pure.
Electrical connection
CAUTION! Check that the machine voltage (see type plate) is equal to your supply voltage. For proper
installation to local code, consult a licensed contractor.
Bring the supply cable in through the hole in the side panel of the electric box. Secure the cable with a
stress relief plug.
3-phase: Connect the phase conductors to the respective L1, L2 and L3 terminals in the supply
disconnecting device. Connect the earth connection to the ground terminal on the fixing plate. Check the
connection against the wiring diagram enclosed in the spare parts list.
Check that the motor rotation is parallel with the arrow on the tank close to the motor. In case the motor
rotates in wrong direction, two phase conductors in the supply disconnecting device must be interchanged.
1-phase: Connect the phase and the neutral to the respective terminals in the supply disconnecting device.
Connect the earth connection to the ground terminal on the fixing plate. Check the connection against the
wiring diagram enclosed in the spare parts list.
Quick Fix-package
Included with the machine, there is a Quick Fix-package which has some basic parts for that machine
model.
keeptool.eps
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OPERATION
Control identification MS -control
1. Supply disconnecting device
for starting and stopping the
motor. The device is used to
separate the machine from
power supply. However, the
undervoltage trip can be made
dead only by disconnecting the
plug or supply cable from the
mains.
2. As long as the crimping push-
button is depressed, the dies
will close until the button is
released or the preset crimping
diameter is reached.
3. Retraction button. When
depressed and held down, the
dies will open until the button is
released or the maximum
retraction is reached.
4. Crimping diameter dial.
5. Die chart with crimping
diameter range for each die set
and corresponding dial
adjustment values.
The main operating area of the machine is in front of the controls.
Control identification IS/AS/VS -controls
1. Control panel
2. Supply disconnecting device
for starting and stopping the
motor. The device is used to
disconnect the machine from
power supply. However the
undervoltage trip can be made
dead only by disconnecting the
plug or supply cable from the
mains.
3. When the stop device is
pressed, the dies will perform a
crimping cycle.
4. When the foot pedal is
pressed, the dies will perform a
crimping cycle. (Optional)
5. IS/AS –models: Die chart with
crimping diameter range for
each die set and corresponding
dial adjustment values.
The main operating area of the machine is in front of the controls.
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Control panel IS/AS
0
0
0
50
90
40
80
30
70
20
60
10
TRIP
1. SUPPLY DISCONNECTING DEVICE
The supply disconnecting device starts and stops the motor. It is used to disconnect the machine from
power supply. However, the undervoltage trip can be made dead only by disconnecting the plug or supply
cable from the mains.
In case of power failure, the motor stops and the handle turns to the so called TRIP position. Restart the
machine by turning the handle first to 0-position (reset) and after that to I-position. In an emergency, the
supply disconnecting device is used as an emergency stop.
2. CONTROL OPERATIONAL
The signal lamp is illuminated when operating voltage is available and the control is ready for use.
3. MODE SELECTOR
The crimping head does not operate when the mode selector is in position 0. The mode selector should be
in 0-position when the machine is started.
MANUAL : Master dies can be opened by pressing retraction button 7 and closed by pressing
crimping button 5. Manual mode is used when changing dies and adjusting settings.
SEMI-AUTOMATIC : Crimping movement gets started when the semi-automatic crimping button 4 is
pressed. The movement can be interrupted by releasing the button. If need be, dies can be opened by
using retraction button 7. Crimping goes on when the button is repressed. After reaching the crimping
diameter, dies return to the retraction position irrespective of whether the button is pressed or not.
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AUTOMATIC : Crimping movement gets started when the fitting is pressed against the stop device.
The movement stops if the stop device is not adequately pressed by the fitting. It can also be stopped by
withdrawing the fitting from the stop device before it is gripped by dies. If need be, dies can be opened by
using retraction button 7. Crimping goes on when the fitting is repressed against the stop device. After
reaching the crimping diameter, dies return to the retraction position irrespective of whether the fitting is
pressed against the stop device or not.
FOOT PEDAL : Crimping starts when the foot pedal is pressed. The movement can be interrupted
by lifting the foot from the pedal. If need be, dies can be opened by using retraction button 7. Crimping goes
on when the foot pedal is repressed. After reaching the crimping diameter, dies return to the retraction
position irrespective of the position of the foot pedal.
CRIMPING DELAY : In automatic modes, a crimping delay can be set in order to improve the forming
of the fitting. The delay is activated by turning the mode selector to the delay position , which makes the
signal lamp beside the symbol light. After this the mode selector is turned to a position indicating the
intended mode of crimping.
The delay has been set to last approx 2 seconds. It occurs after the crimping diameter has been reached
but before the retraction movement, i.e. the dies are kept closed for the time of delay, after which they are
opened. To inactivate the delay, turn the mode selector briefly to 0-postition or stop the motor.
4. SEMI-AUTOMATIC CRIMPING
This button starts crimping movement provided that master dies have reached the set retraction position
(signal lamp 8 is illuminated) and semi-automatic mode has been selected.
5. CRIMPING BUTTON
The dies will close when this button is pressed. The dies move until the button is released or the set
crimping diameter has been reached. When using this button, manual mode must be selected.
When the machine is started with the mode selector in manual mode, crimping cannot be started using the
crimping button before first selecting 0-position or opening dies with retraction button 7. Dies will not open if
they are already in the set retraction position (signal lamp 8 illuminated).
6. CRIMPING DIAMETER REACHED
The signal lamp is illuminated when the dies have reached the set crimping diameter.
7. RETRACTION BUTTON
The dies will open when this button is pressed. The dies open until the button is released or the set
retraction diameter has been reached.
When using this button, manual mode must be selected.
8. RETRACTION DIAMETER REACHED
The signal lamp is illuminated when the dies have reached the set retraction diameter, i.e. retraction
position. Automatic mode cannot get started unless the retraction position has been reached.
9. DELAY SIGNAL LAMP
The signal lamp is illuminated when the delay function is active.
10. RETRACTION DIAMETER CONTROL
The dial is used to adjust the retraction diameter of master dies after the crimping cycle. Adjust the
retraction large enough so that the fitting to be crimped is easy to insert between the dies but the "extra"
movement is as short as possible. The retraction becomes larger when the dial is turned clockwise.
11. CRIMPING DIAMETER CONTROL
The crimping diameter is defined by means of this vernier dial and the die set that is used. The dial covers
0...10 mm. The measuring scale is divided into divisions of either 0.01 mm or 0.1 mm. The crimping
diameter increases when the dial is turned clockwise. If the dial is of multi-turn type, as in IS-models, one
turn is equivalent to a 1 mm change in the crimping diameter. In AS-models the diameter changes by 1 mm
between two digits.
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Control panel VS
25.4
28.4 00.01
32-22
CONNECTOR 1
1. SUPPLY DISCONNECTING DEVICE
The supply disconnecting device starts and stops the motor. It is used to disconnect the machine from
power supply. However, the undervoltage trip can be made dead only by disconnecting the plug or supply
cable from the mains.
In case of power failure, the motor stops and the handle turns to the so called TRIP position. Restart the
machine by turning the handle first to 0-position (reset) and after that to I-position.
In an emergency, the supply disconnecting device is used as an emergency stop.
2. ENTER BUTTON E
3. SELECTOR
All selections and control functions of the VS control are performed by means of the selector and enter
button E. The desired display adjustable from the selector is selected by turning the selector and activated
by pressing Ebutton. The display then gets a bold shaded outline and the display value can be modified by
turning the selector. The new value comes into force after pressing E. The display turns partly shaded
again, after which another display can be selected by turning the selector.
4. SEMI-AUTOMATIC CRIMPING
This button starts crimping movement provided that the symbol of semi-automatic crimping is shown on
the mode display.
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5. CRIMPING BUTTON
The dies will close when this button is pressed. The dies move until the button is released or the set
crimping diameter has been reached.
When using this button, manual mode must be selected.
6. RETRACTION BUTTON
The dies will open when this button is pressed. The dies open until the button is released or the set
retraction diameter has been reached.
This button can be used either in manual mode or in semi-automatic and foot pedal modes in a situation
when you want to open dies in the middle of crimping.
7. CRIMPING DIAMETER
The crimping diameter is defined by selecting a value on this display and by means of the die set that is used.
The crimping range extends from the minimum crimping diameter of the smallest die set programmed up to
the maximum crimping diameter of the largest die set programmed. It is divided into divisions of 0.1 mm. In
addition, the crimping diameter can be modified by correction adjustment.
8. DIE SET
When the crimping diameter is being adjusted, VS control automatically recommends a die set best suited
for the selected diameter. If desired, the operator may use another die set covering the diameter in
question. Thus he may manage to avoid changing die sets but the crimping result will not be as good as if
the recommended die set would have been used.
9. CORRECTION
Different fittings require more or less crimping force. The machine frame design, however contracts and
expands according to the required crimping force. That is why the crimping diameter must be corrected in
order to reach the intended crimping result. It is recommended to use the correction function in modifying
the crimping diameter so that the correct crimping diameter for the fitting in question could be saved on the
crimping diameter display for the next time it is needed.
10. RETRACTION DIAMETER
The retraction diameter indicates the opening of master dies after the crimping cycle. Adjust the retraction
large enough so that the fitting to be crimped is easy to insert between the dies but the ”extra” movement is
as short as possible. The retraction value is the diameter of the opening between the dies in millimetres.
11. CRIMP COUNTER
The counter counts crimps either from zero or from a set value onwards.
12. FITTING TYPE
Crimping data of your own or of the fitting manufacturer can be stored in the memory of the control unit. You
can name a fitting type as you like or use fitting types of the fitting manufacturer.
13. PRESSURE SWITCH AND CRIMPING DELAY
Pressure switch function and crimping delay on/off. See VS control, page 9.
14. RECALL OF STORED CRIMPING DATA
The crimping data of a certain fitting type can be recalled from the control unit memory. See VS control, page
6.
15. STORING OF CRIMPING DATA
Crimping data are stored in the memory for the next time to be used. It is worth while naming a fitting type to
facilitate finding it again. See VS control, page 8.
16. SETUPS
Set-ups of crimping delay, pressure switch, mm/inch and calibration. See VS control, page 10.