SAMWAY FP120D User manual

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SAFETY
For correct use the safe operation
1
CONTENTS OF MANUAL
SPECIFICATIONS & INSTALLATION INSTRUCTION
For correct installation
2
OPERATION
Procedure for operation, and adjustments
3
MAINTENANCE and TROUBLESHOOTING
Inspection and maintenance, and troubleshooting
4
TECHNICAL MANUAL
Technical support, circuit diagram and assembly
5
CE Instruction Manual
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We declare under our sole responsibility that this product is in conformity with the follower standards
or standardzation documents: EN60204-1: 1997, DIN ISO EN12100-1/ -2:2004, EN1050: 1996 and
EN294: 1992 according to the provisions of the regulation 98/37/EC,2006/95/EC,and 89/336/EEC.
Name and Signature
WAENING: FAILURE TO FOLLOW THESE RULES MAY
CAUSE RESULT IN SERIOUS PERAONAL INJURY
Date and Place
EC Declaration of Conformity
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The .................................. Hydraulic Crimping Machine is in the range of professional machinery for
crimping the joint and air, hydraulic and water hode, made by ................ During design & construction
of this machine in addition to local standards and some relative standards for the safely design.
DIN EN ISO
12100-1
2004 Safety of
machinery
Safety of machinery. Basic concepts,general
principles for design. Basic terminology,
methodology.
DIN EN ISO
12100-2
EN 414
2004
1992
Safety of
machinery
Safety
machinery
Safety of machinery. Basic concepts,general
principles for design. Technical principles
Rules for the drafting and preaentation of
safety standards.
EN 1050 1996 Safety of
machinery
Risk assessment.
EN 294 1992 Safety of
machinery
Safety distances to prevent danger zones
being reached by the upper limbs.
EN 982 1997 Safety of
machinery
Safety requirements for air power systems
and components - Hydraulic.
EN 60204-1 1997 Safety of
machinery
Electical equipment of machines. Part 1.
EN 60204-6-2 2005 Electromagentic Generic emission standed.
compatibility
EN 60204-6-4 2005 Electromagentic Generic emission standed.
compatibility
1.Safety Introduction
1.1. Foreword
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The - series are suitable for crimping the joint and air, Hydaulic and water hose. Be careful for
rigidity of the working material(s), don’t try capacity that extend the specification.
1) Supply voltage: 0.9 - 1.1 nominal supply voltage
2) Source frequency: 0.99 - 1.01 nominal frequency
3) Ambient temperature: 5°C - 40°C
4) Altitude: shall be at altitudes up to 1000m above mean sea level
5) Relative humidity: not exceed 50% at 40°C
6) Atmosphere: Free from excessive dust, acid fume, corrosive gases and salt.
7) Avoid exposing to direct sunlight or heat rays which can change the environmental temp.
8) Avoid exposing to abnormal vibration.
9) Please add the Greasing oil timely.
If you have any question, please refer to our agency or company.
This machine was designed for certain applications only. We strongly recommend that this mache
NOT be modified and/or used for any application other than for which it was designed. If you have
any question relative to itsapplication DO NOT use the machine until you have had detail instruction
from your dealer.
Generally, this machine will be installed on the following conditions:
1.2. Using Restriction
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Person(s) who operate the machine must be trained, read and understood to use the safety
measures, and possess the ability to obey and execute the regulation stated in this manual.
Read instruction manual before operating the machine for your safety.
1.3. Safety Instruction
CE Instruction Manual
1.
A terminal for the connection of the external ground conductor is provided in the vicinity of
the associated phase conductor terminals with marked “PE”. It should make sure the “PE”
termainal being connection before power supply.
Ground all machines.
2.
Keep guards in place and in working order.
Keep guards in place and working area clean.
3.
All children and visitors should be kept at a safe distance from work area.
Keep children and visitors away.
5.
No loose clothing, neckties, rings bracelets, or other jewelry to get caught in moving parts.
Wear protective hair covering to contain long hair.
Wear proper apparel.
6.
Watch what you are doing. Do not operate mache when you are tired. Please stand in front
of machine for proper position operation.
Stay alert.
Please wear glove while operation, cleaning and repair.
7.
Access position:
8.
Don’t use machines in damp or wet locations, or expose them to rain.
Keep working area well lighted and ventilation.
Do not operate electrical machines near potentially explosive environment.
Don’t use in dangerous environment.
4.
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Please see the marked on the machine mean access position for maintenance. Do not
stand/acces otherno-marked area!
SHUT OFF the power, removed the products, and isolated energy before leaving the machine.
CE Instruction Manual
9.
Disposing wasted material and wasted lubricating oil shall obey the local regulation and be
deeply careful.
12.
Have your machine repaired by a qualified person.
10.
Repairs should only be carried out by qualified persons using original spare parts; otherwise this
may result in considerable danger to the user.
Check damaged parts.
11.
Before further use of the machine, a guard or other part that is damaged should be carefully
checked to determine what it will operate properly and perform its intended function. Being
check for alignment of moving parts, binding of moving parts, breakage of parts, mounting and
any other conditions that may affect its operation. A guard or other part that is damaged should
be properly repaired or replaced.
Fire extinguisher.
13.
Use recommended ancillary equipment.
14.
The workshop of user shall be with the fire extinguisher or other devices according to the local
safaty regulations and be deeply careful.
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If ancillary equipment is removed the original guards or safety devices shall be replaced. The
connection of ancillary equipment including any necessary modification of the guarding of t he
machine shall not afford unprotected access to danger areas of the machine. And our authorized
agency are responsible for a future connection of the machine with ancillary equipment only if we
ourselves have designed such connection.
CE Instruction Manual
Setting the machine
15.
Use special equipment e.g. gauges for setting the tool when machine standstill. The setting of
machine can be carried out by the qualified person only.
The setting of machine can be carried out only when the power is disconnected from
the power source.
Reduce the risk of unintentional starting.
16.
Make sure switches of control panel are OFF position before operating main disconnector. Never
leave machine running unattended. Turn power off from the main disconnector. Don’t leave
machine until it comes to a complete stop.
Make sure machine is disconnected from power supply:
17.
Shut down the machine before inspction, maintenance and adjustment. Make sure that all people
are away from the revolving or moving parts before testing the mache.
Make sure hand-held disconnecting device is OFF position and locked with key.
Reaction with emergency situation:
18.
The extruder is provided one emergency button. It is self-latching push-button on the control
panel. The emergency button is colored red and yellow background.
After emergency stop, follow the normal stop procedure and to obviate the hazard soon. Please
see the circuit diagram to connect emergency stop circuit with other ancillary equipment by
qualified engineer.
Electrical equipment
19.
Keep electrical equipment in a good and safe performance is necessary.
1) Have to connect to earth.
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2) Electical equipment shall withstand the effects of transportation and storage temperature within a
range of -25°C to 55°C and for short peridos not exceeding 24 hours at up to +70°C .
CE Instruction Manual
Particular safety rule for stroage condition of machine:
20.
1) If the machine is not be operated for a long period of time it shall be stored with the
appropriate protection for the ingress of dust or the other substance in a suitable environment
and place.
2) During storage, any kind of power should be disconnected, and clean the machine.
21. Never open the protective cover or door while the machine is running. Never attempt to change
the settings of all protective devices without consulting ............................................................
When the machine is out of order while running, shut it down and turn to serviceman for help as
soon as possible.
The noise level of this machine is testing on continuous running.
22.
1) Airborne noise emission by the -series are established on the basis of measurements made
on the machinery.
2) The workstation for the measurement of enission sound pressure level is defined according
to European Standard ISO3746.
3) A weighted sound pressure level measuring under load is less than 80.0 dB (A).
23. Ancillary equipment, the presence of which prevents access to a danger area of the machine
and which can be removed without the use of a tool, shall be interlocked with the machine
control circuit in the same way as the movable guard for the area concerned.
24. If machine intend to be used together with ancillary equipment it shall be so designed that the
machine can only be operated if the ancillary equipment is connected in accordance with the
above listed requirements.
25. Before cleaning and maintenance operations shall be carried out only when the machine is
stationary.
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CE Instruction Manual
26. The training of the user/operator should be carried out by our authorized agent or service
engineer in an oral/practical in site of the ordered blown film line, including protective device
explanation, mechanism, personal protective equipment, operation/use.
*Any other maintenance is welcome to be contacted manufacturer or our distributor.
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CE Instruction Manual
1.4 Danger zones and warning labels
(1) (2)
(3) (4)
1) Do not put your hands inside the dies while the motor is running !
2) When swaging a fitting , hold the hose far enough to avoid swaging your hand !
3) High voltage. The electric box is to be opened only by a professional electrician !
4) When changing dies with the quick change tool, hold the handle as shown in the figures above.
Make sure your hand will not get between the gaps of crimping finger.
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FP120D Technical Date Standard die sets
Hose size
Swaging range (mm)
Die type
Max opening (mm)
Master die shoe lenght (mm)
Motor (KW)
Voltage (V)
Pump (l╱min)
Swaging force (KN)
Number of swagings ╱hour *
Overall dimensions :
Length (mm)
Width (mm)
Height (mm)
Weight without oil (kg)
*Theoretical with 1/2” hose △Ø10mm
2”-4S
ø4...87
32
+65
97
5.5
220/440
860
1000
1600
50
2400
2400
1200
Code
32-10
32-13
32-16
32-19
32-22
32-26
32-57
32-64
32-69
32-30
32-39
32-45
32-52
32-78
32-74
Lenght (mm)
55
55
55
55
55
55
100
100
100
75
75
90
90
110
110
2. Specification & Installation
2.1. Specification:
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FP145D Technical Date Standard die sets
Hose size
Swaging range (mm)
Die type
Max opening (mm)
Master die shoe lenght (mm)
Motor (KW)
Voltage (V)
Pump (l╱min)
Swaging force (KN)
Number of swagings ╱hour *
Overall dimensions :
Length (mm)
Width (mm)
Height (mm)
Weight without oil (kg)
*Theoretical with 1/2” hose △Ø10mm
4”
ø4...124
32/80
+70
97
5.5
220/440
980
1000
1600
50
3200
2000
1450
Code
32-10
32-13
32-16
32-19
32-22
32-26
32-57
32-64
32-69
32-30
32-39
32-45
32-52
32-78
32-74
80-84
80-92
80-100
80-116
80-108
Lenght (mm)
55
55
55
55
55
55
100
100
100
75
75
90
90
110
110
120
120
120
120
120
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CE Instruction Manual
2.2 Installation of the machine:
1. The site for the machine should provide the conditions essential for appropriate space.
2. A clear area must be provided along the diagram of the machine and that’s essential to
permit efficient maintenance and assembly.
3. For the required space for the running machine, refer to following figures.
4. The strength must afford the matching weight and vibration.
2.3 Transporting:
1. Please refer to instruction manual in specifications and machine weight to arrange handling
equipment. Be sure t use capable fork-lifter referring to lift of machine.
2. Forklift can be used in handling and shall be operated by qualified driver.
3. Before handling, make sure all movable parts are secured in their positions and all movable
accessories should be removed from machine.
4. Make sure that the strength of forklift is sufficient to handle machine.
5. During handling, people are strictly prohibited from entering into the path of machine movement.
6. While transportation, Keep attention to the balance of machine.
7. About forklift position of machine, please
refer following diagram.
The fork length shall be ≧2/3 machine width length.
After the machine is delivered and positioned on site, to maintain the stability of the equipment,
padding for the four points at the bottom of the equipment shall be properly placed and adjust the
level of the equipment and tight / fixed it.
The machine shall be moved by persons who are qualified.
Persons besides the worker are not allowed to stay in the work place during transporting the
machine.
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CE Instruction Manual
2.4 Adjustment of absorbing base
1. Before installation, the grounding with sufficient space showed as section 2.3.(Machine working
area dimension) should be provided, and the ground for the installation of machinery should be
flat and rigid enough.
2. After the machine to its intended installation position. The machine should be leveling by the
horizontal leveling ruler and adjustable absorbing base.
3. The anchorage and leveling work carrier out by the screws show as the following.
4. After completed installation. Please check the screws of the base and safeguard. If the screws
become unfastened, fasten it and examine all the attached parts and space parts with the
machine.
It is recommended to screw the machine on the floor with four M12 wedge anchors (A). Boreholes in
the floor: Ø12mm, depth 55 mm.
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CE Instruction Manual
2.5 Installation of electrical power supply:
1. The machine should be connected the protective-earth terminal between machine and external
ground before connected to the power source.
2. The cross-section of incoming supply protective conductor and each phase conductors must be
in accordance with the following reference of supply conductor table. It is important to identify
the voltage of source with machine. The voltage of connecting source should be marked on the
electric cabinet.
Model
FP120D
FP145D
Recom. Fuse (400V)
25A>fuse>20A
25A>fuse>20A
Supply wire size
5.5mm²
5.5mm²
PE wire size
5.5mm²
5.5mm²
3. During connecting the power supply, always connect the earth conductor with yellow/green
color before the connection of the other power conductor.
4. A terminal for the connection of the external ground conductor is provided in the vicinity of the
associated phase conductor terminal with marked “PE”. It should make sure the “PE” terminal
being connection before machine operating.
5. Connection should be made to the terminal mark L1, L2 and L3 at the connecting seat in the
electrical cabinet. The Veneer Jointing Machine which electric system is equipped with one
main switch, as a safety measure, the door of cabinet can’t be opened unless main switch is
disconnected.
6. On the contrary while disconnecting from the power supply disconnect the earth conductor with
yellow/green color after the all power conductors at disconnected.
7. Always disconnect the power supply from the hand-operated disconnected device mounted on
the door of electrical cabinet, before you intend to do the work of maintenance or inspection.
8. After disconnected the power for maintenance or inspection, be sure to lock the disconnecting
device in “OFF” position.
Caution! Power supply has to be installed by a trained technician.
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CE Instruction Manual
2.6. Pneumatic system:
9. When the power source is connected to the reverse phase, the chain will wrong rotary.
Please change the incoming wire L1 and L2, as show in the below.
Prior to filling in hydraulic oil, the oil compartment should be checked for cleanliness.
Remove vent cap. Draw gear oil through vent from oil bucket to tank.
The gear oil is poured in with the angled funnel which is the oil should reach the oil level
mark, For the first time, be sure to fill 9/10 of tank.
The suction strainer of the hydraulic pump must be completely submerged in oil,
otherwise the air will be drawn in and cause oil foaming.
Filling cap
Oil level
gauge
Draining plug
All hydraulic oil flash point shall more then 150°C, and shall no seft-igniting/
explosive/ miscibility with water/ decomposition.
Fill the oil tank to center line of the oil level sight glass in the side plate with
hydraulic oil like ESSO Nuto H 46 or equivalent. Volume of the tank is approx 135 liters.
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a) Un tighten or loosened bolt/screw, due to negligence in the assembling line or caused by
the quakes during transportation, might effect unpredictable serious consequence!
Therefore, we strongly suggest that, after initial test running and before commence the
normal production, please check and tighten all the bolts/screws.
Especially, check and tighten those on movable components.
b) Please check and tighten all the bolts/screws every two or there days in the beginning
two weeks.
Check and tighten all the bolt/screw
2.7. Functional tests and Re-testing:
CE Instruction Manual
1.
a) Before test running, Please clean the machine, remove tools, bolt, nut, or any other article
from the conveyor.
b) Open all the cover on this machine, check if everything is in normal.
Cleaning the machine
2.
a) Check wires connected and the power source already connected to the power incoming
terminal.
b) Check the machine already cleaned and without any other article on the machine.
Check the machine very careful before run the machine.
3.
The function of electrical equipment shall be tested per half year normally, particular
emergency push button.
5.
Where a portion of the machine and its associated equiment is changed or modified, that
tests shall be re-verified and retested, such as continuity test of the protective bonding
circuit, insulation resistance tests, voltage tests, protection against residual voltage and
functional tests.
6.
Make sure tue “PE” terminal is properly connected and the machine is grounded before
power connect and push “NO” the main power.
The mechanical parts and electrical parts must be on the position and without loosen.
7.
8.
Check any abnormal noise !9.
All identified numbers on electrical wires must be correct, check if all wire screws are
properly tightened and no electric happens.
10.
Turn on the main disconnector (NFB: No-fuse Breaker) for the power source to the main
cabinet, check if the voltage is correct, then on the NFB of main control panel and sub
control panel.
11.
The function of safety equipment shall be tested before starting machine.
Emergency stop —— actuated the push button; the motor power should be shut down.
4.
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(1) Control panel.
(2) Power supply.
(3) When the stop device is pressed, the dies will perform a swaging-retraction cycle.
(4) When the foot pedal is pressed, the dies will perform a swaging-retraction cycle.
(5) Pressure gauge indicates the pressure in the hydraulic system during swaging.
(6) Storage locker for die sets.
3. Operation
3.1. Functions of Operation Panel
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(1)
Press this button is an emergency or when you for some other reason want to stop the machine
quickly. Pressing the emergency stop push-button stops all machine functions.
The button is released by turning it clockwise (as indicated by the arrow). After an emergency
stop, go on working in manual mode. Open the dies to the set retraction position, after which
you can continue in the normal way if the machine is otherwise in working order.
ENERGENCY STOP
(2)
Press to start electric motor and control unit.
START
(3)
This button is used to stop the machine in a normal situation. It stops both the control and the
motor.
STOP
(4) MODE SELECTOR
MANUAL: Master dies can be opened by pressing retraction button (4) and
Closed by pressing awaging button (5). Manual mode is used when
changing dies and adjusting settings.
SEMI-AUTOMATIC: Swaging movement get started when the semi-automatic swaging
button (3) is pressed. The movement can be interrupted by releasing
the by releasing the button. If need be, dies can be opened by
using retraction button(4). Swaging goes on when the button is
repressed. After reaching the swaging diameter, dies return to the
retraction position of whether the button is pressed or not.
Control panel
CE Instruction Manual
(5)
(2)
(3)
(7) (8) (9)
(11)
(4)
(10)
(6)
(1)
AUTO
FOOT PEDAL
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(5) SEMI-AUTOMATIC: Swaging movement get started when the semi-automatic swaging
button (3) is pressed. The movement can be interrupted by releasing the by releasing the botton.
If need be, dies can be opened by using retraction button (4). Swaging goes on when the button
is repressed. After reaching the swaging diameter, dies return to the retraction position of
whether the button is pressed or not
(6)
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.
RETRACTION BUTTON:
(7)
The dies will close when this button is pressed. The dies move until the button is released or the
set swaging 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, swaging cannot
be started using the swaging button before first selecting O-position or opening dies with
retraction button (4). Dies will not open if they are already in the set retraction position.
SWAGING BUTTON:
(8) SWAGING VALUE
(9) OPENING VALUE
(10) SWAGING CONTROL
(11) OPENING CONTROL
AUTOMATIC: Swaging starts when the fitting is pressed against the stop device. The movement
stops if stop device is not adequately pressed by 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 (4). Swaging goes on when the fitting
is repressed against the stop device. After reaching the swaging diameter, dies return
to the retraction position irrespective of whether the fitting is pressed against the stop
device or not.
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