T-Drill F-200 User manual


FLANGING MACHINE
INSTRUCTION MANUAL

INSTRUCTION MANUAL
2
Version
6391764EN C
29.08.2019 / MT
20.01.2020 / MT Rev. A
27.04.2020 / MT Rev. B
20.10.2020 / MT Rev. C

Instrucons for use and maintenance of the T-Drill F-200 anging machine (cold and hot anging versions).
Type code: 3926
Copyright © 2020 T-DRILL Oy. All rights reserved. This manual, or parts thereof, may not be reproduced in any form or by
any means, nor translated into any other language without a wrien permission of T-DRILL Oy
Is has been our aim to elaborate this instrucon book with the greatest possible care and aenon. The accuracy of the in-
formaon has been carefully checked during the preparaon of the manual. Should any subsequent modicaons be made
to the product, we decline liability for erroneous or incomplete informaon.
Manufacturer:
OY
Ampujane 32 / P.O BOX 20
FIN-66401 Laihia, Finland
Tel.Int [phone]
Telefax: [phone]
www.t-drill.
Sales and Service in the USA:
INDUSTRIES, INC.
1740 Corporate Drive, Suite 820,
Norcross, Georgia 30093, USA
Phone: [phone]
Fax#: [phone]
www.t-drill.com
Your local dealer is:

FLANGING MACHINE
3
F-200
CONTENTS
 ................................................................... 6
1.1 General ........................................................................................................................... 6
1.2 Symbols for warning and danger used in this manual.................................................... 6
1.3 Symbols and warnings used in the machine .................................................................. 7
1.4 Personal protecve equipment for the operator ........................................................... 8
 ............................................................................................ 8
2.1 Flanging machine safety instrucons ............................................................................. 9
.............................................................................................. 
3.1 Introducon of anging.................................................................................................. 10
3.2 Informaon on the equipment....................................................................................... 11
3.3 The use of the machine .................................................................................................. 13
3.4 Methods of anging ....................................................................................................... 13
3.4.1 Cold Flanging......................................................................................................... 13
3.4.2. Flanging at Raised Temperatures......................................................................... 13
3.4.3. Hot Flanging (oponal equipment) ...................................................................... 14
3.4.4 Expansion (oponal equipment) ........................................................................... 14
3.4.5 Beveling (oponal equipment) .............................................................................. 14
3.5 Technical specicaons .................................................................................................. 14
4. Transport, handling and storage..................................................................................... 15
 .................................................................................................................... 16
5.1 Installaon of the F-200 ................................................................................................. 16
5.2 Ambient condions ........................................................................................................ 17
5.3 Connecon of the machine to the sources of energy .................................................... 18
5.3.1 Connecon to the electric network ....................................................................... 18
5.3.2 Connecon to the compressed air system............................................................. 18
5.4 Start-up inspecon ......................................................................................................... 20
 ................................................................. 
6.1 Descripon of the control devices.................................................................................. 21
6.1.1 Main switch........................................................................................................... 21
6.1.2 Control panel......................................................................................................... 21
6.1.3 Key-switch and brake release- push buon .......................................................... 24
6.1.4 Signal lights (oponal) .......................................................................................... 24
6.1.5 Safety Area Scanner (oponal).............................................................................. 24
6.1.6 Control Elements and adjustment points .............................................................. 25
6.1.7 The valve arrangement board............................................................................... 28
6.1.8 Heang unit (Oponal) ......................................................................................... 30
6.2 Stopping of the machine ................................................................................................ 32
6.2.1 Normal stopping of the F-200 machine................................................................. 32
6.2.2 Emergency stopping.............................................................................................. 32
6.3 The machine mechanical sengs................................................................................... 33
6.3.1 Changing of the forming pin ................................................................................. 33
6.3.2 The adjustment of the turning angle of the forming pin....................................... 35
6.3.3 Adjusng of anging radius .................................................................................. 37
6.3.4 Fastening of the pipe and clamp changing ........................................................... 38

INSTRUCTION MANUAL
4
6.3.5 The pressure regulaon of the clamping jaws ...................................................... 42
6.3.6 The seng gauge of the pipe................................................................................ 43
6.4 Machine display and sengs ......................................................................................... 44
6.4.1 Instrucons for the use of the display ................................................................... 44
6.4.2 Menu-screen ......................................................................................................... 44
6.4.2.1 User level selecon- screen............................................................................. 45
6.4.2.1.1 Piece counter............................................................................................. 46
6.4.2.1.2 USB usage ................................................................................................. 46
6.4.2.1.3 Clock seng .............................................................................................. 46
6.4.2.1.4 Frame screen............................................................................................. 47
6.4.2.1.5 Mulphase anging (Oponal equipment) .............................................. 47
6.4.2.2 Edit programs - screen .................................................................................... 48
6.4.2.3 Load program - screen .................................................................................... 50
6.4.2.4 Input/Output- screen ...................................................................................... 52
6.4.2.5 Alarm- screen.................................................................................................. 52
6.4.2.6 Main screen .................................................................................................... 53
......................................................................................... 54
7.1 Sengs of the anging width (tube clamping depth) .................................................... 54
7.1.1 Seng of the pipe end forming device.................................................................. 55
7.2 The work cycle of the cold anging and aring .............................................................. 59
 ............................................................. 
8.1 The work cycle of the hot anging and aring ............................................................... 60
8.2 Adjustment of the heang starng posion .................................................................. 61
8.3 Changing the heang burner.......................................................................................... 62
8.4 The adjustment of the burner ame and heang me.................................................. 63
8.5 Seng of the Infrared temperature measuring unit...................................................... 65
8.6 Seng of the Emissivity ................................................................................................. 66
.................................................................................... 68
9.1 Working instrucons for expansion................................................................................ 68
9.1.1 The adjustment of the forming device for expansion ............................................ 68
9.1.2 The work cycle for cold expansion of the pipe....................................................... 70
........................................................................ 
10.1 Working instrucons for beveling ................................................................................ 72
10.1.1 The installaon of the beveling tool.................................................................... 72
10.1.2 The adjustment of the forming tool for beveling................................................. 73
 ..................................................................... 76
 ................................................................................................. 77
12.1 Installaon of the Roller track (opon) ........................................................................ 77
12.2 How to use the roller track........................................................................................... 79
................................................................................. 83
13.1 Lubricaon and inspecon points ................................................................................ 83
13.2 Regular inspecon........................................................................................................ 86
13.3 Replacement of digital display unit’s baery ............................................................... 87
........................................................................................................... 88
15. Addenda...................................................................................................................... 

FLANGING MACHINE
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F-200
15.1 Capacity of the machine............................................................................................... 90
15.2 Processing mes........................................................................................................... 92
15.3 The measures of the loose ange joints....................................................................... 93
.............................................................................................. 95
17. Ordering spare parts .................................................................................................... 96

INSTRUCTION MANUAL
6
1. NOTES ON THE USE OF THE INSTRUCTION MANUAL
1.1 GENERAL
This manual contains the instrucons for use, maintenance and seng of the T-DRILL
F-200 anging machine.
Before proceeding with the installaon or operaon of F-200 anging machine, read the
general safety instrucons in chapter 2.
If the F-200 anging machine forms part of a system supplied by T-DRILL, then also the
general safety instrucons related to the other appliances should be studied before use.
NOTE!¨


MANUAL
L

a


NOTE!¨

detail.


FLANGING MACHINE
7
F-200

Read the instrucon manual aenvely before carrying out
installaon, operaon, seng or maintenance of the machine.
Electric box. Danger may be caused by electric installaon.
Cauon! Hot!
Don’t look into the pipe during the process relang to the collar.
Don’t stay on the pipe line or beside the holes.
Don’t put your hands on the tube line under the machine or in
the end of the machine during process.
Warning! Moving parts. Be extremely cauous when handling
this area of the machine.
Do not loosen the upper clamps
ghtening screw when clamps are open.
The clamp might fall down.
Tighten the clamp ghtening screws to
40 Nm or so that the ends of the screws’
threads are level with front panel.

INSTRUCTION MANUAL
8
1.4 PERSONAL PROTECTIVE EQUIPMENT FOR THE OPERATOR
Always wear the appropriate personal protecve equipment, and use extreme cauon
when operang the machine.


Use hearing protector when operang with the machine.
Use protecve glasses when operang with the machine.
Use safety gloves when operang with the machine
Use safety boots when operang with the machine

Read the instrucon book aenvely before carrying out installaon, operaon, seng
or maintenance of the machine. The T-DRILL machine is to be used only for the purposes
and in the way as specied in this manual.
Do not allow visitors or unqualied persons to enter the working area or to come near
the machine.
When operang the machine, all protecon devices should be ed in their right place
and be in proper condion.
Do not keep any loose objects or tools on the machine.
Never exceed the capacity of the machine.
Observe special cauon when using the pipe clamp.
Always disconnect the current supply before opening the electric box of the machine.
Disconnect the current supply before carrying out any maintenance or repair inside the
machine.
When pressing the emergency stop switch, all funcons of machine are immediately
stopped.
Aer installaon of the machine, before operang it, carry out the “Start-up Inspecon”,
described in chapter 5.4.
Always use personal protecon equipment when using the machine.
NOTE!¨
USE.

FLANGING MACHINE
9
F-200

Before switching the anging machine on, the work supervising personnel and the employees
shall carefully acquaint themselves with the manual, the structure of the machine and it’s
funconing. Memorize the locaon of each operang switch and the funcon the switch
regulates.
Use the machine for no other purpose than for those allowed in the manual; be careful at all
mes. Ensure that there are no unauthorized persons in the vicinity of the machine.
Flanging shall take place under the supervision of the management in such a manner as
no excess of the machine funconing values may occur and the machine is generally used
according to the manual and safety regulaons.
NOTE!¨





INSTRUCTION MANUAL
10


The machine is intended for widening the end of a pipe to form a ange using a rotang
forming cone. The ange thus formed is used as a sealing and joining element in so-
called loose ange joints.
1. Bolt, 2. Loose ange, 3. Flanged pipe, 4. Seal

The spindle and the ange spinning tool aached to it are made to rotate by an electric
motor. The bearing-mounted forming pin in the ange forming device turns directed by
the guide of the slide and while turning forms the ange in the pipe end. All machine
movements are hydraulic, except for the spindle rotaon and the movement of the arm
of the heang burner.
The anging operaon: 1. Spindle, 2. Flange forming tool, 3. Forming pin, 4. Pipe clamp,
5. Pipe






FLANGING MACHINE
11
F-200
Pipes anged by this method can be used in loose ange joints to replace lapped and
partly also cast pipe ends involving welding or soldering. The maximum dimensions of the
ange are the same as those of equivalent welded on lapped pipe ends.
Depending on the condions of use, EN1092-1 standard or standard derived from this
can be used in dimensioning. The main factor, which denes the maximum diameter of
the ange, is deforming capability of material. In pracce this capability is expressed as
elongaon. This means that the proporon d4/OD should be smaller that the elongaon
value of material to be anged. However, the experimental results show that much
higher elongaon values can be achieved thanks to the muldimensional straining
scheme.
In hot forming the sealing surface can be changed in quality from smooth to rough by
selecng the appropriate prole for the forming cone.

Following equipment is available for th F-200 machine:

The heang unit enables the anging of thick-walled pipes. The equipment
comprises an oponal range of dierent heang nozzles, an infrared thermometer and an
automac ame guard.
 to be used for beveling the edge of the pipe end, to prepare it for
welding.
. Dierent forming pins are available for forming a grooved ange and for
anging stainless steel pipes. The standard forming pin delivered with the machine is for
use on normal steel pipes. For aring not necessary to use grooved forming pin.
• Expansion pin to expand the end of the pipe for a sleeve extension.
 which can be ordered according to pipe diameter, available for
diameters from Ø21.3- Ø219.1mm.
 Indicates the distance
from the surface of the forming pin to the center of the pipe clamp. Read the instrucons
which are supplied with machine (as PDF on memory sck).
Digital measuring device for posioning of the forming pins

INSTRUCTION MANUAL
12

Display for adjusng the potenometer (Diameter of the ange, the rearmost and the
front posion of the frame.)

Designed to help handling of larger and longer pipes, and to ease removal from the
clamps aer the anging. Read the instrucons which are supplied with machine.
The roller track can handle pipes Ø 20 mm … Ø 219,1 mm.
The maximum weight of the pipe is 250 kg, and maximum length of the pipe is 6000 mm.

FLANGING MACHINE
13
F-200
3.3 THE USE OF THE MACHINE
T-DRILL F-200 is a anging machine, the main purpose of which is forming the pipe end
into a 90º ange by means of a revolving spinning tool. This method is indicated for so
steels (f.inst.St 35 DIN 17175), dierent copper alloys (f.inst. CZ110 BS 2871), stainless
steels (f.inst. AISI 316) and so aluminium alloys. The anging can be performed on cold
or hot pipe.
 can be used for stainless steel, mild steel and copper alloys. Some
cases the tube needs a heat treatment to remove tension. With small diameters the
relave tube stretch may be 75%.
The wall thicknesses of the pipe to be used are: s=1,5…5-6mm.
 is used for stainless steels. Before anging, the pipe
end is preheated to 200ºC-300ºC, which prevents hardening of the material during the
anging. The preheang may be done by means of the heang unit or else by heang the
pipe in another way before the anging operaon.
The wall thicknesses of the pipe to be used are: s=1,5…4-5mm
 is used for mild steels. The pipe end is heated to about 900ºC-950ºC, so as
to reduce the force required for the anging. Moreover no further heat treatment aer
anging is then necessary. The heat treatment instrucons regarding the material to be
treated must be observed.
The wall thicknesses of the pipe to be used are: s=3…8mm, depending on the
temperature of the pipe.
Flanging in two or three stages is used for thin-walled pipes. First the ange is being
spinned the me set, aer which it returns, prevenng the pipe to wrinkle at the bending
radius of the ange.
Hereaer the forming pin connues the anging operaon unl completed if no order for
a second return, i.e. a third anging stage, is given.


This is denitely the most ecient method due to its simplicity. However, in most cases,
annealing is required for stress relief aer forming because, for example, with small pipe
dimensions the relave elongaon may be up to 75 %. This is considerably greater than
obtained in tension tests, and results in hard and brile structure.
Wall thicknesses: 2...5 mm for mild steel, stainless steel and copper alloys, up to 219,1
mm (8”) pipes. See chapter 6.3. Cold anging and aring of the pipe.

This method is used for austenic steels. Before anging the pipe end is preheated to
200...300 degrees cengrade, which prevents hardening during the anging operaon.
Wall thicknesses: 2...5 mm. Up to 219,1 mm (8”) pipes. See chapter 8. Hot anging (and
aring) of the pipe.

INSTRUCTION MANUAL
14

With so steels, the part to be anged can be austenized at a temperature of about
900...950 degrees cengrade, thus avoiding the need for heat treatment aer anging
and reducing the force required in machining. When using this method, it is necessary to
adhere to the instrucons for the hot forming of the material being treated. Heang can
be done by gas heang.

The second addional purpose is to expand the pipe end so that the inner diameter will
be expanded to the extent that another tube can be joined in. That kind of expansion
gives a possibility to join pipes by means of “slide on”.

The bevel for welding can be done on carbon steel and copper pipes. The outer diameter
of the pipe to be beveled can be between Ø 42,4 and 219,1mm, and the wall thickness of
the pipe to be beveled must be more than 3mm.
3.5 TECHNICAL SPECIFICATIONS
See 15. Addenda / 15.1 Capacity of the machine.
The Outer Diameter (O.D.) of the ange and its corresponding d4 standard:
21.3 < O.D. < 50 -> d4: EN 1092-1 / PN 6
50 < O.D. < 219,1 -> d4: EN 1092-1 / PN 10
  NOTE!
Type code 3926
Pipe to be anged Ø 21,3-Ø 219,1
Maximum wall thickness 2...5 mm See capacity diagrams
Materials to be formed Copper, Carbon steels, Stainless
steel, Aluminium
Other materials:
Consult T-DRILL Oy
Flanging me See 16.2 Processing mes
Connected power 10 kw See Machine plate
Max size of fuses 3 x 35–100 (min–max) A
Working voltage 200V - 240 V 50/60 Hz
380V - 480V / 50Hz/60Hz.
See Machine plate
Spindle motor 10 kW
Rotaonal speed of spindle approx. 100 rpm
Measurements of machine
(h x w x d)
1605 x 1200 x 2000 mm
Noise level 73 (During anging) dB(A)
Weight 2800 kg
Compressed air supply* 6 bar (0,6 MPa) *Heang unit, oponal
equipment
1 bar = 0,1 MPa

FLANGING MACHINE
15
F-200

For transport the F-200 is packed into a wooden case and bolted to its boom or is bolted
to a wooden base and plasc covered. Weight of the machine is approximately 3150 kg.
For storage the F-200 is to be protected by grease and sucient dehumidicaon should
be provided in the storage accommodaon. Especially the electric equipment must be
kept dry. The machine can be lied with a fork li when aached on the pallet, from
under the pallet.
To remove the machine from the pallet, remove all xing screws rst. The corner plates
have to be removed to reach the screws and adjustable machine feet (adjustment of the
machine feet requires special tools).
To li the machine, use adequately strong liing chains. The machine must be lied from
the liing eyes, do not use fork li to li the machine without the pallet. The liing eyes
can be removed aer the machine is installed.
Before installing the machine, see layout for required space.

4
1. Open the hood
2. Fix the liing
eyes as illustrated
3. Fix a four-part
hoisng chain
NOTE!¨

INSTRUCTION MANUAL
16
5. INSTALLATION

The machine should be installed on a solid and level foundaon, preferably on a concrete
bed.
The F-200 machine must be leveled on its foundaon before use. The leveling tolerance is
± 5 mm on 1000mm. Use a spirit level.
Aer leveling, fastening the machine to the foundaon by means of anchor bolts is
recommended. Use anchor bolts M12 x 150… 200 mm.
Remove the protecve grease from the machine using a detergent, which will not
damage plasc or rubber parts.
Leave enough space around the machine for operaon and maintenance. Also take into
account the space required for the pipe to be formed.
1200
1525
1010
87
2033
130
Posion of the machine feet, measured from the front side of the machine.

FLANGING MACHINE
17
F-200
4500
1500 1000
1000 1000
3150
12
200
2000
54
3
1000
Layout: 1. Space required for the pipe, 2. Space for operator, 3. Space for maintenance, 4.
Gas line connecons, 5. Electric connecon

The F-200 anging machine must be placed in a working area, the environmental
condions of which do not exceed the following limit values:
Temperature: 12,5°…40°C (32…104°F)
Relave humidity of air: 85% or less
Electromagnesm Surrounding appliances should not cause such
electromagnec perturbaons, which exceed the
general standards established for workshop machinery.
Altude: max. 2200m / 7200

INSTRUCTION MANUAL
18


a

a

a

The terminals for connecon of the external supply cable of the F-200 machine are
located in the electric box. Pay special aenon to the correct earthing of the machine.
Check that the working voltage indicated on the machine and the supply voltage
coincide. Also check that the current value of the overload circuit breakers corresponds
to the current value of the motors. The machine can be supplied for a voltage range of
200-240V/50Hz/60Hz and of 380V-480/50Hz/60Hz. Check the correct connecon with
the help of the circuit diagram delivered with the machine. This circuit diagram will be
found in the pocket of the electric box door. Compare the diagram with the nameplate of
the machine.
NOTE!¨


L


The heang equipment demands the machine to be connected to a compressed air
system. Moreover an oxygen supply and a propane supply are required.
Compressed air connecon and regulator

FLANGING MACHINE
19
F-200
Requirements of these supplies:
Compressed air 0,6 MPa
Oxygen 0,4--0,6 MPa
Propane 0,20 MPa

NOTE!¨



Main gas valves
Machine is equipped with main gas valves for oxygen and propane. Gas supplies are
connected to these valves. There are also pressure regulators for gas on these valves.
Main gas valves

INSTRUCTION MANUAL
20

NOTE!¨

NOTE!¨


1. Measure the supply voltage of the machine and check, that it corresponds to the
tension and the frequency values indicated on the nameplate of the machine.
2. Heang equipment: Check the supplies of the compressed air, of the oxygen and of
the propane. If necessary, adjust the values to coincide with the data indicated in the
technical specicaons (chapter 3.6 of the instrucon book).
3. Check the amount of the hydraulic oil and of the lubricaon oil of the machine (see
chapter 14. Maintenance).
4. Check the rotaon direcon of the hydraulic pump motor. Turn the main power switch
on and press the power on push buon , on the control panel. The hydraulic pump
motor will start. Check the rotaon direcon, indicated by an arrow on the end of the
motor. Should the rotaon direcon be wrong, change phases of the supply cable on the
terminal board.
5. Check that the ange forming tool turns in the direcon indicated by the arrow (on its
body), by pressing the push-buon on the control panel.
6. Check the correct funcon of the switches and push-buons of the control panel.