T-Drill F-400 User manual





INSTRUCTION MANUAL
2
Version
6402768EN
10.03.2019 / MT

Instrucons for use of the T-Drill .
Copyright © 2019 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
informa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.

OY
Ampujane 32 / P.O BOX 20
FIN-66401 Laihia, Finland
Tel.Int. [phone]
Telefax: [phone]
www.t-drill.

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-400
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 Methods of anging......................................................................................................11
3.2.1 Cold Flanging.......................................................................................................... 11
3.4 Informaon on the equipment .....................................................................................12
3.5 Formable Materials.......................................................................................................12
3.6 Technical specicaons................................................................................................. 13


5.1 Installaon and levelling of the machine......................................................................15
5.1.1 Layout..................................................................................................................... 15
5.1.2 Space requirement.................................................................................................16
5.1.3 Leveling ..................................................................................................................17
5.2 Ambient condions.......................................................................................................18
5.3 Connecon of the machine to the sources of energy...................................................18
5.3.1 Connecon to the electric network .......................................................................18
5.4 Start-up inspecon ....................................................................................................... 19

6.1 Descripon of the control devices ................................................................................20
6.1.1 Main switch............................................................................................................20
6.1.2 Control panel.......................................................................................................... 20
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....................................................................................................25
6.1.7 The valve arrangement board ................................................................................28
6.2 Stopping the machine...................................................................................................30
6.2.1 The normal stopping of the F-400 machine ...........................................................30
6.2.2 The emergency stopping of the F-400 machine.....................................................30
6.3 The machine seng...................................................................................................... 30
6.3.1 The idencaon of the forming pin .....................................................................30

INSTRUCTION MANUAL
4
6.3.2 Changing of the forming pin...................................................................................31
6.3.3 Adjustment of the angle of the forming pin...........................................................33
6.3.4 How to correct undesirable ange shape ..............................................................34
6.3.5 Adjustment of the forming pin radius....................................................................35
6.3.6 The fastening of the pipe .......................................................................................37
6.3.7 Seng the length of the part of the pipe to be anged ........................................41
6.4 Instrucons for the use of the display ..........................................................................42
6.4.1 Menu-screen .......................................................................................................... 42
6.4.1.1 User level selecon - screen.............................................................................43
6.4.1.2 Programming- screen.......................................................................................44
6.4.1.3 Pipe seng- screen.......................................................................................... 45
6.4.1.3.1 Library- screen............................................................................................. 45
6.4.1.4 Input/Output- screen .......................................................................................46
6.4.1.5 Alarms - screen.................................................................................................46
6.4.1.6 Main screen...................................................................................................... 47
6.5 Adjustment of forming device ......................................................................................48
6.6 Cold anging and aring of the pipe.............................................................................50
6.7 Working instrucons for bevelling ...............................................................................51
6.7.1 The installaon of the bevelling tool......................................................................51
6.7.2 The adjustment of the forming tool.......................................................................52
6.7.3 The work cycle of the bevelling operaon .............................................................53
6.8 Adjustment and operaon of anging machine based on seng value table .............54
55
57
8.1 Lubricaon....................................................................................................................58
8.2 Regular weekly Inspecon ............................................................................................62
8.2.1 Inspecons of Spindle Chain Tightness ..................................................................62
8.2.2 Fastenings of Moving Carriage Cylinders and Piston Shas ...................................62
8.2.3 Fastening of Flanging Tool ......................................................................................62
8.2.4 Seng of Limit Switch............................................................................................ 62
8.3 PLC-baery maintenance..............................................................................................63

9.1 Funconing ................................................................................................................... 64
65
10.1 Clamping Lengths (Standard clamps)..........................................................................65
10.2 F-400 Capabilies........................................................................................................66
10.2.1 Carbon Steels .......................................................................................................66
10.2.2 Austenic Stainless Steels ....................................................................................66
10.2.3 Copper Alloys (copper, copper nickel, aluminium brass) .....................................67

FLANGING MACHINE
5
F-400
10.3 Approximate Operaon Times of Flanging .................................................................68
10.3.1 Fixing of the Pipe into the Clamp ........................................................................68
10.3.2 Flanging (machine me)....................................................................................... 68
10.4 Installaon Times........................................................................................................ 69
10.5 Loose Flange Joint.......................................................................................................70
10.5.1 Lapped Joint .........................................................................................................70
10.5.2 Loose Flange.........................................................................................................70
10.5.3. Gasket ................................................................................................................. 70
72


INSTRUCTION MANUAL
6


This instrucon book contains the instrucons for use, maintenance and seng of the
T-DRILL machine, as well as recommendaons regarding dierent working procedures
and the use of the forming tools.
Before proceeding with installaon and operaon of the machine, read the safety
instrucons in chapter 2 “General safety instrucons”
¨


MANUAL
L

a


¨




FLANGING MACHINE
7
F-400

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.
Sharp edges!
Be extremely cauous when handling this area of the machine.
Mind the rotang spindle.
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.
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.
Danger of collision!
When changing the forming pin note to
adjust the correct anging radius. (See
ange standard tables).

INSTRUCTION MANUAL
8

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.
¨


FLANGING MACHINE
9
F-400

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.
¨





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
The pipe remains immobile during the enre work cycle and consequently also branched
and bent pipes can be anged. The work method makes it possible to ange a great
number of pipes of dierent diameters, since the forming pin and the pipe are linearly in
contact with each other. The wall thickness of the pipe determines almost completely the
necessary amount of force to be exercised on the material for anging.
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

FLANGING MACHINE
11
F-400
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.
Flange O.D. ( d4 ) :42.4 < O.D. < 50 d4: EN1092-1
50 < O.D. < 406.4 d4: EN1092-1


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 406 mm
(16”) pipes. See chapter 6.3. Cold anging and aring of the pipe.

INSTRUCTION MANUAL
12


• Heang unit is equipment used for heang the pipe to be anged or otherwise formed.
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.
• Bevelling unit to be used for bevelling the edge of the pipe end, to prepare it for
welding.
• Forming pin. 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.
• Pipe gripping clamps which can be ordered according to pipe diameter, available for
diameters from Ø42.4-Ø419mm.
• Potenometer and display.
Display for adjusng the potenometer (Diameter of the ange, the rearmost and the
front posion of the frame.)

- Various copper alloys, e.g. CZ110 BS 2871
- Austenic steels, e.g. AISI 316
- So steels, e.g. St 35 DIN 17175
- So aluminium alloys

FLANGING MACHINE
13
F-400

   
Type code 4014
Pipe to be anged mm (Ø33,7**) Ø42.4-Ø419
Maximum wall thickness See capacity diagrams
Materials to be formed Copper, Carbon steels, RST,
Aluminium
Other materials:
Consult T-DRILL Oy
Flanging me See Machine me (13.3)
Connected power kW 15,5 See Machine plate
Max size of fuses A 3 x 100
Working voltage 3 x 200V - 240 V 50/60 Hz
3 x 380V - 480V / 50Hz/60Hz.
See Machine plate
Spindle motor kW 11
Rotaonal speed of spindle rpm approx.41
Measurements of machine
(h x w x d)
mm 1720 x 1625 x 3100
Motor of hydraulics kW 4
Pressure of hydraulic pump
(Max.)
MPa 16
Hydraulic pump output
(adjustable)
ltr/
min
0...25 l/min
Noise level dB 74 (During anging)
Weight kg 4200
Compressed air supply* MPa 0,6
1 bar = 0,1 MPa
**) Flanging pipes Ø33,7 -- Ø42,4 is possible by using forming pin: 5401793

INSTRUCTION MANUAL
14

For transport the F-400 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 4500 kg.
For storage the F-400 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.
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. The liing eyes can be removed
aer the machine is installed.
Before installing the machine, see layout for required space.

1. Remove the rear top mesh lids (1) of the hood to reach the liing eyes (4).
2. Open the hood to reach rear liing points.
3. Fix the liing chains as illustrated.
4. Fix a four-part hoisng chain.
Instrucons for liing and parts: 1. Top mesh lids, 2. Liing chains, 3. Adjustable machine
feet, 4. Liing eyes, 5. Corner plates, remove to detach machine from the pallet, x the
machine to the oor and adjust feet.
¨

FLANGING MACHINE
15
F-400



1. Gas valve*, 2. Oxygen valve*, 3. Electric connecon, 4. Compressed air connecon and
regulator, 5. Machine outline measures.


INSTRUCTION MANUAL
16

Leave enough space around the machine for operaon and maintenance. Also take into
account the space required for the pipe to be formed.

FLANGING MACHINE
17
F-400

The machine should be installed on a solid and level foundaon, preferably on a concrete
bed.
- Required oor load capacity 3.0 t/m²
- Floor level ± 5 mm /m²
The F-400 machine must be leveled on its foundaon before use. The leveling tolerance is
0,05mm 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.
Screw M12, Washer Ø 13, Hole in anchor foot Ø 17, Anchor bolt M12
Remove the protecve grease from the machine using a detergent, which will not
damage plasc or rubber parts.

INSTRUCTION MANUAL
18

The machine must be placed in an working area, the environmental condions of which
do not exceed the following limit values:
Temperature: +5…+40°C (41…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


a

a

a

The terminals for connecon of the external supply cable of the F-400 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.
¨




FLANGING MACHINE
19
F-400

¨

¨

¨


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. If the machine is equipped with 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
4. Check the amount of the hydraulic oil and of the lubricaon oil of the machine.
5. Check the rotaon direcon of the hydraulic pump motor. Turn the main power
switch on and press the push buon of the contactor, 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. A wrong rotaon direcon
may cause the hydraulic pump to be damaged.
6. 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.
7. Check the correct funcon of the switches and push-buons of the control
panel.
¨


INSTRUCTION MANUAL
20



The main switch of the machine is located on the door of the electric box on the backside
of the machine. The power is connected by turning the main switch to the posion “I”
(ON). The power is disconnected by turning the switch to the posion “0” (OFF). The
main switch can be locked in the “0” posion by mains of a separate padlock in order to
prevent unauthorized use of the machine (padlock not included to delivery).


