T-Drill S-80 User manual

INSTRUCTION MANUAL
COLLARING MACHINE 

INSTRUCTION MANUAL
2
Version
5340418EN
27.06.2018 / MT

PRELIMINARY EDITION
Instrucons for the use and maintenance of the T-Drill Collaring machine S-80.
Copyright © 2018 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:

COLLARING MACHINE
3
S-80
CONTENTS
 ................................................................... 5
1.1. General .......................................................................................................................... 5
1.2. Symbols for warning and danger used in this manual................................................... 5
1.3. Symbols and warnings used in the TCC-28 machine ..................................................... 6
1.4. Personal protecve equipment for the operator .......................................................... 7
 ............................................................................................ 7
.............................................................. 
3.1. Introducon................................................................................................................... 8
3.2. The purpose of the machine ......................................................................................... 8
3.3. Technical specicaons ................................................................................................. 8
3.4. Main parts of the machine ............................................................................................ 9
3.4.1. Technical features of main parts .......................................................................... 10
3.5. Axis direcons of the machine ...................................................................................... 10
.................................................................................... 11
4.1. Transport and locaon................................................................................................... 11
4.2. Liing instrucons......................................................................................................... 11
 .................................................................................................................... 12
5.1. Ambient condions ....................................................................................................... 12
5.2. Layout of the S-80 Collaring machine............................................................................ 13
5.3. Installaon of the light curtains (oponal equipment).................................................. 15
5.4. Connecon of the machine to the sources of energy ................................................... 16
5.4.1. Connecon to the electricity network .................................................................. 16
5.4.2. Connecon to the compressed air system............................................................ 17
5.5. Start-up checking........................................................................................................... 17
 .............................................................. 
6.1. Descripon of the control devices................................................................................. 18
6.1.1. Main switch.......................................................................................................... 18
6.1.2. Clamp remote control CB3 ................................................................................... 18
6.1.3. Control panel........................................................................................................ 19
6.2. Descripon of the user interface screens...................................................................... 20
6.2.1. Start-up screen ..................................................................................................... 20
6.2.2. Main screen.......................................................................................................... 21
6.2.2.1. Bar charts screen ........................................................................................... 24
6.2.2.2. Menu screen .................................................................................................. 24
6.2.2.2.1. Programs ................................................................................................. 25
6.2.2.2.2. Manual screen.......................................................................................... 27
6.2.2.2.3. Automac screen ..................................................................................... 29
6.2.2.3. Sengs screen ............................................................................................... 30
6.2.2.3.1. Machine sengs ...................................................................................... 31
6.2.2.3.2. Process sengs ........................................................................................ 32
6.2.2.3.3. Tool sengs.............................................................................................. 34
6.2.2.3.4. Tool magazine .......................................................................................... 40
6.2.2.3.5. Posions ................................................................................................... 42
6.2.2.3.6. Servo motors ............................................................................................ 43

INSTRUCTION MANUAL
4
6.2.2.3.7. References ................................................................................................ 44
6.2.2.4. Alarms screen................................................................................................. 45
6.2.2.5. Users management........................................................................................ 45
6.2.2.6. Counters screen.............................................................................................. 46
6.2.2.7. I/O data screen .............................................................................................. 46
6.3. Stopping the machine ................................................................................................... 47
6.3.1. Emergency stopping............................................................................................. 47
6.3.2. Normal stopping of the S-80 unit ......................................................................... 47
6.4. The lubricaon of the collaring process ........................................................................ 48
6.5. Tools .............................................................................................................................. 49
6.5.1. Milling tool .......................................................................................................... 49
6.5.2. Collaring / trimming tool...................................................................................... 50
6.5.2.1. Collaring tool measuring device 5560252...................................................... 51
6.5.3. Drilling collaring tools .......................................................................................... 54
6.5.4. Tool cone jig 6560093........................................................................................... 55
6.5.5. Fork tool 6560094 ................................................................................................ 55
6.5.6. Reference posion seng tools ........................................................................... 56
6.6. Manual feed table ......................................................................................................... 57
6.7. Control tower signal lights............................................................................................. 59
 ...................................................................................... 
7.1. Machine general setup.................................................................................................. 60
7.1.1. Collaring tool setup ............................................................................................. 60
7.3. Tool magazine................................................................................................................ 62
 ................................................................................................................. 63
8.1. Clamping device maintenance and adjustment ............................................................ 65
8.2. Collaring unit maintenance and adjustment ................................................................. 66
8.2. Collaring tool maintenance ........................................................................................... 68
8.2.1. Dismantling and reassembling of the collaring tool............................................. 68
8.2.2. Replacing the collaring pins ................................................................................. 69
8.2.2.1 Smaller S-80 heads : Fork tool 6560094.......................................................... 71
8.3. Drilling collaring tool maintenance................................................................................ 71
8.5. Screwjack and ball screw drive maintenance................................................................ 77
8.6. Oil collectors.................................................................................................................. 77
8.7. Spindle lubricaon maintenance................................................................................... 78
............................................................................................................. 
 ..................................................................................................................... 
11. Safety data regarding the lubricants............................................................................. 
12. Ordering spare parts .................................................................................................... 
13. Appendix ..................................................................................................................... 
13.1. Capacity table.............................................................................................................. 85
13.2. Pilot hole table ............................................................................................................ 87

COLLARING MACHINE
5
S-80
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
S-80 Collaring machine.
Before proceeding with the installaon or operaon of S-80 collaring machine, read the
general safety instrucons in chapter 2
If the S-80 collaring 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.
¨NOT!¨



MANUAL
LDA¨GTR! May cause a serious accident or even death if the correct
precautions have not been taken.
a

have not been taken.
¨NOT!¨




INSTRUCTION MANUAL
6
1.3. 
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.
Don’t look into the pipe during the process relang to the collar.
Don’t put your hands on the tube line under the machine or in
the end of the machine during process.
Mind the rotang tool.
Warning! Moving parts. Be extremely cauous when handling
this area of the machine.
Use hearing protector when operang with the machine.
Use safety shoes when handling pipes and the tools of the
machine.
Use protecve glasses when operang with the machine.
Always use protecve gloves when handling the tools - the
cung edges and the lubricant used may cause wounds and
inammaons.

COLLARING MACHINE
7
S-80
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.
The local safety guidelines and regulaons are to be followed for safe operaon. The
T-Drill instrucon manual will not repeal the federal, state and local regulaons.
Use overalls when operang the machine.
2. GENERAL SAFETY INSTRUCTIONS
Read the instrucon manual aenvely before installaon, operaon or maintenance of
the machine.
The T-DRILL S-80 is to be used only for collaring in the specic way as described in this
manual.
When operang the T-DRILL S-80 it must be fastened on the oor.
Do not exceed the capacity of the machine.
Before removing or mounng a collaring head or a clamp, the electric current supply
must be disconnected by pushing the power OFF (O) buon in the front panel.
Disconnect power before carrying out any maintenance or repair inside the machine.
Do not keep any loose objects or tools on the machine.
Make sure the venlaon is sucient.
Always use protecve glasses when using the S-80 unit.
Always wear protecve gloves when handling the collaring tool.
Study also the safety data sheet concerning the lubricant which is supplied with the
machine.
When pressing the Emergency switch (STOP-buon) all funcons of the S-80 collaring
machine are immediately interrupted.
Aer installaon of the machine and before using the funcons of the S-80 collaring unit,
carry out the measures described in chapter “start-up checking”.
¨NOT!¨

INSTRUCTION MANUAL
8

3.1. INTRODUCTION
The construcon of the unit consists of the covers, collaring machine body, spindle, a
clamping mechanism and posioning table.
The machine body and the spindle absorb the collaring stress. The feed stroke of the
spindle is servo controlled, which assures the achievement of an opmal eciency and a
great precision. The spindle rotaon is accomplished by means of a ming belt, directly
by the driving motor.
The S-80 collaring machine has safety devices in accordance with the CE requirements.
All this to guarantee that the T-DRILL S-80 unit is reliable even in heavy duty industrial
use.
3.2. THE PURPOSE OF THE MACHINE
The S-80 unit is designed for extrusion of collars to straight and bent tubes (using the
Manual feed table).
3.3. TECHNICAL SPECIFICATIONS
Type Unit S-80 collaring machine NOTE!
Type code 40231 Manuf. no. 118028
Max. run tube O.D. mm 114,3
Max. collar O.D. mm 88,9
Max. wall thickness of run tube mm 3.05 SCH10
Compressed air supply bar 6
Compressed air consumpon l/min 70
Connected power kW 5see machine plate
Fuse sizes A 3 x 32 A (max)
Operang voltage 3 x 400 V / 50 Hz see machine plate
Weight of the unit kg 2200
Weight of the electric cabin kg 110
Weight of the machine cover kg 330
Front cover (with trash drawer) kg 150
1 bar = 100 kPa

COLLARING MACHINE
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S-80
3.4. MAIN PARTS OF THE MACHINE
1
8
7
12
2
3
4
5
6
1
2
34
5
6
7
8
9
11
10
12
2
1Machine main frame
2MFT Manual Feed Table (Oponal equipment)
3Clamping unit
4Moving frame (slide set and frame)
5Spindle
6Tube support
7Covers and doors
8Front cover
9 Chip shield
10 Warning beacon
11 Control panel
12 Oil and chip tray (another oil tray is located inside the machine frame)

INSTRUCTION MANUAL
10
3.4.1. TECHNICAL FEATURES OF MAIN PARTS

• Self-centering clamping device
• Stroke 2x65mm
• Total clamping force 14,7kN
Tool change unit :
• Programmable tool change using x,y,z movements
• Tool breakage monitoring
• Tool in posion sensors
• Chip cover for tool magazine
3.5. AXIS DIRECTIONS OF THE MACHINE
Y-
Y+
Z+
Z-
X+
X-


- Stroke +85 / - 85mm
- Speed max. 10 m/min (~166 mm/s)
- Holding brake (~40kN lin. force)

- Stroke +945 / - 45mm
- Speed max. 10 m/min (~166 mm/s)
- Holding brake (~40kN lin. force)

- Stroke 350mm (nose min. ~70mm from center)
- Speed max. 5 m/min (~83 mm/s)
- Motor brake
- Li force with nominal torque ~50kN (tool taper grip force max.18 kN)

COLLARING MACHINE
11
S-80
4. TRANSPORT, HANDLING AND LOCATION
4.1. TRANSPORT AND LOCATION
For transport the S-80 is bolted to a wooden pallet and covered with plasc. A waterproof
protecon is provided for the electric cabinet.
The machine can be stored in a dry place.
¨NOT!¨
unit to overturn.
4.2. LIFTING INSTRUCTIONS
The machine can be lied / moved using fork li truck, or with a crane and liing chains.
1
2
Liing the S-80 machine: 1. Use a fork truck: drive the forks through the machine frame
holes, ensure that the forks go all the way through the machine frame to the other side!
2. Use a li bar and chains or a strap, li the machine from the liing lugs aached to the
frame.
LWhen lifting the machine with a fork truck: drive the forks through
the machine frame holes, ensure that the forks go all the way through
the machine frame to the other side, otherwise the machine may tip
over!
The covers and electric cabin are lied from the pallet using a crane and liing straps and
chains.

INSTRUCTION MANUAL
12
5. INSTALLATION
The S-80 should be installed on a level and vibraon-free foundaon. Leave enough space
around the table for operaon and maintenance.

- Engineers wrench 46 mm, 36 mm, 27 mm
- ER 25VM
Fasten the machine on oor with chemical anchor bolts M16 through machine base
plate, secure with M16 nuts. Check machine straightness with a spirit level (or a digital
level), adjust with leveling bolts if needed.
The oor under this machine must stand the weight of 1000kg / anchor foot.
Anchor bolt and leveling bolts. Floor plate xing: Use chemical anchor bolts M16, Würth
W-VD or equivalent. Anchor bolt holes, Ø18. Secure with M16 nuts.

Check the horizontal straightness of the S-80 collaring machine from the Z-carriage
slides,using a spirit level. The maximum tolerance is 1 mm/m. Adjust if necessary.
5.1. AMBIENT CONDITIONS
The machine must be placed in an working area, the environmental condions of which
do not exceed the following limit values:
Temperature: +12,5 °C…+ 40°C
Relave humidity of air: 75% or less
Electromagnesm
The surrounding appliances should not cause such
electromagnec perturbaons which exceed the
general standards established for workshop machinery.
Altude: max. 2200m

COLLARING MACHINE
13
S-80

1.
2.
3.
4.
2611
1700
2100
600
5225
4711
R1000
1100
1000 1000
1000
2569
2393
1000
Space requirement for operaon and maintenance of the machine. 1. Door opening areas,
2. Display reach area, 3. Tube line, 4. Operator and service area.

INSTRUCTION MANUAL
14
~3279
2613
2569
2238
1015
3321

COLLARING MACHINE
15
S-80


The light curtains are installed according to layout. For further informaon: See Datalogic
Slim instrucon manual, enclosed.
1. Light curtains, marked with yellow

INSTRUCTION MANUAL
16
5.4. CONNECTION OF THE MACHINE TO THE SOURCES OF ENERGY
1
2
1. Electric supply, into the electric cabinet from below, 2. Air supply hose is lead under the
covers, to the rear of the S-80 machine (see 5.4.2.)

aDANGER! Disconnect the electric current to the supply cable before

a

a

The terminals for connecon of the external supply cable to the S-80 unit are placed in
the electric cabin. The supply cable is lead under the electric cabin into the cabin.
Special aenon is to be paid to correct grounding of the machine. Make sure the
operang voltage of the machine corresponds to the supply voltage of the circuit. The
machine can be supplied with a voltage of 400 V/50Hz.
Check the correct connecon with the help of the circuit diagram supplied with the
machine. Compare the diagram with the values on the idencaon plate of the
machine.

COLLARING MACHINE
17
S-80
5.4.2. CONNECTION TO THE COMPRESSED AIR SYSTEM
¨NOT!¨

The compressed air is to be connected to a pressure regulator supplied with unit. The
pressure regulator is readily assembled and xed in the correct posion. Compressed air
supply requirements: 6-9 bar (85-130 psi).
The air supply valve can be equipped with a padlock to ensure safety during maintenance
of the machine.
¨NOT!¨

Klämpin liikenopeus
Tehdasasetus! Älä säädä! Takuu päättyy.
Clamping speed
Factory setting! Warranty expires if
adjusted.
Klämhastighet
Fabriksinställning! Garantin löper ut om
den justeras.
¨NOT!¨

Planeettavaihteiston lukon paine
Planetary gear lock pressure
Planetväxel lås tryck
Bar

¨NOT!¨

Before using the machine, proceed as follows:
1. Measure the supply voltage of the machine and check if it corresponds to the voltage
and frequency indicated on the idencaon plate of the machine.
2. Check the air supply. Open the main valve of the machine and set the value of the
operaon pressure to 6 bar (85 psi).

INSTRUCTION MANUAL
18

6.1. DESCRIPTION OF THE CONTROL DEVICES

The main switch of the unit is placed on the electric cabin door. The main switch can be
locked with a padlock in order to prevent unauthorized use of the machine.
The power is switched on by turning the main switch to “ON” (I) posion. The power is
switched o by turning the main switch to “OFF” (O) posion.
When the power is switched “ON” the machine “OFF”-buon on the control panel is lit
red, and the start screen opens to the display.
6.1.2. CLAMP REMOTE CONTROL CB3
1
2
3
Clamp remote control: 1. Manual control ON-OFF, 2. Clamps close, 3. Clamps open.
The remote control is for posioning of the tube to the clamps: nal clamp ghtening is
done automacally when the work cycle starts. Turn machine to MANUAL from control
panel switch and acvate remote control from pendant switch (1).
LOhere is a continuous pressure on the clamp control pneumatic line
to keep the tube from falling off the clamps when the emergency stop
is pushed!



COLLARING MACHINE
19
S-80
¨NOT!¨

6.1.3. CONTROL PANEL
1
2
3
4
5
6
8
9
107
1Touch panel display Operaon modes and adjustments
2Work cycle STOP
PAUSE
Controlled stopping of the automac work cycle.
Push shortly to PAUSE. When on PAUSE of the cycle the pilot
lamp blinks. The cycle can be started again by pressing the
“cycle start” push-buon.
If the buon is pushed for 2 sec. the automac work cycle
stops completely.
3Work cycle START Push to start the automac work cycle. A pilot lamp signals that
the automac work cycle is on.
4MAN - 0 - AUTO
5Enter the safety area
request buon
Request to enter safety area. A controlled stopping of the
machine to next step of the program.
6Reset safety curtain buon
/ Reset air pressure supply
The buon blue light is not lit, when the machine is ready,
power is on, and the safety curtain is acvated. Push the buon
for approx. 1 sec.
Reset air supply after Emergency stop, push the button.
To make a controlled machine reset, push 10 sec! See
troubleshoot!
7USB-connecon. Only for memory sck!
8Emergency stop (release
by turning) Stops the machine in case of danger.
9 Machine OFF push-buon Disconnects the control power from the S-80 machine. The PC
is on and can be used to program.
10 Machine ON push-buon Puts the cung machine in state of readiness, switches the
control on to the machine. Green light in a pilot lamp is lit.

INSTRUCTION MANUAL
20
6.2. DESCRIPTION OF THE USER INTERFACE SCREENS

When the power is switched “ON” the start screen opens to the display.
Tap the display to enter.