Uniflex HM 200 User manual

OPERATING MANUAL
- HM 200
- HM 200 Ecoline
- HM 200 Ecoline DC
- HM 250
- HM 260
Technical Details subject to change EN
Copying and distributing this document and the use or communication of the contents thereof are forbidden without
expressed authority. Offenders are liable to the payment of damages. All rights are reserved in the event of the grant of a
patent or the registration of a utility model or design.

UNIFLEX-Hydraulik - 2 - www.uniflex.de
CE-Declaration of Conformity
within the meaning of Directive Machines 2006/42/EC.
The following machine
HM 200 / HM 200 Ecoline / HM 200 Ecoline DC
HM 250
HM 260
was developed, designed and manufactured in accordance with Directive 2006/42/EC under the sole responsibility
of
Company UNIFLEX - Hydraulik GmbH
Robert-Bosch-Straße 50 - 52
D - 61184 Karben
Documentation officer Carsten Baumgartner
The following standards, directives and specifications were applied:
• EG-Richtlinie 2006/42/EG - Directive 2006/42/EEC
• EG-Richtlinie 2014/35/EU - Directive 2014/35/EEC
• EMV Richtlinie 2014/30/EU - EMC Directive 2014/30/EEC
• EN ISO 12100: 2010
• EN 60204: 2006
If the machine is changed in any way without consulting us beforehand or if any non-tested and non-accepted
outside parts are used, this declaration shall lose its validity.
Complete technical documentation is available.
This Operating Manual of the machine is a translation; the original version is in German.
---------------------------------- -------------------------------------- --------------------------------------
Place, Date Signature Function of the signee
Geschäftsführer / / Gérant /
Karben
,
21. Juni 2016

UNIFLEX-Hydraulik - 3 - www.uniflex.de
CE-Declaration of Conformity................................................................................................................................................2
Chapter 1Introduction.............................................................................................................................................5
General information regarding the operating instructions..............................................................................................5
Safety and accident prevention......................................................................................................................................5
Pictograms.....................................................................................................................................................................5
Chapter 2Security..................................................................................................................................................6
Safety.................................................................................................................................................................................6
Safety information provided in the Operating manual....................................................................................................6
Obligations of the owner ................................................................................................................................................6
Obligations of the personnel ..........................................................................................................................................6
Hazards when operating the machine............................................................................................................................6
Usage to the intended purpose......................................................................................................................................7
Warranty and liability......................................................................................................................................................7
Informal Security Measures ...........................................................................................................................................7
Training of the personnel ...............................................................................................................................................7
Control of the hose crimper............................................................................................................................................7
Safety measures for normal operation...........................................................................................................................7
Hazards caused by electrical energy.............................................................................................................................7
Dangers of hydraulic oil..................................................................................................................................................7
Maintenance and servicing, trouble-shooting.................................................................................................................7
Constructional modifications of the machine..................................................................................................................8
Cleaning the machine and waste disposal.....................................................................................................................8
Safety installations.........................................................................................................................................................9
Emergency switch(if applicable) ................................................................................................................................9
Security installations ......................................................................................................................................................9
Safety-switch back stop (if applicable)...........................................................................................................................9
Path limitation.................................................................................................................................................................9
Hazards and safety measures .......................................................................................................................................9
Personal safety ..............................................................................................................................................................9
Chapter 3Description of the system ........................................................................................................................10
Design..............................................................................................................................................................................10
Technical Details HM 200 Ecoline, HM 200 Ecoline DC, HM 200, HM 250, HM 260..................................................11
Chapter 4Commissioning.....................................................................................................................................12
Unpacking / set up .......................................................................................................................................................12
Hydraulic Power Unit – Only ECOLINE DC: ................................................................................................................13
Filling with hydraulic oil ................................................................................................................................................13
Ventilate the Hydraulic System....................................................................................................................................13
Connecting the electric supply.....................................................................................................................................14
HM200Ecoline Connecting the electric supply.............................................................................................................15
Connecting the electric supply (Ecoline DC only)........................................................................................................16
Chapter 5Crimping ..............................................................................................................................................17
Quick die change QDC 239.5..........................................................................................................................................17
Insert the crimp dies 239 / 239L in the machine ..........................................................................................................17
Take the crimp dies 239 / 239L out of the machine.....................................................................................................17
Set the crimp diameter / Crimp die table PB 239.........................................................................................................18
General Notes for Crimping .........................................................................................................................................19
Control of the hose crimper..........................................................................................................................................19
Chapter 6Maintenance.........................................................................................................................................20
Daily Maintenance works.............................................................................................................................................20
Monthly maintenance...................................................................................................................................................20
Six-month maintenance ...............................................................................................................................................20
Annual maintenance ....................................................................................................................................................20
Calibrate the crimp micrometer....................................................................................................................................21
Exchange Slide Bearings.............................................................................................................................................22

UNIFLEX-Hydraulik - 4 - www.uniflex.de
_Anhang / Appendix / Apéndice / Appendice.......................................................................................................23
Ersatzteilliste / Spare Parts List / Pièces détachées / Lista de piezas de recambio........................................................23
Haltebolzen für Standard Pressbacken / Pins for standard dies / Tourillon de mors standard / Gorrón de mordza
estándar...........................................................................................................................................................................30
Wo Sie Ersatzteile bestellen können / Where to obtain spare parts /..............................................................................31
Adresse pour nous contacter / La dirección para encargar piezas de recambio:............................................................31
HM 200 Ecoline............................................................................................................................................................32
Elektro- & Hydraulikplan / Electric & Hydraulic Circult Diagram...................................................................................32
HM 200 Ecoline............................................................................................................................................................33
Elektroplan für Unteröl-Aggregat PUU 45L 3.0_04/ Electric Circuit Diagram for Aggregate under oil PUU 45L 3.0_04
(440V-60Hz-3~) ...........................................................................................................................................................33
HM 200.........................................................................................................................................................................34
Elektroplan (Steuerteil) / Electric Circuit Diagram (Control Part) .................................................................................34
HM 200.........................................................................................................................................................................35
Elektroplan (Leistungsteil) / Electric Circuit Diagram (Power Section).........................................................................35
HM 250 / HM 260.........................................................................................................................................................36
Elektroplan / Electronic Circuit Diagram (480V 50/60Hz 3P).......................................................................................36
HM 250 / HM 260.........................................................................................................................................................37
Elektroplan / Electric Circuit Diagram (220/239V 50/60Hz 3Ph).................................................................................37
HM 200 / HM 250 / HM 260 .........................................................................................................................................38
Hydraulikplan / Hydraulic Diagram...............................................................................................................................38
HM 200 / HM 250 / HM 260 .........................................................................................................................................39
Wartungsbuch / Maintenance book / Carnet d’entretien / Libro de mantenimiento / Libretto die manutenzione /
Onderhoud boek ..........................................................................................................................................................40
Erklärung des geschulten Personals / Declaration of Trained Personnel....................................................................41
Gültig seit: 21.06.16
Änderungszustand: t
Erstellt: Jarrasch
Genehmigt

UNIFLEX-Hydraulik - 5 - www.uniflex.de
Chapter1 Introduction
General information regarding the operating instructions
This operating manual forms part of the scope of delivery of your UNIFLEX machine and it is intended for the user
and maintenance / service staff.
The manual describes how the hose crimper works, provides information on hazards that may arise during its
operation, contains detailed information on how to operate the machine, and describes the steps necessary for
servicing and checking the accuracy of the hose crimper. Even if you have attended a training course for operating
this machine, please read these operating instructions completely before starting up the machine.
By signing your name on the last page >Appendix<, you confirm that you have read completely and understood
this Operating Manual. The owner of the machine shall be obliged to only let such persons operate and carry out
maintenance work on the hose crimper, who satisfy the above-mentioned prerequisite.
Safety and accident prevention
This hose crimper is a state-of-the-art machine and it is safe to use. Nonetheless, certain rules have to be
observed to minimize the risk of injuries and protect the machine.
Please pay particular attention to Chapter 2 >Safety< in these operating instructions.
Pictograms
This pictogram indicates texts providing useful information on the application of the machine and
how it can be handled and used optimally.
This symbol points out critical points, which can lead to damage of the machine, incorrect
functioning, or faulty production.
This symbol points out hazards to life and health as well as risks of injuries.
This symbol refers to hazards arising during the crimping process.

UNIFLEX-Hydraulik - 6 - www.uniflex.de
Chapter2 Security
Safety
Attention:
Serious accidents may occur if the machine is handled incorrectly.
Safety information provided in the Operating manual
All rules and regulations regarding the prevention of accidents, which are applicable at the place of use, have to be
observed.
Obligations of the owner
The owner undertakes to only let such persons work on the machine who are familiar with the basic regulations on
work safety and accident prevention, have been instructed in the operation of the hose press, and have read and
understood the operating manual. The owner shall check at regular intervals whether the personnel is operating the
machine according to the safety regulations.
Obligations of the personnel
All persons authorized to work with this Uniflex machine are obliged to observe the basic regulations on work
safety and accident prevention and read the operating manual.
Hazards when operating the machine
This machine has been constructed according to state-of-the-art engineering and acknowledged safety regulations.
Nonetheless, dangers can arise for the operator and third persons. Additionally the machine and/or other property
can be damaged during incorrect operation. The machine may therefore only be used:
for its proper purpose and intended use,
when it is in perfect and safe working order.
Any faults have to be remedied immediately.
Compliance with all existing safety guidelines is mandatory for the safe operating of the hydraulic press.
Necessary slits for inserting the workpiece must be minimized by limiting the opening stroke.
Due to the diversity of changing, customized workpieces it is not possible for Uniflex Hydraulik to include
additional safety devices in the machine’s delivery that could avert any remaining dangers resulting from
the machine.
The operator must check the necessity for additional safety devices, tailored to the workpiece, before
putting the machine into operation. This may for example, become necessary for angled workpiece
geometries that require a large opening of the press for insertion.
If additional safety devices become necessary, they must be installed prior to commissioning to ensure the
continuous safety of the operator.
We particularly point out that the machine may only be used for its intended purpose. Especially non-metal
workpieces can, by the pressing procedure, be stressed in such a manner that this may lead to a sudden
failure of the material. Chips or strongly accelerated workpiece parts also present a high potential risk of
danger for the operator and persons and objects even beyond the work area.
On request Uniflex Hydraulik can provide individual solutions for safety devices. For a consultation please
contact your personal contact partner.

UNIFLEX-Hydraulik - 7 - www.uniflex.de
Usage to the intended purpose
This UNIFLEX machine is designed only for crimping hose assemblies. Any other usage or any usage exceeding
the tasks described above shall not be considered usage to the intended purpose. Operating the machine in a
potentially explosive atmosphere is prohibited.
The object to be pressure-joined must be positioned in the tool centre in order to achieve good conicity and a long
machine lifetime.
Usage to the intended purpose also includes the observance of all information and instructions provided in the
operating manual and the timely execution of the inspection and maintenance work.
Note:
Other types of application are only permissible following prior consultation with the manufacturer!
Warranty and liability
As a rule our "General Terms and Conditions of Sale and Delivery" shall apply. These are available to the buyer on
demand. Warranty and liability claims for injuries to persons and/or damage to property shall be excluded if such
claims can be attributed to one or several of the causes listed below:
Use of the machine not to the intended purpose.
Improper assembly, start up, operation and/or maintenance/repair of the machine.
Operation of the machine without the protective coverings being mounted correctly.
Non-observance of the information concerning the transport, storage, assembly, start up, operation and
maintenance of the machine provided in the operating manual.
Unauthorized constructional changes on the machine.
Unauthorized modification of programs that affect the control of the machine.
Inadequate inspection of wearing parts.
Incorrectly performed repair work.
Emergencies due to external causes and/or force majeure.
Improper work on automatic-program P3 with the pedal switch or back stop (if applicable)
Informal Security Measures
The operating manual needs to be at the location of the machine at all times. Additionally to the operating manual
the local regulations for accident prevention and environmental protection need to be available and they need to be
observed. All safety notes and danger indication need to be kept in legible condition.
Training of the personnel
Only adequately trained and instructed personnel should be authorized to work on the machine. The
responsibilities of the personnel as to the assembly, start up, operation, maintenance and repair of the machine
should be clearly defined. Personnel undergoing training should only work at the machine under the supervision of
an experienced person.
Control of the hose crimper
Warning:
Under no circumstances may the control system be modified in any way!
Safety measures for normal operation
The machine must only be operated when all protective coverings have been mounted correctly. Prior to switching
on the machine it must be certain that no one can be injured or endangered by the working machine. Inspect the
outside of the machine at least once during every shift to check for any damages.
Hazards caused by electrical energy
Only qualified electricians should carry out work on the electric power supply. The electrical components of the
machine need to be checked at regular intervals. Any loose connections and damaged cables should be repaired
immediately. The housing must always be kept closed and access should only be permitted to authorized
personnel.
If works are needed on any electrical components of the machine, a second person must take
part to activate the main switch in case of an emergency.
Dangers of hydraulic oil
Be sure to prevent any hydraulic oil from seeping into the ground, water and/or sewage system. Hydraulic oil is not
water soluble and hardly biologically degradable. Therefore hydraulic oil is water polluting according to the German
Water Resources Management Law (WHG, WHG 1). Avoid long and intensive skin contact.
Maintenance and servicing, trouble-shooting
Carry out prescribed maintenance work in time. Inform the operating personnel before you begin with the
maintenance and servicing work. Always make sure that the machine is off circuit when any maintenance,

UNIFLEX-Hydraulik - 8 - www.uniflex.de
inspection or repair work is to be carried out and that the main switch cannot be switched on unexpectedly (i.e. by
securing it accordingly). Put up a warning sign prohibiting any third persons from starting up the machine. Mount all
protective and safety guards again as soon as the maintenance work has been completed and check that all
screwed connections are fastened.
Constructional modifications of the machine
The machine may not be modified and no parts may be built on or modified without the manufacturer’s approval.
Any modifications need to be confirmed in writing by UNIFLEX-Hydraulik GmbH. Any parts that are not in perfect
working order should be replaced immediately. Only original spare parts and wearing parts should be used. It
cannot be guaranteed that other parts are designed and manufactured in such a way that they will meet the load
and safety requirements.
Cleaning the machine and waste disposal
All substances and materials used have to be handled and disposed of properly, in particular when work with
lubricants was carried out. The national regulations on waste disposal have to be observed.

UNIFLEX-Hydraulik - 9 - www.uniflex.de
Safety installations
Emergency switch (if applicable)
Note:
the emergency switch must be activated in all situations where injuries of people or damage on
the machine can arise:
The emergency switch is located on the control board.
Security installations
Before each use of the crimping machine or the system, all safety installations must be fitted and working correctly.
Authorized personnel may only remove safety installations:
After the complete stop of the machine.
After safeguarding against accidental switching on.
In the case of partial delivery of components the provided safety instructions and notes need to be displayed
correctly by the user.
Safety-switch back stop (if applicable)
For safety reasons the back stop stops whenever during the crimping process the hose no longer touches the back
stop.
Path limitation
Adjust the opening diameter of the crimping tool so that it exceeds the diameter of the hose fitting only fractional.
This setting protects the operator from reaching into the crimping area with his or her hand.
Hazards and safety measures
Personal safety
Irrespective of the local accident prevention regulations, the following instructions should be observed as a means
of protecting the health and safety of the maintenance and operating personnel:
Never reach into the machine with your hands during operation.
Always keep a copy of the operating manual at the place of use of the machine.
Make sure that all safety and danger notices on the machine (if applicable) are always legible.
Only operate the machine when all safety devices are in working order.
Before starting up the hydraulic unit, make sure that the running machine can endanger no one.
Do not place any objects on the floor near the workplace.
Wear working gloves, especially when heavy work pieces have to be loaded.
Do not bring work materials to the machine with a fork lift truck.
Wear safety shoes.
Danger:
Never reach into the crimp tool with your hands while the electric motor is running! Always make
sure that there is an adequate safety distance of at least 120 mm to the crimp tool when you are
inserting a hose fitting.
Warning:
Switch off the machine using the main switch during all maintenance and setting works!
Danger:
When the machine is handled improperly, there is the danger of hands getting caught and
crushed!

UNIFLEX-Hydraulik - 10 - www.uniflex.de
Chapter 3 Description of the system
Design
Warning:
Always keep a safety distance of at least 120 mm to the crimp tool if the machine is switched on.
1 Crimp tool 3 Hydraulic-oil tank
2 Control 4 Main Switch
1
2
3
4
4
HM 200 Ecoline /
HM 200 Ecoline DC HM 2..
HM 2.. E
HM 2.. B
1
2
3