Tube end forming machine

Operating instructions Translation of the original operating instructions

Tube end forming machine SFO-F-A-A

6010014619 R04_en, valid from firmware 1.7.x 22-10-2020

To avoid injuries and damage, read these operating instructions thoroughly and attentively. Retain it for further reference.

Tube end forming machine 2 / 66 www.stauff.com

Additional operating instructions in other languages can be downloaded at www.stauff.com.

Walter Stauffenberg GmbH & Co. KG

Im Ehrenfeld 4 58791 Werdohl, Germany

+49 2392 916-0

[email protected]

www.stauff.com

http://www.stauff.com/


mailto:[email protected]


SFO-F-A-A www.stauff.com 3 / 66

Table of contents

Table of contents 1 Information about the instructions ........................................................ 5

1.1 Target group of the operating manual ............................................ 5

1.2 Structure of warnings ...................................................................... 5

1.3 Structure of instructions .................................................................. 6

1.4 Structure of additional information .................................................. 6

1.5 Structure of references ................................................................... 6

2 For your safety ......................................................................................... 7

2.1 General safety instructions ............................................................. 7

2.2 Intended use ................................................................................... 8

2.3 Tasks and obligations of the operating company ........................... 8

2.4 Personnel qualification .................................................................... 9

2.5 Personal protective equipment ....................................................... 9

2.6 Safety labels ................................................................................... 9

2.7 Safety devices .............................................................................. 10

2.8 Securing the machine against reactivation ................................... 10

3 Machine description .............................................................................. 12

3.1 Machine overview ......................................................................... 12

3.2 Technical data .............................................................................. 12

3.3 Function ........................................................................................ 13

3.4 Tools and product ......................................................................... 13

3.5 Type plate ..................................................................................... 15

3.6 Serial number ............................................................................... 15

3.7 Spare parts and wear parts .......................................................... 16

4 Transport and storage ........................................................................... 17

4.1 Safety ............................................................................................ 17

4.2 Transport....................................................................................... 17

5 Installation .............................................................................................. 18

5.1 Safety ............................................................................................ 18

5.2 Installing the machine ................................................................... 19

5.3 Attaching supply connections ....................................................... 19

5.4 Establishing readiness for operation ............................................ 19

6 Operation ................................................................................................ 20

6.1 Safety ............................................................................................ 20

6.2 Switching on the machine ............................................................. 20

6.3 Establishing readiness for operation after emergency stop ......... 26

6.4 Warm-up program ....................................................................... 27



Table of contents

6.5 Setting up the machine ................................................................. 28 6.5.1 Language setup ................................................................ 28 6.5.2 Setting up the system properties ...................................... 30

6.6 Setting up a job ............................................................................. 34 6.6.1 Setting the material ........................................................... 35 6.6.2 Setting the tube size .......................................................... 36 6.6.3 Setting the wall thickness .................................................. 37 6.6.4 Setting the production quantity ......................................... 37 6.6.5 Inserting/changing the tool ................................................ 38

6.7 Forming tube ends........................................................................ 44

6.8 Foot switch operation ................................................................... 46

6.9 Cleaning the machine ................................................................... 48

6.10 Switching off the machine ............................................................ 48

7 Troubleshooting .................................................................................... 49

7.1 Safety ........................................................................................... 49

7.2 Troubleshooting ............................................................................ 50

7.3 Malfunctions/error messages ....................................................... 50 7.3.1 Reshaping path ................................................................. 50 7.3.2 Target position .................................................................. 51 7.3.3 Reference run ................................................................... 51 7.3.4 Parameters ........................................................................ 52 7.3.5 Direction of rotation ........................................................... 53 7.3.6 Motor protection switch ..................................................... 53 7.3.7 Assembly ........................................................................... 54 7.3.8 Moving to the start position ............................................... 54 7.3.9 Tool ................................................................................... 55 7.3.10 Other faults ........................................................................ 55

8 Maintenance ........................................................................................... 57

8.1 Safety ........................................................................................... 57

8.2 Inspection and maintenance ........................................................ 57

8.3 Checking the emergency stop ...................................................... 57

9 Decommissioning .................................................................................. 58

9.1 Safety ........................................................................................... 58

9.2 Dismantling ................................................................................... 59

9.3 Disposal ........................................................................................ 59

10 EC Declaration of Conformity .............................................................. 61

List of figures ......................................................................................... 62

Index ....................................................................................................... 64



1 Information about the instructions

1 Information about the instructions These operating instructions include important instructions and information on the intended use. Keep the operating instructions where they can be accessed by the operating personnel.

1.1 Target group of the operating manual The operating personnel tasked with the following work has to read and observe this operating manual:

• Installation

• Operation

• Malfunction

• Maintenance

See “Personnel qualifications” chapter 2.4, p. 9.

1.2 Structure of warnings Coloured signal word boxes emphasise the warnings. Always read the full warning text for effective protection against hazards!

The different colours and signal words of the following boxes designate various hazard levels:

DANGER

Ignoring this warning results in serious or lethal injuries.

WARNING

Ignoring this warning can result in serious or lethal injuries.

CAUTION

Ignoring this warning can result in minor or moderate injuries.

ATTENTION

Ignoring this warning can result in damage.

Warnings always have the same structure. They include the signal word, hazard type and source, consequences of ignoring them and steps to avert/avoid hazards.


1 Information about the instructions


Example:

WARNING

Risk of shearing off and crushing fingers

► Ensure before start-up that all safety equipment is properly installed and in working order.

► Ensure that your fingers are not in the forming area when carrying out the machine functions!

1.3 Structure of instructions Instructions are a direct request to carry out a task. They are structured in line with the operation involved. Always carry out the operating steps in the prescribed sequence.

The instructions are structured as follows and marked with the appropriate symbols:

Objective of the instructions

1. Action step

Effect of the action step to check if the step has been executed correctly.

2. Additional action step

Result of the overall instruction

1.4 Structure of additional information

Text marked with an information symbol provide additional information and tips.

1.5 Structure of references References are shown in this manual as follows:

Example:

“… only operate the machine as intended chapter 2.2, p. 8.“



2 For your safety

2 For your safety To avoid accidents and injuries, …

• follow all safety instructions and warnings in these operating instructions

• observe hazard, prohibitory and instruction signs

• follow the accident prevention regulations and directives applicable at the place of operation

• observe all inspection and maintenance intervals

• ensure to comply with the intended use

2.1 General safety instructions Safety instructions help you in avoiding injuries and damage. Ensure that you have read and understood all the safety instructions in these operating instructions.

Safe working entails doing more that just reading the general safety instructions in this chapter. Also read and follow the specific safety instructions in each chapter affecting your work. Also observe information in the referenced product documents.

The following general safety instructions apply to all work undertaken on the machine:

• Observe the applicable national and international health and safety regulations.

• Only operate the machine …

– in a technically satisfactory condition

– taking into account safety and hazards

– according to the intended use

– in compliance with this operating manual and

– with all safety devices unchanged, properly installed and functional

• Wear the appropriate personal protective equipment for all work on the machine chapter 2.5, p. 9.

• Observe all safety markings attached to the machine chapter 2.6, p. 9.

• Work on electrical equipment may only be carried out by Walter Stauffenberg GmbH & Co. KG.

• Immediately eliminate any malfunctions which affect your safety and/or reliable operation of the machine. Take the machine out of service until the fault is rectified.

• Components – except tools – may only be replaced by Walter Stauffenberg GmbH & Co. KG.


2 For your safety


• Keep away from moving parts. Wear close-fitting clothes. Tie long hair back to prevent it from being drawn into the machine. Remove any rings and necklaces before the work.

• Be aware of the presence of residual energies in mechanical, hydraulic and electrical components.

2.2 Intended use The tube end forming machine is designed exclusively for machine forming of seamless precision steel tubes according to EN 10305-1 with an outer tube diameter between 6 mm and 42 mm.

The machine is used together with internal tube support, tube shaper and shaping jaws which are specially designed for machine forming of tube ends.

The machine may only be used within the specifications provided in the chapter “Technical data” chapter 3.2, p. 12 and in

compliance with the maintenance instructions and information in these operating instructions and in the referenced documents.

No changes, attachments or conversions may be carried out without consulting the manufacturer. Such modifications could limit the operating safety of the machine and are considered to be a violation of intended use.

Any use other than the intended use is not permitted.

2.3 Tasks and duties of the operating company In addition to the instructions and information in these operating instructions, the general, statutory and other mandatory regulations on accident prevention and environmental protection also have to be observed.

To ensure safe machine operation, the operating company has to at least …

• ensure that the machine is only operated as intended, in proper condition, with all safety devices fully installed and without damage

• establish the area of application and prepare the corresponding operating instructions

• always keep the safety markings attached to the machined in a complete and legible condition

• make the operating instructions available in a complete and legible form at the operating location of the machine at all times

• instruct the personnel in safe working

• acquire the regulations applicable to the machine in their most recent version and to familiarise personnel working on the machine with these

• provide personnel with the required personal protective equipment


2 For your safety


• carry out a safety instruction

• ensure sufficient ventilation and lighting of the work areas

2.4 Personnel qualification Any work on the machine may only be carried out by qualified and authorised personnel. Personnel instructed, trained or briefed in the work involved is considered to be qualified. This has to be backed up by appropriate certificates and records.

A distinction is made in this manual between the following groups of persons:

• Operating personnel are those who have been demonstrably briefed in the operation and function of the machine. They input the data required for the operation and carry out the required operating steps to operate the machine. They are also responsible for simple maintenance work and fault rectification as described in chapter 7, p. 49 and chapter 8, p. 57.

• Personnel learning on the job may only work on the machine under the constant supervision of personnel qualified for this work.

2.5 Personal protective equipment The following personal protective equipment is mandatory for those working on the machine:

2.6 Safety markings The following safety markings are attached to the machine in a clearly visible and legible manner:

Warning – hand injuries ISO 7010 – W024

Warning – dangerous electrical voltage! ISO 7010 – W012

Wear safety boots!

Wear close-fitting work clothes!


2 For your safety


2.7 Safety devices Safety devices protect operating personnel against hazards.

Before each startup of the machine, all safety devices have to be fitted correctly and in working order.

Safety devices may only be removed when the machine has stopped and is protected against being accidentally switched on again by means of a padlock or a similarly suitable measure.

The following safety devices are attached to the machine or have to be fitted by the operating company:

Electrical main switch The electrical main switch is located at the front of the machine. The electrical main switch de-energizes the entire machine (position: 0). The electrical main switch is secured against reactivation chapter 2.8, p. 10.

Emergency stop button Pressing the emergency stop button triggers an emergency stop resulting in all machine movements being stopped. To start the machine up again, the activated emergency stop has to be released chapter 6.3, p. 26.

1 Electrical main switch

2 Emergency stop button

Fig. 1: Safety devices

2.8 Securing the machine against reactivation Secure the machine against reactivation:

1. Ensure that …

a padlock is available for securing the machine against reactivation (not included in the delivery).

2. Switch off the machine as described.

3. Secure the electrical main switch with a padlock.

1 2


2 For your safety

SFO-F-A-A www.stauff.com 11 /

Fig. 2: Electrical main switch protected with padlock

The machine is secured against reactivation


3 Machine description


1 2 3 4

5 6


3.1 Machine overview

Fig. 3: Overview of the controls

No. Designation Description 1 Grip head Machine workpiece

2 Electrical main switch Switch machine on/off

3 “Ready/ Process runs” lamp

Machine ready for operation, machine running

4 Operating panel Setting up the machine

5 Acknowledge Acknowledge message

6 Emergency stop button Stop machine in an emergency RJ45 interface PC connection;

At the rear of the machine Power supply At the rear of the machine Optional foot switch Connection at the back of the machine

3.2 Technical data

General data Dimensions (W x D x H) 850 mm x 890 mm x 330 mm

Weight incl. oil: 210 kg

Electrical power Electrical connection: 400 V / AC3 / 50 Hz

460 V / AC3 / 60 Hz

Current consumption: 2.55 / 2.5 A




Hydraulic energy Oil capacity: 6.1 litres

Max. operating pressure: 700 bar

Installation requirements Ambient temperature: Dry between 15 °C and 35 °C

Position Horizontal

Sound pressure level in acc. with EN ISO 11202:2009: 68 dB(A)

3.3 Function The machine forms tube ends to make them suitable for use with fittings according to ISO 8434-1. Seamless precision steel tubes according to EN 10305-1 with an outer tube diameter between 6 mm and 42 mm can be used.

The machine is used together with internal tube support, tube shaper and shaping jaws which are specially designed for machine forming of tube ends.

3.4 Tools and product The tube end forming machine forms tube ends. These form the basis for threaded fittings, consisting of the standard fitting body according to ISO 8434-1, the standard sleeve nut and the Stauff form ring with integrated soft seal.

Fig. 4: Product

1 Internal tube support 2 Tube shaper

3 Shaping jaws

1 2 3




The lettering on tube shaper and shaping jaws provide the following information:

Fig. 5: Size

ATTENTION

Damage to the tool from incorrect internal tube support

► Tube shapers with internal hole are designed for forming with internal tube supports. Ensure to always use the correct internal tube support for the wall thickness selected as otherwise the tool can be damaged! Also see chapter 6.6.5, p. 38.

Please refer to the Stauff product catalogue for additional information on selecting the size.




3.5 Type plate The type plate is located on the side of the machine.

Fig. 6: Type plate

3.6 Serial number The serial number is stamped into the frame at the front right!

Fig. 7: Serial number




3.7 Spare and wear parts

ATTENTION

Replacing components

Machine damage, malfunctions, faults

► Any work for which the machine has to be opened may only be performed by Walter Stauffenberg GmbH & Co. KG!

► Only authorised setup and maintenance personnel may carry out maintenance work!

► Only use suitable tools in proper condition!

► Replace components only with genuine spares or those authorised by the manufacturer.

Authorized spare parts and wear parts lists can be obtained from Walter Stauffenberg GmbH & Co. KG.


4 Transport and storage


4 Transport and storage

4.1 Safety

WARNING

Lifting loads

Serious or lethal injuries from falling/suspended loads

► Secure all moving components before raising the load.

► Only use undamaged lifting equipment which is approved for the weight of the load to be lifted.

► Attach load attachment gear only at the indicated attachment points.

► Never leave loads suspended in the lifting devices without supervision.

► Never stand underneath suspended loads.

WARNING

Transporting the machine

Serious or lethal injuries from tilting or slipping loads

► Before transporting the machine, secure all its moving components.

► Secure the machine against overturning or slipping out of position during transport.

► Only use transport vehicles which are suitable for the weight of the machine.

4.2 Transport

Information on dimensions and weight can be found in chapter 3.2, p. 12.

Note the following during transport:

• The attachment points are the side bars/grips of the machine.

• Keep the machine horizontal during all transport. Note that the centre of gravity is in the installation area.

• Transport may only be carried out by an authorised specialist company or by qualified personnel.

• Dispose of all packaging material in a proper and environmentally compatible manner after transport.


5 Installation


5 Installation

5.1 Safety

WARNING

Lifting loads







WARNING

Carrying out installation work

Serious or lethal injuries or machine damage due to incorrect installation

► Installation work may only be carried out by authorised specialist personnel.


► Wear your personal protective equipment for all work.

WARNING

Connecting the machine to the power supply

Serious or lethal injuries from dangerous voltage

► Work on electrical equipment may only be carried out by qualified electricians.

► Work on live parts is only permitted under supervision of a second person.

WARNING





5 Installation


5.2 Installing the machine The machine is assembled ready for operation by the manufacturer and delivered with the control unit set up.

Control unit updates can be requested from the

manufacturer. Note the following before the installation:

• Set up the machine on a sturdy base.

• Set up the machine so there is space to work around it.

• Inspect the machine for any signs of damage.

5.3 Attaching supply connections Attach the machine to the following supply connections:

• Power supply

5.4 Establishing readiness for operation A visual check and function test has to be carried out on the machine before startup. Ensured that …

• all parts are mounted correctly, are undamaged and in full working order

• all outer fittings are installed and fully tightened

• all safety devices are functioning chapter 8.3, p. 57.


6 Operation


6 Operation To ensure safe operation, the machine may only be used in accordance with the intended use chapter 2.2, p. 8.

6.1 Safety

WARNING



► Ensure that your fingers are not in the forming area while the machine functions are executed.

CAUTION

Incorrect operation

Hazard from incorrect operation and operator errors

► Operators must have read and understood the operating manual.

► Operating personnel must have received training and instruction in the handling of the machine.

CAUTION

Faulty safety devices

Danger from the operator interfering with the safety equipment

► Before startup of the machine, ensure that all safety devices are installed correctly and are functioning.

6.2 Switch on the machine Switch on the machine as follows:

1. Turn the electrical main switch to “I / ON”.

The message Release emergency stop and confirm with “Acknowledge” appears after a few seconds.


6 Operation


Fig. 8: Start screen

The English start screen appears at the first startup after machine delivery. If you want to keep this language, continue with step 5.

2. Press the Globe button to set the language.

The Language settings menu opens.

Fig. 9: Menu – Language settings

1. Press the button for the language to be set.

The flag in the upper area of the menu indicates the selected language.

2. Press the Arrow button to exit the menu.

3. Pull out the emergency stop button if necessary.

4. Press the Acknowledge button.

The Reference run/material menu opens.


6 Operation


Fig. 10: Menu – Reference run/material

The Ready/Process runs lamp flashes.

The machine is ready for operation.

Check whether a tool is installed. If not, set up a new job chapter 6.6, p. 34.

If a tool is already installed, you can continue with the existing job. Start the reference run as described on the following pages.

How to carry out the reference run without tool change:

1. Press the Reference run button.

The message Start reference run opens.

ATTENTION

Incorrectly executed reference run

Machine damage

► Never carry out the reference run with a tube! Do not place a tube into the tool until the reference run is completed.


6 Operation


Fig. 11: Starting the reference run

2. Simultaneously press and hold the Reference run and Acknowledge buttons.

The reference run starts.

The Ready/Process runs lamp lights up continuously.

The message Release grip head opens.

Fig. 12: Releasing the grip head

Fig. 13: Pulling out the grip head


6 Operation


3. Rotate the grip head to the left using the provided handles and pull it out using both hands

Fig. 14: Releasing and pulling out the grip head

The grip head is released and opened.

4. Check tool and remove any dirt.

ATTENTION

Objects in the forming area

Machine damage

► Before starting the reference run, remove auxiliary tools and other objects which are not required for the reference run!

The message Insert and lock grip head opens.

Fig. 15: Inserting and locking the grip head


6 Operation


5. Insert the grip head with both hands and turn to the right.

The grip head is locked. The message To continue reference run, push and

hold “Reference run” and “Acknowledge”!



The reference run continues.

The Start reshaping process menu opens after the reference run is complete.

Fig. 17: Start reshaping process



Please refer to chapter 6.4, p. 27, if the reference run is cancelled.


6 Operation


6.3 Establishing readiness for operation after emergency stop How to establish readiness for operation after the emergency stop:

1. Rectify the fault as described in chapter 7, p. 49.

Fig. 18: Emergency stop message

2. Release the Emergency stop button.


The Reference run/material menu opens.

Fig. 19: Menu – Reference run/material


ATTENTION

Damage to the machine from incorrectly executed reference run

► Never carry out the reference run with a tube! Do not place a tube into the tool until the reference run is completed.


6 Operation


6.4 Warm-up program If the machine independently cancels the reference run, the message “Illicit startup pressure! Confirm with “Acknowledge”, remove tube or check tool!” is shown on the screen. It is possible that the hydraulics temperature of the machine is too low. In this case, the machine has to be warmed up with the warm-up program.

Fig. 20: Impermissible startup pressure

How to start the warm-up program.

1. Press the Warm-up button which is automatically shown when the reference run was interrupted. The warm-up screen opens.

Fig. 21: Start

2. Do not remove any tools from the machine and do not insert any tools into the machine. Remove all objects as well as your fingers from the installation area.

3. Press and hold the Start button.

It takes about 2 minutes to warm up the machine. The warm-up program moves the installation cylinders back and forth several times.


6 Operation


WARNING

Fingers in the forming area



1. When the warm-up program has been completed, a confirmation is shown on the screen and you can release the button.

2. Press the “Arrow left” button to return to the Reference run menu.

Reference run interrupted again Please repeat the warm-up process for the machine.

6.5 Setting up the machine

6.5.1 Setting the language How to set the language:

1. In the Processing order menu, press the Properties button.

Fig. 22: Menu – Processing order

The Properties > level menu opens.


6 Operation


Fig. 23: Menu – Properties > level

2. In the Properties > level menu, press the Languages button.

The Language settings menu opens.

Fig. 24: Menu – Language settings

3. Press the button for the language to be set.

The flag in the upper area of the menu indicates the selected language. Press the Arrow button to exit the menu.

The language is now set.


6 Operation


6.5.2 System properties setup How to open the system properties:

1. In the Main menu, press the Properties button.

The Properties > level menu opens.

Fig. 25: Menu – Properties > level

2. In the Properties > level menu, press the System button.

The System menu opens.

Fig. 26: Menu – System

How to set the date and time:

1. Press the date/time display and enter the desired data.


6 Operation


Fig. 27: Menu – Input pad for date and time

2. Confirm your entry by pressing the green tick.

The input pad for date/time closes.

The set data are displayed.

How to see information on the quantity for each tool size:

1. Press the Tool counter button.

Fig. 28: Tool counter

The quantities for each tool size are displayed. Use the arrow buttons to scroll.

How to switch off the control panel for cleaning:

1. Press the Clean screen button.

The control panel switches itself off for 20 seconds.

How to see information on the function of the inputs and outputs:

1. Press the PLC DI/DO button.


6 Operation


Fig. 29: Overview – Function of the inputs and outputs

The function of the inputs and outputs is displayed.

How to reset the actual production quantity:

1. Press the Reset OK quantity button.

The Number of pieces menu opens.

Fig. 30: Menu – Number of pieces

2. Press the Reset button.

The actual production quantity number is reset.

How to access the warm-up menu.

1. Press the Warm-up button.

The Warm-up menu is shown.


6 Operation


Fig. 31: Menu – Warm-up

Refer to chapter 6.4, p. 27

This provides you with information about the material quantity.

1. Press the Material counter button.

The material counter menu is shown.

Fig. 32: Menu – Material counter


6 Operation


6.6 Setting up a job How to set up the job:

1. In the Processing order menu, press the Setup button.


The Setup > order menu opens.

Fig. 34: Menu – Setup > order

2. Carry out the following steps in the order indicated:

3. Set the material chapter 6.6.1, p. 35.

4. Set the tube size chapter 6.6.2, p. 36.

5. Set the wall thickness chapter 6.6.3, p. 37.

6. Set the production quantity chapter 6.6.4, p. 37.

7. Insert/change tool chapter 6.6.5, p. 38.


6 Operation


6.6.1 Setting the material How to set up the material:

1. In the Setup > order menu, press the Material button.

The Setup > material menu opens.

Fig. 35: Menu – Setup > material

2. Select the material and press the corresponding button.

3. Confirm the selection with the Confirm button.


The selected material is displayed.



6 Operation


6.6.2 Setting the tube size How to set up the tube size:

1. In Setup > order menu, press the Tube size button.

The Setup > tube size menu opens.

Fig. 37: Menu – Setup > tube size

2. Press the button for the desired tube size.

The menu only displays the tube sizes which can be combined with the selected material. If the required tube size is not displayed, change the set parameters or contact Walter Stauffenberg GmbH & Co. KG.



The selected tube size is displayed.



6 Operation


6.6.3 Setting the wall thickness How to set up the wall thickness:

1. In Setup > wall thickness menu, press the Wall thickness button.

The Setup > wall thickness menu opens.

Fig. 39: Menu – Setup > wall thickness

2. Press the button for the desired wall thickness.

The menu only displays the wall thicknesses that can be combined with the selected tube size. If the required wall thickness is not displayed, change the set parameters or contact Walter Stauffenberg GmbH & Co. KG.



The selected wall thickness is displayed.

6.6.4 Setting the production quantity

Changing the production quantity automatically resets the OK quantity to 0!

How to set up the production quantity:

1. In the Setup > order menu, press the Production qty. button.

The input pad for entering the quantity opens.


6 Operation


Fig. 40: Menu – Input pad for quantity

2. Enter the quantity.

3. Confirm the quantity by pressing the green tick.

The input pad for entering the quantity closes.

The selected production quantity is displayed.

6.6.5 Inserting/changing the tool

WARNING




How to set up the tool:

1. In the Setup > order menu, check the material and adjust if necessary chapter 6.6.1, p. 35.



6 Operation



The Tool change menu opens.

Fig. 42: Checking the tool

3. Rotate the grip head to the left using the provided handles, pull it out and swivel it open.

Fig. 43: Releasing and pulling out the grip head

The grip head is released and opened.

The forming cylinder moves out.

ATTENTION

Damage to the machine from objects in the forming area

► Before starting the forming process, remove all auxiliary tools and other objects that are not required for forming!

4. Check the forming area and remove any dirt.


6 Operation


ATTENTION

Damage to the machine due to different tool sizes.

► Ensure to use the same sizes for the tube shapers, the shaping jaws and the internal tube support. The use of different tool sizes can result in damage to tools and machine!

5. Select the tube shaper, the shaping jaws and, if necessary, the internal tube support according to the set size.

ATTENTION

Damage to the machine due to worn tools

► Ensure that the tools are in perfect technical condition. The use of worn tools can result in damage to the machine!

6. Check the tools for technically perfect condition.

ATTENTION

Damage to the tool due to incorrect internal tube support

► Tube shapers with internal hole are designed for forming with internal tube supports. Ensure to always use the correct internal tube support for the wall thickness selected as otherwise the tool can be damaged!

7. If an internal tube support is required, screw it firmly into the tube shaper.

Fig. 44: Reference run displaying internal tube support


6 Operation


ATTENTION

Incorrectly inserted tube shapers

Damage to the machine due to incorrectly inserted tube shapers.

► Ensure that the tube shaper is turned fully to the right against the stop in the bayonet!

8. Insert the tube shaper into the bayonet lock of the machine.

Fig. 45: Inserting the tube shaper

To remove the tube shaper, rotate it back to the left by approx. 90°.

9. Insert the shaping jaws into the grip head of the machine at a slight angle and slide back to the stop.

Fig. 46: Installing the shaping jaws


6 Operation


Fig. 47: Shaping jaws installed

The message To insert tool, press “Acknowledge” opens.

Fig. 48: Inserting the tool

10. To insert the tool, press the Acknowledge button.

The message Insert and lock grip head opens.

Fig. 49: Inserting the grip head


6 Operation


11. Swivel the grip head to a straight position, push in with both hands and turn to the right.

The grip head is locked.

The Reference run menu opens.

ATTENTION

Damage to the machine from incorrectly executed reference run

► Never carry out the reference run with a tube!



The reference run starts.


The Processing order menu opens after the reference run is complete.





6 Operation


Please refer to chapter 6.4, p. 27, if the reference run is cancelled.

6.7 Forming tube ends

WARNING




How to form the tub ends:

1. Ensure that …

the tube has been prepared according to the requirements in the Stauff product catalogue

the job has been set up as described in chapter 6.6, p. 34.

the Start reshaping process button is shown

We recommend lightly oiling the front end of the tube (HLP32, no lubricating grease) to minimize tool wear.

ATTENTION

Tool damage when forming stainless steel

The original STAUFF forming oil (type SFO-FO-1L) must be used when forming stainless steel tubes. Otherwise, damage to the tool and the machine can occur!

Fig. 52: Start reshaping process


6 Operation


1. Slide a suitable sleeve nut onto the tube end.

2. Note the correct alignment:

The sleeve nut thread has to point towards the tube end which is to be formed.

Fig. 53: Product with sleeve nut

3. Slide the tube into the tool to the stop, ensuring not to twist to the left.

Fig. 54: Pushing in the tube

4. Press the Start reshaping process button.

The forming process starts.


5. When the light flashes, remove the tube and then press the Startup start position button.


6 Operation


Fig. 55: Removing the tube

Information on checking the tube can be found in the Stauff product catalogue.

6. Continue the forming process until Rest i.o. quantity is 0.

The message Stop job. Continue with setup is displayed.

Fig. 56: Job completed

The job has been processed.

You can now set up a new job chapter 6.6, p. 34 or switch off the machine chapter 6.10, p. 48.

6.8 Foot switch operation How to activate foot switch operation:

1. Plug the foot switch connector into the appropriate socket at the rear of the machine.

2. Open the Settings menu as described in chapter 6.5.2, p. 30.


6 Operation


3. When the machine has recognized the foot switch, the Foot switch option – foot switch inactive is shown in the Properties menu.

Fig. 57: Option “Foot switch option – foot switch inactive

4. Press the Foot switch option – foot switch inactive button.

5. The PIN prompt opens. Request the PIN from Stauff.

When the correct PIN has been entered, the foot switch is active and the button changes to “active”.

6. Return to the main menu.

Working in foot switch mode

1. Prepare assembly as described in chapter 6.7, p. 44.

2. In contrast to assembly in button mode, assembly is started by actuating the foot switch.

Fig. 58: Foot switch active

3. Rework as well as preparations for further assembly is also carried out as described in chapter 6.7, p. 44.


6 Operation


How to deactivate foot switch operation.

1. The foot switch is deactivated by pulling the connector from the socket, by deactivating it in the Settings menu or by restarting the machine.

6.9 Cleaning the machine The machine and its components have to be cleaned after each use.

How to clean the machine:

1. Use a cotton cloth to clean the surfaces.

2. Switch off the control panel before cleaning chapter 6.5.2, p. 30.

3. Use water with a grease-dissolving, non-caustic cleaning agent. Do not allow any moisture to get into the cylinders.

4. Remove stubborn dirt with a suitable cleaning agent and apply corrosion protection.

Corrosion protection After removing stubborn dirt or after an extended downtime, apply a light oil film to the moving machine parts for corrosion protection.

6.10 Switching off the machine How to switch off the machine:

1. Turn the main switch to 0 / OFF.

The machine is switched off and de-energized.


7 Troubleshooting


7 Troubleshooting

7.1 Safety

WARNING

Eliminating malfunctions

Serious injuries or machine damage


► The faults described in chapter 7, p. 49 may only be eliminated by authorised and qualified personnel!

► Wear the appropriate personal protective gear for all work undertaken on the machine.

WARNING

Working on electrical equipment

Serious or lethal injuries from dangerous voltage


► Work on electrical appliances may only be carried out by qualified electricians!

► Switch off the machine and secure it against reactivation.

► Work on live parts must always be carried out in the presence of a second person!

► Check electrical components for any residual charges!

CAUTION

Working on the hydraulic system

Eye injuries from ejected hydraulic oil

► Depressurise the machine!


► Wear your personal protective equipment including safety goggles for all work undertaken on the hydraulic system!

u How to proceed in case of a fault:

1. Determine the reason for the fault.

2. Trace the cause of the fault on the corresponding display element.

3. Eliminate the cause of the fault and replace any defective components, if necessary.


7 Troubleshooting


4. If you cannot identify the reason for the fault, contact the manufacturer.

7.2 Troubleshooting For troubleshooting, please note that …

• the fault may only be corrected by the setup and maintenance personnel chapter 2.4, p. 9.

• appropriate personal protective equipment is worn for all troubleshooting work chapter 2.5, p. 9.

Faults which can be eliminated by operating personnel are listed in the following section.

7.3 Faults/error messages

7.3.1 Reshaping path

Fig. 59: Reshaping path not reached

Error message on the machine display:

Possible cause:

Reshaping path not reached! Confirm the message

The machine does not reach the defined end position

with “Acknowledge”. • Wrong tube material

• Wrong wall thickness • Wrong tube diameter • Wrong parameters • Tool dirty

Hydraulic system • Lack of oil

• Pump no longer has the required power. Contact the manufacturer.


7 Troubleshooting


7.3.2 Target position

Fig. 60: Target position not reached


Possible cause:

Target position has not been reached! Confirm the message with “Acknowledge”, restart if necessary.

Control • Control fault. Contact

the manufacturer.

7.3.3 Reference run

Fig. 61: Reference run interrupted


7 Troubleshooting



Possible cause:

Reference run interrupted. Lock the bell for new run, then press “Acknowledge”.

Handling • Buttons were not pressed until the

end of the reference run. Execute reference run again.

• Hydraulics too cold. Execute warm-up program. See chapter 6.4, p. 27

Caution! Reference run with tube inserted! Remove tube and press “Acknowledge”.

Handling • Object detected in the forming jaws

during the reference run. Remove the object, press “Acknowledge” and repeat the reference run.

7.3.4 Parameters

Fig. 62: Wrong parameters


Possible cause:

Wrong parameter combination. No shaping path stored.

Handling • No parameter set is stored for the

selected parameter combination material/tube diameter/wall thickness. Check the parameter combination and change it if necessary. Contact the manufacturer if the desired combination is not available.


7 Troubleshooting


7.3.5 Direction of rotation

Fig. 63: Wrong turning direction


Possible cause:

Wrong turning direction • Phase reverser of the connector set incorrectly. Phase reversers rotating.

7.3.6 Motor protection switch

Fig. 64: Motor protection switch triggered


Possible cause:

Motor protection switch triggered Hydraulic system • Overload of hydraulic system. Leave

machine to cool down, reset motor protection switch – please contact the manufacturer for this.


7 Troubleshooting


7.3.7 Assembly

Fig. 65: Tube not inserted correctly


Possible cause:

Caution! Tube not inserted correctly! Operation Confirm, remove tube and repeat the process.

• The tube is not inserted into the tool to the stop. Confirm, remove tube and repeat the process.

7.3.8 Moving to the start position

Fig. 66: Impermissible startup pressure


Possible cause:

Impermissible startup pressure! Confirm with “Acknowledge”, remove tube or check tool.

Operation • The tube shaper is not in the

correct position. Please check the positioning and “Acknowledge”:


7 Troubleshooting


7.3.9 Tool

Fig. 67: No tool


Possible cause:

No tool! Insert tool and repeat reference run!

Tool • Open grip head, then tool

change chapter 6.6.5, p. 38.

7.3.10 Other faults

Other faults (cannot be integrated into the machine):

Possible cause:

Contour not processed correctly Fault: Visual check shows insufficient diameter

Tool • Tool wear • Wrong shaping jaws • Wrong tube shaper • Wrong internal tube support

Tube • Wrong wall thickness • Tolerance exceeded • Material too hard or too soft • Wrong preparation

Handling • Tube not pressed against

the tool bottom correctly • Tube bend too close to the forming

end Tube is stuck in the shaper after forming Fault: Tube is not pulled out far enough

Tool • Tool wear

Tube • Tube slips in the shaping jaws

Pressing does not start Fault: No reaction from the machine

Machine • Defectiv

e Control

• Defective

Operation • Machine not at the correct

menu item • Production quantity reached

Oil loss Fault: Oil leak

Hydraulic system • Seals defective


7 Troubleshooting


Other faults (cannot be integrated into the machine):

Possible cause:

• Machine tipped too far from horizontal position

• Hose/tube leaking. Contact the manufacturer.

Machine does not start Power supply • Device not connected to the power

supply • Power supply not switched

on • Cable or connector damage • Screen defective

Tube slips Tool • Shaping jaws dirty • Dirt between the tool

segments • Shaping jaws worn

Shaping jaws do not open Tool • Shaping jaws dirty • Dirt between the tool

segments • Springs broken

Tube cannot be inserted Tool • Tool dirty • Wrong shaping jaws • Wrong tube shaper • Wrong internal tube support

Tube • Poor deburring • Wrong tube • Tube bend too close to the forming

end


8 Maintenance


8 Maintenance

8.1 Safety

WARNING

Carrying out maintenance work

Serious or lethal injuries or machine damage

► Maintenance work may only be carried out by Walter Stauffenberg GmbH & Co. KG!

8.2 Inspection and maintenance The machine has to be sent to Walter Stauffenberg GmbH & Co. KG for maintenance and an oil change every two years or after 200,000 forming processes.

8.3 Checking the emergency stop All emergency stop buttons have to be regularly checked for proper functioning.

This is the way to check the emergency stop:

1. Switch on and start the machine.

2. Actuate the emergency stop and check whether the machine stops.

Fig. 68: Emergency stop message

3. Release the Emergency stop button.


The Reference run menu opens.




9 Decommissioning


9 Decommissioning

9.1 Safety

WARNING

Carrying out dismantling work

Serious or lethal injuries

► Dismantling work may only be carried out by authorised qualified personnel.


► Wear your personal protective equipment for all work.

WARNING

Lifting loads







CAUTION

Working on the hydraulic system

Eye injuries from ejected hydraulic oil

► Depressurise the machine!


► Wear your personal protective equipment including safety goggles for all work undertaken on the hydraulic system!


9 Decommissioning


9.2 Dismantling

ATTENTION

Solvents and lubricants

Environmental contamination of water and soil

► When dismantling, collect lubricants and cleaning fluids containing solvents and oils in suitable receptacles!

► For disposal, note the safety data sheets for the emulsions, cleaning agents and lubricants used.

Collect operating media and cleaning fluids containing solvents in appropriate containers to prevent substances with water-toxicity from entering the ground or the sewage system!

Dismantle the machine as follows:

1. Take the machine out of service and disconnect it from the power supply.

2. Dismantle protective panels and housing.

3. Remove all operating media.

4. Remove cables and leads.

5. Remove seals from the bearings.

6. Remove any lubricant from machine parts.

7. Sort plastic, electrical and metal parts.

9.3 Disposal Following final dismantling of the machine, the operating company has to dispose of all used materials and components in keeping with the applicable provisions in the country where the machine is operated.

Particular care is required for disposing of materials which are hazardous to the environment, e.g.:

• plastic parts

• rubber parts

• electrical parts

• metal parts

• operating fluids and additives

u How to handle substances with water toxicity:

1. Use appropriate containers to collect, store, transport and dispose of substances with water toxicity.

2. Dispose of all parts separated by materials at the appropriate disposal points.


9 Decommissioning


3. Always sort by materials for recycling.


10 EC Declaration of Conformity


10 EC Declaration of Conformity


Table of figures


Table of figures

Fig. 1 Safety devices ..................................................................................... 10 Fig. 2 Electrical main switch protected with padlock ...................................... 11 Fig. 3 Overview of controls ............................................................................ 12 Fig. 4 Product ................................................................................................ 13 Fig. 5 Size ...................................................................................................... 14 Fig. 6 Type plate ............................................................................................ 15 Fig. 7 Serial number ...................................................................................... 15 Fig. 8 Start screen ......................................................................................... 21 Fig. 9 Menu – Language settings .................................................................. 21 Fig. 10 Menu – Reference run/material ........................................................... 22 Fig. 11 Starting the reference run ................................................................... 23 Fig. 12 Releasing the grip head ...................................................................... 23 Fig. 13 Pulling out the grip head....................................................................... 23 Fig. 14 Releasing and pulling out the grip head .............................................. 24 Fig. 15 Inserting and locking the grip head ..................................................... 24 Fig. 16 Starting the reference run .................................................................... 25 Fig. 17 Start reshaping process ...................................................................... 25 Fig. 18 Emergency stop message ................................................................... 26 Fig. 19 Menu – Reference run/material ........................................................... 26 Fig. 20 Impermissible startup pressure ........................................................... 27 Fig. 21 Start ..................................................................................................... 27 Fig. 22 Menu – Processing order .................................................................... 28 Fig. 23 Menu – Properties > level ................................................................... 29 Fig. 24 Menu – Language settings .................................................................. 29 Fig. 25 Menu – Properties > level ................................................................... 30 Fig. 26 Menu – System ................................................................................... 30 Fig. 27 Menu – Input pad for date and time .................................................... 31 Fig. 28 Tool counter ........................................................................................ 31 Fig. 29 Overview – Function of the inputs and outputs ................................... 32 Fig. 30 Menu – Number of pieces ................................................................... 32 Fig. 31 Menu – Warm-up ................................................................................ 33 Fig. 32 Menu – Material counter ..................................................................... 33 Fig. 33 Menu – Processing order …................................................................ 34 Fig. 34 Menu – Setup > order ......................................................................... 34 Fig. 35 Menu – Setup > material ..................................................................... 35 Fig. 36 Menu – Setup > order ......................................................................... 35 Fig. 37 Menu – Setup > tube size ................................................................... 36 Fig. 38 Menu – Setup > order ......................................................................... 36 Fig. 39 Menu – Setup > wall thickness ........................................................... 37 Fig. 40 Menu – Input pad for quantity ............................................................. 38 Fig. 41 Menu – Setup > order ......................................................................... 38 Fig. 42 Checking the tool ................................................................................ 39 Fig. 43 Releasing and pulling out the grip head ............................................. 39 Fig. 44 Reference run displaying internal tube support .................................. 40 Fig. 45 Inserting the tube shaper .................................................................... 41 Fig. 46 Installing the shaping jaws .................................................................. 41 Fig. 47 Shaping jaws installed ........................................................................ 42


Table of figures


Fig. 48 Inserting the tool .................................................................................. 42 Fig. 49 Inserting the grip head ......................................................................... 42 Fig. 50 Starting the reference run .................................................................... 43 Fig. 51 Menu – Processing order ..................................................................... 43 Fig. 52 Start reshaping process ....................................................................... 44 Fig. 53 Product with sleeve nut ....................................................................... 45 Fig. 54 Pushing in the tube .............................................................................. 45 Fig. 55 Removing the tube ............................................................................... 46 Fig. 56 Job stopped ......................................................................................... 46 Fig. 57 Option “Foot switch option – foot switch inactive ................................ 47 Fig. 58 Foot switch active ................................................................................ 47 Fig. 59 Reshaping path not reached ............................................................... 50 Fig. 60 Target position not reached ................................................................. 51 Fig. 61 Reference run interrupted .................................................................... 51 Fig. 62 Wrong parameters .............................................................................. 52 Fig. 63 Wrong turning direction ....................................................................... 53 Fig. 64 Motor protection switch triggered ........................................................ 53 Fig. 65 Tube not inserted correctly .................................................................. 54 Fig. 66 Impermissible startup pressure ........................................................... 54 Fig. 67 No tool ................................................................................................. 55 Fig. 68 Emergency stop message ................................................................... 57


Index


Index C Cleaning 48 Commissioning 21 Controls 12

D Decommissioning 58

E Emergency stop 26, 57

F Forming cylinder 39 Function 13 G Grip head 12, 24, 39 I Instruction 6 Internal tube support 40 M Machine

Switching off 48 Decommissioning 58 Switching on 20 Cleaning 48 Overview 10

Machine description 12 Maintenance 57 O Operating company Task 8

P Personal protective equipment 9 Personnel 9 PPE 9 Product 13 Protective equipment 9 Q Qualification 9

R Reference run 22, 43 References 6 S Safety devices 10 Safety features 10 Safety instructions 7 Safety markings 9 Setting up a job 34 Shaping jaws 40 Signal word 5 Signal word boxes 5 Spare parts 16 Switching off 48 Switching on 20 System properties 30 T Tasks of the operating company 8 Technical data 15 Tool Setting up 38 Changing 38 Transport 17 Troubleshooting 50 Tube shapers 40 Type plate 15 U Union nut 45 W

Warnings 5


Index



66 / 66

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